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TM-10-4320-303-13 - Liberated Manuals

1. Reducer Y Connection Reducer Y Connection Disassembly 0001 6 Inch Butterfly Valve Assembly 6 Inch Butterfly Valve Assembly Disassembly 4 22 000 Hose Assembly 6 Inch x 500 Foot Collapsible Hose Assembly Flaking Box Assembly Swivel Joint Pressure Reducing Valve Assembly Pressure Reducing Valve Assembly Pressure Reducing Valve Assembly Tubing and Pressure Reducing Control Enron Pressure Relief Valve Assembly 4 Inch Gate Valve Assembly Hypochlorination Unit Model 1955 1 Outlet Hose Assembly Pressure Gauge and Fill Assembly Strainer Maitena NCE Water Meter and Gear Box Assembly Hypochlorinator Assembly TM 10 4320 303 13
2. Unit Troubleshooting Table nennen nnns vii 10 4320 303 13 HOW TO USE THIS MANUAL DESCRIPTION OF THE MANUAL Manual Organization This manual is designed to help you operate and maintain the TWDS Read the warning pages located in the front of the manual before operating or doing maintenance on the equipment The front cover of this manual provides an index that lists subjects that are commonly used Each item indexed on the front cover has a black box at the edge of the cover There is a corresponding black box on the first text page for each subject listed on the cover index The Table of Contents is provided for quick reference to the subjects covered by each chapter section and appendix Chapters 2 through 6 also have a subject index that lists the major paragraphs in alphabetical order under the section title The major elements of this manual are its chapters and appendixes The chapter and appendixes can be divided into one or more sections This manual has six chapters and seven appendixes A glossary follows the last appendix The glossary lists and explains the special or unique abbreviations and the unusual terms used in this manual An alphabetical index follows the glossary That index is for use in locating specific items of information Locating a Malfunction Finding the cause of a malfunction troubleshooting is the first step in
3. 5 11 5 1 10 4320 303 13 SECTION REPAIR PARTS SPECIAL TOOLS TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT TMDE AND SUPPORT EQUIPMENT 5 1 COMMON TOOLS AND EQUIPMENT For Authorized common tools and equipment refer to the Modified Table of Organization and Equipment MTOE applicable to your unit 5 2 SPECIAL TOOLS AND SUPPORT EQUIPMENT No special tools and test equipment are required for the TWDS 5 3 REPAIR PARTS Repair parts are listed and illustrated in the repair parts and special tools list TM 10 4320 303 24P covering unit direct support and general support maintenance for this equipment 10 4320 303 13 SECTION Il DIRECT SUPPORT MAINTENANCE PROCEDURES 5 4 10 MILE SEGMENT EQUIPMENT 5 4 1 Flaking Box Assembly Repair This task covers 5 4 1 1 Repair INITIAL SETUP Equipment Conditions General Safety Instructions Hoseline Segment removed from flaking Do not work on equipment that is not secure box assembly ly stabilized to prevent sliding Do not work on equipment without following standard shop safety precautions 5 4 1 1 Repair WARNING Do not work on equipment that is not securely stabilized to prevent sliding Failure to do so may result in personal injury NOTE Newer model flaking boxes can hold two 500 foot hose assemblies Older model flaking boxes can hold only one 500 foot hose assembly a Repair of the flaking box assembly consists o
4. 2 114 This manual together with TM 10 4320 344 10 TM 10 4320 344 24 and LO 10 4320 344 12 supersede TM 5 4320 303 10 dated 14 April 1986 and TM 5 4320 303 24 dated 13 June 1986 Change 1 i 3 Section Section Il Section Ill CHAPTER 4 Section Section Il Section Ill Section IV Section V Section VI CHAPTER 5 Section Section Il Section Section Il Section Ill Section IV Section Section Il Section Ill TM 10 4320 303 13 TABLE OF CONTENTS CONTINUED OPERATOR MAINTENANCE INSTRUCTIONS Lubrication Instructions Operator Troubleshooting Procedures Operator Maintenance Procedures UNIT MAINTENANCE INSTRUCTIONS J see Repair Parts Special Tools Test Measurement and Diagnostic Equipment TMDE and Support Equipment Service Upon Receipt Unit Preventive Maintenance Checks and Services PMCS Unit Troubleshooting Unit Maintenance Procedures Preparation for Shipment and DIRECT SUPPORT MAINTENANCE Repair Parts Special Tools Test Measurement and Diagnostic Equipment TMDE and Support Equipment Direct Support Maintenance REFERENCES anua A MAINTE NCE ALLOCATION Introduction Maintenance Allocation Chart Tool and Test Equipment
5. EXS LHELELTITILTLLLLLEVEETLI FELI PUMPING STATION NO 3f 1 j no STATON ee LLT B so I II DSL PRESSURE REDUCING amp a LLLI EE STATION NO 2 1 Ff J VALVE 1140 FT a Se Soo be am if ol fla Ga Us ao FPEM E ud E DRE ER RE E E E d D AE RE EE Det i a d ETE EN RE B DR E ES DRE 112 xd E EE BER ES ET I E AER BR E E B EU EE E FE ES D ERR UU 8 E rec EN Gs EM ER B et a E RE RUE CE E S e pe ES 1000 Figure 2 10 First Boost Pulping Station Location 2 3 1 8 Determine Location of Second Boost Pumping Station To determine second boost pumping station location place pump spacing triangle zero mark on the first boost pumping station mark on ground profile graph Mark point at which pump spacing triangle hypotenuse crosses ground profile This identifies second boost pumping station location Locations of successive boost pumping stations are determined using the same procedure 2 3 1 9 Determine Location of Pressure Reducing Valve Assembly After locations of pumping stations have been plotted check ground profile for any sharp declines in elevation a
6. rerrnnn nn 4 4 Siting and Location 4 4 1 Sling Assembly Maintenance 4 18 Special Instructions Operator PMCS 2 2 4 Special Instructions Unit 2 4 8 2 Special Tools and Support Equipment Direct Support 5 2 Special Tools and Support Equipment Unit Maintenance 4 2 Stand Assembly 4 13 9 Stations Pumping Functional Description 1 19 1 SlOrage ico ee ee 4 22 Storage Administrative 4 23 Storage Assemblies Assembly of 2 3 6 Storage Assemblies Operation of 2 5 4 Storage Assemblies Preparation for Movement of 2 8 5 Storage Assembly Failure of 2 12 3 Storage Assembly Functional Description 1 19 2 Storage Assembly Maintenance ODOralOr eee 3 5 Storage Assembly Maintenance 4 12 INDEX 4 S Continued Storage Assembly TWDS Controls and Indicators for Storage or Shipment Preparation for Strainer Assembly Maintenance Suspension Kit Maintenance Swivel Joint Replacement T 10 Mike Segmen
7. Ia LII RR COMPONENTS OF END ITEM COEI AND BASIC ISSUE ITEMS BII LISTS Introduction Components of End Basic Issue Items ADDITIONAL AUTHORIZED ITEMS LIST 0 Page 3 1 3 1 3 1 3 5 4 1 4 1 4 2 4 9 5 1 5 2 5 3 B 1 B 1 4 7 8 TM 10 4320 303 13 TABLE OF CONTENTS CONTINUED Page EXPENDABLE AND DURABLE ITEMS LIST i E 1 Section 81 e 1 Section Il Expendable Durable Items E 2 ILLUSTRATED LIST OF MANUFACTURED ITEMS F 1 TORQUE LIMITS E 1 E Section Abbreviations Section Il Definition of Unusual Terms ssssse eene MSA RKR5sS 6c uM INDEX 1 TM 10 4320 303 13 Figure Title Page 1 1 Tactical Water Distribution Equipment System TWDS Set 10 Mile Segment eee oce ote Location of Major Components for TWDS Lead Pumping Location of Major Components for TWDS 10 Mile Hoseline Segment Location of Major Components for TWDS Boost Pumping Station Location of Major Components for TWDS Storage 1 6 Location of Major Components for TWDS Di
8. 0 2 0 00 enne nennen nnne nnne nnne nnne PDE INGICALON nn Hypochlorination Unit Model 1955 1 CAUTION Plate Ball Receiver nnn Pneumatic Coupler Cap IMStallation Flaking Box Assembly Pullboard Flange and Coupling Sleeve Start H seline PaCKN meer Compress 0000 0 Hose Retaining Bracket Installation Tailgate Assembly nennen Disassembly of Suspension Disassembly of Road Crossing Disassembly of Pressure Reducing Valve Assembly Disassembly of Lead Pumping Station Suction Disassembly of Lead Pumping Assembly Discharge Disassembly of Boost Pumping Station Suction Disassembly of Boost Pumping Station Discharge
9. 5 6 5 Repair Kit Maintenance 4 17 Repair Main Valve Assembly 5 5 2 Repair Parts Direct Support 5 3 Repair Parts Unit 1 4 3 Repair Pressure Reducing Control 5 5 1 TM 10 4320 303 13 Repair Pressure Reducing Valve Assembly Skid Assembly iiare 5 5 3 Repair Pressure Regulating VEU 5 6 4 Repair Pull Board Assembly 4 16 2 Replacement Collapsible Hose Assembly 6 Inch x 500 essen DEVI 4 11 1 Replacement Fill Assembly 4 13 3 Replacement Frame Assembly 4 13 8 Replacement Hose Assembly 4 10 3 Replacement Pressure Gauge 4 13 3 Replacement Pressure Reducing Valve Assembly 22 4 11 4 Replacement Pressure Regulator VEL 4 13 7 Replacement Swivel Joint 4 11 3 Replacement Water Meter and Gear Box Assembly 4 13 5 Replacement And Repair Hypochlorination Unit Model 19551055 A RES 4 13 1 S Safety Care and Handling 1 9 SCOPE Me 1 1 Segment Hoseline 10 Mile Functional Description of 1 19 3 Segment Hoseline 10 Mile Operator Maintenance of 3 4 Service Upon Receipt of
10. Disassembly of Bypass Disassembly of Storage Assembly Disconnecting 20 000 Gallon Pillow Cleaning of 36 Gallon Drinking Water Storage Bag Disassembly of Model 1955 1 Hypochlorination Unit Disassembly of Distribution Flushing of Hypochlorination Unit Model 1955 1 Removal of 125 GPM Pumping Assembly and Hypochlorination Unit Hose Clamp Damaged Hose Section Male Quick Disconnect Coupling Half and Banding Installation Strapping Preparation PANNE REN NS AERE tuned Preparing Banding Tool for 0 nennen enne nnne Tightening SWAPPING pret Rolling of Banding REMOVING Banding Securing Buckle and Spacing of Buckles on Repaired 6 Inch Hose Repaired Hose Doubled Ended Adapter
11. Preliminary Servicing and Adjustment of TWDS ns sn nenas SECTION Ill UNIT PREVENTIVE MAINTENANCE CHECKS AND 4 9 Introduction to Unit PMCS 4 9 SECTION IV UNIT 5 2 70 00 2 2 0 0000 000000009000 00000000 4 10 Troubleshooting RR 4 10 SECTION V UNIT MAINTENANCE PROCEDURES TWDS Supply Connection Items 10 Mile Segment Equipment Storage Assembly Distribution Point nnn 7 nnne nnns Suspension Kit n Displacement and Evacuation Kit Packing Kit Repair Kit Sling Assembly nnne Preservation ProC CUures
12. 2 5 3 Boost Pumping Station Operator s Controls and Indicators 2 1 3 Boost Pumping Stations Preparation for Movement of 2 8 4 Butterfly Valve Assembly 6 Inch Maintenance 4 10 2 Calibration 1 11 Capabilities and 1 14 2 1 14 1 Checking Unpacked Equipment 4 4 3 Collapsible Hose Assembly 6 Inch x 500 Foot Replacement 4 11 1 Color Comparator 4 13 10 Common Tools and Equipment Direct Support Maintenance 5 1 Common Tools and Equipment Unit Maintenance 4 1 Configuration Equipment 1 18 TM 10 4320 303 13 C Continued Controls and Indicators 2 1 Corrosion Prevention and Control 1 10 Coupling Grooved Pipe Removal and Installation 2 3 2 Coupling Clamp Grooved End Pipe Quick Disconnect Removal and Installation sess 2 3 8 D Data 1 17 Decals and Instruction Plates 2 6 Decontamination Nuclear 2 10 Deprocessing
13. 2 8 Operator Preventive Maintenance Checks and Services for TWDS 2 15 2 8 Components Required from Pumping Station Crate for Assembly of Lead Pumping Station nennen inneren 2 9 Components Required from 10 Mile Segment Crate for Assembly of Lead Pumping Station nennen nennen nnns Components Required from Pumping Stations Crate for Assembly of Boost Pumping rouen read rasis 2 11 Components Required from Storage Assembly Crate for Assembly of Storage Assembly cccccccccsssccecssssececesseeeecessseeeeecseeeececsaeeeesessseeesesseeeseesaeeeeeesaaeeeses Components Required from Distribution Point Crate for Assembly of Distribution Points nnn nemen nnn nnne nennen nnne nennen nennen 2 51 2 13 Components Required from 10 Mile Segment Crate for Assembly of 10 Mile Hoseline Hypochlorite Solution Strength Operator Troubleshooting Pumping Station Crate Storage Assembly Distribution Point Crate nnn 10 Mile Segment nnne Hose Assembly 6 Inch 500 Feet Unit Preventive Maintenance Checks and Services PMCS
14. 10 4320 303 13 Figure 1 8 Suspension Kit and Displacement and Evacuation Kit Table 1 8 Description of Suspension Kit and Displacement and Evacuation Kit SUSPENSION KIT Description and Purpose Used to construct suspensions across streams ponds or gullies Reference item 112 Appendix AND Used to remove water and air from 500 foot hose sections prior to packing Reference item 98 1 11 DISPLACEMENT EVACUATION KIT 10 4320 303 13 1 15 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED Figure 1 9 Packing Kit and Repair Kit Table 1 9 Description of Packing Kit and Repair Kit Item Description and Purpose No 1 PACKING KIT Used to pack 500 foot hose sections into flaking box Reference item 89 of Appendix 2 REPAIR KIT Used to repair 6 inch hose sections Reference item 124 1 12 1 16 DIFFERENCES BETWEEN MODELS TM 10 4320 303 13 Differences between the TWDS models are identified in Table 1 10 An X under the applicable model number column heading indicates that the item is a component of that model Table 1 10 Differences Between Models Equipment Characteristics Trailer Mounted Pumping Assembly Model 609 A Model Model Model 110 00 919 10 X X Trailer Mounted Pumping Assembly Model 609 C X Trailer Mounted Pumping Assembly Model X US636HCCD 1 Hypochlorination Unit Model 1955 1 X X Hypochlorination Unit Model 1955 3 X X X Hypochlorinati
15. 4 16 2 Pumping Assemblies Trailer Mounted Equipment Data for 1 17 1 Pumping Assembly 125 GPM Equipment Data for 1 17 3 Pumping Assembly 125 GPM Maintenance Operator 3 6 Pumping Station Boost Assembly 2 3 5 Pumping Station Boost Operator s Controls and Indicators 2 1 3 Pumping Station Boost Preparation for Movement of 2 8 4 Pumping Station Lead Assembly 2 3 4 Pumping Station Lead Operation of 2 5 2 Pumping Station Lead Operator s Controls and Indicators 2 1 1 Pumping Station Lead Preparation for Movement of 2 8 3 Pumping Station Maintenance 3 3 Pumping Station Spacing TWDS Site Location and 2 3 1 Pumping Stations Functional Description 1 19 1 Q Quality Assurance QA 1 5 R Reducer Y Connection 4 10 1 Removal and Installation Grooved Pipe Coupling 2 3 2 Removal and Installation Grooved End Pipe Quick Disconnect Coupling Clamp 2 3 3 Repair 6 Inch Hose Assembly 3 4 1 Repair Flaking Box Assembly 5 4 1 Repair Hypochlorination Unit Frame Assembly
16. 1 7 EQUIPMENT IMPROVEMENT RECOMMENDATION EIR If your TWDS 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 Put it on Standard Form SF 368 Product Quality Deficiency Report Mail it to us at Commander U S Army Aviation And Troop Command ATTN AMSAT I MDO 4300 Goodfellow Boulevard St Louis MO 63120 1798 We will send you a reply 1 8 WARRANTY INFORMATION The TWDS is not a warranted system 1 9 SAFETY CARE AND HANDLING WARNING and CAUTION statements have been strategically placed throughout this manual prior to operating or maintenance procedures practices or conditions considered essential to the protection of personnel WARNING or equipment or property CAUTION Prior to the performance of any task read and understand all WARNINGS and CAUTIONS pertaining to the task at hand Failure to do so may result in personnel injury damage to equipment or both 1 10 CORROSION PREVENTION AND CONTROL CPC Corrosion Prevention and Control CPC of Army materiel is a continuing concern lt is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items While corrosion is typically associated with the rusting of metals it can also include deterioration of other materia
17. 10 4320 303 13 TECHNICAL MANUAL OPERATOR S UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL TALE OF CONTENTS EQUIPMENT DESCRIPTION OPERATING INSTRUCTIONS OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES OPERATOR AZINTENANCE PROCEDURES UNIT MAINTENANCE PREVENTIVE CHECKS AND SERVICES UNIT MAINTENANCE PROCEDURES DIRECT SUPPORT MAINTENANCE TACTICAL WATER DISTRIBUTION PROCEDURES EQUIPMENT SYSTEM TWDS SET 10 MILE SEGMENT MAINTENANCE ALLOCATION CHART MODELS 06749 0183 81 110 00 0000 919 AND 10 INDEX NSN 4320 01 122 3547 NSN 4320 01 168 0591 NSN 4320 01 168 0590 NSN 4320 01 221 6006 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited This manual together with TM 10 4320 344 10 TM 10 4320 344 24 LO 10 4320 344 12 supersede TM 5 4320 303 10 dated 14 April 1986 and TM 5 4320 303 24 dated 13 June 1986 HEADQUARTERS DEPARTMENT OF THE ARMY 30 JUNE 1993 TM 10 4320 303 13 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY NO 1 WASHINGTON D C 19 August 1996 Operator s Unit and Direct Support Maintenance Manual TACTICAL WATER DISTRIBUTION EQUIPMENT SYSTEM TWDS SET 10 MILE SEGMENT MODEL 06749 0183 81 110 00 0000 919 AND 10 NSN 4320 01 122 3547 NSN 4320 01 168 0591 NSN 4320 01 168 0590 NSN 4320 01 221 6006 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TM 10 4320 303 13 30 June 1993 is changed as follows 1 Remove and ins
18. Qty Mem E mee Coupling pipe for stripped or worn threads fitting Displacement and Inspect kit chest for broken handles evacuation kit latches and hinges Open chest and check inner partitions for broken seam welds Check kit contents listed in appendix C for damaged or missing items Check for damage to sealing surfaces 15 6inch Grooved pipe Check for damaged or missing gasket coupling Check for damaged or missing components 1 Lifting sling Inspect lifting sling ring for cracks or breaks Inspect U bolt for cracks breaks and looseness Inspect lower cables to spreader bar rings for broken strands worn thimbles and loose clips Inspect four lift hooks for cracks breaks or distortions Inspect wire cables for broken strands worn cable thimbles at rings and eyes and loose cable clips 1 Packing kit Inspect kit chest for broken handles latches and hinges Open chest and check inner partitions for broken seam welds Check contents in each kit listed in appendix C for damaged or missing items 1 Pressure reducing Inspect skid for broken welds Inspect valve assembly valve for bent or broken tubing missing parts or other damage Ensure valve is properly attached to skid 1 6 inch Pressure relief Inspect relief valve and nipple for valve and nipple cracked or broken parts Ensure valve is firmly seated in nipple Repair kit Inspect kit chest for broken handles latches an
19. Table 4 5 Hose Assembly 6 Inch 500 Feet Crates Qy item i e 132 Flaking box USD all accessible frame seam welds for cracks or separated metal Inspect four lifting clevises for cracks or distortions Inspect four clevis attach brackets for cracked holes and cracked or separated seam welds Inspect tailgate assembly for cracks breaks holes or any other defects 6 inch x 500 Hose assembly Inspect hose for punctures cuts or foot collapsible scrapes Ensure bands that secure adapters are tight 4 4 4 Deprocessing Unpacked Equipment a b Remove all tape and packing film if any from equipment Remove all plastic tie wraps if any necessary to place the equipment in operation Remove all shipping tags from components and retain for future reference Refer to DA Form 2258 Depreservation Guide for Vehicles and Equipment packed with the equipment The depreservation guide explains what was done to the 4 8 10 4320 303 13 equipment prior to packaging It also explains what has to be done before placing the equipment in operation Perform all depreservation actions required by the depreservation guide 4 5 INSTALLATION INSTRUCTIONS Refer to paragraph 2 3 of this manual for TWDS installation instructions 4 6 PRELIMINARY SERVICING AND ADJUSTMENT OF EQUIPMENT Refer to paragraph 2 4 of this manual for preliminary servicing and adjustment of TWDS 4 7 TWDS LUBRICATION The
20. 2 97 10 4320 303 13 2 8 2 Preparation for Movement of 10 Mile Hoseline Continued CAUTION Be careful not to bend pullboard assembly when compressing hose x Crank ratchet handle of chain hoist 7 until hose 2 is compressed into one third of space in flaking box assembly 4 3 5 Figure 2 63 Hose Retaining Bracket Installation y Place two hose retaining brackets Figure 2 68 1 one or two folds in front of pullboard assembly 2 Position brackets on top of metal rim 3 on inside of flaking box assembly 4 z Push up on toggle levers 5 locking brackets 1 against metal rim 3 on inside of flaking box assembly 4 aa Release chain 6 on hoist 7 Remove pullboard assembly 2 from hoist 7 ab Flake next 150 feet of hose 8 into flaking box assembly 4 Repeating steps u through x compress hose 8 into two thirds of space in flaking box assembly 4 ac Push down on two toggle levers 5 and remove two hose retaining brackets 1 installed in step y ad Reinstall two hose retaining brackets 1 one or two folds in front of pullboard assembly 2 ae Push up on two toggle levers 5 and lock two hose retaining brackets 1 against metal rim 3 on inside of flaking box assembly 4 af Release chain 6 on hoist 7 Remove pullboard assembly 2 from hoist 7 ag Flake remaining hose 8 into flaking box assembly 4 Repeating steps u through x compress hose into remaining s
21. 1 3 Description of Major Components for TWDS 10 Mile Hoseline Segment 1 4 Description of Major Components for TWDS Boost Pumping Station Description of Major Components for TWDS Storage Assembly Description of Major Components for TWDS Distribution Point Description of Major Support Components for 5 1 8 Description of Suspension Kit and Displacement and Evacuation Kit Description of Packing Kit and Repair Kit c cccccccccccscsscsecseecsetscsecsesecsetecsecssecsteaesees Differences Between 040 0000 n Description of Operator s Controls and Indicators for TWDS Lead Pumping 2 2 2 2 Description of Operator s Controls and Indicators for TWDS 10 Mile Hoseline n nnn nnns 2 3 Description of Operator s Controls and Indicators for TWDS Boost Pumping 2 4 2 4 Description of Operator s Controls and Indicators for TWDS Storage Assembly eee errr errs 2 5 Description of Operator s Controls and Indicators for TWDS Distribution 2 6 2 6 Description of Operator s Controls and Indicators for Hypochlorination Unit Model 1955
22. Attach 6 inch x 10 foot hose assembly 3 to suction port 1 with grooved end pipe quick disconnect coupling clamp 2 para 2 3 3 2 Install 6 inch butterfly valve 5 on end of 6 inch x 10 foot hose assembly 3 with grooved end pipe quick disconnect coupling clamp 4 para 2 3 3 2 Install 6 inch lateral grooved pipe fitting 7 on end of 6 inch butterfly valve 5 with grooved end pipe quick disconnect coupling clamp 6 para 2 3 3 2 Install grooved end pipe quick disconnect coupling clamp 8 on end of lateral grooved pipe fitting 7 para 2 3 3 2 and connect 500 foot hose assembly 9 2 45 10 4320 303 13 2 3 5 Boost Pumping Station Assembly Continued Figure 2 19 Boost Pumping Station and Discharge Components Assembly f Remove plastic cap from discharge port Figure 2 19 1 on 600 GPM pumping assembly reference applicable technical manual for discharge port location on 600 GPM pumping assemblies not shown If plastic cap has not been removed remove it and retain cap for movement or storage CAUTION To prevent damage to pump make sure arrow on check valve points away from pump g Install 6 inch check valve 3 on pump discharge port 1 with grooved end pipe quick disconnect coupling clamp 2 OER Ensure 6 inch check valve 3 is installed with arrow pointing away from 600 gpm pumping assembly discharge port 1 h Install 6 inch x 20 foot hose assembly 5 on end of 6 inch check
23. WARNING Not Fully Mission Capable if Hose is damaged Class Ill leak Connection is loose kinked or twisted Suspension wire for hose assembly is under tension Death or personal injury may result if care is not used Always loves while working with suspension components wear helmet and 6 Before Suspension Device Inspect for damage Inspect security of suspended hoseline Inspect for damaged or broken saddle assemblies Ensure saddles are spaced at 5 foot intervals Inspect wire rope for damage and fraying Ensure wire rope is securely anchored Suspension device damaged or suspended hoseline not secure Saddle assemblies damaged or broken Wire rope damaged frayed or not securely anchored 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Item Interval Item to Check Service Procedure Not Fully No Mission Capable if 10 MILE HOSELINE STATION CONT aues uat 7 Before Road Crossing Ensure road crossing guards Road crossing Guard are providing protection for guard is not the hose line If road providing crossing guard has collapsed protection to or hose line is damaged the hose line notify supervisor 8 Before Pressure Relief Inspect valve for presence of Dirty pressure Valve grit sand or dirt If relief valve dirty clean using soft Pressure relief brush Inspect for damage or valve damaged leaks If
24. 30 to 200 psi 138 to 1 034 kPa 6 in 15 cm 4 stroke 6 cylinder air cooled turbocharged diesel 102 mm 4 015 in 125 mm 4 922 in 6 128 cu cm 374 cu in 15 511 515 kg 1 133 Ib 160 hp 118 kW at 2 500 2 800 rpm 2 500 rpm 650 rpm diesel or JP 4 forced lubrication 0 15 mm 0 006 in 15 136 L 16 qt 45 42 L 12 gal 10 4320 303 13 1 17 2 20 000 Gallon Pillow Tank Refer to applicable technical manual for equipment data on the 20 000 Gallon Pillow Tank 1 17 3 125 GPM Pumping Assembly Refer to applicable technical manual for equipment and performance data on the 125 GPM pumping assembly 1 17 4 Hypochlorination Units Refer to applicable technical manual for equipment and performance data on model 1955 3 Refer to applicable technical manual for equipment and performance data on model A 506131 The equipment and performance data for model 1955 1 is detailed below Weight 166 Ib 75 kg Length 26 inches 66 cm Width 18 inches 45 cm Height 28 inches 71 cm Flow 100 gom maximum 2 minimum Ambient Temperature Range 350 to 1300 F 1 70 to 54 4 Range 10 1 Hypochlorinator Feed Rate 55 Reservoir Container Capacity 5 gal 19 L Inlet and Outlet Pipe Size 2 inch female pipe thread 1 18 EQUIPMENT CONFIGURATION The TWDS can be deployed in multiple configurations The configurations are dependent on the application of the TWDS and the terrain over which the system is de
25. oa S16 10 11 12 Figure 4 13 4 Inch Gate Valve Assembly Maintenance 4 12 1 5 Assembly a Position two discs 15 and 16 on pull nut 17 b Install two screws 14 in discs 15 and 16 c Install disc assembly 14 on valve stem 13 d Screw valve stem 13 into bonnet 10 e install new gasket 11 and bonnet 10 on valve body 12 f Ensure mounting holes in bonnet 10 gasket 11 and valve body 12 are aligned g Install eight new lock washers 9 and screws 8 Tighten screws 8 h Insert new packing 6 in bonnet 10 i Install spring 7 and packing gland 5 on bonnet 10 j Install packing nut 4 on stem of bonnet 10 k Install handwheel 3 and nut 2 on stem of bonnet 10 Tighten nut 2 4 36 10 4320 303 13 4 12 1 6 Installation Install 4 inch gate valve assembly 1 in accordance with paragraph 2 3 6 2 24 4 37 10 4320 303 13 4 13 DISTRIBUTION POINT MAINTENANCE 4 13 1 Hypochlorination Unit Model 1955 1 Replacement And Repair This task covers 4 13 1 1 Removal 4 13 1 3 Repair 4 13 1 2 Inspection 4 13 1 4 Installation INITIAL SETUP Tools Equipment Conditions Continued Tool Kit General Mechanic s 125 GPM pumping assembly shutdown refer to Automotive Section Ill Item 1 applicable technical manual General Safety Instructions Equipment Conditions Do not work on equipment without following Pumping station shutdown refer to standard shop safety prec
26. 10 4320 303 13 2 8 2 Preparation for Movement of 10 Mile Hoseline Continued au Push down on two toggle levers Figure 2 63 5 and remove hose retaining brackets 1 installed in step ai av Remove nut Figure 2 61 5 eyebolt 2 and nut 1 from rear of flaking box assembly 8 aw Load and nest empty flaking box assembly on top of full flaking box assembly 8 Repeating steps n through aw pack next length of hoseline Continue this procedure until all remaining lengths of hoseline have been packed ax As flaking box assemblies are packed transport them to lead pumping station installation site for packing in crates 2 8 2 4 Preparation for Movement of Suspension Device NOTE Set aside all removed components for repacking a Remove 6 inch grooved pipe coupling 2 3 2 1 connecting upline hoseline length to suspended hoseline length b Install 6 inch grooved pipe coupling para 2 3 2 2 leading end of suspended hoseline length c Repeat steps a and b with trailing end of suspended hosel ine length and downline hoseline segment installing 6 inch grooved pipe coupling on leading end of downline segment 11 Figure 2 65 Disassembly of Suspension Device 2 100 10 4320 303 13 WARNING When removing saddle assemblies manually support hose until assemblies have been removed d Remove nul Figure 2 65 1 bolt 2 saddle 3 and shackle 4 from each saddle assembly to outside of upl
27. 10 4320 303 13 4 16 PACKING KIT MAINTENANCE This task covers 4 16 1 Inspect 4 16 3 Replace 4 16 2 Repair INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equipment without following Automotive Section Ill Item 1 standard shop safety precautions Figure 4 26 Packing Kit Components 4 63 10 4320 303 13 4 16 PACKING KIT MAINTENANCE Continued 4 16 1 Inspect a Inspect kit for presence of all components as detailed in Components of End b Inspect chest and all components for damage 4 16 2 Repair a Repair of the packing kit consists of replacing missing or damaged components b For repair to a damaged hose retaining bracket refer to paragraph 4 16 1 Hose Retaining Bracket Maintenance 4 16 3 Replace Replace packing kit if either chest is damaged or more than half of the packing kit components are damaged or missing 4 64 10 4320 303 13 4 16 1 Hose Retaining Bracket Maintenance This task covers 4 16 1 1 Disassembly 4 16 1 3 Repair 4 16 1 2 Inspection 4 16 1 4 Assembly INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equipment without following Automotive Section Ill Item 1 standard shop safety precautions Equipment Conditions Hose Retaining Bracket removed from packing kit 4 16 1 1 Disassembly Figure 4 27 Hose Retaining Bracket Maintenance NOTE Th
28. 120 4730 01 333 1899 SADDLE 6 INCH 97403 13226E1570 121 SHACKLE 1 2 INCH EA 300 81349 RR C 271 TYPE IV CLASS 2 122 THIMBLE WIRE ROPE 1 2 INCH EA 20 81349 FF T 276 TYPE II 123 TURNBUCKLE 12 INCH X 12 INCHES EA 20 81349 FF T 791 TYPE 1 FORM 1 CLASS 5 C 27 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable a NUMBER NUMBER CAGEC and Part Number On Code Rqd 124 4730 01 199 4016 REPAIR KIT HOSELINE 6 IN 97403 13226E1581 125 HOSE ADAPTER ASSEMBLY GROOVED END 6 EA 30 IN 79154 060480 0 126 HOSE MENDER ASSEMBLY GROOVED END 6 IN EA 6 74154 060482 0 127 ADAPTER ASSEMBLY HOSE MALE 2 IN EA 2 79154 020483 0 128 ADAPTER ASSEMBLY HOSE MALE 4 IN EA 2 79154 040483 0 C 28 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 2 129 ADAPTER ASSEMBLY HOSE MALE 6 IN 79154 060483 0 130 ADAPTER ASSEMBLY HOSE FEMALE 2 IN EA 2 79154 C020484AE0 131 ADAPTER ASSEMBLY HOSE FEMALE 4 IN EA 2 79154 040484 0 132 ADAPTER ASSEMBLY HOSE FEMALE 6 IN EA 2 79154 C060484AEO0 133 ADAPTER GROOVED PIPE 6 IN EA 6 81349 M10387ADII C 29 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 4
29. 4 45 10 4320 303 13 4 13 5 Water Meter and Gear Box Assembly Replacement Continued gt o o op 4 13 5 2 4 13 5 3 O o Loosen two unions Figure 4 18 1 from two close nipples 2 Remove four nuts 3 lock washers 4 and two u bolts 5 Discard lock washers 4 Remove four flat washers 6 and nuts 7 from two u bolts 8 Remove water meter and gear box assembly 9 from hypochlorination unit 10 Remove two close nipples 2 from pipe tees 11 and 12 Remove two pipe tees 11 and 12 from water meter and gear box assembly 9 Inspection Inspect water meter and gear box assembly 9 for corrosion leaks cracks missing components or damage Notify direct support maintenance if water meter and gear box assembly 9 is damaged or defective Inspect two close nipples 2 and pipe tees 11 and 12 for corrosion cracks holes bends or damage Inspect mounting hardware for damage Replace all defective components Installation NOTE e Wrap all threaded portions of pressure gauge and fill assembly components with antiseize tape prior to installation e Wrap antiseize tape in direction of threads Install two pipe tees 11 and 12 on water meter and gear box assembly 9 Install two close nipples 2 in pipe tees 11 and 12 Position water meter and gear box assembly 9 on hypochlorination unit 10 for installation Install four nuts 7 and fla
30. Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace Service Inspect Replace Repair Inspect Replace 6 6 TOOLS AND EQUIPMENT REMARKS REF CODES CODES 10 4320 303 13 SECTION Il MAINTENANCE ALLOCATION CHART FOR TACTICAL WATER DISTRIBUTION EQUIPMENT SYSTEM TWDS SET 10 MILE SEGMENT continued 1 2 3 5 6 GROUP COMPONENT MAINTENANC P TOOLS AND NUMBER ASSEMBLY FUNCTION EQUIPMENT REMARKS REF CODES CODES 05020401 GearBox Inspect Replace Repair 05020402 Water Meter Inspect Replace Repair 050205 Hypochlorinator Inspect Assembly Replace Repair 050206 Manifold Inspect Assembly Replace Repair 05020601 Pressure Inspect Regulating Replace Valve Repair 050207 Frame Assembly Inspect Replace Repair 0503 Stand Assembly Inspect Replace Repair 0504 Comparator Inspect Color Replace Repair 06 Suspension Kit Inspect Replace Repair 07 Displacement Inspect and Evacuation Replace Kit Repair Ball Inlet Inspect Replace Repair Ball Outlet Inspect Replace Repair Packing Kit Inspect Replace Repair 10 4320 303 13 SECTION Il MAINTENANCE ALLOCATION CHART FOR TACTICAL WATER DISTRIBUTION EQUIPMENT SYSTEM TWDS SET 10 MILE SEGMENT continued 1 2 3 5 6 gv LEVEL GROUP COMPONENT MAINTENANCE UNIT DS GS DEPOT TOOLS AND NUMBER ASSEMBLY FUNCTION EQUIPMENT REMARKS REF CODES CODES Bracket Hose I
31. Refer td paragraph 2 3 7 and reconnect loose 2 ith hoseline connection or refer to 2 3 7 and reconnect loose 4 inch hoseline connection Notify supervisor if 2 inch or 4 inch hoseline is damaged or has a Class IlI leak Check nozzles and elbow valve assemblies for damage or defective parts If damaged or defective parts are found notify unit maintenance Check hypochlorination unit adjustment range to ensure that flow is at 14 gpm If 14 gpm flow rate can not be obtained notify unit maintenance 4 NO DISCHARGE OF WATER AT PRESSURE REDUCING VALVE Step 1 a b Step 2 a Check that isolation cock valves are open If not fully open isolation cock valves If no discharge of water go to step 2 Ensure pressure reducing valve is correctly installed If water still does not flow and pressure reducing valve is correctly installed notify unit maintenance 5 PRESSURE RELIEF VALVE ACTIVATES Step 1 a b Step 2 a Step 3 a b Step 4 a Step 5 Check for obstructions and closed butterfly valves downline Clear obstructions Open butterfly valves Check for proper installation of pressure reducing valve Reposition pressure reducing valve if required Check for malfunctioning pressure reducing valve Check that isolation check valves are open If still malfunctioning notify unit maintenance Refer to technical manual for 600 gpm pumping assemblies and ensure 600 gpm pumping assemblies
32. Replace all defective or damaged components Service Service consists of scrubbing down and rinsing off strainer screen 5 weekly Installation NOTE e Wrap all threaded portions of pressure gauge and fill assembly components with antiseize tape prior to installation e Wrap antiseize tape in direction of threads Install close nipple 7 in pilot valve assembly 8 Install strainer body 2 on close nipple 7 Install gasket 6 and strainer screen 5 in strainer body 2 Install strainer cap 4 in strainer body 2 Insert pipe plug 3 in strainer cap 4 Tighten pipe plug 3 Install street elbow 1 on strainer body 2 4 44 10 4320 303 13 4 13 5 Water Meter and Gear Box Assembly Replacement This task covers 4 13 5 1 Removal INITIAL SETUP Tools Tool Kit General Mechanic s Automotive Section Item 1 Material Parts Antiseize Tape Item 9 Appendix Lock washers TM 10 4320 303 23 4 13 5 1 Removal 4 13 5 2 Inspection 4 13 5 3 Installation Equipment Conditions Hypochlorination Unit Model 1955 1 removed refer to paragraph 4 13 1 Inlet Outlet Drain and Discharge Hose Assemblies removed refer to paragraph 4 13 2 Strainer Assembly removed refer to paragraph 4 13 4 General Safety Instructions Do not work on equipment without following standard shop safety precautions Figure 4 18 Water Meter and Gear Box Assembly Replacement
33. ccccccscsscsscsesscsses essent nnne rennen tnnt tnter nnns s 4 20 PACKING Cp Storage 4 23 Administrative 10 4320 303 13 SECTION REPAIR PARTS TOOLS SPECIAL TOOLS TEST MEASUREMENT AND 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 applicable to your unit 4 2 SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT There are no special tools or support equipment required for TWDS maintenance Refer to the paragraphs below for references to special tools and support equipment for TWDS components 4 2 1 600 GPM Pumping Assemblies Refer to applicable technical manual 4 2 2 125 GPM Pumping Assembly Refer to applicable technical manual 4 2 3 Hypochlorination Unit Model 1955 3 Refer to applicable technical manual 4 2 4 Hypochlorination Unit Model A 506131 Refer to applicable technical manual 4 2 5 20 000 Gallon Pillow Tank Refer to applicable technical manual 4 3 REPAIR PARTS Repair parts are listed and illustrated in the repair parts and special tools list TM 10 4320 303 24P covering unit direct support and general support maintenance for this equipment Refer to the paragraphs below for references to repair parts listings and illustrations for TWDS components 4 3 1 600 GPM Pumping Assemblies Re
34. direct coupled to diesel engine Output volume Designed working pressure Designed suction pressure Suction and discharge size Engine Type Bore Stroke Piston displacement Compression ratio Weight Power output maximum Speed maximum Idle speed minimum Fuel Lubrication Valve clearance cold Crankcase capacity Fuel tank capacity 1 17 1 3 Pumping Assembly Model US636HCCD 1 Weight dry Length Width Height Pump Type Output volume Designed working pressure Designed suction pressure Suction and discharge size Engine Type Bore Stroke Piston displacement entire inch Compression ratio Weight Power output maximum Speed maximum Idle speed minimum Fuel Lubrication Valve clearance cold Crankcase capacity Fuel tank capacity TM 10 4320 303 13 Self priming centrifugal 600 gpm at 350 ft tdh 150 5 psi 1 034 34 kPa 30 to 200 psi 138 to 1 034 kPa 6 in 15 cm 4 stroke 6 cylinder air cooled altitude compensated turbocharged diesel 100 mm 3 937 in 120 mm 4 724 in 5 655 cu cm 345 cu in 17 1 440 kg 970 Ib 109 hp 80 kW at 2 400 rom 3 000 650 rpm diesel or JP 4 forced lubrication 0 15 mm 0 006 in 11 82 L 12 5 qt 113 55 L 30 gal 2 400 Ib 1 090 kg 135 in 343 cm 70 in 178 cm 69 in 174 cm Self priming centrifugal direct coupled to diesel engine 600 gpm at 350 ft tdh 150 5 psi 1 034 34 kPa
35. 1 18 Page 2 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 10 4320 303 13 RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT QUT FOLD IT L ae IN THIS SPACE TELL WHAT IS WRONG TRAR MONG LYNE AND WHAT SHOULD BE DONE ABOUT IT PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER SIGN HERE DA TRUM 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR JUL 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS The Metric System and Equivalents Linear 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 Weights lcentigram 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 To change inche
36. 3 with attached 6 inch coupling half 4 on end of 6 inch butterfly valve 1 on suction port of 600 gpm pumping assembly using grooved end pipe quick disconnect coupling clamp 2 unpacked from PUMP STATION crate para 2 3 3 2 k Locate 6 inch x 10 foot lengths of rigid walled wire reinforced suction hose assemblies 5 with quick disconnect fittings Push cam arms on 6 inch coupling half 4 forward to open position CAUTION To prevent leakage close both cam arms at the same time Do not strike cam arms to close Damage to couplings could result m Connect suction hose 5 to 6 inch coupling half 4 Close cam arms n Install additional 6 inch suction hose assembly lengths 5 as required until lead pumping station can be connected to water source Push cam arms on last suction hose 5 forward to open position 2 43 10 4320 303 13 2 3 4 Lead Pumping Station Assembly Continued CAUTION To prevent leakage close both cam arms at the same time Do not strike cam arms to close Damage to couplings could result p Connect last 6 inch suction hose assembly 5 to Y connection reducer 6 6 inch x 4 inch x 4 inch Close cam arms q Connect Y connection reducer 6 to water source Close cam arms 2 3 5 Boost Pumping Station Assembly Each boost pumping station assembly requires one trailer mounted pumping assembly and the tools personnel and components listed below Remove the required comp
37. 5 ILLUS NERONE STOCK DESCRIPTION Usable e NUMBER NUMBER CAGEC and Part Number On Code Rad 135 3540 01 101 1625 SEALER STEEL STRAP 70847 C001 136 BUCKLE BANDING IN EA 100 137 4730 01 359 7166 CLAMP HOSE 6 IN EA 2 138 5350 00 584 4654 CLOTH ABRASIVE EA 3 06565 EMERYCLOSEKOTE 139 4730 01 176 5772 COUPLING CLAMP 6 INCH EA i 81349 M10387 1 D 11 See note 7 at end of Components of End Item table C 30 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 140 4730 01 270 6555 COUPLING CLAMP 6 INCH 79154 6 791 A 141 5120 01 270 7428 WRENCH SPANNER EA 79154 792 142 FILE 1 ROUND 8 INCH EA 1 43786 00136 143 HACKSAW BLADE 10 INCH EA 10 78735 00 106 144 HACKSAW FRAME ADJUSTABLE EA 1 03914 70 865 See note 7 at end of Components of End Item table C 31 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 0 amp oW 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad 145 HAMMER BALL PEEN 6 INCH EA 1 89428 5855A15 146 5120 00 287 4152 HANDLE SOCKET WRENCH 3 4 INCH DRIVE EA 1 39485 547A51 147 WRENCH SOCKET 3 4 DRIVE 12 POINT EA 1 1 25 OPENING 81348 GGG W 641 TY Il CL 2 STY A 148 WRENCH SOCKET 9 16 12 P
38. 5 6 2 4 Assembly a Install gear box 10 on meter mounting cup 28 b Insert four socket head screws 27 Tighten screws 27 c Install spring lock nut 26 on spring lock sleeve 27 d Install spring screw 25 on spring lock nut 26 e Install flat washer 24 spring 23 spring collar screw 22 lock washer 21 and spring cap link 20 on spring screw 25 f Install spring link coupling 19 in spring link cap 20 h Install drive bushing and gear assembly 18 on main drive shaft 8 i Install new cotter pin 17 in main drive shaft 8 j Install gear assembly 16 and crank 15 k Install crank arm assembly 13 on crank 15 Align crank arm 13 in spring lock sleeve 14 and install crank arm 12 m Install new gasket 11 and gear box cover 3 on gear box 10 n Install four mounting screws 9 Tighten screws 9 Install register gear 7 on main drive shaft 8 p Tighten socket head screw 6 q Install new gasket 5 and register mechanism subassembly 4 on gear boxcover 3 r Install valve cap 2 on gear box cover 3 s Install two screws 1 Tighten screws 1 5 16 10 4320 303 13 5 6 3 Water Meter Maintenance This task covers 5 6 3 1 Disassembly 5 6 3 3 Repair 5 6 3 2 Inspection 5 6 3 4 Assembly INITIAL SETUP Tools Equipment Conditions Continued Tool Kit General Mechanic s Gear Box removed refer to paragraph 5 6 2 Automotive Section
39. CAUTION Overhanging of gasket on grooved fittings may result in damage to gasket when tightening nuts Ensure gasket does not overhang grooved fittings b Place gasket 2 over grooved fitting 3 on first component being sure that gasket 2 does not overhang end of grooved fitting 3 c Align end of second grooved fitting 6 with first grooved fitting 3 Slide gasket 2 to center position between grooves No portion of gasket 2 should overhang grooves of grooved fittings 3 and 6 d Place coupling halves 5 over gasket 2 Ensure that coupling half keys are in grooves of grooved fittings 3 and 6 e Install two bolts 4 Place nuts 1 on bolts 4 and hand tighten CAUTION Over tightening nuts may cause gasket to pinch Tighten nuts only until coupling halves are firmly together metal to metal f Tighten nuts 1 alternately and equally until coupling halves 4 are firmly together 2 37 10 4320 303 13 2 3 3 Grooved End Pipe Quick Disconnect Coupling Clamp Removal and Installation Remove and install grooved end pipe quick disconnect coupling clamp Figure 2 13 as follows Tools Used To Rubber Mallet and Clamping Tool Items Install 6 inch and 4 inch grooved 157 and 3 Appendix end pipe quick disconnect coupling clamps Personnel Two required NOTE This is a general procedure for removal and installation of grooved end pipe quick disconnect coupling clamps Follow this procedure when
40. Close butterfly valves on suction and discharge ports of boost pumping stations e Once all pumping stations have been shut down and isolated from hoseline use 125 GPM pumping assembly to drain storage tanks Empty solution from reservoirs on hypochlorination units Temporarily leave units in operation to flush parts with untreated water After flushing for 10 minutes disconnect hypochlorination units and continue to empty storage tanks Detailed procedures for removing water from storage tanks are provided in paragraph 2 8 6 f Pumping stations can be disassembled when they are shut down Distribution points can be partially disassembled while storage tanks are being drained and completely disassembled when tanks are empty Storage assemblies can be disassembled when tanks are collapsed g Begin hoseline shutdown at the first 500 foot length and move down the line Move air compressor down two hose lengths Evacuate trailing hose then load hose length to minimize number of times air compressor is to be moved Repack hoseline lengths when they are evacuated and collapsed Personnel repacking hoseline segments can follow behind those evacuating and collapsing hoseline Suspension devices road crossing guards and the pressure reducing valve assembly that were placed along hoseline route are removed when crews reach installation sites h The pumping stations storage assemblies and distribution points can be repacked in any sequence Pack t
41. WARNING e Calcium hypochlorite can cause injury if not handled properly Heed safety measures below e f calcium hypochlorite comes into contact with skin or eyes flush right away with water Seek medical help e Store calcium hypochlorite in a cool dry place Keep container closed e Mix only in accordance with directions for use DO NOT allow calcium hypochlorite to mix with any other materials such as fuels oils paint products or ammonia This can cause fire or hazardous gases e Failure to obey this warning may result in personal injury or death b Add required amount of calcium hypochlorite powder item 2 appendix E for desired solution strength table 2 19 to solution reservoir Thoroughly mix powder in water Loosen tube nut 3 at injection point d Insert foot valve 4 into solution in reservoir 2 Rapidly move foot valve 4 up and down several times to fill suction line 5 e Tighten tube nut 3 at injection point 91912191914 1 a 4 ayn Figure 2 46 Hypochlorination Unit Model 1955 1 Control and Water Meter f Open range adjusting valve Figure 2 46 1 g When flow rate is at maximum close range adjusting valve 1 slowly until water meter register 2 indicates flow rate of 14 2 81 10 4320 303 13 2 5 5 4 Operation of Hypochlorination Unit Model 1955 1 Continued Figure 2 47 Stroke Adjust Thimble Operation NO
42. When 20 000 gallon pillow tank is full close 4 inch gate valve Figure 2 43 1 2 5 5 Operation of Distribution Points 2 5 5 1 Distribution Point General Operating Procedures a Before placing distribution point in operation determine proper strength of hypochlorite solution paral 2 5 5 3 b After solution strength has been determined reference applicable technical manual and start 125 GPM pumping assembly Prepare solution and place hypochlorination unit into operation 2 5 5 5 or 2 5 5 6 When hypochlorination unit has been adjusted open gate valves in hoseline network Water may now be distributed at manual disbursing stations c When distribution point is not being used refer to applicable technical manual and shut down 125 GPM pumping assembly Hypochlorination unit will stop automatically Make sure nozzles and elbow valves are hanging from nozzle stand assemblies If distribution point will not be used for a long period refer to paragraph 2 3 9 2 step an and install dust plugs on elbow valves and nozzles d If hypochlorination unit stops working properly or residual test para 2 5 5 7 does not give satisfactory reading immediately shut down operation of distribution point Notify other operators and take corrective action 2 5 5 2 125 GPM Pumping Assembly Refer to applicable technical manual to operate 125 GPM pumping assembly under usual conditions 2 78 10 4320 303 13 2 5 5 3 Determining Hypochlorite Solu
43. install reducers to match truck fitting on discharge hoses 9 or 15 e When reducers are installed on hose ends water flow is controlled by 2 inch gate valves 5 or 11 e Wrap antiseize tape in direction of threads Wrap antiseize tape item 9 appendix E around threads on two reducers 16 Screw reducers 16 into two hose swivels 17 NOTE Wrap antiseize tape in direction of threads Wrap antiseize tape item 9 appendix E around threads of two hose swivels 17 Screw two hose Swivels 17 into two nozzles 18 Push cam arms on two reducers 16 forward to open position CAUTION e To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result Connect two reducers 16 to two discharge hoses 15 Close cam arms Push cam arms on ends of two elbow valves 19 forward to open position CAUTION e To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result Connect two elbow valves 19 to two discharge hoses 9 Close cam arms Push cam arms on open ends of two elbow valves 19 forward to open position CAUTION e To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result Connect two dust plugs 20 to two elbow valves 19 Close cam arms 2 59 10 4320 303 13 2 3 7 Assembly of Distribution Points Continued
44. on close nipple 5 e Install nipple 3 on pipe tee 6 Install elbow 2 on nipple 3 g Install pressure gauge 1 on elbow 2 4 42 10 4320 303 13 4 13 4 Strainer Assembly Maintenance This task covers 4 13 4 1 Removal 4 13 4 3 Service 4 13 4 2 Inspection 4 13 4 3 Installation INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s Hypochlorination Unit Model 1955 1 removed Automotive Section Ill Item 1 refer to paragraph 4 13 1 Inlet Hose Assembly removed refer to Material Parts paragraph 4 13 2 Antiseize Tape Item 9 Appendix General Safety Instructions Do not work on equipment without following standard shop safety precautions 4 13 4 1 Removal Figure 4 17 Strainer Maintenance a Remove street elbow Figure 4 1 7 1 from strainer body 2 b Remove pipe plug 3 from strainer cap 4 and allow water to drain from strainer body 2 c Remove strainer cap 4 from strainer body 2 d Remove strainer screen 5 and gasket 6 4 43 10 4320 303 13 4 13 4 Strainer Assembly Maintenance Continued 4 13 4 3 4 13 4 4 Remove strainer body 2 from close nipple 7 Remove close nipple 7 from pilot valve assembly 8 Inspection Inspect street elbow 1 strainer body 2 strainer cap 4 strainer screen 5 and close nipple 7 for corrosion cracks bends or damage Inspect pipe plug 3 for corrosion or damage
45. securely in upper mounting hole of disc 13 e Install new preformed packing 11 and lower stem 10 in lower housing 9 Install lower housing 9 on body 12 and upper housing 6 assembly Ensure lower stem 10 is inserted through body 12 and installed securely in mounting lower hole of disc 13 g Carefully align upper housing 6 and lower housing 9 and install two bolts 8 and nuts 7 Tighten nuts 7 h Place mounting plate 4 on upper housing 6 Install two screws 5 Tighten screws 5 i j Install handle assembly 3 on mounting plate 4 Install two new lock washers 2 and bolts 1 Tighten bolts 1 4 10 2 6 Installation a Install 6 inch butterfly valve assembly Figure 4 3 2 next to 6 inch X 20 foot hose assembly 3 and lateral grooved pipe fitting 4 b Install two grooved end pipe quick disconnect coupling clamps 1 securing 6 inch butterfly valve assembly 2 to 6 inch X 20 foot hose assembly 3 and lateral grooved pipe fitting 4 4 18 10 4320 303 13 4 10 3 Hose Assembly Replacement This task covers 4 10 3 1 Removal 4 10 3 2 Installation INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equipment without following Automotive Section Ill Item 1 standard shop safety precautions Equipment Conditions Pumping station shutdown refer to applicable technical manual 4 10 3 1 Removal NOTE This procedure is applic
46. 1 19 4 Distribution Points Each distribution point consists of a 125 GPM pumping assembly a hypochlorination unit a network of hoses two stands for nozzles and elbow valves and four water storage bags The 125 GPM pumping assembly draws water from the water storage assembly and delivers it to the hypochlorination unit The hypochlorination unit injects chlorine into the water supply to purify it for personnel consumption The water is then routed through the hose network to manual dispersing stations for distribution to personnel A functional description of each functional unit comprising the distribution point is provided in the following 1 19 4 1 125 GPM Pumping Assembly The 125 GPM pumping assembly is used to extract water from the 20 000 gallon storage assembly and deliver it to the hypochlorination unit The 125 GPM pumping assembly is a skid mounted gasoline engine driven pump which is manually controlled Refer to applicable technical manual for a functional description of the 125 GPM pumping assembly 1 16 10 4320 303 13 1 19 4 2 Hypochlorination Unit The hypochlorination unit is used to inject chlorine into the water supply at steady rate to purify water for personnel consumption The hypochlorination unit is skid mounted and powered by an impulse diaphragm motor which operates on water pressure Chlorine injection rate is controlled by adjustment of pump stroke Water flow rate through the hypochlorination unit is control
47. 1 4 4 13 4 4 14 4 11 3 5 4 4 11 1 17 2 1 17 1 3 2 4 9 2 1 5 2 5 1 4 7 2 8 1 2 3 1 2 1 4 4 10 1 19 5 2 1 2 4 8 4 4 2 2 9 2 3 1 8 9 6 8 4 13 5 INDEX 5 INDEX 6 Blank TM 10 4320 303 13 10 4320 303 13 By Order of the Secretary of the Army GORDON R SULLIVAN General United States Army Official Chief of Staff MILTON H HAMILTON Administrative Assistant to the Secretary of the Army 04680 DISTRIBUTION To be distributed in accordance with DA FORM 12 25 E block no 6077 requirements for TM 10 4320 303 13 0 5 GOVERNMENT PRINTING OFFICE 1995 388 421 42265 10 4320 303 13 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 whomever 2avma27 army mil gt To mpmtYoavma28 st louis emh7 army mil Subject Form 2028 From Joe Smith 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 2840 229 23 9 Pub Title TM 10 Publication Date 04 JUL 85 11 Change Number 7 12 Submitter Rank MSG 13 Submitter FName Joe 14 Submitter MName T 15 Submitter LName Smith 16 Submitter Phone 123 123 1234 17 Problem
48. 13 4 11 3 Swivel Joint Replacement This task covers 4 11 3 1 Removal 4 11 3 3 Installation 4 11 3 2 Inspection INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equpment without following Automotive Section Ill Item 1 standard shop safety precautions Equipment Conditions Pumping station shutdown refer to applicable technical manual 4 11 3 1 Removal Figure 4 8 Swivel Joint Replacement a Remove 6 inch grooved pipe coupling clamp Figure 4 8 1 b Remove grooved end pipe quick disconnect coupling clamp 2 c Remove swivel joint 3 4 24 10 4320 303 13 4 11 3 2 Inspection a Inspect swivel joint 3 for corrosion cracks holes and damage b Replace damaged or defective swivel joint 3 4 11 3 3 Installation a Align swivel joint 3 for installation into hoseline segment b Install grooved end pipe quick disconnect coupling clamp 2 to secure swivel joint 3 to hoseline segment c Install 6 inch grooved pipe coupling clamp 1 to secure swivel joint 3 to hose line segment 4 25 10 4320 303 13 4 11 4 Pressure Reducing Valve Assembly Replacement This task covers 4 11 4 1 Removal 4 11 4 2 Inspection 4 11 4 3 Installation INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equipment without following Automotive Section Ill Item 1 standard shop safety precautions Equipment
49. 2 89117 GL 1 106 4730 01 178 0317 CAP PIPE 6 INCH EA 48 81349 M10388 AO5AKIC 107 BALL INLET ASSEMBLY EA 2 97403 13225E9198 108 4730 01 350 3773 REDUCER GROOVED PIPE 8 INCH X 6 INCH EA 2 79154 50A8X6 109 4730 01 350 3773 REDUCER GROOVED PIPE 8 INCH X 6 INCH EA 2 MODIFIED AS BALL RECEIVER 79154 50A8X6 110 VALVE BALL 1 INCH NPT EA 1 81348 WW V 35 TYPE Il COMP BZ ST 3 C 24 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad 111 KIT CHEST METAL EA 2 63317 100 04 011 112 SUSPENSION KIT HOSELINE 6 INCH 113 4030 01 206 5035 STAKE GUY EA 70 97403 13225E9188 114 4030 01 259 2504 CLAMP WIRE ROPE EA 125 71741 FF C 450 TY 1 CL 2 115 STAKE DRIVING HEAD EA 5 97403 13225E9189 C 25 1 ILLUS NUMBER 116 117 118 119 TM 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 4010 00 542 2257 4 5 U M Qty Rad EA 5 KIT CHEST METAL 81348 PPP B 636 SNATCH BLOCK EA 20 81348 GGG B 490 TYPE Il SINGLE SHEAVE ROPE MANILA 1 2 IN X 300 FT EA 5 81349 T R 605 TYPE M CLASS 5 ROPE WIRE EA 5 81349 RR W 410 TYPE 1 CLASS2 C 26 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 4 5 ILLUS TONAL STOCK DESCRIPTION Usable E NUMBER NUMBER CAGEC and Part Number On Code Rad
50. 2 24 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Item Interval Item to Check Service Procedure Not Fully No Mission Capable if 10 MILE HOSELINE STATION CONT 31 During Pressure Relief Inspect valve for presence of Dirty pressure Valve grit sand or dirt If relief valve dirty clean using soft Pressure relief brush Inspect for damage or valve damaged or leaks If damaged or Class Class III leak Ill leaks are present notify supervisor 32 During Pressure Reducing Inspect skid for cracks and Skid has crack Valve Assembly damaged welds Inspect or damaged valves lines and assembly welds Valve for damage and leaks If and lines are skid is damaged valve is damaged damaged or Class III leaks Isolation cock are present notify valve s is supervisor Make sure closed Class isolation cock valves are Ill leak open BOOST PUMPING STATION 2 25 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Item Interval Item to Check Service Procedure Not Fully No Mission Capable if BOOST PUMPING STATION CONT 33 During Hose Assemblies Inspect for damage leaks Hose is damaged and loose connections collapsed or Tighten loose connections leaking If hose is damaged or Class Connection is leak is present notify loose supervisor STORAGE ASSEMBLY 34 During 4 Inc
51. 2 Inspection 5 6 1 4 Assembly INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s 125 GPM pumping assembly shutdown refer to Automotive Section Ill Item 1 applicable technical manual Strainer Assembly removed paragraph 4 13 4 Goggles Section Ill Item 2 Water Meter and Gear Box Assembly removed Materials Parts General Safety Instructions Cleaning Solvent Item 8 Appendix Gloves Item 4 Appendix E Do not work on equipment without following Apron Item 1 Appendix standard shop safety precautions 5 6 1 1 Removal Remove two screws Figure 5 3 1 Remove end cap 2 and lock spring cap 3 Remove thumbscrew 4 Remove yoke cover 5 from gear box 6 Loosen rod lock nut 7 gt o o p Remove valve rod 8 from link spring coupling 9 Remove four screws 10 Remove valve housing 11 and gasket 12 from gear box 6 Discard old gasket 12 2 Q i Remove retainer ring 13 j Remove rod lock nut 7 from valve rod 8 k Slide entire valve rod 8 and slug assembly 14 out of valve housing 11 Remove valve sleeve 15 from valve housing 11 m Remove four screws 16 valve housing cap 17 and pipe plug 18 from valve housing 11 5 11 10 4320 303 13 5 6 1 Pilot Valve Assembly Maintenance Continued Figure 5 3 Pilot Valve Assembly Maintenance 5 6 1 2 Inspection a Inspect end cap 2 lock spring cap 3 yoke cov
52. 3 is firmly secured to flaking box 2 i Repeat steps c through h for other three flaking boxes Figure 2 32 Positioning Breakaway on Flaking Box Assembly NOTE e Do not secure breakaways too tightly e Breakaways must fall away automatically during hose laying operation e Recover and retain breakaways for reuse j Position breakaway Figure 2 32 1 so that holes in breakaway 1 are aligned with cleats 2 on tie bar 3 and flaking box 4 Leave both ends of hose Figure 2 33 1 outside openings on either side of breakaway 2 Locate three lengths of wire 3 provided with breakaway 2 m Wrap end of one wire 3 around tie bar 4 at point where one of cleats 5 is welded to tie bar 4 Wire 3 should not pass over outside of cleat 5 n Loop wire 3 through notch 6 in cleat 5 as shown o Bring wire 3 over outside of breakaway 2 and back through notch 6 in cleat 5 on bottom of flaking box 7 p Leave bottom end of wire hanging q Repeat steps 1 through o to attach two remaining lengths of wire 3 to other cleats 5 on tie bar 4 and flaking box 7 2 66 10 4320 303 13 Figure 2 33 Breakaway Installation r Repeat steps 1 through q for other three flaking boxes 2 3 8 5 Hose Laying and Installation CAUTION After removing components from boxes be sure to protect them from sand and grit NOTE Remove caps or packaging material from ends of hose a Remove 6 inch
53. 600 GPM pumping assembly Ensure 600 GPM pumping assemblies are shutdown prior to performing maintenance on 6 inch hoseline segments Failure to shutdown 600 GPM pumping assemblies will result in excessive water pressure in 6 inch hoseline segment Components of hypochlorinator assembly main valve assembly and pressure regulating valve are under spring pressure Maintain pressure on covers when removing covers during maintenance activities on these items Do not work on equipment that is not securely stabilized to prevent sliding Dry cleaning solvent PD 680 used to clean parts is potentially dangerous to personnel and property Avoid repeated or prolonged skin contact Do not use near open flame or excessive heat Flash point of solvent is 100 138 degrees Fahrenheit 38 600 C Do not use petroleum based lubricants for installation of o rings and gaskets Failure to obey these warnings may result in serious injury or death to individuals or personnel FOR FIRST AID SEE FM 21 11 a b Blank TM 10 4320 303 13 TECHNICAL WANUAL HEADQUARTERS DEPARTMENT OF THE ARMY NO 10 4320 303 13 WASHINGTON D C 30 June 1993 Operator s Unit and Direct Support Maintenance Manual TACTICAL WATER DISTRIBUTION EQUIPMENT SYSTEM TWDS SET 10 MILE SEGMENT MODEL 06749 0183 81 110 00 0000 919 AND 10 NSN 4320 01 122 3547 NSN 4320 01 168 0591 NSN 4320 01 168 0590 NSN 4320 01 221 6006 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
54. 81 110 00 0000 919 AND 10 TM 10 4320 303 13 C 35 C 36 Blank 10 4320 303 13 APPENDIX D ADDITIONAL AUTHORIZATION LIST SECTION I INTRODUCTION D 1 SCOPE This appendix lists additional items you are authorized for the support of the TWDS D 2 GENERAL This list identifies items that do not have to accompany the TWDS and that do not have to be turned in with it These items are all authorized to you by CTA MTOE TDA or JTA D 3 EXPLANATION OF LISTING National stock numbers descriptions and quantities are provided to help you identify and request the additional items you require to support this equipment If item required differs for different models of this equipment see the Used On Code for the applicable model or models Codes used are Code Used On DTC Model 06749 0183 81 DTQ Model 110 00 0000 DTR Model 919 EAM Model 10 1 National Stock Description Usable Number CAGEC amp Part Number On Code 4310 01 158 3262 Compressor Rotary Air DED 250 cfm 100 psi Trailer Mounted 33968 P N P250W D M H268 D 1 D 2 Blank 10 4320 303 13 Figure F 2 Weldless Chain MATERIALS ITEM DESCRIPTION CAGEC AND PART NUMBER ae oe Chain Weldless 81384 RR C 271 PROCEDURES 1 Cut chain 1 to length such that legs of tripod assembly will separate between 34 and 35 inches when the tripod is deployed F 3 F 4 Blank 10 4320 30
55. B 4 3 Column 3 Nomenclature Name or identification of the tool or test equipment B 4 4 Column 4 National Stock Number The National Stock Number of the tool or test equipment B 4 5 Column 5 Tool Number The manufacturer s part number model number or type number B 5 EXPLANATION OF COLUMNS IN REMARKS SECTION IV B 5 1 Column 1 Remarks Code The code recorded in Column 6 Section Il B 5 2 Column 2 Remarks This column lists information pertinent to the maintenance function being performed as indicated in the MAC Section Il 5 This maintenance category is not included in Section II column 4 of the Maintenance Allocation Chart To identify functions to this category of maintenance enter a work time figure in the column of Section Il column 4 and use an associated reference code in the Remarks column 6 Key the code to Section IV Remarks and explain the SRA complete repair application there The explanatory remark s shall reference the specific Repair Parts and Special Tools List RPSTL TM which contains additional SRA criteria and the authorized spare repair parts B 3 10 4320 303 13 SECTION Il MAINTENANCE ALLOCATION CHART FOR TACTICAL WATER DISTRIBUTION EQUIPMENT SYSTEM TWDS 10 MILE SEGMENT 1 2 3 4 5 6 MAINTENANCE LEVEL GROUP COMPONENT MAINTENANC DS GS DEP TOOLS AND NUMBER ASSEMBLY FUNCTION EQUIPMENT REMARKS REF CODES CODES Tactical Water Distribution
56. Conditions Pumping station shutdown refer to applicable technical manual 4 11 4 1 Removal Figure 4 9 Pressure Reducing Valve Assembly Replacement a Remove grooved end pipe quick disconnect coupling clamp Figure 4 9 1 from downline 6 inch x 500 foot collapsible hose assembly 2 and pressure reducing valve assembly 3 b Remove grooved end pipe quick disconnect coupling clamp 4 from pressure relief valve assembly b and pressure reducing valve assembly 3 c Remove pressure reducing valve assembly 3 4 11 4 2 Inspection a Inspect pressure reducing valve assembly 3 for leaks cracks holes missing components or damage b Replace damaged or defective pressure reducing valve assembly 3 4 11 4 2 Installation a Align pressure relief valve assembly 5 and pressure reducing valve assembly 3 4 26 10 4320 303 13 Install grooved end pipe quick disconnect coupling clamp 4 to secure pressure relief valve 5 to pressure reducing valve assembly 3 Align downline 6 inch x 500 foot collapsible hoseline assembly 2 and pressure reducing valve assembly 3 Install grooved end pipe quick disconnect coupling clamp 1 to secure downline 6 inch x 500 foot collapsible hose assembly 2 and pressure reducing valve assembly 3 4 27 10 4320 303 13 4 11 5 Pressure Reducing Valve Assembly Maintenance This task covers 4 11 5 1 Removal 4 11 5 2 Disassembly INITIAL SETUP Tools
57. Equipment System 10 Mile Segment TWDS Supply Connection Items Y Connection Inspect Reducer Replace Repair Pumping Station Valve Inspect Butterfly Replace 6 inch Gear Repair Actuated Hose Assembly Inspect 6 inches x 10 Replace 20 and 75 feet Repair 600 GPM Pumping Assembly 10 Mile Segment Equipment Hose Assembly Inspect Collapsible 6 Replace inches x 500 Repair feet 030101 Flaking Box Inspect Assembly Replace Repair 0302 Swivel Joint Inspect Replace 0303 Valve Assembly Inspect Pressure Replace Reducing 030301 Control Inspect Pressure Replace Reducing Repair 1 GROUP NUMBER 030302 030308 050201 050202 050203 050204 SECTION Il FOR MAINTENANCE ALLOCATION CHART TM 10 4320 303 13 TACTICAL WATER DISTRIBUTION EQUIPMENT SYSTEM TWDS SET 2 COMPONENT ASSEMBLY Valve Assembly Main Skid Assembly Valve Assembly Pressure Relief Storage Assembly Valve Gate 4 inches Flanged Tank Pillow 20 000 Gallons Distribution Point Pumping Assembly 125 GPM Hypochlori nation Unit 1955 1 Hose Assemblies Outlet Pressure Inlet Drain and Fill Strainer Assembly Pilot Valve Assembly Water Meter and Gear Box Assembly 10 MILE SEGMENT continued MAINTENANCE LEVEL MAINTENANCE UNIT ps TGs DEPOT NN 0 1 Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair
58. Item 1 General Safety Instructions Materials Parts Do not work on equipment without following standard shop safety precautions Gasket TM 10 4320 303 23P Equipment Conditions 125 GPM pumping assembly shutdown refer to applicable technical manual 5 6 3 1 Disassembly CS tc b 2 j Remove two screws Figure 5 5 1 Remove meter mounting cup 2 from top casing 3 Remove six nuts 4 and bolts 5 Remove top casing 3 and gasket 6 from bottom casing 7 Discard gasket 6 Remove top gear 8 first intermediate gear 9 and intermediate pinion 10 from gear plate 11 Remove two gear plate screws 12 and gear plate 11 Remove rubber roller 13 from drive shaft 14 Remove drive shaft 14 from disc chamber top 15 Remove top disc chamber 15 from rubber disc 16 Remove diaphragm 17 from rubber disc 16 Remove rubber disc 16 and bottom disc chamber 18 from bottom casing 7 5 6 3 2 Inspection a b Inspect meter mounting cup 2 top casing 3 bottom casing 7 top disc chamber 15 and bottom disc chamber 18 for corrosion cracks holes or damage Inspect rubber roller 11 rubber disc 16 and diaphragm 17 for corrosion cracks tears slices or damage Inspect all other components for corrosion cracks or damage 5 6 3 3 Repair Repair consists of replacing all damaged or defective components 5 17 10 4320 303 1
59. LIST OF ILLUSTRATIONS CONTINUED Figure Title Page Manifold Assembly Maintenance ccccccsccsecscssesscesessessesecsacsesssssessessaeassassasasassaeenees 4 21 Chlorine Reservoir and Tool Box Replacement Stand Assembly Maintenance Color Comparator Maintenance nennen nnne nnn nnne Suspension Kit 4 25 Displacement and Evacuation Kit Components 4 26 Packing Kit 9 Hose Retaining Bracket Repair Kit Components nennen risen nnn nnn 4 2 Sling Assembly 5 1 Pressure Reducing Control Main Valve Assembly Maintenance c ccccccccssscccsseceesscecssececeecesseeccaeeecssecesaeecenseeecsaes Pilot Valve Assembly Gear Box Water Meter Pressure Regulating Valve Maintenance vi TM 10 4320 303 13 Number Title Page Nomenclature Cross Reference List 20 00444 Description of Major Components for TWDS Lead Pumping Station
60. Mile Hoseline Segment Components of the 10 mile hoseline segment are packed in 34 crates Thirty three crates contain hoseline and are marked HOSE ASSEMBLY 6 INCH 500 FEET Each crate contains four older model flaking boxes or two newer model flaking boxes Each older model flaking box contains one 500 foot hose assembly Each newer model flaking box contains two 500 foot hose assemblies The remaining crate is marked 10 MILE SEGMENT This crate contains all other components necessary for installation of the 10 mile hoseline segment Transport these crates to the area of the lead pumping station 4 4 2 6 General Crate Unpacking Instructions CAUTION Do not use excessive force when unpacking TWDS crates Packing crates or components may be damaged Be careful during unpacking not to damage container contents or packing materials Remove lid from crate As required remove blocking bracing and anchoring securing contents within crate Save all packing materials and store them in their opened containers after removal of crate contents Return unused components to crates Return all fiberboard and plywood boxes to original crates Retain all packing materials at installation site This will speed repacking when moving TWDS to a new site or returning to storage om 4 4 3 Checking Unpacked Equipment Tables 4 1 through 4 5 contain a listing of all components contained in the TWDS packing crates Each table ident
61. Replacement This task covers 4 13 8 1 Removal 4 13 8 4 Repair 4 13 8 2 Disassembly 4 13 8 5 Assembly 4 13 8 3 Inspection INITIAL SETUP Tools Equipment Conditions Continued Tool Kit General Mechanic s Outlet Pressure Regulator Inlet Drain Automotive Section Ill Item 1 and Fill Hose Assemblies removed refer to paragraph 4 13 2 Material Parts Pressure Gauge and Fill Assembly removed refer to paragraph 4 13 3 Strainer removed refer to paragraph 4 13 4 Reservoir TM 10 4320 303 23p Toolbox TM 10 4320 303 23P Water Meter and Gear Box Assembly removed Lock washers TM 10 4320 303 23P refer to paragraph 4 13 5 Equipment Conditions Manifold Assembly removed refer to paragraph 4 13 7 Hypochlorination Unit Model 1955 1 removed refer to paragraph 4 13 1 General Safety Instructions Do not work on equipment without following standard shop safety precautions 4 13 8 1 Removal Placing the frame assembly Figure 4 21 1 in the equipment conditions specified above will remove the frame assembly 1 from the hypochlorination unit 4 13 8 2 Disassembly a Remove chlorine reservoir 1 from frame 2 b Open top of tool box 3 c Remove four nuts 4 lock washers 5 and screws 6 Discard lock washers 5 d Remove tool box 3 from frame 2 4 13 8 3 Inspection a Inspect chlorine reservoir 1 for cracks holes or damage b Inspect frame 2 for cracks bends or separation of welds c Inspect
62. Suspension Kit Components 4 59 10 4320 303 13 4 14 SUSPENSION KIT MAINTENANCE Continued 4 14 1 Inspect a Inspect kit for presence of all components as detailed in Components of End Item Appendix C b Inspect chest and all components for damage 4 14 2 Repair Repair of the suspension kit consists of replacing missing or damaged components 4 14 3 Replace Replace suspension kit if either the chest is damaged or more than half of the suspension kit components are damaged or missing 4 60 10 4320 303 13 4 15 DISPLACEMENT AND EVACUATION KIT MAINTENANCE This task covers 4 15 1 Inspect 4 15 3 Replace 4 15 2 Repair INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equipment without following Automotive Section Ill Item 1 standard shop safety precautions Figure 4 25 Displacement and Evacuation Kit Components 4 61 10 4320 303 13 4 15 DISPLACEMENT AND EVACUATION KIT MAINTENANCE Continued 4 15 1 Inspect a Inspect kit for presence of all components as detailed in Components of End Item Appendix C b Inspect chest and all components for damage 4 15 2 Repair Repair of the displacement and evacuation kit consists of replacing missing or damaged components 4 15 3 Replace Replace displacement and evacuation kit if either the chest is damaged or more than half of the displacement and evacuation kit components are damaged or missing 4 62
63. TWDS does not require any general lubrication Refer to the applicable technical manuals for 125 GPM and 600 GPM Pumping Assemblies SECTION Ill UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES 4 8 INTRODUCTION TO UNIT PMCS TABLE Table 4 7 has been provided so you can keep your TWDS equipment in good operating condition and ready for its primary mission Additional PMCS procedures for TWDS equipment are contained in Table 2 7 Operator PMCS and Chapter 2 Section II of this manual Refer to applicable technical manuals for specific component PMCS 125 GPM Pumping Assembly 20 000 Gallon Pillow Tank Hypochlorination Unit Model A 506131 Hypochlorination Unit Model 1955 3 600 GPM Pumping Assemblies 4 8 1 Explanation of Table Entries 4 8 1 1 Item No Column Numbers in this column are for reference When completing DA Form 2404 Equipment Inspection and Maintenance Worksheet include the item number for the check service indicating a fault Item numbers also appear in the order that you must do checks and services for the intervals listed 4 8 1 2 Interval Column This column tells you when you must do the procedure in the procedure column BEFORE procedures must be done before you operate or use the equipment for its intended mission DURING procedures must be done during the time you are operating or using the equipment for its intended mission AFTER procedures must be done immediately after you have operated t
64. Unpacked Equipment 4 4 4 Differences Between Models 1 16 Displacement and Evacuation Kit Maintenance 4 15 Distribution Point Failure p E 2 12 4 Distribution Point 4 13 Distribution Point TWDS Control and Indicators for 2 1 5 Distribution Points Assembly 2 3 7 Distribution Points Functional Description 1 19 4 Distribution Points Operation 2 5 5 Distribution Points Preparation for Movement of 2 8 6 Description Functional 1 19 Destruction of Army Materiel To Prevent Enemy Use 1 3 Drain Fill Hose Assembly 4 13 2 Emergency Procedures 2 12 Equipment Checking Unpacked 4 4 3 Equipment Common Tools and Direct Support Maintenance 5 1 Equipment Common Tools and Unit Maintenance 4 1 Equipment Characteristics Capabilities and Features 1 14 Equipment Configuration 1 18 Equipment 1 17 Equipment Deprocessing esse 4 4 4 Equipment Preliminary Servicing
65. a If found remove obstructions Step 2 Ensure that inlet and cover isolation cock valves are open then close outlet isolation cock valve a If main valve closes replace pressure reducing control valve b If main valve opens notify direct support for diaphragm and spring maintenance 4 HYPOCHLORINATION UNIT MODEL 1955 1 PRESSURE GAUGE SHOWS HIGH PRESSURE Check pressure gauge for damage Refer to paragraph 4 13 3 and replace pressure gauge 5 HYPOCHLORINATION UNIT MODEL 1955 1 CAMSHAFT IS TURNING BUT SPRING IS NOT MOVING Check to see if pressure regulator setting is not accurate Correct valve setting 4 11 10 4320 303 13 Table 4 7 Unit Troubleshooting Table Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 6 LITTLE OR NO WATER FLOW AT DISTRIBUTION POINTS Step 1 Check nozzles and elbow valve assemblies for damage or defective parts a Refer to paragraph 2 8 6 replace damaged or defective nozzle b Refer to paragraph 2 8 6 hnd replace damaged or defective elbow valve assemblies 4 12 10 4320 303 13 SECTION V UNIT MAINTENANCE PROCEDURES 4 10 TWDS SUPPLY CONNECTION ITEMS MAINTENANCE 4 10 1 Reducer Y Connection Maintenance This task covers 4 10 1 1 Removal 4 10 1 4 Repair 4 10 1 2 Disassembly 4 10 1 5 Assembly 4 10 1 3 Inspection 4 10 1 6 Installation INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s Lead pumping station shutdown refer to Automo
66. a total of 54 flaking boxes supplied with a TWDS 2 3 8 2 1 Hoseline is packed in 33 crates Each crate contains four flaking boxes Each flaking box contains one 500 foot length of hoseline Installation of 10 mile segment will require at least 27 crates 108 flaking boxes of hoseline Use enough hoseline to provide approximately three feet of slack so that connections to pumping stations and storage assemblies are easily made 2 3 8 2 2 Hoseline is installed by flaking hose from rear of truck and manually positioning hose The lengths of hose are connected together using 6 inch grooved pipe couplings Every 1 000 feet a swivel joint is installed to eliminate twisting and possible damage to the equipment during hoseline packing 2 61 10 4320 303 13 2 3 8 Assembly of 10 Mile Hoseline Segment Continued CAUTION Minimum capacity of truck should be no less than 2 1 2 tons Damage may result to trucks that do not have the minimum load capacity 2 3 8 2 3 A maximum of four flaking boxes are loaded onto a 2 1 2 ton cargo truck Some TWDS may contain flaking boxes which can be lifted only from the sides and cannot be approached from tailgate end If truck used does not have removable side walls or stakes the bottom flaking box must have forklift openings at tailgate end or be loaded by lifting sling CAUTION e Hose lengths should be snaked slightly to allow at least feet of slack for each hoseline length e Contraction of taut h
67. and Adjustment of 4 6 INDEX 1 E Continued Equipment Improvement Recommendation EIR 1 7 F Failure of Distribution Point 2 12 4 Failure of Storage Assembly 2 12 3 Features Capabilities 1 14 2 Fill Assembly Replacement 4 13 3 Fill Hose Assembly 4 13 Flaking Box Assembly 4 11 2 Flaking Box Assembly Repair 5 4 1 2 2 11 Frame Assembly Replacement 4 13 8 Functional Description 1 19 G Gate Valve Assembly 4 Inch 4 12 1 Gear Maintenance 5 6 2 1 13 Grooved End Pipe Quick Disconnect Coupling Clamp Removal and Installation 2 3 3 Grooved Pipe Coupling Removal and Installation 2 3 2 H Hose Assembly 6 Inch Repair 3 4 1 Hose Assembly Replacement 4 10 3 Hose Retaining Bracket 4 16 1 Hoseline 10 Mile Preparation for Movement 2 8 2 Hoseline 10 Mile Segment Functional Description of 1 19 3
68. are operating properly If 600 pumping assemblies are not operatng properly refer to proper technical manual and troubleshoot 600 gpm pumping assemblies Install new pressure relief valve 3 4 10 4320 303 13 SECTION Ill OPERATOR MAINTENANCE PROCEDURES 3 3 PUMPING STATION MAINTENANCE Refer to applicable technical manual for operator maintenance procedures for the 600 GPM pumping assemblies 3 4 10 MILE HOSELINE SEGMENT MAINTENANCE 3 4 1 6 Inch Hose Assembly Repair This task covers 3 4 1 1 Male Quick Disconnect 3 4 1 2 Double Ended Adapter Repair Coupling Half Repair INITIAL SETUP Tools Equipment Conditions Tools required for repair of 6 inch Pumping Stations shutdown refer to hose assemblies are contained in applicable technical manual Hoseline Repair Kit Section Il Item 124 Appendix General Safety Instructions Materials Parts Ensure pumping stations are shutdown to eliminate pressure build up in hoseline Rags Item 7 Appendix E Do not work on equipment without following Items to be used for repair of 6 inch standard safety precautions hose assemblies are contained in Hoseline Repair Kit Section Il Item 124 Appendix 3 4 1 1 Male Quick Disconnect Coupling Half Repair WARNING Ensure pumping assemblies are shut down before performing this procedure Failure to shut down pumping assemblies will result in excessive water pressure in hoseline which may rupture causing personal
69. assembly 4 Place nut 5 on eyebolt 2 Tighten nut 5 until eyebolt 2 is securely fastened to flaking box assembly 4 CAUTION Clear sharp objects out of flaking box before packing Any object pressed against hose during packing could puncture it p Place leading end of hose 6 at left front corner 7 of flaking box assembly 4 Leave about 3 feet of hose dangling beyond front of flaking box assembly 4 q Route hose 6 along left side and then across rear 8 off flaking box assembly 4 r At right rear corner 9 of flaking box assembly 4 fold hose 6 back to left rear corner 10 Then fold hose back to right rear corner 9 s Continue to fold hose 6 in a right to left left to right pattern Make every other fold 1 2 inch shorter than width of flaking box assembly 4 t Stop flaking hose 6 after about 150 feet of hose 6 is in flaking box assembly 4 Figure 2 62 compress Hoseline Place pullboard assembly Figure 2 62 1 against hose 2 Make sure eyebolt Figure 2 60 14 on pullboard assembly Figure 2 62 1 faces eyebolt 3 on rear of flaking box assembly 4 Position pullboard flanges Figure 2 60 1 and 6 beneath metal Figure 2 62 5 on inside of flaking box assembly 4 v Attach hook 6 of chain hoist 7 to eyebolt 3 in rear of flaking box assembly 4 w Attach hook 8 of chain hoist 7 to eyebolt Figure 2 60 14 on pullboard assembly Figure 2 62 1
70. c Remove four clevis pins 5 and clevises 6 from flaking box assembly 3 d Remove tailgate assembly 7 from flaking box assembly 3 4 11 2 2 Inspection and Cleaning a Inspect tie bar 2 flaking box assembly 3 clevis pin 5 clevis 6 and tailgate assembly 7 for corrosion cracks bends and damage b Inspect two bolts 1 for corrosion and damage WARNING Dry cleaning solvent used to clean parts is potentially dangerous to personnel and property Avoid repeated or prolonged skin contact Do not use near open flame or excessive heat Flash point of solvent is 100 138 degrees Fahrenheit 38 600 C Wear goggles and gloves when using cleaning solvent Failure to obey these warnings may result in death or personal injury Clean two bolts 1 tie bar 2 clevis pin 5 and clevis 6 which are not damaged d Allow cleaned components to thoroughly air dry 4 11 2 3 Repair Repair of flaking box assembly 3 consists of replacing damaged or defective components Notify Direct Support Maintenance for welding 4 11 2 4 Assembly a Insert tailgate assembly 7 into flaking box assembly 3 b Align mounting holes of four devises 6 with clevis mounting holes on flaking box assembly 3 c Install four clevis pins 5 and new cotter pins 4 d Align mounting holes of tie bar 2 with tie bar mounting holes of flaking box assembly 3 e Install two bolts 1 Tighten bolts 1 4 23 10 4320 303
71. c Using the dropper 1 add the indicator solution to the sample cell 3 in the left hand cell space Figure 2 51 4 only Water sample without indicator solution in right opening compensates for color and turbidity 2 86 10 4320 303 13 Figure 2 53 pH Indicator d Refer tb paragraph 2 5 5 7 and perform steps k through m replacing chlorine color disc with ph color disc e In making the pH test be careful to avoid touching the sample or indicator cell Figure 2 50 4 with the dropper Figure 2 52 1 Never place the dropper on a laboratory bench or other surface because the adherence of the slightest amount of acid or alkali to it will produce incorrect results f Refer td paragraph 2 5 5 7 and perform steps o through s 2 87 10 4320 303 13 2 6 DECALS AND INSTRUCTION PLATES For information 600 GPM pumping assembly decals and instruction plates reference applicable technical manual 2 6 1 Hypochlorination Unit Model 1955 1 CAUTION FOR SAFE OPERATION FOLLOW ALL SAFETY PRECAUTIONS IN INSTRUCTION MANUAL LIQUID IS UNDER PRESSURE AND MAY BE HAZARDOUS USE PERSONAL PROTECTIVE EQUIPMENT Figure 2 54 Hypochlorination Unit Model 1955 1 CAUTION Plate 2 6 2 Hypochlorination Unit Model 1955 3 For decals and instruction plates on hypochlorination unit 1955 3 reference applicable technical manual 2 6 3 Hypochlorination Unit Model A 506131 For decals and instruction plates on hypochlor
72. connections or collapsed Tighten loose connections Class III leak If hose is damaged or Class Connection is Ill leaks are present notify loose supervisor 10 MILE HOSELINE SEGMENT 28 During 6 Inch x 500 Foot Inspect for damage leaks Hose is damaged Hose Assembly and loose connections or class Ill Tighten loose connections leak Inspect for kinks twists Connection is rubbing or chafing against loose trees rocks suspension device tripods or other objects that might damage hoseline Reposition hose as required 2 23 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Item Interval Item to Check Service Procedure Not Fully No Mission Capable if 10 MILE HOSELINE STATION CONT 28 29 During Suspension Device Inspect for damage Inspect Suspension security of suspended device damaged hoseline Inspect for or suspended damaged or broken saddle hoseline not assemblies Ensure saddles secure Saddle are spaced at 5 foot assemblies intervals Inspect wire rope damaged or for damage and fraying broken Wire Ensure wire rope is securely rope damaged anchored frayed or not securely anchored 30 During Road Crossing Ensure road crossing guards Road crossing Guard are providing protection for guard is not the hose line If road providing crossing guard has collapsed protection to or hose line is damaged the hose line notify supervisor
73. damaged or Class Class III leak Ill leaks are present notify supervisor 9 Before Pressure Reducing Inspect skid for cracks and Skid has cracks Valve Assembly damaged welds Inspect or damaged valves lines and assembly welds Valve for damage and leaks If and lines are skid is damaged valves are damaged damaged or Class IIl leaks Isolation cock are present notify valve s is supervisor Make sure closed Class isolation cock valves are leak open 2 17 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Item Interval Item to Check Service Procedure Not Fully No Mission Capable if 10 MILE HOSELINE STATION CONT 10 Before Flaking Box Inspect all frame seam welds Seam weld is for cracking and damage damaged Inspect lifting devises and Lifting clevis clevis attach brackets for or clevis attach cracks bends or broken seam bracket are welds Inspect tailgate damaged assembly side walls and Tailgate base for damage If any of assembly is these items are damaged damaged notify supervisor BOOST PUMPING STATION 11 Before 6 Inch Butterfly Ensure butterfly valves on Valves do not Valve hose assemblies move freely move freely 2 18 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Item Interval Item to Check Service Procedure Not Fully No Mission Capable if BOOST PUMP
74. fixing the equipment and returning it to operation Follow these simple steps to determine the root of the problem a Turn to the Table of Contents in the manual b Locate Troubleshooting under the chapter that covers your level of maintenance Turn to the page indicated Preparing for a Task Be sure that you understand the entire maintenance procedure before beginning any maintenance task Make sure that all parts materials and tools are handy Read all steps before beginning Prepare to do the task as follows a Carefully read the entire task before starting It tells you what you will need and what you have to know to start the task b Obtain all listed equipment tools and parts How to do the Task Read the entire task Be sure that you understand the entire procedure Perform the task Be sure to obey all WARNINGS and CAUTIONS viii 10 4320 303 13 STORAGE ASSEMBLY DISTRIBUTION POINT SUSPENSION DEVICE e o x i HOSELINE 4 Aa 4 d Na BOOST PUMPING STATIONS DISTRIBUTION POINT LEAD PUMPING STATION STORAGE ASSEMBLY BOOST PUMPING STATIONS ROAD CROSSING GUARD HOSELINE Figure 1 1 Tactical Water Distribution Equipment System TWDS Set 10 Mile Segment 1 0 TM 10 4320 303 13 CHAPTER 1 INTRODUCTION SECTION I GENERAL INFORMATION 1 1 SCOPE This manual is for your use in operating and maintaining the Tactical Water Distribution Equipment System TWDS Set 10 Mile Segment mode
75. following tasks 1 Straighten out kinks or bends in hoseline 2 Remove small obstructions branches and sharp rocks which can damage hoseline 3 Check that swivel joint is installed at every 1 000 foot connection 2 3 8 2 6 Empty hose is easily blown by strong winds causing damage to installations and equipment To avoid high wind problems pack newly laid hose as soon as possible Once lead pump and first boost pump are connected by hoseline reference applicable technical manual for pump operating procedures and packing hoseline 2 3 8 2 7 During hose laying operations it is essential that operators at pumping stations and storage assemblies communicate with each other and with hose laying crews If a problem develops with the hose laying operation immediately notify operators who are packing hoseline If a problem occurs when hoseline is packed immediately notify hose laying supervisor and other operators 2 3 8 3 Assembly Requirements a Assembly of the 10 mile hoseline segment requires the equipment and personnel outlined in Tem EE 2 3 8 2 These requirements generally remain the same in each situation However the number of components required for assembly will vary depending on the route and terrain being crossed as well as TWDS assigned mission b Hoseline is packed in 33 crates marked HOSE ASSEMBLY 6 INCH 500 FEET Each crate contains either two or four flaking boxes each flaking box contains either one or two 500 f
76. gear box cover 3 c Remove register mechanism subassembly 4 ard gasket 5 d Loosen socket head screw 6 and remove register gear 7 from main drive shaft 8 e Remove four screws 9 f Gently pry around edge of gear box cover 3 and remove gear box cover 3 from gear box 10 g Remove gasket 11 Discard gasket 11 h Remove crank arm pin 12 Turn crank arm assembly 13 away from spring lock sleeve 14 i Remove crank arm assembly 13 from crank 15 j Remove crank 15 and gear assembly 16 k Remove cotter pin 17 Discard cotter pin 17 Remove drive bushing and gear assembly 18 from main drive shaft 8 m Remove spring link coupling 19 from spring link cap 20 n Remove spring link cap 20 lock washer 21 spring collar screw 22 spring 23 and flat washer 24 o Remove spring screw 25 from spring link lock nut 26 p Remove spring link lock nut 26 from spring lock sleeve 14 q Loosen four socket head screws 27 5 14 10 4320 303 13 14 25 26 Mi Figure 5 4 Gear Box Maintenance r Remove gear box 10 from meter mounting cup 28 5 6 2 2 Inspection a Inspect all components for cracks holes corrosion or damage b Inspect all mounting hardware and other items for corrosion or damage 5 6 2 3 Repair Repair consists of replacing all damaged or defective components 5 15 10 4320 303 13 5 6 2 Gear Box Maintenance Continued
77. if elevation continues to drop excessively beyond first pressure reducing valve assembly installation point a second pressure reducing valve assembly must be installed in hoseline Using formula provided below determine point at which next pressure reducing valve assembly must be installed in hoseline altitude at first pressure Second pressure reducing valve assembly 346 5 reducing valve assembly installation point installation point 346 5 allowed additional vertical footage before reaching safety limit 2 3 2 Grooved Pipe Coupling Removal and Installation Remove and install grooved pipe coupling Figure 2 12 as follows Tools Used To 1 1 4 1 1 16 inch wrench sockets and Install 6 inch and 4 inch grooved Handle Items 85 86 and 146 pipe couplings Appendix C Personnel Two required NOTE This is a general procedure for removal and installation of bolt secured model grooved pipe couplings Follow this procedure when using a bolt secured model grooved pipe coupling to connect two TWDS components 2 36 TM 10 4320 303 13 2 3 2 1 Removal Figure 2 12 Grooved Pipe Coupling a Disassemble grooved pipe coupling by removing two nuts Figure 2 12 1 bolts 4 coupling halves b and gasket 2 b Check gasket 2 for damage If gasket 2 is damaged replace it 2 3 2 2 Installation a Apply thin coat of non petroleum silicone lubricant item 5 appendix E to gasket lips and outside of gasket 2
78. link 11 Install nut 13 on connecting link 11 Insert connecting link 11 valve retainer disk 10 valve diaphragm 9 and valve piston 8 in pressure valve retainer 12 Install spring 7 seat 6 and pressure valve cap 3 Align holes in pressure valve cap 3 with holes in pressure valve retainer 12 Secure pressure valve cap 3 and pressure valve retainer 12 Install six bolts 5 and nuts 4 Tighten nuts 4 Install setscrew 2 in pressure valve cap 3 k Install jam nut 1 5 21 10 4320 303 13 5 6 5 Hypochlorination Unit Frame Assembly Repair This task covers 5 6 5 1 Repair INITIAL SETUP Equipment Conditions General Safety Instructions Hypochlorination Unit Frame Assembly Do not work on equipment that is not secure removed paragraph 4 13 8 ly stabilized to prevent sliding Do not work on equipment without following standard shop safety precautions 5 6 5 1 Repair WARNING Do not work on equipment that is not securely stabilized to prevent sliding Failure to do so may result in personal injury a Repair of hypochlorination unit frame assembly consists of welding cracked seams and frame members in accordance with MIL STD 1261 and TM 9 237 5 22 SCOPE REFERENCES TM 10 4320 303 13 This appendix lists all forms field manuals technical manuals and miscellaneous publications referenced in this manual A 2 FORMS Recommended Changes to Publ
79. of Operator s Controls and Indicators for TWDS 10 Mile Hoseline Segment Item Item Name Description and Purpose No 1 ISOLATION COCK VALVE Used to manually turn pressure reducing valve assembly on and off Three are present on the pressure reducing valve assembly 2 TOP ISOLATION COCK Applies pressure to diaphragm VALVE 3 OUTLET PRESSURE Releases water from pressure regulator into pressure reducing VALVE valve 4 INLET PRESSURE VALVE Supplies water from 10 mile hoseline segment to pressure regulator 5 PRESSURE RELIEF Releases pressure in 10 mile hoseline segment when pressure VALVE exceeds 200 pounds per square inch psi 2 3 10 4320 303 13 2 1 3 Boost Pumping Station Sde figure 2 3 and table 2 3 Figure 2 3 Operator s Controls and Indicators for TWDS Boost Pumping Station Table 2 3 Description of Operator s Controls and Indicators for TWDS Boost Pumping Station Item Item Name Description and Purpose No 1 BOOST PUMPING 600 gpm pumping assembly Reference applicable technical STATION manual for a description of the operator s controls and indicators for the 600 gpm pumping assemblies 2 6 INCH BUTTERFLY Used to control flow through bypass hose assembly Closed to VALVE BYPASS shut off bypass hose assembly Open to direct water through bypass hose assembly 3 6 INCH BUTTERFLY Used to control water flow into lead pumping assembly Open VALVE SUCTION to route water flow from water source through p
80. on the vertical scale to the 39 000 feet mark on the horizontal scale This line will form the hypotenuse or long side of the triangle d Making sure all lines have a straight edge cut the triangle along the three sides drawn horizontal vertical and diagonal 2 3 1 7 Determining Location of First Boost Pumping Station Using ground profile graph and pump spacing triangle refer to figure 2 10 and determine first boost pumping station as follows a Place pump spacing triangle on ground profile graph b Align vertical side of pump spacing triangle with vertical elevation side of ground profile graph Ensure zero mark of pump spacing triangle is on lead pumping station mark of ground profile graph c Ensure horizontal side of spacing triangle is exactly parallel with horizontal base of ground profile graph Horizontal space on both the pump spacing triangle and ground profile graph should be exactly aligned NOTE If level of ground profile is below base of pump spacing triangle extend pump spacing triangle hypotenuse line until it crosses the ground profile d Mark point at which the hypotenuse long side of pump spacing triangle crosses ground profile This will be the first boost pumping station location 2 33 10 4320 303 13 beoe LH ER GN ET RR GER E ES ED EHE ER 2 a 1 PUMPING STATION NO 5 veo Es 180 EEL TT ET T Pt tel yet 1499 tobe LL PUMPING STATION NO 4 ALT
81. on truck A forklift or crane with lifting sling 2 is used for loading Remove flaking boxes 1 from crate and proceed as follows 2 64 10 4320 303 13 a Make sure each flaking box 1 is properly aligned and nested in top angle 3 of flaking box 1 below WARNING Make sure crane or forklift has minimum lifting capacity of 6 000 pounds DO NOT stand under load being lifted as death or serious injury may result NOTE If using lifting sling 2 attach hooks to lifting clevises 4 on bottom flaking box S Ensure open ends of hooks face outward Ensure tailgate assemblies of flaking boxes face rear of truck b Using crane or forklift with 6 000 pound lifting capacity lift and stack flaking boxes on truck bed DO NOT load or stack more than four flaking boxes on one truck at a time Position flaking boxes on truck bed with tailgate assemblies facing to rear c If truck does not have side walls use lifting devises 4 as attachment points and securely tie boxes to truck Figure 2 31 Tailgate Assembly Removal d Remove two screwE Figure 2 31 1 on rear of bottom flaking box 2 that secure tie bar 3 to flaking box 2 e Lift and remove tie bar 3 from flaking box 2 f Lift and remove tailgate assembly 4 0 Install tie bar 3 on flaking box 2 2 65 10 4320 303 13 2 3 8 Assembly of 10 Mile Hoseline Segment Continued h Install two screws 1 Tighten screws 1 until tie bar
82. pipe quick disconnect coupling clamp 6 para 2 3 3 2 2 3 6 Assembly of Storage Assemblies Assembly of a storage assembly requires the tools personnel and components listed below Remove the required components from the STORAGE ASSEMBLY crate Perform inspections of each part for damage and operability Refer to applicable technical manual for the assembly installation and preparation of use for the 20 000 gallon pillow tank 2 3 6 1 Assembly Requirements Tools Used To Rubber Mallet and Clamping Tool Items Install 6 inch and 4 inch grooved end 157 and 3 pipe quick disconnect coupling clamps Pipe wrench 2 7 8 inch minimum and 4 Install components with threaded inch maximum fittings Notify unit maintenance to install components with threaded fittings Personnel Two required 2 47 10 4320 303 13 Components Table 2 11 Components Required from Storage Assembly Crate for Assembly of Storage Assembly 0 375 16 UNC 2A Bolt X 3 25 inches 4 inch Coupling half female quick disconnect 4 inch Coupling half male quick disconnect 4 inch Coupling pipe fitting NOTE Required number of discharge hose assemblies depends on distance between hoseline segment and storage assembly Any unused hose assemblies can be used as spares 4 inch x 10 foot Discharge hose assembly quick disconnect 4 inch Male flanged coupling half 0 046 ID x 0 812 Flat washer OD 4 inch Class 150 Gasket 4 inch Gate valve flanged 4
83. points for dispensing to personnel Refer to applicable technical manual for a functional description of the 20 000 gallon storage assembly 1 19 3 10 Mile Hoseline Segment The 10 mile hoseline segment consists of 6 inch x 500 foot collapsible hose assemblies The 10 mile hoseline segment transfers water to the major components of the TWDS This segment is used to connect pumping stations and storage assemblies A swivel joint is installed every 1 000 feet to prevent damage and kinking of the hoseline segment during hoseline packing or pressure surges during operation of the TWDS The 500 foot hose sections are stored in flaking boxes The flaking boxes can be stacked four high and can be loaded or unloaded by either a forklift or lifting sling and crane A skid mounted pressure reducing valve assembly is installed where hoseline pressure is expected to exceed 225 psi usually if there is an elevation drop of 75 feet or greater between pumping stations A pressure relief valve is installed just before the pressure reducing valve assembly to reduce water pressure when water pressure exceeds 200 psi Suspension devices are used to route the 10 mile hoseline segment over obstacles in terrain A road crossing guard is used to protect hose segments from damage when the hose segments are buried under a road bed An end cap can be installed if dead end service is required or the hoseline can be coupled with an additional TWDS or distribution and storage unit
84. pumped into water per stroke Micrometer barrel is marked 0 to 10 Stroke adjustment thimble is marked 0 to 20 6 COLOR COMPARATOR Used to determine amount of chlorine solution present in water SECTION Il OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS 2 2 GENERAL Figure 2 7 routing diagram and able 2 7 PMCS table have been provided so you can keep your TWDS equipment including hypochlorination unit 1955 1 in good operating condition and ready for its primary mission Refer to the applicable technical manuals for specific component PMCS 125 GPM Pumping Assembly 20 000 Gallon Pillow Tank Hypochlorination Unit Model A 506131 Hypochlorination Unit Model 1955 3 600 GPM Pumping Assemblies 2 2 4 Warnings Cautions Always observe the WARNINGS and CAUTIONS appearing in your PMCS table WARNINGS and CAUTIONS appear before applicable procedures You must observe these WARNINGS and CAUTIONS to prevent serious injury to yourself and others or prevent your equipment from being damaged 2 2 2 Explanation of Table Entries 2 2 2 1 Item No Column Numbers in this column are for reference When completing DA Form 2404 Equipment Inspection and Maintenance Worksheet include the item number for the check service indicating a fault Item numbers also appear in the order that you must do checks and services for the intervals listed 2 2 2 2 Interval Column This column tells you when you must do
85. storage or distribution units or can be chlorinated and dispensed to personnel through two distribution points A functional description of each functional unit comprising the TWDS is provided in the following paragraphs 1 19 1 Pumping Stations There are two different types of pumping stations required for the TWDS Each pumping station consists of a trailer mounted pumping assembly a check valve three 6 inch butterfly valves various 6 inch hose assemblies as detailed below The pump assembly is powered by a 6 cylinder diesel engine Pump operation is controlled through a control panel mounted on the pump assembly Refer to applicable technical manual for a complete functional description of the 600 GPM pumping assembly A functional description of each type of pumping station is provided below 10 4320 303 13 1 19 1 1 Lead Pumping Station Draws water from desalination units wells or large storage and distribution units Y Connection Reducer and 6 inch by 10 foot rigid walled hose assembly connect the lead pumping station to the water source The lead pumping station pumps water down line to first boost pump station A hose assembly connects the lead pumping station to the 10 mile hose segment Manual operation of 6 inch butterfly valves on the hose assemblies controls water flow into and away from lead pump check valve is installed on the discharge elbow of the pumping assembly to restrict reverse water flow Refer to applicable tech
86. the procedure in the procedure column BEFORE procedures must be done before you operate or use the equipment for its intended mission DURING procedures must be done during the time you are operating or using the equipment for its intended mission AFTER procedures must be done immediately after you have operated the equipment 2 2 2 3 Location and Item to Check Service Column This column provides the location and the item to be checked or serviced The item location is underlined 2 8 10 4320 303 13 2 2 2 4 Procedure Column This column gives the procedure you must do to check or service the item listed in the Check Service column to know if the equipment is ready or available for its intended mission or for operation You must do the procedure at the time stated in the interval column 2 2 2 5 Not Fully Mission Capable if Column Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission If you make check and service procedures that show faults listed in this column do not operate the equipment Follow standard operating procedures for maintaining the equipment or reporting equipment failure 2 2 3 Other Table Entries Be sure to observe all special information and notes that appear in your table 2 2 4 Special Instructions Preventive maintenance is not limited to performing only those checks and services listed in the PMCS Table Covering unused receptacles s
87. vr eed Vos EUR Degrees Fahrenheit oM ENS Centimeters a ee a AaS Corrosion Prevention Control p ERE Department of the Army oet eere e N Equipment Improvement Recommendation anni nan de peto muove Gee hin ee Ee Gallons Per Minute pom ERE Horsepower Nm EE Jet Petroleum Kop EE Kilograms dg EE KiloPascal KW osse eere ehe veau epe eo era ev eR e e e uu ee tee Kilowatts FTH ce ces deem ene e eve ce veh dep eet er e e vete ce ces dumm t eee e e nani ee ee e due a Millimeters DAUM Em Pamphlet ele EE Parts per Million ecl Pounds per Square Inch Gauge SE ie sedit ped verde te ee D reae Sh heed ee Ted E Standard Form SPM Bae crate aee eate votre ed ee ee nae nee Ve vo vo Mode Rn vd avail ee Se Strokes per Minute TAMMS Whalen e ve The Army Maintenance Management System The Army Maintenance Management System Aviation ep E total dynamic head Mc Technical Manual TMWDS Tactical Water Distribution Equipment System Set 10 Mile Segment SECTION Il DEFINITION OF UNUSUAL TERMS UNUSUAL TERMS This section provides definitions for terms used in this manual which are not defined in the United States Army Dictionary AR 310 25 The term appears on the left of the hyphen The definition
88. when attached to hose end 2 1 5 1 125 GPM Pumping Assembly Reference applicable technical manual for a description of the operator s controls and indicators for the 125 GPM pumping assembly 2 1 5 2 Hypochlorination Unit 56 figure 2 6 anl table 2 6 for a description of the operator s controls and indicators for the hypochlorination unit model 1955 1 Reference applicable technical manuals for a description of the operator s controls and indicators for the hypochlorination units model 1955 3 and model A 506131 2 6 10 4320 303 13 Figure 2 6 Operator s Controls and Indicators for Hypochlorination Unit Model 1955 1 2 7 10 4320 303 13 Table 2 6 Description of Operator s Controls and Indicators for Hypochlorination Unit Model 1955 1 Item Description and Purpose No 1 WATER METER REGISTER Used to display amount of water flowing through hypochlorinator unit up to 999 999 gallons 2 WATER RESERVOIR FILL GLOBE Used to fill plastic reservoir with water Open to fill reservoir VALVE 3 RANGE ADJUSTING GLOBE VALVE Used to control water flow through hypochlorination unit Open to route water through hypochlorination unit Close to eliminate water flow through hypochlorination unit 4 WATER PRESSURE GAUGE Displays operating pressure of hypochlorination unit Range is 0 to 100 psi 5 STROKE ADJUST KNOB Used to set stroke length of impulse diaphragm Stroke length determines the quantity of chlorine solution
89. within the hose is forced through the hose As the ball passes through the hose it displaces the water The ball is captured by a receiver after exiting the hose The hose end is then plugged and a vacuum is applied until the air within the hose is evacuated and the hose collapses As the hose collapses end caps are installed to prevent the hose from expanding before it is packed 1 19 5 3 Hoseline Repair Kit This kit includes enough adapters and couplings to make up to three hose repairs on the 6 inch hose assemblies Two hose clamps are provided to isolate hose sections while repairs are being performed 1 17 1 18 Blank 10 4320 303 13 CHAPTER 2 OPERATING INSTRUCTIONS Subject Index Page SECTION I DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS iss t vana eese 2 2 Operator s Controls and irre eee eue 2 2 SECTION Il OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS 5 40 es Ua n aee vae rure 2 8 General ect ete reete tete 2 8 SECTION OPERATION UNDER USUAL CONDITIONS 2 16 Assembly and Preparation for 0 Initial Adjustments Checks and Self Test Operating Procedures ecrire nio eh nh CR n Decals and Instruction Operation of Auxiliary Equipment Preparation for Mo
90. 0 01 138 8986 5310 00 004 5034 1 ILLUS NUMBER 27 28 29 30 TM 10 4320 303 13 SECTION II COMPONENTS OF END ITEM 4 5 STOCK DESCRIPTION Usable 98 NUMBER CAGEC and Part Number On Code Rad 5310 00 763 8920 4730 01 180 4057 5430 01 106 9678 NUT PLAIN HEXAGON 0 375 16 UNC 2B 96906 MS51967 20 PIPE FITTING COUPLING 4 INCH EA 2 81349 M10388 A07AI1A6A TEE PIPE 6 X 6 X 4 INCH EA 2 81349 M10388 A 30 EB 1 A 6C TANK STORAGE 20 000 GALLONS EA 2 81349 M53029 20 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable ES NUMBER NUMBER CAGEC and Part Number On Code Rad 31 4820 01 159 0439 VALVE GATE 4 INCH FLANGED 8171 8 OPW 676 FRAW DISTRIBUTION POINTS 32 4610 01 117 8271 BAG DRINKING WATER STORAGE 36 GALLONS EA 4 81349 MIL B 273 33 4730 00 088 9285 COUPLING HALF QUICK DISCONNECT EA 6 96906 527026 11 34 4730 00 938 7997 COUPLING HALF QUICK DISCONNECT EA 6 96906 MS27022 11 10 4320 303 13 SECTION Il COMPONENTS END ITEM P 1 4 5 ILLUS STOCK DESCRIPTION Usable NUMBER NUMBER CAGEC and Part Number On Code Rad 35 4720 01 163 3088 HOSE ASSEMBLY 2 INCH X 10 FEET 97403 13225E91 36 1 36 4720 01 138 8986 HOSE ASSEMBLY 2 INCH X 20 FEET EA 14 97403 13225E91 36 2 37 4720 01 163 4684 HOSE ASSEMBLY 2 INCH X 20 FEET EA
91. 0 01 279 7772 HOSE ASSEMBLY 6 INCH X 10 FEET EA 6 97403 13225E9088 7 5 4720 01 346 7216 HOSE ASSEMBLY 6 INCH X 20 FEET EA 6 97403 13225E9088 5 6 4720 01 276 5952 HOSE ASSEMBLY 6 INCH X 75 FEET EA 6 97403 13225E9088 6 7 4730 01 182 3449 PIPE FITTING LATERAL GROOVED 450 6 EA 12 INCH 81349 M10388 A18AK1C See note 1 at end of Components of End Item table 10 4320 303 13 SECTION II COMPONENTS OF END ITEM 720 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 6 8 4320 01 184 7494 PUMPING ASSEMBLY WATER 600 GPM UNIT 609 A 97403 13225E9088 3 DTC DTQ 9 4320 01 201 6937 PUMPING ASSEMBLY WATER 600 GPM UNIT EA 6 609 C 97403 46121 209 EAM 10 4320 01 261 6470 PUMPING ASSEMBLY WATER 600 GPM UNIT EA 6 US636HCCD 1 97403 PD80366 DTR C 3 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 6 11 4820 01 201 7138 VALVE ASSEMBLY PRESSURE RELIEF 6 INCH 97403 13225E9196 12 4820 01 186 0744 VALVE BUTTERFLY 6 INCH GEAR ACTUATED EA 18 79154 700E6IN 13 4820 01 186 0738 VALVE CHECK EDPM 6 INCH EA 6 79154 V 060 710 P E3 STORAGE ASSEMBLIES 14 5305 00 724 7236 BOLT 0 375 16 UNC 2A X 3 25 INCHES EA 32 80204 B1821BH063C325N 15 4730 01 177 51
92. 00 GPM pumping assemblies 4 19 3 20 000 Gallon Pillow Tank Preservation Refer to applicable technical manual for preservation procedures for the 20 000 gallon pillow tank 4 19 4 125 GPM Pumping Assembly Preservation Refer to applicable technical manual for preservation procedures for the 125 GPM pumping assembly 4 19 5 Hypochlorination Unit Model 1955 1 Preservation a Clean and rinse reservoir with water b Rinse dirt from exterior of hypochlorination unit model 1955 1 c Refer fo paragraph 4 13 2 and remove outlet inlet pressure regulating fill and drain hose assemblies NOTE Tilt hypochlorination unit model 1955 1 to aid in drainage d Allow hypochlorination unit model 1955 1 and hose assemblies removed in step c to drain for several hours WARNING To prevent eye injury wear safety glasses when using compressed air e Using compressed air thoroughly dry model 1955 1 hypochlorination unit and hose assemblies removed in step c 4 19 6 Hypochlorination Unit Model 1955 3 Preservation Refer to applicable technical manual for preservation procedures for the model 1955 3 hypochlorination unit 4 19 7 Hypochlorination Unit Model A 506131 Preservation Refer to applicable technical manual for preservation procedures for the model A 506131 hypochlorination unit 4 20 PACKING Packing procedures for the TWDS are contained in paragraphs 4 22 1 through 4 22 6 4 20 4 TWDS Components Packing Refer for packing proce
93. 03 13 2 3 8 Assembly of 10 Mile Hoseline Segment Continued Figure 2 36 Swivel Joint Connection 1 Retain empty flaking boxes tailgates and breakaways for reuse 2 3 8 6 Installation of Road Crossing Guard a Dig trench 1 18 inches deep across road b Engineering support is required if hoseline 2 is being run beneath a railroad bed c Lay hoseline 2 in trench 1 d Position roadway crossing guards 3 over hoseline 2 at appropriate intervals Nail guards 3 to planks 4 if planks 4 are used Figure 2 37 Road Crossing Guard Installation 2 70 10 4320 303 13 e Backfill trench 1 using dirt removed from step a Fill trench 1 to a level 1 to 2 inches above original roadbed before packing earth down Ensure dirt is securely packed around sides of railroad crossing guard 2 3 8 7 Assembly and Installation of Suspension Devices Figure 2 38 Tripods and Wire Rope Installation a Using available materials construct a tripod Figure 2 38 1 on either side of stream 2 gap or other obstruction to be spanned Tripods 1 should be strong enough and high enough to support hoseline Use manila rope to cross gully NOTE Depending on the type of suspension kit issued with the equipment anchor stakes will either be angled or round b Using driving head 6 drive an anchor stake 3 into ground at a 30 degree angle approximately 15 feet from each tower Anchor stakes 3 should be in lin
94. 2 97403 13225E9135 2 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 2 3 4 5 NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER CAGEC and Part Number On Code Rad EA 2 38 4610 00 937 6862 HYPOCHLORINATION UNIT 1955 1 09680 MIL H 12732 DTC DTR 39 HYPOCHLORINATION UNIT A 506131 EA 2 79172 A 506131 DTQ 40 4610 01 250 3724 HYPOCHLORINATION UNIT 1955 3 EA B 31922 1955 3 EAM C 10 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 2 41 6630 01 044 0334 KIT COMPARATOR COLOR 12308 U25337 42 6630 01 336 9215 COLOR COMPARATOR EA 2 97403 13200E7400 43 CONTAINER KIT EA 2 97403 13216E9016 44 DISC CHLORINE EA 2 45 DISC pH EA 2 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable ay NUMBER NUMBER CAGEC and Part Number On Code Rqd 46 INSTRUCTIONS 2 47 SAMPLE CELLS EA 4 48 SOLUTION pH 4 OUNCE 02 2 49 STIRRING ROD EA 2 50 TABLETS DPD BX 2 C 12 10 4320 303 13 SECTION II COMPONENTS OF END ITEM 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 4 51 2910 01 188 8198 NOZZLE 1 14 INCH 81718 190 GW 52 4730 00 915 5127 PLUG DUST QUICK DISC
95. 27183 18 93 5310 01 338 7322 NUT PLAIN HEXAGON EA 4 96906 MS51967 14 94 KIT CHEST METAL EA 1 C 21 1 ILLUS NUMBER 95 96 97 TM 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 4 5 STOCK DESCRIPTION Usable ui NUMBER CAGEC and Part Number On Code Rad 4610 01 355 8567 5340 01 359 5640 PULLBOARD ASSEMBLY 97403 13226E1572 HOSE RETAINING BRACKET LEFT HAND EA 2 97403 13225E9186 HOSE RETAINING BRACKET RIGHT HAND EA 2 97403 13225E9187 C 22 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad 98 DISPLACEMENT AND EVACUATION KIT 99 BALL DISPLACEMENT HOSELINE EA 4 97403 13228E9872 100 4730 01 176 5772 COUPLING CLAMP PIPE 6 INCH EA 81349 M10387 1 D 11 101 4730 01 270 6555 COUPLING CLAMP 6 INCH EA 79154 6 791 102 5120 01 270 7428 WRENCH SPANNER EA 79154 792 See note 6 at end of Components of End Item table C 23 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED o 69 4 5 ids NATIONAL STOCK DESCRIPTION Ll E NUMBER NUMBER CAGEC and Part Number On Code Rad 4 103 4730 00 844 9014 COUPLING HALF QUICK DISCONNECT PNEUMATIC 81348 WW C 633 10 B 104 COUPLER SNAPJOINT PIPE 8 INCH EA 2 97403 13226E1575 10 105 4320 01 212 9621 EJECTOR ASSEMBLY EA
96. 3 5 6 3 Water Meter Maintenance Continued Figure 5 5 Water Meter Maintenance 5 6 3 4 Installation a Install bottom disc chamber 18 and rubber disc 16 in bottom casing 7 5 18 10 4320 303 13 b Install diaphragm 17 in rubber disc 16 c Install top disc chamber 15 on rubber disc 16 d Install drive shaft 14 in top disc chamber 15 e Install rubber roller 13 on drive shaft 14 f Install gear plate 11 on drive shaft 14 and insert two screws 12 Tighten screws 12 g Install intermediate pinion 10 first intermediate gear 9 and top gear 8 on gear plate 11 h Place new gasket 6 and top casing 3 on bottom casing 7 i Install six bolts 5 and nuts 4 Tighten nuts 4 j Install meter mounting cup 2 on top casing 3 k Install two screws 1 Tighten screws 1 5 19 10 4320 303 13 5 6 4 Pressure Regulating Valve Repair This task covers 5 6 4 1 Disassembly 5 6 4 3 Assembly 5 6 4 2 Inspection INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s 125 GPM pumping assembly shutdown refer to Automotive Section Ill Item 1 applicable technical manual Pressure Regulating removed paragraph Materials Parts 4 13 7 Gasket TM 10 4320 303 23P General Safety Instructions Do not work on equipment without following standard shop safety precautions 5 6 4 1 Disassembly Figure 5 6 Pressure Regulating Valve Mainte
97. 3 EA 12 13225E9135 6 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 1 79 PIPE FITTING COUPLING 6 IN 81349 M10388 A07AKIA6A 80 REDUCER Y CONNECTION EA 1 6X4X4 IN 97403 13225E9190 81 3940 01 199 4010 SLING MULTIPLE EA 1 97403 13226E1582 82 SWIVEL JOINT ASSY 6 INCH EA 65 97403 13225E9195 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 1 83 4820 01 264 6203 VALVE ASSEMBLY PRESSURE REDUCING 97403 13225E9090 13 84 4820 01 201 7138 VALVE ASSEMBLY PRESSURE RELIEF EA 1 97403 13225E9196 85 WRENCH SOCKET 1 INCH EA 2 81348 GGG W 641 TYPE Il CLASS 2 86 WRENCH SOCKET 1 1 16 INCH EA 2 81348 GGG W 641 TYPE I CLASS 2 87 LUBRICANT GASKET ONE QUART CAN EA 2 97403 13225E9192 88 8030 00 889 3535 TAPE ANTISEIZE PTFE EA AR 80244 P5025 2R C 20 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad 89 PACKING KIT HOSELINE 6 IN 90 CHAIN HOIST EA 1 81349 MIL H 904 91 5306 00 141 7179 BOLT EYE EA 2 96906 MS27950 8 92 5310 00 809 5998 WASHER FLAT EA 4 96906 MS
98. 3 attached to 2 inch gate valve 14 2 112 10 4320 303 13 x Push cam arms on female quick disconnect coupling half 15 forward to open Remove 2 inch gate valve 14 with attached male quick disconnect coupling half 13 and female quick disconnect coupling half 15 from end of Y connection 16 y Remove male quick disconnect 13 and female quick disconnect 15 coupling halves from ends of 2 inch gate valve 14 z Push both sets of cam arms on elbow valves 16 forward to open Remove two dust plugs 17 from ends of elbow valves 16 aa Remove elbow valves 16 from ends of two hose assemblies 18 ab Repeat steps u through y to disconnect hose assemblies 18 Y connection 19 hose assembly 20 2 inch gate valve 21 male quick disconnect 22 and female quick disconnect 23 coupling halves ac Push cam arms on Y connection 16 forward to open Remove Y connection 16 from end of hose assembly 1 ad Refer to applicable technical manual and shut down 125 GPM pumping assembly 4 3 1 2 10 1i 12 13 14 D Figure 2 79 Removal of 125 GPM Pumping Assembly and Hypochlorination Unit NOTE If disconnecting hypochlorination unit model 1955 1 or model A 506131 perform steps ae and af If disconnecting hypochlorination unit model 1955 3 perform steps ag through aj ae Push cam arms on inlet port female quick disconnect coupling half Figure 2 79 1 forward to open Remove hose assembly 2 from fema
99. 3 13 APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST SECTION INTRODUCTION E 1 SCOPE This appendix lists expendable and durable items that you will need to maintain the TWDS This listing is for informational purposes only and is not authority to requisition the listed items These items are authorized to you by CTA 50 790 expendable items except medical class V repair parts and Heraldic Items E 2 EXPLANATION OF COLUMNS E 2 1 Column 1 Item Number This number is assigned to the entry in the listing referencing when required E 2 2 Column 2 Level This column identifies the lowest level of maintenance that requires the listed item Operator Crew Unit Maintenance Direct Support Maintenance General Support Maintenance E 2 3 Column 3 National Stock Number This is the national stock number assigned the item use it to request or requisition the item E 2 4 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 Commercial and Government Entity Code CAGEC parentheses followed by the part number E 2 5 Column 5 Unit of Measure UM Unit of Issue Ul This measure is expressed by a two character alphabetical abbreviation eg EA IN PR If the unit of measure differs from the unit of issue as shown in the Army Master Data File AMDF requisition the lowest unit of issue that will satisfy your require
100. 320 303 13 4 13 9 Stand Assembly Maintenance Continued d Remove two straight pins 4 from two devises 5 e Separate two clevis legs 6 and 7 from pivot leg 8 4 13 9 2 Inspection a Inspect two clevis legs 6 and 7 and pivot leg 8 for missing or damaged devises 5 pivot 9 hooks 10 clips 11 and plugs 12 or separated or cracked welds b Inspect three S hooks 1 for corrosion cracks or nicks c Inspect three chains 2 for damaged or missing links 4 13 9 3 Repair a Refer td Appendix F and manufacture new chain b Replace damaged or missing components 4 13 9 4 Assembly Align two clevis legs 6 and 7 in pivot 9 Install two straight pins 4 through two devises 5 a b c Install two new cotter pins 3 in two straight pins 4 Bend tines of cotter pins 3 d Install three chains 2 in three S hooks 1 e Install three S hooks 1 on pivot leg 8 and two clevis legs 6 and 7 4 56 10 4320 303 13 4 13 10 Color Comparator Maintenance This task covers 4 13 10 1 Disassembly 4 13 10 3 Repair 4 13 10 2 Inspection 4 13 10 4 Assembly INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equipment without following Automotive Section Ill Item 1 standard shop safety precautions Equipment Conditions Color Comparator removed from color comparator kit 4 13 10 1 Disassembly Figure 4 23 Color Comparator Maintenance
101. 4 3 Distribution Point Crate Color comparator Check kit for damaged or missing i contents Check shelf life of chemicals Ensure lock securely fastens lid on kit 2 inch Coupling half Check for stripped or worn threads female Ensure cam arms move freely Check for damaged or missing gasket 2 S ERAI aea 1 half Check for stripped or worn threads Check for damage to sealing surface 2 inch x 10 Discharge hose Inspect hose for punctures cuts or foot assembly scrapes Ensure cam arms move freely Check for damaged or missing gasket ME inch x 20 Discharge hose Inspect hose for punctures cuts or assembly scrapes Ensure cam arms move freely Check for damaged or missing gasket 36 gallon Drinking water Inspect bag for punctures tears and storage bag worn areas Check for broken or missing faucets Ensure faucets operate smoothly 2 inch Dust plug quick Ensure dust plug is not cracked or disconnect damaged 4 5 10 4320 303 13 4 4 3 Checking Unpacked Equipment Continued Table 4 3 Distribution Point Crate Continued Oty MNT NNNM inspection 2 inch x 2 Elbow valve Make sure cam arms move freely Check inch for damaged or missing gasket Make sure handwheel is firmly secured to valve stem and operates smoothly 5 Gate valve Check for stripped or worn threads Ensure handwheel is firmly secured to valve stem and operates smoothly BM gpm Hypochlorination M
102. 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 Temperature Exact 5 9 after subtracting 32 Celsius temperature 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 Multiply by 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 PIN 071497 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and s
103. 6 2 Disassembly Procedures WARNING DANGEROUS CHEMICALS e Calcium hypochlorite can cause injury if not handled properly Heed safety measures below e f calcium hypochlorite comes into contact with skin or eyes flush right away with water Seek medical help Mix only in accordance with directions for use DO NOT allow calcium hypochlorite to mix with any other materials This cause fire or hazardous gases a Locate packing crate marked DISTRIBUTION POINT Remove tubes of calcium hypochlorite Item 2 Appendix E b Dissolve one tube in each gallon of potable water used to make a cleaning solution Scrub inside of each 36 gallon drinking water storage bag Figure 2 75 1 with solution prepared in step b d Rinse each drinking water storage bag 1 several times with potable water to get rid of all traces of cleaning solution prepared in step b Do not use cleaning solution to rinse drinking water storage bags 2 109 10 4320 303 13 2 8 6 Preparation for Movement of Distribution Points Continued Figure 2 75 Cleaning of 36 Gallon Drinking Water Storage Bag e Dry drinking water storage bags 1 completely and set aside Figure 2 76 Disassembly of Model 1 955 1 Hypochlorination Unit NOTE Perform step f if model 1955 1 hypochlorination unit was used with distribution point f Following steps below clean plastic reservoir on 1955 1 hypochlorination unit 1 Remove reserv
104. 66 COUPLING CLAMP PIPE 4 INCH EA i 81349 M10387 1 D 09 See note 2 at end of Components of End Item table 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 16 4730 01 270 6554 COUPLING CLAMP 4 INCH 79154 4 791 A 17 5120 01 270 7428 WRENCH SPANNER EA 79154 792 18 4730 01 176 5772 COUPLING CLAMP PIPE 6 INCH EA 81349 M10387 1 D 11 19 4730 01 270 6555 COUPLING CLAMP 6 INCH BA 79154 6 791 20 4730 00 840 0796 COUPLING HALF QUICK DISCONNECT MALE 4 EA 2 INCH 96906 MS27020 17 21 4730 00 088 9286 COUPLING HALF QUICK DISCONNECT FLANGED EA 2 FEMALE 4 INCH 96906 MS27027 17 See note 2 at end of Components of End Item table See note 3 at end of Components of End Item table 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 4 5 ILLUS MORAL STOCK DESCRIPTION Usable E NUMBER NUMBER CAGEC and Part Number On Code Rad COUPLING HALF QUICK DISCONNECT 4 INCH MALE 96906 MS27023 17 FLAT WASHER 0 046 ID X 0 812 OD 96906 MS27183 21 GASKET CLASS 150 4 INCH NOMINAL 97403 13220E1069 1 HOSE ASSEMBLY 4 INCH X 10 FEET 97403 13225E9136 3 WASHER LOCK 0 375 INCH 26916 004 003005 059 4730 00 840 5347 5310 00 823 8803 5330 01 141 1864 472
105. 9 pipe tee 14 and pipe nipples 16 and 18 for corrosion cracks and damage Inspect isolation cock valves 5 10 and 17 for corrosion cracks smooth operation of handle and damage Inspect pressure reducing control 15 for cracks holes missing components and damage Return damaged or defective pressure reducing control 15 to direct support maintenance Replace all damaged or defective components 4 30 10 4320 303 13 4 11 5 3 Assembly NOTE e Wrap all male threaded surfaces with antiseize tape prior to installation in the following procedures Wrap antiseize tape in direction of threads a Install reducer Figure 4 11 20 on main valve assembly 2 b Install elbow 19 on reducer 20 c Install pipe nipple 18 in elbow 19 d Install isolation cock valve 17 on pipe nipple 18 e Install pipe nipple 16 on isolation cock valve 17 CAUTION Make sure pressure reducing control is installed with arrow pointing in direction of water flow Failure to do so may result in damage to the equipment f Install pressure reducing control 15 on pipe nipple 16 g Install pipe tee 14 on pressure reducing control assembly 15 h Install reducer 12 and elbow 13 on pipe tee 14 i Install reducer 11 in cover of main valve assembly 2 j Install isolation cock valve 10 on reducer 11 k Install elbow 9 on isolation cock valve 10 Install tubing 8 on elbows 9 and 13 m Ins
106. ATERIEL TO PREVENT ENEMY USE Destruction of Army materiel to prevent enemy use shall be in accordance with TM 750 244 3 1 4 PREPARATION FOR STORAGE OR SHIPMENT Reference paragraph 4 19 through 4 23 for instruction for the preparation for storage or shipment of the TWDS 1 5 QUALITY ASSURANCE Q4 There are no QA procedures applicable to the equipment covered in this technical manual 1 6 NOMENCLATURE CROSS REFERENCE Shortened nomenclature is used in this manual to make procedures easier for you to read A cross reference between the shortened nomenclature and the official nomenclature is shown Table 1 1 10 4320 303 13 Table 1 1 Nomenclature Cross Reference List Official Nomenclature Pump Centrifugal Frame MTD 2 Inch 125 GPM 50 Foot Head Pumping Assembly Water 600 GPM Model 609 A Model 609 C and Model US636HCCD 1 20 000 Gallon Collapsible Fabric Tank Water Purification Hypochlorination Unit Frame Mounted Automatically Controlled 100 GPM Model 1955 1 Water Purification Hypochlorination Unit Frame Mounted Automatically Controlled 350 GPM Model 1955 3 Hypochlorination Unit Water Purification Frame Mounted Water Driven 100 GPM Bag Water Sterilizin Common Nomenclature 125 GPM Pumping Assembly 600 GPM Pumping Assembly Assemblies 20 000 Gallon Pillow Tank Hypochlorination Unit Model 1955 1 Hypochlorination Unit Model 1955 3 Hypochlorination Unit Model A 506131 Water Storage
107. BUTION POINT HYPOCHLORINATION UNIT MODEL 1955 1 CONT Solution Reservoir Valves 10 MILE HOSELINE SEGMENT FLAKING BOX Flaking Box Inspect for damage and leaks Check solution level Add solution as required para 2 5 5 3 If damaged or Class Ill leak is present notify supervisor Inspect valves for damage leaks and improper operation If valve is damaged operating improperly notify unit maintenance If Class Ill leak is present notify supervisor Inspect all frame seam welds for damage Inspect lifting devises and clevis attach brackets for cracks bends or broken seam welds Inspect tailgate assembly side walls and base for damage 2 29 Reservoir is damaged Not enough solution in reservoir Class 1 leak Valve s is damaged or operating improperly Class Ill leak Seam weld is damaged Lifting clevis or clevis attach bracket is damaged Tailgate assembly is damaged 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Not Fully Item Item to Mission Capable No Interval Check Service Procedure if DISTRIBUTION POINT HYPOCHLORINATION UNIT MODEL 1955 1 Foot Valve Flush hypochlorination unit with clean water Refer to paragraph 2 8 6 2 and flush hypochlorination unit SECTION Ill OPERATION UNDER USUAL CONDITIONS 2 3 ASSEMBLY AND PREPARATION FOR USE 2 3 1 TWDS Site Location and Pumping Statio
108. DS operation and or disassembly 2 8 2 2 Disconnecting and Evacuating Hoseline NOTE Begin evacuating hoseline at lead pumping station and proceed downline a Remove grooved end pipe quick disconnect coupling clamp Figure 2 55 1 2 3 3 1 connecting end of hoseline segment 2 to next downline hose segment 3 or swivel joint 2 90 10 4320 303 13 Figure 2 55 Ball Receiver Installation Separate two hoseline segments 2 and 3 or hoseline segment and swivel joint Locate ball receiver 4 consisting of two 8 X 6 inch reducers 5 and 6 One reducer 6 has been modified to prevent displacement ball from being ejected from ball receiver 4 Connect 6 inch end of unmodified reducer 5 to downline end of first hoseline segment 2 using grooved end pipe quick disconnect coupling clamp 1 para 2 3 3 2 Locate 8 inch snaplock coupling 7 Open coupling Fit snaplock coupling halves 7 over joined ends of reducers 5 and 6 Close coupling halves 7 over reducer 5 and 6 ends Lock snap lock coupling halves 7 Connect nipple Figure 2 58 1 to upline end of first hoseline segment 2 using grooved end pipe 23 32 quick disconnect coupling clamp 3 para 2 3 3 2 Place displacement ball 4 inside nipple 1 i Locate pneumatic coupler 5 and modified end cap 6 with tapped hole Attach pneumatic coupler b to end cap 6 Connect end cap 6 with pneumatic coupl
109. End Cap Installation p Locate end cap Figure 2 5 1 Connect end cap 1 to end of hoseline segment 2 using grooved para 2 3 3 2 end pipe quick disconnect coupling clamp 3 para 2 3 3 2 q Disconnect air compressor lind Figure 2 56 9 with pneumatic coupler 8 from pneumatic coupler b on end cap 6 Figure 2 58 Collapsing Hoseline r Locate ejector assembly Figure 2 58 1 and two pneumatic couplers 2 Install pneumatic couplers 2 on threaded fittings on ejector assembly 1 s Install ejector assembly 1 on end cap 3 with pneumatic coupler 4 t Connect air compressor line 5 with pneumatic coupler 6 to ejector assembly 1 u Apply air pressure to ejector assembly 1 Operate compressor for 10 minutes to collapse hoseline 7 for repacking v Turn off air compressor and disconnect air compressor line b with pneumatic coupler 6 w Disconnect ejector assembly 1 and set aside 2 93 10 4320 303 13 2 8 2 Preparation for Movement of 10 Mile Hoseline Continued x Remove grooved end pipe quick disconnect coupling clamp 8 para 2 3 3 1 connecting end cap 3 with pneumatic coupler 4 to nipple 9 y Remove grooved end pipe quick disconnect coupling clamp 10 para 2 3 3 1 connecting nipple 9 to hoseline segment 7 NOTE End caps must be installed on collapsed hoseline to prevent hose from expanding before it is packed z Connect end cap Figure 2 57 1 to
110. Figure 2 26 Hypochlorination Unit az Store color comparator kit in metal box Figure 2 26 1 mounted on skid of hypochlorination unit 2 Figure 2 27 Tripod Stand Assembly ba Install two nozzle stand assemblies Figure 2 27 1 Spread three tripod legs 2 and secure legs with rocks or embed pointed ends in ground Locate nozzle stand assemblies 1 at convenient spots for hanging distribution point nozzles 3 and elbow valves 4 2 60 10 4320 303 13 Figure 2 28 Tripod and Water Storage Drinking Bag WARNING Tripods must be at least 6 feet tall and capable of supporting 400 pounds Personal or personnel injury may result if tripods are not built to correct height or cannot support 400 pounds bb Using locally available materials construct tripod supports Figure 2 28 1 on which to hang drinking water storage bag 2 Hang drinking water storage bag 2 on tripod 1 2 3 8 Assembly of 10 Mile Hoseline Segment 2 3 8 1 Requirements Assembly of 10 mile hoseline segment requires the tools personnel and components listed in paragraph 2 3 8 2 Remove the required components from the 10 MILE SEGMENT crate Perform inspection of each part for damage and operability 2 3 8 2 General Information This paragraph provides general instructions for assembly of the 10 mile hoseline segment NOTE Newer model flaking boxes contain two 500 foot hose assemblies If newer model flaking boxes are used there will be
111. Hoseline TWDS 10 Mile Segment Operator s Control and Indicators 2 1 2 Hoseline 10 Mile Segment Assembly of 2 3 8 Hoseline 10 Mile Segment Operator Maintenance of 3 4 Hypochlorination Unit Frame Assembly 5 6 5 Hypochlorination Unit Model 1955 1 5 6 Hypochlorination Unit Model 1955 1 Replacement And Repair 4 13 1 Hypochlorination Units Equipment Data 1 17 4 Hypochlorinator Assembly 2 4 13 6 Initial Adjustment Checks and ntt e ts 24 TM 10 4320 303 13 Continued Inlet Hose Assembly 4 13 2 Installation Instructions 4 5 Installation Removal and Grooved Pipe Coupling 2 3 2 Installation Removal and Grooved End Pipe Quick Disconnect Coupling Clamp 2 3 3 Instruction Plates Decals 2 6 Instructions Installation 4 5 Introduction to Unit PMCS Table eo ciate 4 8 K Kits TWDS Support and Supply Functional Description of 1 19 5 L Lead Pumping Station Assembly 2 3 4 Lead Pumping Station Operation Olsen Co i roe ts fe 2 5 2 Lead Pumping Station Operator s Controls and Indicat
112. ILLUS NATIONAL STOCK DESCRIPTION Usable E NUMBER NUMBER CAGEC and Part Number On Code Rad 66 SWIVEL HOSE 97403 18225E9139 3 10 MILE HOSELINE SEGMENT 67 4720 01 257 1423 BOX FLAKING 2 WAY EA 97403 13225 9182 1 68 ASSEMBLY FLAKING BOX EA i 97403 13227E9787 See note 4 at end of Components of End Item table 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad 69 4730 01 176 5772 COUPLING CLAMP PIPE 6 INCH EA 82349 M10387 1 D 11 70 4730 01 270 6555 COUPLING CLAMP 6 INCH EA 79154 6 791 A 71 5120 01 270 7428 WRENCH SPANNER EA 79154 792 72 4730 01 186 0817 COUPLING HALF QUICK DISCONNECT FEMALE EA 1 6 INCH 96906 MS27024 19 See note 5 at end of Components of End Item table C 17 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 4 5 STOCK DESCRIPTION Usable d NUMBER CAGEC and Part Number On Code 73 END CAP GROOVED PIPE 6 INCH E 81349 M10388 A05AK1A 74 3835 01 187 1556 GUARD ROAD CROSSING 6 INCH EA 24 97403 13226E1576 75 5120 00 249 1076 HANDLE SOCKET WRENCH EA 4 77053 9649 76 4720 01 346 7216 HOSE ASSEMBLY COLLAPSIBLE 6 INCH X 500 EA 128 FEET 97403 M53027 5000 77 NAILS STEEL ROOFING 1 INCH EA 240 96906 MS90714 8B 78 4720 01 163 4686 HOSE ASSEMBLY 6 INCH X 10 FEET 9740
113. INATION UNIT MODEL 1955 1 IS NOT INJECTING SOLUTION INTO WATER Step 1 a b Step 2 a b Step 3 a b Step 4 a Check to see if range adjusting valve is closed or damaged Open range adjusting valve Notify supervisor if range adjusting valve is damaged or has a Class Ill leak Check to see if solution reservoir is empty or leaking Refer to paragraph 2 5 5 4 and add hypochlorite solution Notify supervisor if solution reservoir is damaged or has a Cass Ill leak Check to see if foot valve is clogged or damaged Clear clog from clogged foot valve Notify supervisor if foot valve is damaged Check hypochlorite feeder Refer tq paragraph 2 5 5 4 steps g h i and prime hypochlorite feeder 3 NO DISCHARGE OF WATER AT MANUAL DISBURSING STATION Step 1 a Step 2 a b Check to see if 125 GPM pumping assembly is working Refer to applicable technical manual and troubleshoot 125 GPM pumping assembly Check to see if 2 inch gate valves are closed or leaking Open 2 inch gate valve Notify supervisor if 2 inch gate valve is damaged or has a Class III leak 3 3 10 4320 303 13 Table 3 1 Operator Troubleshooting Table Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 3 NO DISCHARGE OF WATER AT MANUAL DISBURSING STATION CONTINUED Step 3 a b Step 4 a Step 5 a Check 2 inch and 4 inch hoseline sections for loose connections or leaks
114. ING STATION CONT 12 Before Hose Assemblies Inspect for damage leaks Class Ill three and loose connections leaks Tighten loose connections If hose is damaged or Class Ill leaks are present notify supervisor 13 Before Check Valve Ensure check valve is Check valve is installed properly Arrow on not installed body casing must point in properly direction of water flow Connection is Inspect for leakage and loose loose Class connections Tighten loose Ill leaks connections 14 Before Pressure Relief Inspect valve for presence of Dirty pressure Valve grit sand or dirt If relief valve dirty clean using soft Pressure relief brush Inspect for damage or valve damaged leaks Class III leak If discharge port is obstructed STORAGE ASSEMBLY 15 Before 4 Inch Gate Valve Inspect for damage and 4 inch gate improper operation Check to valve is damaged be sure valve turns freely or does not turn Check for leaks freely Class Ill leak 16 Before 4 Inch x 10 Foot Inspect for damage leaks Hose is damaged Discharge Hose and loose connections Class Ill leak Tighten loose connections Connection is loose 2 19 10 4320 303 13 Table 2 7 pert etiem e Preventive Maintenance Checks and Services for TWDS Continued Location Item Interval Item to Check Service Procedure Not Fully No Mission Capable if DISTRIBUTION POINT 17 Before 2 Inch Gate Valve Inspect for damage
115. Inch x 500 Foot Collapsible Hose Assembly Replacement a Remove two 6 inch grooved pipe coupling Figure 4 6 1 from 6 inch x 500 foot collapsible hose assembly 2 b Remove 6 inch x 500 foot collapsible hose assembly 2 4 11 1 2 Installation a Align 6 inch x 500 foot collapsible hose assembly 2 with upline and downline 6 inch x 500 foot collapsible hose assemblies b Install two 6 inch grooved pipe couplings 1 to secure 6 inch x 500 foot collapsible hose assembly 2 with upline and downline 6 inch x 500 foot collapsible hose assemblies 4 21 4 11 2 Flaking Box Assembly Maintenance This task covers 4 11 2 1 Disassembly 4 11 2 2 Inspection and Cleaning INITIAL SETUP Tools Tool Kit General Mechanic s Automotive Section Item 1 Goggles Section Ill Item 2 Material Parts Cleaning Solvent Item 8 Gloves Item 4 Appendix Rags Item 7 Appendix E Cotter Pin TM 10 4320 303 23P 4 11 2 1 Disassembly TM 10 4320 303 13 4 11 2 3 Repair 4 11 2 4 Assembly Equipment Conditions Hose s removed Pumping station shutdown refer to applicable technical manual General Safety Instructions Do not work on equipment without following standard shop safety precautions Figure 4 7 Flaking Box Assembly Maintenance 4 22 10 4320 303 13 Remove two bolt Figure 4 1 and tie bar 2 from flaking box assembly 3 d b Remove and discard four cotter pins 4
116. LY from excess pressure Installed in hoseline where water pressure is expected to exceed 225 pounds per square inch psi and reduces pressure to 75 psi Figure 1 4 Location of Major Components for TWDS Boost Pumping Station Table 1 4 Description of Major Components for TWDS Boost Pumping Station Item Item Name Description and Purpose No 1 BOOST PUMPING 600 GPM pumping assembly Pumps water from lead STATION pumping station or boost pumping station and delivers it down line of three pumping assemblies may be supplied with the TWDS Refer to applicable technical manual for detailed information concerning the pumping assemblies 1 6 10 4320 30313 Table 1 4 Description of Major Components for TWDS Boost Pumping Station Continued Item Item Name Description and Purpose No 2 6 INCH BUTTERFLY Three are used for the boost pumping station layout Used to VALVE control water flow into boost pumping assembly around boost pumping assembly and from boost pumping assembly to hoseline 3 LATERAL PIPE FITTING Two are used for the boost pumping station layout Used to connect 6 inch x 500 foot collapsible hose assembly 6 inch x 10 foot 20 foot and 75 foot hose assemblies 4 HOSE ASSEMBLY 6 inch x 10 foot collapsible hose assembly Directs flow of water into suction port of boost pumping assembly 5 HOSE ASSEMBLY 6 inch x 20 foot collapsible hose assembly Directs water flow from pumping assembly to hosel
117. NOTE Steps x through ad are for the installation of hypochlorination units 1955 1 and A 506131 Refer to applicable technical manual for preparation for use of hypochlorination unit A 506131 Unscrew two dust caps 22 from inlet port 10 and outlet port 11 of unit 1955 1 13 Store dust caps 22 for later use 2 55 10 4320 303 13 2 3 7 Assembly of Distribution Points Continued Figure 2 24 Hypochlorination Unit Model 1955 1 and Model A 506131 Installation NOTE Wrap antiseize tape in direction of threads Wrap antiseize tape item 9 appendix E around threads on female quick disconnect coupling half 1 into i Figure 2 23 10 on y Figure 2 24 1 Screw female quick disconnect coupling half 1 into inlet port i it Figure 2 24 2 hypochlorination unit z Push cam arms on female quick disconnect coupling half 1 forward to open position CAUTION To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result 3 to female quick disconnect coupling half 1 attached to aa Connect discharge hose hypochlorination unit 2 Close cam arms NOTE Wrap antiseize tape in direction of threads ab Wrap antiseize tape item 9 appendix E around threads on male quick disconnect coupling half 4 Screw male quick disconnect coupling half 4 into outlet port Figure 2 23 11 hypochlorination unit Figure 2 24 2 Push cam arms o
118. OINT 3 4 EA 5 DRIVE 81348 GGG W 641 TY Il CL 2 STY A 149 WRENCH SOCKET 11 16 12 POINT EA 5 DRIVE 81348 GGG W 641 TY Il CL 2 STY A 150 BOLT TRACK HEAD 9 16 INCH EA 5 81346 ASTM A 449 151 NUT HEX 9 16 INCH EA 5 81346 ASTM A 1449 152 BOLT TRACK HEAD 11 16 EA 20 81346 ASTM A 449 153 NUT HEX 11 16 EA 20 81346 ASTM A 449 C 32 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 2 3 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER NUMBER CAGEC and Part Number On Code Rad EA 2 154 HOSE RUBBER 6 INCH X 15 FEET 19099 53027 15AR 155 KIT CHEST METAL EA 1 63317 100 04 011 156 KNIFE RUBBER CUTTING 8 X 1 INCH EA 1 29891 60870 157 MALLET RUBBER 32 OUNCE EA 1 03914 69 490 158 PLIERS LINESMANS EA 1 81348 GGG P 00471D 1 C 33 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 2 3 4 5 NATIONAL STOCK DESCRIPTION Usable U M Qty NUMBER CAGEC and Part Number On Code Rad SCREWDRIVER 6 INCH EA 1 63317 100 10 003 5140 01 248 2692 TOOL BOX METAL EA 1 75206 K 20 20 NOTES TWDS pumping stations may contain eight 8 6 inch pipe coupling clamps item 1 or eight 8 6 inch coupling clamps item 2 If pumping station contains item 2 it will also contain one 1 spanner wrench item 3 TWDS storage assemblies may contain one 1 4 inch pipe coupling clamp item 15 or one 1 4 inch coupling clam
119. ONNECT 200 DP EA 4 96906 MS27029 11 53 4320 00 542 3347 125 GPM PUMPING ASSEMBLY EA 2 97403 13200E8800 54 4730 01 192 1624 COUPLING HALF QUICK DISCONNECT EA 4 96906 MS49002 9 55 4730 00 951 3297 REDUCER QUICK DISCONNECT EA 4 96906 MS49000 5 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 4 5 ILLUS NATIONAL STOCK DESCRIPTION Usable E NUMBER NUMBER CAGEC and Part Number On Code Rad 56 4730 00 951 3297 REDUCER QUICK DISCONNECT 96906 MS49000 11 57 4730 01 186 0821 REDUCER QUICK DISCONNECT EA 4 96906 MS49000 19 58 4730 01 064 0560 REDUCER QUICK DISCONNECT EA 4 96906 MS49000 17 59 4930 01 120 7426 STAND ASSEMBLY NOZZLE EA 4 97403 13225E9140 60 4820 01 167 6550 VALVE ELBOW COUPLER 2 INCH X 2 INCH EA 4 97403 13219E0491 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 4 5 ILLUS NEGRA STOCK DESCRIPTION Usable RS NUMBER NUMBER CAGEC and Part Number On Code Rad 61 4820 00 810 4250 VALVE GATE 2 INCH 82666 B120 2 62 4730 01 068 5070 WYE CONNECTION QUICK DISCONNECT EA 6 81718 319 2 63 4730 00 840 0797 COUPLING HALF QUICK DISCONNECT MALE EA 2 96906 MS 27022 17 64 4730 00 088 9286 COUPLING HALF QUICK DISCONNECT FEMALE EA 2 96906 MS 27024 17 65 NIPPLE 4 INCH DIAMETER 6 INCHES LONG EA 2 81348 WW N 351 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM CONTINUED 1 4 5
120. PROCEDURES 2 12 1 General Performance of the entire TWDS depends on continuous operation of each major component In most cases when part of the equipment fails the entire system must be shut down Procedures for partial operation are limited The only emergency procedures possible are listed below In all other situations the entire TWDS must be shut down until the problem is corrected 2 12 2 Failure of Boost Pumping Station CAUTION Do not attempt to operate other pumping stations when one unit fails The bypass hose assembly is used only to keep downline pumps primed Enough pressure will not exist to operate downline pumps even at a partial rate a Refer to the applicable technical manual and shut off engine b Open butterfly valve in bypass line c Close butterfly valves in suction and discharge lines to and from 600 gpm pumping assembly to shut off water flow through malfunctioning pump d Notify operators at other pumping stations of equipment failure e Refer to the applicable technical manual and decrease lead pump operation so that discharge rate will be enough to keep downline pumps primed 2 115 10 4320 303 13 2 12 2 Failure of Boost Pumping Station Continued f Boost pumps operating in electric automatic mode should decrease to idle automatically Operators at boost pumping stations should make certain their units have adjusted properly Operators must also monitor readings on pressure gages Ref
121. RIPTION CAGEC AND PART NUMBER QTY 1 19099 100 56 001 PROCEDURES NOTE Always mark score and cut hose squarely Do not leave ragged or uneven edges 1 Cut hose 1 2 or 3 to length of 10 20 or 75 feet as required 2 Refer to paragraph 3 4 1 assemble hose assembly F 2 10 4320 303 13 APPENDIX TORQUE LIMITS SAE Grade Number Quality of Indeterminate Minimum Medium Best Commercial Material Commercial Commercial Capscrew Head Markings NOTE Head marking may vary with different manufacturers Capscrew Body Size Torque Torque Torque Torque Inches Thread Ft Lb Nem Ft Lb Nem Ft Lb Nem Ft Lb Nem CAUTION If replacement capscrews are of a higher grade than originally supplied use torque specifications for that placement This will prevent equipment damage due to over torquing NOTE Always use the torque values listed above when specific torque values are not available G 1 G 2 Blank 10 4320 303 13 GLOSSARY SECTION ABBREVIATIONS COMMON ABBREVIATIONS The common abbreviations used in this manual are in accordance with MIL STD 12D SPECIAL OR UNIQUE ABBREVIATIONS The following is a list of abbreviations and symbols that are used in this manual but are not listed in MIL STD 12D ABBREVIATION DEFINITION cA AE Degrees Celsius OTs Sea ea ead ve reatu Duo a es t
122. Relief Valve Assembly removed Material Parts refer to paragraph 2 8 2 6 Antiseize Tape Item 9 Appendix General Safety Instructions Do not work on equpment without following standard shop safety precautions 4 11 6 1 Disassembly Figure 4 12 Pressure Relief Valve Assembly Maintenance a Unscrew and remove safety relief valve Figure 4 12 1 from pipe coupling 2 4 11 6 2 Inspection a Inspect safety relief valve 1 for cracks holes or damage b Inspect pipe coupling 2 for cracks holes bends or damage 4 11 6 3 Repair Repair of pressure relief valve assembly consists of replacing damaged or defective safety relief valve 1 or pipe coupling 2 4 33 10 4320 303 13 4 11 6 Pressure Relief Valve Assembly Maintenance Continued NOTE Wrap antiseize tape in direction of threads 4 11 6 4 Assembly Wrap antiseize tape around threads of safety relief valve 1 and install in pipe coupling 2 4 34 4 12 STORAGE ASSEMBLY MAINTENANCE TM 10 4320 303 13 4 12 1 4 Inch Gate Valve Assembly Maintenance This task covers 4 12 1 1 Removal 4 12 1 2 Disassembly 4 12 1 4 Repair 4 12 1 5 Assembly 4 12 1 3 Inspection INITIAL SETUP Tools Tool Kit General Mechanic s Automotive Section Item 1 Material Parts Gasket TM 10 4320 303 23P Packing TM 10 4320 303 23P Equipment Conditions Pumping station shutdown refer to Equipment Conditions Continued Quick Disconnect Coupling Ha
123. SEMBLY QUICK DISCONNECT WYE CONNECTION NOZZLE ELBOW VALVE NOZZLE ASSEMBLY DRINKING STORAGE BAG REDUCER ADAPTER Description and Purpose 2 inch x 20 foot rigid walled hose assembly Used to direct water flow from 20 000 gallon pillow tank to 125 GPM pumping assembly Gas driven 125 GPM pumping assembly used to pump water from the 20 000 gallon pillow tank to the hypochlorination unit and water dispensing devices Refer to applicable technical manual for detailed information concerning the 125 GPM pumping assembly 2 inch x 10 foot collapsible hose assembly Directs flow of water from 125 GPM pumping assembly to hypochlorination unit Equipped with quick disconnect fittings for rapid installation Used to chlorinate water to levels acceptable for consumption One of three hypochlorination units may be supplied with the TWDS Refer to applicable technical manuals for detailed information concerning models A 506131 and 1955 3 Detailed information concerning model 1955 1 is contained within this manual Seven hose assemblies are used with each distribution point 2 inch x 20 foot collapsible hose assembly Directs flow of water from 2 inch gate valve to nozzle and elbow valve Two are used with each distribution point Used to control water flow from hypochlorination unit to water dispensing points Three are used with each distribution point water flow to distribution equipment Two are used with each distribution
124. TE Stroke adjust thimble is marked to measure revolutions Turning thimble from 0 to 10 equals one half revolution Turning thimble from 0 to 20 equals one complete revolution One half revolution of thimble equals one number setting on micrometer barrel scale One complete revolution of thimble equals two number settings on micrometer barrel scale h Turn stroke adjust thimble Figure 2 47 1 left two and one half revolutions Stroke adjust thimble 1 will be set at 5 on micrometer barrel scale 2 i If hypochlorite feeder Figure 2 48 1 becomes air bound after startup 1 Loosen top hose connection 2 on hypochlorite feeder 1 2 Set stroke adjust thimble Figure 2 47 1 to 10 on micrometer bar scale 2 This allows air to escape through small vent Figure 2 48 3 in top of pump 4 3 When air is vented set stroke adjust thimble Figure 2 47 1 back to 5 on micrometer barrel scale 2 4 Tighten top hose connection Figure 2 48 2 on feeder 1 NOTE Thirty minute contact time is required to obtain an accurate chlorine residual as prescribed by TB MED 577 or by area medical officer j After unit operates for 10 minutes take chlorine residual test para 2 5 5 7 k If residual reading is high 1 Turn stroke adjust thimble Figure 2 47 1 setting to 2 5 on micrometer barrel scale 2 2 Run unit for 10 minutes and take another residual test para 2 5 5 7 3 If reading remains high add water
125. TION e To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result i Connect rigid walled hose assembly 3 to female quick disconnect coupling half 7 on 125 GPM pump 6 Close cam arms NOTE Wrap antiseize tape in direction of threads j Wrap antiseize tape item 9 appendix E around threads on male quick disconnect coupling half 8 Screw male quick disconnect coupling half 8 into discharge port 5 of 125 GPM pumping assembly 6 CAUTION e To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result k Connect discharge hose 9 to male quick disconnect coupling half 8 on 125 GPM pumping assembly 6 Close cam arms NOTE If installing hypochlorination unit 1955 3 refer to steps 1 through w If installing hypochlorination units 1955 1 or A 506131 refer to steps x through ad Locate inlet port 10 and outlet port 11 on hypochlorination unit 1955 3 12 Refer to applicable technical manual for preparation for use of hypochlorination unit 1955 3 NOTE Wrap antiseize tape in direction of threads m Wrap antiseize tape item 9 appendix E around threads on both ends of pipe nipple 16 Screw pipe nipple 16 into hypochlorination unit 1955 3 12 n Screw female quick disconnect coupling half 17 onto pipe nipple 16 o Push cam arms on female quick disconnect coupling hal
126. Tool Kit General Mechanic s Automotive Section III Item 1 Material Parts Antiseize tape Item 9 Appendix Lock washers TM 10 4320 303 23P 4 11 5 1 Removal 4 11 5 3 Inspection 4 11 5 4 Assembly 4 11 5 5 Installation Equipment Conditions Pumping station shutdown refer to applicable technical manual Pressure Reducing Valve Assembly removed refer to paragraph 4 11 4 Personnel Two 2 personnel are required for lifting main valve assembly from skid assembly General Safety Instructions Do not work on equipment without following standard shop safety precautions Figure 4 10 Pressure Heducing Valve Assembly Maintenance a Remove four nuts Figure 4 10 1 securing main valve assembly 2 to two mounting brackets 3 4 28 10 4320 303 13 b Remove two nuts 4 lock washers 5 and mounting bolts 6 securing each mounting bracket 3 to skid assembly 7 Discard lock washers 5 c Remove mounting brackets 3 WARNING Two personnel are required for lifting main valve assembly Failure to obey this warning may result in personnel injury CAUTION When removing main valve assembly ensure that tubing does not become damaged d Carefully remove main valve assembly 2 from skid assembly 7 4 11 5 2 Disassembly 13 Figure 4 11 Pressure Reducing Valve Assembly Tubing and Pressure Reducing Control Maintenance a Open cover isolation cock valves Figure 4 11 1 to release p
127. Total hoseline footage x 0 024 Vertical feet of friction loss in hoseline 0 024 friction loss conversion factor h Using formula provided below determine total feet of friction loss Vertical feet of Feet of elevation Total feet friction loss in between pumping of friction hoseline station and hill loss crest i Using formula provided below convert total feet of friction loss into psi Total feet of friction loss friction loss in psi 2 31 2 31 psi conversion factor 2 35 10 4320 303 13 2 3 1 9 Determine Location of Pressure Reducing Valve Assembly Continued j Using formula provided below determine existing psi at hill crest 150 psi psi of friction loss psi at hill crest 150 psi pumping station discharge pressure k Using formula provided below determine allowed additional psi before safety limit is reached 225 psi psi at hill crest Allowed additional psi before reaching safety limit 225 psi safety limit pressure Using formula provided below convert allowed additional psi into vertical feet Allowed additional psi x 2 31 Allowed additional vertical footage before reaching safety limit 2 31 psi vertical footage conversion factor m Using formula provided below determine point at which pressure reducing valve assembly must be installed in hoseline Altitude at Allowed additional Pressure reducing valve hill crest vertical footage assembly installation point
128. Unit Model 1955 1 removed Automotive Section Ill Item 1 refer to paragraph 4 13 1 Fill Hose Assembly removed refer to Material Parts paragraph 4 13 2 Antiseize Tape Item 9 Appendix General Safety Instructions Do not work on equipment without following standard shop safety precautions 4 13 3 1 Removal a rn can Figure 4 16 Besson Gauge and Fill Assembly Maintenance a Remove pressure gaugb Figure 4 15 1 from elbow 2 b Remove elbow 2 from nipple 3 c Remove globe valve 4 from close nipple 5 d Remove close nipple 5 from pipe tee 6 e Remove pipe tee 6 from close nipple 7 4 41 10 4320 303 13 4 13 3 Pressure Gauge and Fill Assembly Replacement Continued f Remove close nipple 7 from inlet nipple 8 4 13 3 2 Inspection a Inspect pressure gauge 1 for cracked face holes or damage b Inspect globe valve 4 for corrosion smooth operation of handle cracks holes or damage c Inspect all piping hardware for corrosion cracks holes bends or damage d Replace all defective or damaged components 4 13 3 3 Installation NOTE e Wrap all threaded portions of pressure gauge and fill assembly components with antiseize tape prior to installation e Wrap antiseize tape in direction of threads a Install close nipple 7 on inlet nipple 8 b Install pipe tee 6 on close nipple 7 c Install close nipple 5 on pipe tee 6 2 Install globe valve 4
129. You can help improve this manual If you find any mistakes or if you know of a way to improve these procedures please let us know Mail your letter or DA Form 2028 Recommended Changes to Publications and Blank Forms or DA Form 2028 2 located in the back of this manual directly to Commander US Army Aviation and Troop Command AITN AMSAI I MP 4300 Goodfellow Blvd St Louis MO 63120 1798 You may also submit your recommended changes by E mail directly to lt mpmt avma2g8st louis emh7 army mil gt A reply will be furnished directly to you Instructions for sending an electronic 2028 may be found at the back of this manual immediately preceding the hard copy 2028 Distribution Statement A Approved for public release distribution is unlimited TABLE OF CONTENTS Page HOW TO USE THIS MANUAL 2 22 0 0 1 vii NT ACU UCTION 1 1 Section General 1 1 Section Il Equipment Description 1 3 Section Principles qaa qva vd a a QV EU va Edu d 21 Section Description and Use of Operator s Gomtrols ets tein ie anten s 2 2 Section Il Operator Preventive Maintenance Checks and Services PMCS 2 8 Section Ill Operation Under Usual 2 30 Section IV Operation Under Unusual
130. a Remove two front cover screws Figure 4 23 1 b Remove front cover 2 from comparator body 3 c Remove four back cover screws 4 d Remove back cover assembly 5 from comparator body 3 4 57 10 4320 303 13 4 13 10 Color Comparator Maintenance Continued 4 13 10 2 Inspection a Inspect front cover 2 and comparator body 3 for cracks holes or damage b C Inspect back cover assembly 5 for cracks holes broken or missing diffusing glass 6 or damaged spring 7 Inspect mounting hardware for damage 4 13 10 3 Repair Repair of the color comparator consists of replacing damaged or defective components If diffusing glass 6 or spring 7 is damaged replace back cover assembly 5 4 13 10 4 Assembly a Align mounting holes of back cover assembly 5 with mounting holes of comparator body 3 b Install four back cover screws 4 Tighten screws 4 c Align mounting holes of front cover 2 with mounting holes of comparator body 3 d e Place color comparator in color comparator kit Install two front cover screws 1 Tighten screws 1 4 58 10 4320 303 13 4 14 SUSPENSION KIT MAINTENANCE This task covers 4 14 1 Inspect 4 14 3 Replace 4 14 2 Repair INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equipment without following Automotive Section Ill Item 1 standard shop safety precautions Figure 4 24
131. able to the 6 inch x 20 foot hose assembly The procedures for replacing the 6 inch x 10 foot and 6 inch x 75 foot hose assemblies are similar in nature Figure 4 5 Hose Assembly Replacement a Remove 6 inch grooved pipe coupling Figure 445 1 from check valve 2 and 6 inch x 20 foot hose assembly 3 b Remove grooved end pipe quick disconnect coupling clamp 4 from 6 inch butterfly valve assembly 5 and 6 inch x 20 foot hose assembly 3 c Remove 6 inch x 20 foot hose assembly 3 4 10 3 2 Installation a Align 6 inch x 20 foot discharge hose assembly 3 for installation 4 19 10 4320 303 13 4 10 3 Hose Assembly Replacement Continued b Install grooved end pipe quick disconnect coupling clamp 4 to secure 6 inch x 20 foot hose assembly 3 to 6 inch butterfly valve assembly 5 c Install 6 inch grooved pipe coupling 1 to secure 6 inch x 20 foot hose assembly 3 to check valve 2 4 20 10 4320 303 13 4 11 10 MILE SEGMENT EQUIPMENT MAINTENANCE 4 11 1 6 Inch x 500 Foot Collapsible Hose Assembly Replacement This task covers 4 11 1 1 Removal 4 11 1 2 Installation INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equipmentwithout following Automotive Section Ill Item 1 standard shop safety precautions Equipment Conditions Pumping station shutdown refer to applicable technical manual 4 11 1 1 Removal 2 Figure 4 6 6
132. ad Pumping Station Discharge Port and TWDS Components Assembly Pressure Relief Valve Installation eese TWDS Water Source Connection Components Boost Pumping Station and Suction Components Boost Pumping Station and Discharge Components Boost Pumping Station and Bypass Components Storage Assembly Connection Components Final Assembly of Storage Hypochlorination Unit and 125 GPM Pump Hypochlorination Unit Model 1955 1 and Model A 506131 Installation Distribution Point Assembly ertt aaa RR ERO Hypochlorination Tripod Stand Assembly 2 t td teet a eR UNE Tripod and Water Storage Drinking 10 Mile Hoseline Segment Loading and Securing Flaking Tailgate Assembly Positioning Breakaway on Flaking B
133. aded fittings and 2 inch maximum Notify unit maintenance to install components with threaded fittings Personnel Two required Components Table 2 12 Components Required from Distribution Point Crate for Assembly of Distribution Points 1 Color comparator kit 2 4 inch x 2 inch Reducer male by female and female by male quick disconnect 1 2 inch x 20 feet Hose assembly 3 2 inch Coupling half quick disconnect female external pipe thread 3 2 inch Coupling half quick disconnect male external pipe thread 1 2 inch x 10 feet Suction hose assembly 2 2 inch x 4 inch Reducer male by female and female by male quick disconnect 1 4 inch Coupling half quick disconnect female internal pipe thread 1 4 inch Nipple 1 100 gpm Hypochlorination Unit 2 51 10 4320 303 13 2 3 7 Assembly of Distribution Points Continued Table 2 12 Components Required from Distribution Point Crate for Assembly of Distribution Points Continued 4 inch Coupling half quick disconnect male external pipe thread 2 inch x 20 feet Hose assembly 2 inch x 2 inch x 2 inch Y connector quick disconnect 1 5 inch x 2 inch Reducer external pipe thread quick disconnect female 2 inch Hose swivel Nozzle 2 inch Dust plug 2 inch x 2 inch Elbow valve 36 gallon Drinking water storage bag Nozzle stand assembl 1 7 3 2 2 2 2 2 2 2 2 3 7 2 Assembly and Installation a Locate male filler discharge elbow Figure 2 23 1 o
134. aintenance Hypochlorination Unit Model 1955 1 5 6 Maintenance Hypochlorinator Assembly 2 du renti ded 4 13 6 Maintenance Inlet Hose Assembly eee 4 13 2 Maintenance Manifold Assembly eee 4 13 7 Maintenance Outlet Hose Assembly see 4 13 2 Maintenance Packing Kit 4 16 Maintenance Pilot Valve Assembly ee 5 6 1 Maintenance Pressure Reducing Valve Assembly Direct Support 5 5 Maintenance Pressure Reducing Valve Assembly Unit 4 11 5 Maintenance Pressure Regulator Hose 4 13 2 Maintenance Pressure Relief Valve 4 11 6 Maintenance Pumping Station Operator nn 3 3 Maintenance Reducer Y Connection 4 10 1 Maintenance Repair Kit 4 17 Maintenance Sling Assembly 4 18 Maintenance Stand Assembly 4 13 9 Maintenance Storage Assembly Bcc ET 4 12 Maintenance Strainer Assembly 4 13 4 Maintenance Suspension Kit 4 14 Maintenance TWDS Supply Connection Items 4 10 Maintenance Water Meter 5 6 3 Manifold Assembly Maintenance 4 13 7 4 21 Materiel Service Upon Receipt 4 4 Models Differences Between 1 16 Movem
135. and packed after buried hoseline has been pulled free from guards a Dig out road crossing guards Figure 2 66 1 b If planks 2 were nailed to bottom of road crossing guards 1 remove nails and remove planks 2 2 101 10 4320 303 13 2 8 2 Preparation for Movement of 10 Mile Hoseline Continued Figure 2 66 Disassembly of Road Crossing Guard Clean road crossing guards 1 and transport them to lead pumping installation site for final packing 2 8 2 6 Preparation for Movement of Pressure Reducing Valve Assembly Figure 2 67 Disassembly of Pressure Heducing Valve Assembly NOTE e Set aside all removed components for repacking e Notify unit maintenance for removal of threaded pipe fittings a Remove grooved end quick disconnect coupling clamp Figure 2 61 1 2 3 3 1 connecting pressure reducing valve assembly 2 to downline hoseline segment 3 2 102 10 4320 303 13 b Install grooved end quick disconnect coupling clamp 1 2 3 3 2 on end of hoseline segment 3 c Remove grooved end quick disconnect coupling clamp 4 para 2 3 3 1 connecting pressure relief valve assembly 7 to upline hoseline segment 5 d Remove grooved end quick disconnect coupling clamp 6 para 2 3 3 1 connecting pressure relief valve assembly 7 to pressure reducing valve assembly 2 2 8 3 Preparation for Movement of Lead Pumping Station This is a general procedure for m
136. and personnel injury NOTE This procedure is applicable to 6 inch by 10 20 and 75 foot hose assemblies and 6 inch by 500 foot hoseline segment a Install hose clampsi Figure 3 1 1 3 feet up line and downline from hose section 2 to be removed 10 4320 303 13 3 4 1 6 Inch Hose Assembly Repair Continued Figure 3 1 Hose Clamp Installation b Tighten hose clamps 1 until hose 2 is pinched closed Figure 3 2 Damaged Hose Section Removal NOTE Always mark score and cut hose squarely Do not leave ragged or uneven edges c Cut both sides of hosel Figure 3 2 1 6 inches from leak d Remove damaged section of hose 2 e Inspect inside of hose ends 3 for further damage f Cut hose 1 back again as required to reach an undamaged area 3 6 10 4320 303 13 Figure 3 3 Male Quick Disconnect Coupling Half and Banding Installation g Drain hose ends 3 and wipe dry h Insert male end of quick disconnect coupling half Figure 3 8 1 into hose end 2 until shoulder 3 is flush with hose end 2 i Cut strapping to sufficient length to accommodate double wrap around hose and have an additional 10 inches of strapping j Bend strapping approximately 2 inches from either end k Install buckle on opposite end of strapping Slide buckle to bend ensuring ears of buckle are up and in bend of strapping Place both ends of strapping 4 through buckle 5 Figure 3 4 Stra
137. and plywood boxes stored in each crate 2 Return components to original containers reference paragraph 2 3 4 3 Pack fiberboard boxes in plywood boxes 4 Install blocking bracing and anchoring securing contents within each crate as required 5 Install plywood sheathing on top of each crate Nail down plywood sheathing 6 Roll out polyethylene barrier and position over plywood sheathing on top of each crate 7 Install cross sheathing boards on top of each crate Nail down cross sheathing boards n After repacking TWDS is ready for movement to another location 2 8 2 Preparation for Movement of 10 Mile Hoseline 2 8 2 1 Disassembly and Packing Requirements a Disassembly for the 10 mile hoseline segment requires sufficient tools equipment and personnel to perform the tasks outlined in paragraph 2 3 10 The displacement and evacuation kit and the packing kit will be required to pack hoseline segments in flaking boxes If a forklift is not available the lifting sling will be required to load unload and stack flaking boxes b When flaking boxes are returned to packing site stack them in groups of four Pack each group in crate marked HOSE ASSEMBLY 6 INCH 500 FEET Number of groups packed in crates will depend on number of hoseline segments used during TWDS operation Reference Table 2 11 for the total number size and type of components packed in the 10 MILE SEGMENT Crate Repack components that were removed for TW
138. aps back on the bottles NOTE Readings must be made within one minute of adding chemical to indicator cell h Squirt with force one dropper full not less than 0 75 ml of arsenite red cap solution into the right hand sample cell 3 Then squirt with force one dropper full not less than 0 75 ml of orthotolodine yellow cap solution into the right hand sample cell 3 i Refill the arsenite and orthotolodine droppers and let the droppers sit loosely in the bottles j Squirt with force the dropper full of orthotolodine yellow cap solution into the left hand sample cell b Immediately squirt with force the dropper full of arsenite red cap solution into the same cell 5 This is the indicator Figure 2 52 Viewing Water Samples 2 85 10 4320 303 13 2 5 5 7 Performing Chlorine Residual Tests Continued CAUTION e DO NOT hold comparator to direct sunlight or artificial light when comparing colors Test results will not be correct e NOT cover light window in rear of body Hold the comparator Figure 2 52 1 to your eye and face a good light source daylight but not the direct rays of the sun daylight illuminator or artificial light reflected from a white surface Look through the prism eyepiece 2 at a distance of about 10 inches 3 Rotate chlorine color disk Figure 2 49 4 until a color on the disc matches the color on the left hand sample cell or indicator cell Figure 2 51 4 The readings
139. aragraph 2 3 6 1 Pack the components listed in table 2 11 in the STORAGE ASSEMBLY crate after removing them from the storage assembly 2 8 5 2 Disassembly Procedures NOTE Set aside all removed components for repacking a Remove grooved end quick disconnect coupling clamp 1 para 2 3 3 1 connecting reducing tee 2 to upline hoseline segment 3 b Install grooved end quick disconnect coupling clamp 1 para 2 3 3 2 on end of hoseline segment 3 c Remove 6 inch grooved pipe coupling 4 para 2 3 2 1 connecting reducing tee 2 to downline hoseline segment 5 d Remove grooved end quick disconnect coupling clamp 6 para 2 3 3 1 connecting coupling pipe fitting 7 to reducing tee 2 e Remove reducing tee 2 f Push cam arms on female quick disconnect coupling half 8 forward to open Remove male coupling half 9 with attached coupling pipe fitting 7 from female quick disconnect coupling half 8 2 107 10 4320 303 13 2 8 5 Preparation for Movement of Storage Assemblies Continued t Figure 2 73 Disassembly of Storage Assembly Components g Unscrew male coupling half 9 and remove from coupling pipe fitting 7 h Push cam arms on discharge hose assembly 10 forward to open Remove valve assembly 24 from end of discharge hose 10 i Remove eight nuts 12 lock washers 13 flat washers 14 and bolts 15 and flat washers 16 Remove female quick disconnect
140. as follows a Notify operators at other stations of equipment failure 600 GPM pumping assemblies may require adjustment if necessary refer to the applicable technical manual and adjust operation of 600 GPM pumping assemblies accordingly b Close gate valve connected to 20 000 gallon pillow tank in use with defective distribution point 2 5 5 c Shut down operation of defective distribution point 2 5 5 Refer to the applicable technical manual and shut down engine on 125 GPM pumping assembly 2 5 5 2 2 116 10 4320 303 13 CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS Subject Index Page Section LUBRICATION INSTRUCTIONS sssssesssse nnne nnne senes 3 1 INVleTie uo 9 3 1 Section Il OPERATOR TROUBLESHOOTING PROCEDURES ed 3 1 3 1 Section III OPERATOR MAINTENANCE PROCEDURES eee 3 5 Pumping Station nennen 3 5 10 Mile Hoseline Segment Storage Assembly 3 12 125 GPM Pumping Assembly 13 12 3 1 10 4320 303 13 SECTION LUBRICATION INSTRUCTIONS 3 1 LUBRICATION There are
141. ations for Use on Drawings and in Specifications Standards and Technical Documents Marking for Shipment and Storage Arc Welding Procedures for Structural Steels Dictionary of United States Army Terms Army Logistics and 0 Functional User s Manual for the Army Maintenance Management System TAMMS Functional User s Manual for the Army Maintenance Management System Aviation TAMMS A Occupational and Environmental Health A 1 A 2 Blank DA Form 2028 DA Form 2028 2 DA Form 2258 DA Form 2404 SF 364 SF 368 FM 3 3 FM 3 4 FM 3 4 1 FM 3 5 FM 3 6 FM 3 8 FM 21 11 TM 9 237 TM 750 244 3 TM 5 5430 226 12 TM 5 4310 452 14 amp P TM 10 4320 303 23P MIL STD 12 MIL STD 129 MIL STD 1261 AR 310 25 AR 700 138 DA Pam 738 750 DA Pam 738 751 TB MED 577 10 4320 303 13 APPENDIX B MAINTENANCE ALLOCATION CHART MAC SECTION I INTRODUCTION B 1 THE ARMY MAINTENANCE SYSTEM B 1 1 Introduction This introduction Section 1 provides a general explanation of all levels of maintenance and repair functions authorized at various maintenance levels under the standard Army Maintenance System concept B 1 2 Maintenance Allocation Chart Section Il The Maintenance Allocation Chart MAC in section 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 th
142. autions applicable technical manual NOTE This procedure is applicable to the model 1955 1 hypochlorination unit The replacement of model 1955 3 and model A 506131 hypochlorination units are similar 4 13 1 1 Removal Placing the hypochlorination unit Figure 4 14 1 in the equipment conditions specified above will remove the hypochlorination unit 1 from the TWDS Figure 4 14 Hypochlorination Unit Model 1955 1 Replacement 4 13 1 2 Inspection Inspect hypochlorination unit 1 for leaks faulty operating components or damage 4 13 1 3 Repair Replace damaged or defective hypochlorination unit 1 4 13 1 4 Installation Install hypochlorination unit 1 in accordance with paragraph 2 3 7 2 4 38 10 4320 303 13 4 13 2 Outlet Pressure Regulator Inlet Drain and Fill Hose Assemblies Maintenance This task covers 4 13 2 1 Removal 4 13 2 2 Inspection 4 13 2 3 Installation INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s Hypochlorination Unit Model 1955 1 removed Automotive Section Ill Item 1 refer to paragraph 4 13 1 General Safety Instructions Material Parts Do not work on equipment without following Antiseize Tape Item 9 Appendix standard shop safety precautions 4 13 2 1 Removal NOTE This procedure is applicable to the outlet hose assembly The procedures for the pressure regulator inlet drain and fill hose assemblies are similar Figure 4 15 Outlet Hose A
143. bly and from lead pumping assembly to hoseline 6 inch x 10 foot rigid walled wire reinforced hose assembly Connects Y Connection reducer to lead pumping station Equipped with quick disconnect fittings for rapid installation Provides connection capability between the TWDS and water source 6 inch x 20 foot collapsible hose assembly Directs water from pumping assembly to hoseline Activates at water pressures over 200 psi to relieve excessive water pressure in hoseline assemblies Retards water from flowing into pumping assembly through discharge elbow 10 4320 303 13 Figure 1 3 Location of Major Components for TWDS 10 Mile Hoseline Segment 1 5 10 4320 30313 1 15 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED Table 1 3 Description of Major Components for TWDS 10 Mile Hoseline Segment Item Item Name Description and Purpose No 1 6 INCH X 500 FOOT Lightweight collapsible rubber hose used to transport water COLLAPSIBLE HOSE up to 10 miles and to interconnect TWDS components ASSEMBLY 2 FLAKING BOX Each new Flaking Box holds two 500 foot hose assemblies Older models hold one 500 foot hose assembly Allows hose assembly to be flaked from back of truck Adapted for forklift and lifting sling 3 SWIVEL JOINT Placed between every 1 000 feet of hoseline to relieve twisting and kinking of hoseline 4 PRESSURE REDUCING Provides protection for hoseline and other TWDS components VALVE ASSEMB
144. broken or missing cam arms or damage Inspect quick disconnect male coupling half 1 grooved pipe coupling fitting 2 two reducer pipe fittings 4 and Y fitting 6 for corrosion cracks holes or damage 4 14 10 4320 303 13 4 10 1 Reducer Y Connection Maintenance Continued 4 10 1 4 Repair Repair of reducer Y connection consists of replacing all defective components 4 10 1 5 Assembly a Place Y fitting 6 together with grooved pipe coupling fitting 2 b Install one grooved end pipe quick disconnect coupling clamp 5 c Place two reducer pipe fittings 4 together with Y fitting 6 d Install two grooved end pipe quick disconnect coupling clamps 5 NOTE Wrap antiseize tape in direction of threads e Wrap antiseize tape around threads of two reducer pipe fittings 4 and grooved pipe coupling fitting 2 f Coat two new gaskets with non petroleum based silicone lubricant and install them in two female quick disconnect couplings 3 Install two female quick disconnect couplings 3 on two reducer pipe fittings 4 g Install quick disconnect male coupling half 1 on grooved coupling pipe fitting 2 4 10 1 6 Installation a Open cam arms on 6 inch x 10 foot suction hose assembly Figure 4 1 2 and install reducer Y connection 1 in 6 inch x 10 foot suction hose assembly 2 CAUTION To prevent leakage close both cam arms at the same time Do not strike cam arms to close Damage to couplings could res
145. bstantial rise or fall in elevation along the hoseline route may require adjustment of standard spacing intervals between pumping stations When substantial rise or fall in elevation occurs between two consecutive pumping stations the following pumping station movements must be performed e f the next downline pumping station is substantially higher in elevation than the upline pumping station decrease distance between pumping stations f the next down line pumping station is substantially lower in elevation than the upline pumping station increase distance between pumping stations Adjusting distance between pumping stations when elevation changes occur assures that water pressure will be maintained within optimum operational range Under normal conditions TWDS will deliver water to the suction port of each boost pumping station at a pressure of 20 pounds per square inch gage psig Whenever pressure falls below 20 psig boost pumping station pumping assemblies are designed to begin reducing speed when operated in the electric automatic mode Therefore if an upline pumping station is substantially lower than the next down line station and the elevation difference has not been offset by spacing adjustment between pumping stations suction pressure at the down line pumping station may fall below 20 psig and cause that pump to slow down This in turn will cause remaining down line boost pumping stations to slow down seriously degrading overal
146. can be made directly from the number display window Figure 2 49 6 The value is expressed in milligrams per liter mg l m Record value number shown in number display window Figure 2 49 6 If color of indicator cell Figure 2 51 4 is between colors on the chlorine color disk Figure 2 49 4 the value number must be estimated n The readings must be made within one minute of adding the chemicals to the indicator cell o When test has been completed empty the samples and wash the sample cells Figure 2 51 1 and 4 with clean water p Remove prism eyepiece Figure 2 5 1 and place in kit container Remove two screws Figure 2 49 1 and front cover 2 on comparator body 3 Remove chlorine color disc 4 and place in kit container r Place front cover 2 on comparator body 3 Install and tighten screws 1 Place color comparator 1 2 and 3 in kit container Fasten latch on kit container s Store kit in metal box mounted on hypochlorination unit skid 2 5 5 8 Performing PH Test a Refer tb paragraph 2 5 5 7 and perform steps a through f ensuring that either the WIDE RANGE INDICATOR D or pH disc is installed CAUTION e sure correct disc is used for pH test Tag on disc should either read WIDE RANGE INDICATOR D or pH e f wrong disc is used test results will be incorrect b Fill the dropper Figure 2 53 1 of the wide range indicator solution white cap bottle to the 0 50 ml mark 2
147. ces Table 4 6 Unit Maintenance Preventive Maintenance Checks and Services Item Interval Item to Procedure Not Fully No Check Service Mission Capable if Hypochlorination Unit 1955 1 1 Weekly Strainer Assembly Refer to paragraph Strainer is 4 13 4 and service damaged or strainer assembly corroded Inspect for corrosion or damage SECTION IV UNIT TROUBLESHOOTING 4 9 TROUBLESHOOTING The malfunction index lists faults that may be observed by unit maintenance personnel The faults are then cross referenced to the troubleshooting table Table 4 7 Table 4 7 contains information useful in diagnosing and correcting unsatisfactory conditions which may be encountered during operation or maintenance of the TWDS Use the malfunction index to locate specific troubleshooting procedures contained in Table 4 7 After locating the troubleshooting procedure perform the test inspections and corrective actions in the order listed The malfunction index and Table 4 7 cannot list all of the malfunctions that may occur all tests and inspections needed to find the fault or all the corrective actions needed to correct the fault If the equipment malfunction is not listed or actions listed do not correct the fault notify your supervisor Refer to the applicable technical manuals for 125 GPM and 600 GPM Pumping Assemblies Hypochlorination Units and for 20 000 Gallon Pillow Tank unit troubleshooting procedures UNIT MALFUNCTION INDEX Malfuncti
148. cked or broken components Make sure relief valve is firmly seated in nipple Table 4 2 Storage Assembly Crate 0 375 16 UNC 2A x 3 25 32 inch Bolt threads Coupling half female quick disconnect Coupling half male quick disconnect 2 4 inch Coupling pipe fitting Discharge hose assembly quick disconnect Flange adapter 4 inch x 10 foot 2 4 inch 4 4 tem 2 Pes Check for worn stripped or damaged Make sure cam arms move freely Check for damaged or missing gasket Check for damaged threads Check for stripped or worn threads Check for damaged sealing surfaces Check for stripped or worn threads Inspect hose for punctures cuts or scrapes Make sure cam arms move freely Check for damaged threads Check for damage to sealing surfaces 10 4320 303 13 Table 4 2 Storage Assembly Crate Qty 0812 OD Hp 150 damage 4 inch Gate valve make sure assembly is tight Check for flanged loose damaged or missing nuts and bolts Check for damage to valve Make sure handwheel is firmly secured to valve stem M peu Grooved pipe Check for damaged or missing gasket IE ct Check for damaged or missing components Mi inch Grooved pipe Check for damaged or missing gasket coupling Check for damaged or missing bolts and nuts EE ERE 2B 0375 inch 6 inch x 6 Reducing tee CES SUR SUPE for damage to sealing surfaces inch x 4 inch and tee Table
149. coupling half 11 on inlet port of 125 GPM pumping assembly 9 aq Unscrew and remove female quick disconnect coupling half 11 from 125 GPM pumping assembly 10 inlet port ar Push cam arms on hose assembly 12 forward to open Remove hose 12 from 2 inch end of reducer 13 attached to filler discharge elbow 14 on 20 000 gallon pillow tank as Push cam arms on reducer 13 forward to open Remove reducer 13 from elbow 14 on 20 000 gallon pillow tank SECTION IV OPERATION UNDER UNUSUAL CONDITIONS 2 9 OPERATION IN UNUSUAL WEATHER The instructions for operation under unusual conditions are provided in paragraphs 2 9 1 through 2 9 5 2 9 1 600 GPM Pumping Assemblies For the operation of 600 GPM pumping assemblies under unusual environmental weather conditions reference applicable technical manual 2 9 2 125 GPM Pumping Assembly For the operation of 125 GPM pumping assembly under unusual environmental weather conditions reference applicable technical manual 2 9 3 Hypochlorination Units Models 1955 3 and A 506131 For the operation of hypochlorination units models 1955 3 and A 506131 under unusual environmental weather conditions reference applicable technical manual 2 9 4 20 000 Gallon Pillow Tank For the operation of 20 000 gallon pillow tank under unusual environmental weather conditions reference applicable technical manual 2 114 10 4320 303 13 2 9 5 Other TWDS Components The follow
150. coupling half 8 from 4 inch gate valve assembly 17 j Carefully remove gasket 18 k Remove eight nuts 19 lock washers 20 flat washers 21 bolts 22 and flat washers 23 Remove male flanged quick disconnect coupling half 11 from 4 inch gate valve assembly 17 Carefully remove gasket 24 m Disconnect first discharge hose assembly Figure 2 74 1 from female to female filler discharge elbow 2 of 20 000 gallon storage tank 3 2 108 10 4320 303 13 Figure 2 74 Disconnecting 20 000 Gallon Pillow Tank n Disconnect additional discharge hose assemblies as required to reach reducing tee gate valve assembly 2 8 6 Preparation for Movement of Distribution Points This is a general procedure for moving the distribution points For the preparation for movement disassembly requirements and disassembly procedures of the 125 GPM pumping assembly reference applicable technical manual For the preparation for movement disassembly requirements and disassembly of the model 1955 3 Hypochlorination unit reference applicable technical manual and for the model A 506131 Hypochlorination Unit reference applicable technical manual 2 8 6 1 Disassembly Requirements Disassembly of a distribution point requires the tools personnel and components referenced paragraph 2 3 7 1 Pack the components listed n table 2 12 in the DISTRIBUTION POINT crate after removing them from the distribution points 2 8
151. ct kit for presence of all components as detailed in Components of End Item Appendix C b Inspect chest and all components for damage 4 17 2 Repair Repair of the repair kit consists of replacing damaged or missing items 4 17 3 Replace Replace repair kit if either the chest is damaged or more than half of the repair kit components are damaged or missing 4 68 10 4320 303 13 4 18 SLING ASSEMBLY MAINTENANCE This task covers 4 18 1 Disassembly 4 18 3 Repair 4 18 2 Inspection 4 18 4 Assembly INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s There are no equipment conditions for this Automotive Section Ill Item 1 procedure General Safety Instructions Material Parts Do not work on equipment without following Lubricant Item 6 standard shop safety precautions Rags Item 8 Appendix E 4 18 1 Disassembly Figure 4 29 Sling Assembly Maintenance 4 69 10 4320 303 13 4 18 SLING ASSEMBLY MAINTENANCE Continued a Remove eight Figure 4 29 1 and four flat washers 2 b Remove two U bolts 3 c Remove 3 4 inch 1 9 cm wire rope assembly 4 two 1 2 inch 1 3 cm wire rope assemblies 5 and spreader bar 6 4 18 2 Inspection a Inspect U bolts 3 for distortion and worn or stripped threads b Carefully inspect 3 4 inch 1 9 cm wire rope assembly 4 and two 1 2 inch 1 3 cm wire rope assemblies 5 for loose splices worn or broken wires unraveled strand
152. d pumpin from th g assembly and the tools personnel and components listed below Remove the required components e crates marked PUMPING STATION and 10 MILE SEGMENT Perform inspections for each part for damage and operability 2 3 4 1 Assembly Requirements Tools Used To Rubber Mallet and Clamping Tool Items Install 6 inch grooved end pipe quick 157 and 3 Appendix C disconnect coupling clamps Pipe Wrench 6 Inch Install components with threaded fittings Notify unit maintenance to install components with threaded fittings Personnel Two required 2 39 10 4320 303 13 2 3 4 Lead Pumping Station Assembly Continued Components Table 2 8 Components Required from Pumping Station Crate for Assembly of Lead Pumping Station 6 inch Butterfly Valve 6 inch Check Valve 6 inch x 20 foot Discharge Hose Assembly 6 inch Grooved End Pipe Quick Disconnect Coupling Clamp 6 inch Pressure Relief Valve and Nipple Table 2 9 Components Required from 10 Mile Segment Crate for Assembly of Lead Pumping Station Coupling Half Quick Disconnect Female Coupling Pipe Fitting NOTE Required number of suction hose assemblies depends on distance between water source and lead pumping station Extra suction hose assemblies may be used as spares 6 inch x 10 foot Suction Hose Assembly 6 inch x 4 inch x 4 inch Y Connection Reducer 2 3 4 2 Assembly and Installation Procedures Reference applicable technica
153. d Class III leak 2 21 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Item Interval Item to Check Service Procedure Not Fully No Mission Capable if DISTRIBUTION POINT HYPOCHLORINATION UNIT MODEL 1955 1 CONT 23 Before Solution Inspect for damage and leaks Reservoir is Reservoir Check solution level Add damaged or has a solution as required para Class III leak 2 5 5 3 Inspect foot valve Not enough for obstruction solution in reservoir Foot valve obstructed 24 Before Valves Inspect valves for damage Valve s is leaks and improper damaged class operation Check to be sure Ill leak or valve turns freely does not turn freely 25 Before Frame Inspect frame for cracks damaged welds and corrosion TWDS SUPPORT KITS 26 Before TWDS Support Kits Inspect displacement and Item in kit is evacuation packing repair damaged or and suspension kits for missing damage Inspect each kit for damaged or missing items Ensure items in each kit are clean and dry Inspect latches hinges lid and box on each kit for damage 2 22 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Item Interval Item to Check Service Procedure Not Fully No Mission Capable if LEAD PUMPING STATION 27 During Hose Assemblies Inspect for damage leaks Hose is damaged and loose
154. d hinges Open chest and check inner partitions for broken seam welds Check contents in each kit listed in appendix C for damaged or missing items guards other damage E rss as m wrench spe for serviceability 1141 6 inch x 10 Suction hose NN hose for punctures cuts or foot assembly scrapes Ensure cam arms move freely Check for damaged or missing gasket 4 7 10 4320 303 13 4 4 3 Checking Unpacked Equipment Continued Table 4 4 10 Mile Segment Crate Continued Gy Size inspection O NOTE Some suspension kits may contain a round stake 5 Suspension kit Inspect kit chest for broken handles latches and hinges Open chest and check inner partitions for broken seam welds Check contents in each kit listed in appendix C for damaged or missing items 65 i Swivel joint and Check for smooth swivel operation coupling Check for damaged or missing gasket Check for damaged or missing components 6 inch x 4 Y connection Inspect reducer assembly for missing inch x 4 inch reducer parts Ensure coupling pipe fitting is tightly screwed into male quick disconnect coupling half Inspect grooved pipe coupling for tightness Ensure female quick disconnect couplings are tightly screwed onto reducer pipe fittings Ensure cam arms move freely Check for damaged or missing gaskets on quick disconnect and grooved pipe couplings
155. dures Perform the packing procedures detailed i subparagraphs The packing procedures for the hypochlorination unit model 1955 1 are contained in paragraph 2 8 4 71 10 4320 303 13 4 20 2 600 GPM Pumping Assemblies Packing Refer to applicable technical manual for packing procedures for the 600 GPM pumping assemblies 4 20 3 20 000 Gallon Pillow Tank Packing Refer to applicable technical manual for packing procedures for the 20 000 gallon pillow tank 4 20 4 125 GPM Pumping Assembly Packing Refer to applicable technical manual for packing procedures for the 125 GPM pumping assembly 4 20 5 Hypochlorination Unit Model 1955 3 Packing Refer to applicable technical manual for packing procedures for the model 1955 3 hypochlorination unit 4 20 6 Hypochlorination Unit Model A 506131 Packing Refer to applicable technical manual for packing procedures for the model A 506131 hypochlorination unit 4 21 MARKING Refer to MIL STD 129 for information on marking 4 22 STORAGE a Store equipment so as to provide maximum protection from the elements and to provide access for inspection maintenance and servicing b Take into account environmental conditions such as extreme cold or heat high humidity blowing snow or combinations thereof and take adequate precautions 4 23 ADMINISTRATIVE STORAGE a Placement of equipment in administrative storage should be for short periods of time when a shortage of maintenanc
156. e or high discharge pressure and take corrective action immediately 2 5 2 Operation of Lead Pumping Station Open butterfly valves on suction and discharge Refer to applicable technical manual for the operation of the 600 GPM pumping assembly 2 5 3 Operation of Boost Pumping Station Open butterfly valves on suction and discharge lines and close the butterfly valve on the bypass line Reference applicable technical manual for the operation of the 600 GPM pumping assembly 2 5 4 Operation of Storage Assemblies Reference applicable technical manual for the operation of 20 000 gallon pillow tank Figure 2 43 20 000 Gallon Pillow Tank Fill up a Open 4 inch gate valve Figure 2 48 1 to fill 20 000 gallon pillow tank 2 Check to see that drain valve 3 on 20 000 gallon pillow tank 2 is closed 2 77 10 4320 303 13 2 5 4 Operation of Storage Assemblies Continued Figure 2 44 Sandbag Installation b If 20 000 gallon pillow tank Figure 2 44 rolls when being filled place sandbags 2 along edge of 20 000 gallon pillow tank 1 to prevent further rolling c Whenever a 20 000 gallon pillow tank 1 is being filled inform operators at downline pumping stations to expect reduction in hoseline pressure The reduction in pressure can cause engines on downline stations to reduce speed Whenever possible do not fill 20 000 gallon pillow tank s 1 at a rate that causes downline pumping stations to reduce speed d
157. e efforts exists Items should be in mission readiness within 24 hours or within the time factors as determined by the directing authority During the storage period appropriate maintenance records will be kept b Before placing equipment in administrative storage current maintenance services and Preventive Maintenance Checks and Services PMCS should be completed shortcomings and deficiencies should be corrected and all modification work orders MWO s should be applied c Storage site selection Inside storage is preferred for items selected for administrative storage If inside storage is not available trucks vans conex containers and other containers may be used 4 72 10 4320 303 13 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS Subject Index Page SECTION I REPAIR PARTS SPECIAL TOOLS TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT TMDE AND SUPPORT EQUIPMENT EET 5 2 Common Tools and 0 0 2 0100 essere nnns Special Tools and Support Equipment ccccccccccsssses sesenta 5 2 Repair crier enr 5 2 SECTION II DIRECT SUPPORT MAINTENANCE 4 5 3 10 Mile Segment esses ener Pressure Reducing Valve Assembly Hypochlorination Unit Model 1955 1
158. e end item or component will be consistent with the capacities and capabilities of the designated maintenance levels which are shown on 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 B 1 3 Tools and Test Equipment Introduction Section Ill lists the tools and test equipment both special tools and common tool sets required for each maintenance function as referenced from section Il B 1 4 Supplemental Instructions Introduction Section IV contains supplemental instructions and explanatory notes for a particular maintenance function B 2 MAINTENANCE FUNCTIONS Maintenance functions are limited to and defined as follows B 2 1 Inspect To determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination e g by sight sound or feel B 2 2 Test To verify serviceability by measuring the mechanical pneumatic hydraulic or electrical characteristics of an item and comparing those characteristics with prescribed standards B 2 3 Service Operations required periodically to keep an item in proper operating condition i e to clean includes decontaminate when required to preserve to drain to paint or to replenish fuel lubricants chemical fluids or gases B 2 4 Adjust T
159. e functions see paragraph B 2 B 3 4 Column 4 Maintenance Level Column 4 specifies each level of maintenance authorized to perform each function listed in Column 3 by indicating work time required expressed as manhours in whole hours or decimals in the appropriate subcolumn This work time figure represents the active time required to perform that maintenance function at the indicated level of maintenance If the number or complexity of the tasks within the listed maintenance function vary at different maintenance levels appropriate work time figures are to be shown for each level 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 1 Services 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 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 identified as maintenance significant Actions weld
160. e three nuts 8 lock washers 9 flatwashers 10 and bolts 11 Discard lock washers 9 Remove hypochlorinator frame 12 from hypochlorination unit Disassembly Turn stroke adjust knob 13 fully counterclockwise and remove stroke adjust knob 13 from diaphragm cap 14 Remove preformed packing 15 from stroke adjust knob 13 Discard preformed packing 15 WARNING Items in hypochlorinator assembly are under spring tension Maintain pressure on and slowly back diaphragm cap out to release spring pressure Failure to obey this warning may result in personal injury Remove four screws 16 flat washers 17 and square nuts 18 Slowly remove diaphragm cap 14 Remove nut 19 and washer 20 from pushrod 21 Remove impulse diaphragm 22 diaphragm clamping washer 23 spring spacer 24 spring 25 and preformed packing 26 from pushrod 21 Discard preformed packing 26 4 47 10 4320 303 13 4 13 6 Hypochlorinator Assembly Maintenance Continued Figure 4 19 Hypochlorinator Assembly Maintenance g Remove eight screws 27 and lock washers 28 Discard lock washers 28 h Remove liquid head 2 from hypochlorinator frame 12 i Remove liquid head pushplate 29 diaphragm 30 and flat washer 31 from pushrod 21 j Remove pushrod 21 from hypochlorinator frame 12 4 13 6 3 Inspection a Inspect discharge tube 1 and suction tubes 2 for slice cracks holes t
161. e with tripods 1 and extend approximately 6 inches above ground c Hang a pulley block 4 from each tripod 1 and thread wire rope 5 through pulley 4 on near side Tie manila rope to wire rope 5 d Pull wire rope 5 across stream 2 or obstruction by manila rope e When wire rope 5 reaches far side of stream 2 or obstruction remove manila rope from wire rope 5 f Thread wire rope 5 through pulley block 4 on far side of stream 2 or obstruction Construct loop of wire Figure 2 39 1 about 9 inches from one end of wire rope 2 and insert thimble 3 into loop h Locate two clamp assemblies 4 5 and 6 Remove two nuts 4 and one clamp 5 from each U bolt 6 2 71 10 4320 303 13 2 3 8 Assembly of 10 Mile Hoseline Segment Continued Figure 2 39 Securing Wire Rope NOTE Assemble as shown in Figure 2 36 i Place one U bolt 6 over double portion of wire rope 2 approximately 2 inches from end of wire rope thimble 3 j Install clamp 5 and two nuts 4 Tighten nuts 4 until double portion of wire rope 2 is held firmly together k Place second U bolt 6 over double portion of wire rope 2 approximately 4 inches down from first clamp l Install clamp 5 and two nuts 4 Tighten nuts 4 until doubled portion of wire 2 is held snugly together m Install thimble 3 Tap U bolt assembly towards thimble 3 until thimble 3 is secure Ti
162. ears or damage 4 48 10 4320 303 13 b Inspect hypochlorinator frame 12 stroke adjustment knob 13 diaphragm cap 14 push rod 21 impulse diaphragm 22 diaphragm clamping washer 23 spring 25 liquid head pushplate 29 and diaphragm 30 for corrosion cracks bends or damage c Inspect check valves 3 and washers 4 for damage d Inspect all mounting hardware and washers for corrosion or damage 4 13 6 4 Repair Repair of the hypochlorinator assembly consists of replacing defective or damaged components 4 13 6 5 Assembly a Insert pushrod 21 into hypochlorinator frame 12 b Install flat washer 31 diaphragm 30 and liquid head pushplate 29 on pushrod 21 c Install liquid head 2 on hypochlorinator frame 12 d Align mounting holes of liquid head 2 with mounting holes of hypochlorinator frame 12 e Install eight new lock washers 28 and screws 27 Tighten screws 27 f Install new preformed packing 26 spring 25 spring spacer 24 diaphragm clamping washer 23 and impulse diaphragm 22 on pushrod 21 g Install washer 20 and nut 19 on pushrod 21 Tighten nut 19 h Install diaphragm cap 14 on hypochlorinator frame 12 and align mounting holes of diaphragm cap 14 with mounting holes on hypochlorinator frame 12 Install four square nuts 18 flat washers 17 and screws 16 Tighten screws 16 Install new preformed packing 15 on stroke adjust k
163. ect spring 4 for bends corrosion or damage c Inspect diaphragm 8 for holes slices tears or damage d Inspect all mounting hardware for damage e Replace damaged screws 1 spring 4 diaphragm 8 disc retainer assembly 11 f If any other pressure reducing control components are damaged replace pressure reducing control 5 5 1 3 Assembly a Install yoke 13 in body 12 b Insert disc retainer assembly 11 through hole in body 12 and thread disc retainer assembly 11 into yoke 13 until it bottoms NOTE Disc retainer assembly must enter guide hole in plug as it is being assembled c Install new gasket 10 on plug 9 Install plug 12 d Install diaphragm 8 diaphragm washer 7 belleville washer 6 on yoke 13 e Install nut 5 Do not tighten nut 5 f Adjust diaphragm 8 so that holes in diaphragm 8 align with holes in body 12 g Torque nut 5 to 45 to 55 Ib in 5 5 10 4320 303 13 5 5 1 Pressure Reducing Control Repair Continued h Check alignment of diaphragm 8 Move diaphragm left and right as far as possible Holes in diaphragm 8 should move equal distance to either side of holes in body 12 within 1 8 in If diaphragm does not align repeat steps d through g above i Move yoke 13 to OPEN and CLOSE positions Make sure yoke 13 moves back and forth smoothly and does not make contact with nozzle on body 12 j Install spring guide 3 on top of spring 4 Install sprin
164. ed pipe coupling para 2 3 2 2 g Connect leading end of hose assembly Figure 2 35 1 in flaking box one Figure 2 34 1 to pressure Figure 2 35 relief valve Figure 2 35 2 on discharge hose 3 at lead pumping station 4 Attach leading end of hose 1 with grooved end pipe quick disconnect coupling clamp 5 para 2 3 3 2 2 68 10 4320 303 13 Figure 2 35 Connection to Lead Pumping Station CAUTION DO NOT leave hose on roadway or track that will be used by other vehicles Hoseline is easily damaged by rough handling or abrasive contact with rocks NOTE Restrain hose assembly manually until first 50 feet of hose assembly is in position After 50 feet of hose assembly is in position the weight of the hose will hold line in place h Refer tq paragraphs 2 3 8 2 4 through 2 3 8 2 7 and deploy hose assembly i Continue to lay hose until hoseline in all four boxes has been flaked CAUTION Swivel joints Figure 2 36 1 must be installed at every 1 000 feet in hoseline 2 If not installed hoseline 2 will twist during startup and cause damage to equipment j Repeat steps a through i leaving out step g to connect each truckload of hoseline to sections already laid Be sure to install swivel joints Figure 2 36 1 at every 1 000 feet in hoseline 2 k Connect hoseline 2 to each boost pumping station and storage assembly as those installation sites are reached 2 69 10 4320 3
165. eet hose assemblies respectively Installation of a full 10 mile segment along a direct route across even terrain will require at least 108 54 if newer model flaking box flaking boxes of hoseline 2 3 8 2 1 c One 6 inch grooved pipe coupling is required for each 500 foot hoseline assembly used One swivel point is required for every 1 000 feet of hoseline For example if 108 flaking boxes of hoseline are used then 108 grooved pipe couplings and 54 swivel joints are required for installation 2 3 8 5 If the newer style flaking boxes are used then only 54 grooved pipe couplings are required and swivel joints are required d Road crossing guards and suspension kits are used when the hoseline crosses roads or obstacles in the terrain such as streams rivers gullies and ravines Each road crossing guard is 5 feet in length If the width of a road being crossed is 15 feet for example then three or four road crossing guards are required to protect the hoseline Each suspension kit contains enough wire rope to construct a span of 200 feet Therefore one suspension kit is required to cross a 150 foot wide gap or one suspension kit can be used to construct spans across two 75 foot wide gaps 2 3 8 7 e The pressure reducing valve assembly is required when pressure at a certain point in the hoseline is expected to exceed 225 psi If the hoseline crosses over a steep hill or ridge then a pressure reducing valve may be required on the dow
166. ent Preparation for 2 8 Nomenclature Cross Reference 1 6 Nuclear Biological and Chemical NBC 2 10 Operating Procedures 2 5 Operating Procedures TWDS General oi eet ees 2 5 1 Operation in Unusual Weather 2 9 Operation of Auxiliary Equipment 2 7 TM 10 4320 303 13 O Continued Operation of Boost Pumping ooi er aeree eee 2 5 3 Operation of Distribution Points 2 5 5 Operation of Lead Pumping Station 2 5 2 Operation of Storage Assemblies 2 5 4 Operator s Controls and IndiGalors 2 2 2 9 a 2 1 Outlet Hose Assembly Maintenance 4 13 2 P Packing etenim 4 20 Packing Kit Maintenance 4 16 Pilot Valve Assembly 5 6 1 Points Distribution Assembly fo CURRO M 2 3 7 Points Distribution Functional Description 1 19 2 Preliminary Servicing and Adjustment of Equipment 4 6 Preparation for Movement 2 8 Preparation for Movement of 10 Mile Hoseline 2 8 2 Preparation for Movement of Boost Pumping Stations 2 8 4 Preparation for Movement
167. er 5 valve sleeve 9 valve housing 11 and valve housing cap 17 for cracks holes corrosion or damage b Inspect all mounting hardware for corrosion and damage 5 12 10 4320 303 13 WARNING e Dry cleaning solvent used to clean parts is potentially dangerous to personnel and property Avoid repeated or prolonged skin contact Do not use near open flame or excessive heat Flash point of solvent is 100 138 degrees Fahrenheit 38 60 C e To prevent injury to eyes safety glasses must be worn when using compressed air e Failure to obey these warnings may result in personal injury or death Clean all reusable components with compressed air or cleaning solvent as appropriate d Dry all components cleaned using cleaning solvent with compressed air 5 6 1 3 Repair Repair consists of replacing all damaged or defective components 5 6 1 4 Assembly a Install pipe plug 18 valve housing cap 17 and four screws 16 in valve housing 11 Tighten screws 16 b Install valve sleeve 15 in valve housing 11 c Install slug assembly 14 and valve rod 8 in valve housing 11 d Install rod lock nut 7 on valve rod 8 Turn rod lock nut 7 two or three times for installation of valve rod 8 in spring link coupling 9 e Install retainer ring 13 lock spring cap 3 with two screws 1 on valve housing 1 1 f Place new gasket 12 and valve housing 11 on gear box 6 g Insert four screws 10 Tigh
168. er 5 to end of nipple 1 Use grooved end pipe quick disconnect coupling clamp 7 para 2 3 3 2 from displacement and evacuation kit Locate pneumatic coupler 8 Screw pneumatic coupler 8 into air compressor line 9 2 91 10 4320 303 13 Figure 2 56 Pneumatic Coupler Installation WARNING Stand clear of receiver during displacement process Hoseline jumps when ball arrives at receiver Failure to obey this warning may result in personal injury Connect pneumatic coupler 8 to pneumatic coupler 5 on end cap 6 Pressurize hoseline to 80 to 90 psi Displacement ball 4 will be forced through hose displacing any residual water A sound will be heard when the displacement ball 4 reaches receiver Figure 2 52 4 NOTE e f ball gets stuck straighten kinks in hoseline e t may be necessary to increase air pressure DO NOT exceed 150 psi m Shut off compressor when displacement ball Figure 2 56 4 reaches receiver Figure 2 55 3 n Open snaplock coupling Figure 2 58 7 connecting two reducers 5 and 6 Pull snaplock coupling 7 back and separate two hinged coupling halves of snaplock coupling 7 Set snaplock coupling 7 displacement ball Figure 2 56 4 and modified reducer Figure 2 55 6 aside o Remove grooved end pipe quick disconnect coupling clamp 1 para 2 3 3 1 connecting unmodified reducer 5 to hoseline segment 2 2 92 10 4320 303 13 Figure 2 57
169. erence the applicable technical manual and immediately shut down 600 GPM pumping assemblies that fail to remain primed g Close gate valves connected to storage assemblies h Distribution points continue to operate as long as enough water remains in storage tanks When water in storage tanks drops to inoperable level shut down operation of distribution points 2 5 5 Refer to the applicable technical manual and shut down engine on 125 GPM pumping assembly paral 2 5 52 2 12 3 Failure of Storage Assembly f storage assembly fails operation is possible ONLY under the following conditions 1 Two storage assemblies are in use and 2 The unaffected storage assembly is being used with a distribution point To temporarily adapt operation proceed as follows a Notify operators at other stations of equipment failure 600 GPM pumping assemblies may require adjustment if necessary refer to applicable technical manual and adjust operation of 600 GPM pumping assemblies accordingly b Close gate valve connected to defective storage tank para 2 5 4 c If distribution point is being used with defective storage tank shut down distribution point para 2 5 5 Refer to the applicable technical manual and shut down engine on 125 GPM pumping assembly 2 12 4 Failure of Distribution Point a distribution point fails TWDS operation is possible ONLY if two distribution points are in use To temporarily adapt TWDS operation proceed
170. ert pages as indicated below New or changed text material is indicated by a vertical bar in the margin An illustration change is indicated by a miniature pointing hand Remove pages Insert pages i and ii 1 9 1 10 1 9Jand 1 10 2 Retain this sheet in front of manual for reference purposes By Order of the Secretary of the Army DENNIS J REIMER General United States Army Chief of Staff Official JOEL B HUDSON Administrative Assistant to the Secretary of the Army 02186 DISTRIBUTION To be distributed in accordance with DA Form 12 25 E block no 6077 requirements for TM 10 4320 308 13 10 4320 303 13 WARNING Do not stand under load being lifted Do not allow sand or grit to contaminate chlorine solution Calcium hypochlorite can cause injury if not handled properly Do not use calcium hypochlorite without proper clothing Wear goggles rubber gloves and apron to protect eyes and skin Wash exposed skin thoroughly If calcium hypochlorite comes into contact with skin or eyes flush right away with water and seek medical attention Store calcium hypochlorite in a cool dry place Keep container closed Mix calcium hypochlorite only in accordance with directions Do not allow calcium hypochlorite to mix with other chemicals such as fuels oils paint products or ammonia This could cause fire or hazardous gas Hearing protection must be worn be personnel within 50 meters of an operating
171. f 17 forward to open position 2 54 E lt 10 4320 303 13 CAUTION e To prevent leakage close both cam arms at the same time e Donotstrike cam arms to close Damage to couplings may result Connect male by female reducer 18 to female quick disconnect coupling half 17 Close cam arms Push cam arms on male by female reducer 18 forward to open position CAUTION e To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result Connect discharge hose 9 to male by female reducer 18 Close cam arms NOTE Wrap antiseize tape in direction of threads Wrap antiseize tape item 9 appendix E around threads on male quick disconnect coupling half 19 Screw male quick disconnect coupling half 19 into outlet port 11 on hypochlorination unit 1955 3 12 Push cam arms on reducer 20 forward to open position CAUTION e To prevent leakage close both cam arms at the same time e Donotstrike cam arms to close Damage to couplings may result Connect reducer 20 to male quick disconnect coupling half 19 attached to hypochlorination unit 1955 3 12 Close cam arms Push cam arms on discharge hose 21 forward to open position CAUTION e To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result Connect discharge hose 21 to reducer 20 Close cam arms
172. f welding cracked seams and frame members in accordance with MIL STD 1261 and TM 9 237 10 4320 303 13 5 5 PRESSURE REDUCING VALVE ASSEMBLY MAINTENANCE 5 5 1 Pressure Reducing Control Repair This task covers 5 5 1 1 Disassembly 5 5 1 2 Inspection INITIAL SETUP Tools Tool Kit General Mechanic s 5 5 1 3 Assembly Equipment Conditions Pressure Reducing Control removed paragraph Automotive Section Ill Item 1 4 11 5 General Safety Instructions Torque Wrench Section Ill Item 2 Do not work on equipment without following Materials Parts standard shop safety precautions Gasket TM 10 4320 303 23P 5 5 1 1 Disassembly wi U KEREKE menu N Figure 5 1 Pressure Reducing Control Maintenance 5 4 10 4320 303 13 Adjusting screw has been factory calibrated and should not be adjusted a Remove eight cover screws Figure 5 1 1 b Remove cover 2 c Remove spring guide 3 and spring 4 d Remove nut 5 e Remove belleville washer 6 diaphragm washer 7 and diaphragm 8 f Remove plug 9 g Remove gasket 10 from plug 9 Discard gasket 10 h Unscrew disc retainer assembly 11 CCW i Remove disc retainer assembly 11 through hole in bottom of body 12 j Remove yoke 13 from body 12 5 5 1 2 Inspection a Inspect all metal parts for cracks holes corrosion or signs of wear and damage b Insp
173. fer to applicable repair parts and special tools list 4 3 2 125 GPM Pumping Assembly Refer to applicable repair parts and special tools list 4 3 3 Hypochlorination Unit Model 1955 3 Refer to applicable repair parts and special tools list 4 3 4 Hypochlorination Unit Model A 506131 Refer to applicable repair parts and special tools list 4 3 5 20 000 Gallon Pillow Storage Tank Refer to applicable repair parts and special tools list SECTION Il SERVICE UPON RECEIPT 4 4 SERVICE UPON RECEIPT OF MATERIEL 4 4 1 Siting and Location For information on locating and positioning of TWDS refer td paragraph 2 3 1 of this manual 4 4 2 Unpacking 4 4 21 TWDS Components Packing Groups TWDS consists of four equipment groups divided into eight packing groups The packing groups contain a total of 47 crates Each crate is plywood sheathed skidded and equipped with headers for using a forklift Each crate is marked with the equipment name and packing group to which it belongs To unpack the TWDS perform unpacking procedures detailed below that apply to each equipment group Equipment utilized depends on the specific TWDS mission Unpack only those components required to complete the intended mission The 4 2 10 4320 303 13 following paragraphs detail each equipment group the number of crates comprising each group crate markings general contents of each crate and crate deployment 4 4 2 2 Pumping Stations The six trailer mounted pu
174. for the term appears immediately to the right of the hyphen TERM DEFINITIONS Hoseline Packing filling of hoseline with water Hypochlorination injection of large concentrations of chlorine into water for purification purposes Hypochlorination Unit a mechanical assembly used to inject large concentrations of chlorine into potable water GLOSSARY 1 GLOSSARY 2 Blank Abbreviations List of 1 12 Administrative Storage 4 23 Assemblies Pumping Trailer Mounted Equipment Data for 1 17 1 Assemblies Storage Operation o MEER 2 5 4 Assembly and Preparation TOP USC inate ep terere tere 2 3 Assembly of 10 Mile Hoseline SegrmieriL cet dete ee 2 3 8 Assembly of Distribution 2 3 7 Assembly of Storage ts 2 3 6 Assembly Boost Pumping SEallO Maori vete ete eee e eee 2 3 5 Assembly Lead Pumping iege 2 3 4 Assembly Pumping 125 GPM Equipment Data 1 17 3 Assembly Pumping 125 GPM Maintenance Operator 3 6 Assembly Storage Functional Description 1 19 2 Assembly Storage Operator 3 5 Auxiliary Equipment Operation 2 7 B Boost Pumping Station Assembly 2 2 3 5 Boost Pumping Station Operation
175. function or failure in a part subassembly module component or assembly end item or system B 2 10 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 publication 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 B 2 11 Rebuild Consists of those services 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 materiel maintenance applied to Army equipment The rebuild operation includes the act of returning to zero those age measurement e g hour miles considered in classifying Army equipment components EXPLANATION OF COLUMNS IN THE MAC SECTION B 3 1 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 3 2 Column 2 Component Assembly Column 2 contains the item names of components assemblies subassemblies and modules for which maintenance is authorized B 3 3 Column 3 Maintenance Function Column 3 lists the functions to be performed on the item listed in Column 2 For detailed explanation of thes
176. g 4 and spring guide 3 Install cover 2 on body 12 Align holes in cover 2 with holes in body 12 Install eight screws 1 Tighten screws 1 10 4320 303 13 5 5 2 Main Valve Assembly Repair This task covers 5 5 2 1 Disassembly 5 5 2 3 Assembly 5 5 2 2 Repair INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s Main Valve Assembly removed paragraph Automotive Section Ill Item 1 4 11 5 General Safety Instructions Material Parts Do not work on equipment without following Sandpaper Section Il Item 138 standard shop safety precautions 5 5 2 1 Disassembly Figure 5 2 Main Valve Assembly Maintenance a Remove twelve hex nuts Figure 5 2 1 5 7 10 4320 303 13 5 5 2 Main Valve Assembly Repair Continued WARNING Remove cover slowly to release spring tension Failure to do so may result in personal injury and injury to personnel CAUTION Pull cover straight up when removing cover from main valve Failure to do so may result in damage to cover bearing or valve stem o Slowly lift cover 2 from valve body 3 o Remove spring 4 from valve stem 5 CAUTION Use vise with soft brass jaws Failure to do so may result in damage to valve stem Secure lower end of valve stem 5 in vice with soft jaws Examine threads on valve stem 5 above stem nut 6 for signs of corrosion or mineral deposits If needed clean threads on va
177. ghten nuts 4 on U bolts 6 n Unscrew turnbuckle hook 8 until it is almost fully extended This will allow for adjustment to take up wire rope 2 slack Attach one turnbuckle hook 8 to loop in wire rope 2 Attach other turnbuckle hook 8 to anchor stake 9 2 72 10 4320 303 13 p Repeat steps f through m with opposite end of wire rope 2 q Using turnbuckles 7 adjust slack in wire rope with no load until wire rope 2 is taut Figure 2 40 Saddle Installation Tie manila rope Figure 2 40 1 to leading end of hoseline 2 Make sure manila rope 1 is long enough to cross span NOTE As each saddle assembly is disassembled inspect saddle for tears and damaged or missing metal eyelets Replace damaged saddles S Locate saddles 3 bolts 4 shackles 5 and nuts 6 t Place shackle 5 over wire rope 8 beyond pulley 7 on span side Lift hose 2 end and wrap saddle 3 around hose 2 v Install bolt 4 through eyes of saddle 3 shackle 5 and nut 6 Tighten nut 6 until saddle assembly 3 4 5 and 6 is secured to wire rope 8 Using manila rope Figure 2 40 1 pull hoseline Figure 2 41 1 across stream 2 gap or obstruction Repeat steps p through t attaching additional saddles 3 to hoseline 1 at 5 feet intervals Saddles 3 will travel along wire rope 4 providing support for hoseline 1 2 73 10 4320 303 13 2 3 8 Assembly of 10 Mi
178. grooved pipe coupling para 2 3 2 1 from leading ends of hose assemblies in flaking boxes Figure 2 34 1 2 3 and 4 CAUTION After removing components from boxes be sure to protect them from sand and grit b Connect leading end of hose in flaking box fout figure 2 34 4 to trailing end of hose in flaking box three 3 with 6 inch grooved pipe coupling para 2 3 2 2 2 67 10 4320 303 13 2 3 8 Assembly of 10 Mile Hoseline Segment Continued Figure 2 34 Grooved Pipe Coupling and Swivel Joint installation CAUTION Install swivel joint after every 1 000 feet of hoseline 2 hoseline segments Failure to install swivel joint every 1 000 feet may result in damage to equipment NOTE Newer flaking boxes contain 1 000 foot sections of hose c Connect swivel joint 5 to leading end of hose in flaking box three 3 with 6 inch grooved pipe coupling para 2 3 2 2 d Connect trailing end of hose in flaking box two 2 to swivel joint 5 with grooved end pipe quick disconnect coupling para 2 3 3 2 e Connect leading end of hose in flaking box two 2 to trailing end of hose in flaking box one 1 with 6 inch grooved pipe coupling para 2 3 2 2 CAUTION Install swivel joint after every 1 000 feet of hoseline 2 hoseline segments Failure to install swivel joint every 1 000 feet may result in damage to equipment f Connect swivel joint 5 to trailing end of hose in flaking box four 4 with 6 inch groov
179. h Gate Valve Inspect for damage improper 4 inch gate operation and leaks If valve is damaged valve is damaged or not or not operating operating properly notify properly Class unit maintenance If Class Ill leak Ill leaks are present notify supervisor 35 During 4 Inch x 10 Foot Inspect for damage leaks Hose is damaged Hose Assembly and loose connections or leaking Tighten loose connections Class III leak If hose is damaged or Class Connection is leaks are present notify loose supervisor 2 26 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Not Fully Item Item to Mission Capable No Interval Check Service Procedure if DISTRIBUTION POINT 36 During 2 Inch Gate Valve Inspect for damage leaks 2 inch gate and improper operation If valve is damaged valve is damaged not or not operating properly operating properly or Class Class III leak lll leaks are present notify supervisor 37 During Elbow Valve Inspect for damage leaks Elbow valve is and improper operation If damaged or not valve is damaged not operating properly operating properly or Class Class III leak Ill leaks are present notify supervisor 38 During Nozzle Inspect for damage and leaks Nozzle is Ensure triggers work damaged properly If nozzle is Trigger is not damaged trigger is not properly working properly or Class operating Ill leak is presen
180. he 10 mile hoseline segment crate containing kits required to repack the hoseline last i Pack all components for the six pumping stations in one crate except for trailer mounted pump assemblies Refer to applicable technical manual for preparation of movement for 600 GPM pumping assemblies Collect pumping station components and packing materials at a single site before repacking crate Otherwise all packing materials must be shuttled to each installation site for packing 2 89 10 4320 303 13 2 8 1 Procedures for Preparation for Movement of TWDS Continued j Pack all components for the two storage assemblies except 20 000 gallon pillow tanks together in one crate Collect all components for both storage assemblies and all packing materials at a single site before repacking crate k Pack all components for two distribution points except 125 GPM pumping assemblies in one crate Refer to applicable technical manual for preparation for movement of 125 GPM pumping assembly Collect all components for both distribution points at a single site before repacking crate Pack all components for the 10 mile hoseline segment except for hoseline and flaking boxes in one crate Collect all 10 mile hoseline segment components at a single site before repacking crate m Packing TWDS requires the following general steps 1 Remove lids from crates As required remove blocking bracing anchoring packing materials and fiberboard
181. he equipment 4 8 1 3 Location and Item to Check Service Column This column provides the location and the item to be checked or serviced The item location is underlined 4 8 1 4 Procedure Column This column gives the procedure you must do to check or service the item listed in the Check Service column to know if the equipment is ready or available for its intended mission or for operation You must do the procedure at the time stated in the interval column 4 8 1 5 Not Fully Mission Capable if Column Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission If you make check and service procedures that show faults listed in this column do not operate the equipment Follow standard operating procedures for maintaining the equipment or reporting equipment failure 4 9 10 4320 303 13 4 8 2 Special Instructions Preventive maintenance is not limited to performing only those checks and services listed in the PMCS Table Covering unused receptacles stowing unused accessories and other routine procedures such as equipment inventory cleaning components and touch up painting are not listed in the table These are things you should do any time you see that they need to be done If a routine check is listed in the PMCS Table it is because experience has shown that problems may occur with this item Take along tools and cleaning cloths needed to perform the required checks and servi
182. hlorination unit can chlorinate water at a rate of up to 100 gpm A 2 inch hose network and 2 inch gate valves direct water flow from the hypochlorination unit to the manual dispersing stations Chlorinated water can be dispensed from a hand held nozzle an elbow valve or a 36 gallon water storage bag 1 14 2 Capabilities and Features Can transport water at 600 GPM across level terrain Can transport 720 000 gallons of water within a 24 hour period Can be deployed and operational within 48 hours 1 15 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS figures 1 2 through 1 9lillustrate the major components of the TWDS Tables 1 2 through 1 9 list the major components and provide a description of each major component 10 4320 303 13 1 15 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED Item Figure 1 2 Location of Major Components for TWDS Lead Pumping Station Table 1 2 Description of Major Components for TWDS Lead Pumping Station Item Name LEAD PUMPING STATION 6 INCH BUTTERFLY VALVE HOSE ASSEMBLY Y CONNECTION REDUCER HOSE ASSEMBLY PRESSURE RELIEF VALVE 200 PSI CHECK VALVE Description and Purpose 600 GPM pumping assembly Pumps water from source and delivers it down line One of three pumping assemblies may be supplied with the TWDS Refer to applicable technical manual for detailed information concerning the pumping assemblies Used to control water flow into lead pumping assem
183. hose end 2 until shoulder 3 is flush hose end 2 Refer to paragraph 3 4 1 and perform steps i through v Refer to paragraph 3 4 1 1 and perform steps a through g to install hose 2 on other end of double ended adapter 1 Refer t paragraph 3 4 1 1 and perform steps i through v Release hose clamps Figure 3 1 1 and inspect repaired section for leaks 3 5 STORAGE ASSEMBLY MAINTENANCE Refer to applicable technical manual for operator maintenance procedures for the 20 000 gallon pillow tank maintenance 3 6 125 GPM PUMPING ASSEMBLY MAINTENANCE Refer to applicable technical manual for operator maintenance procedures for the 125 GPM pumping assembly 3 12 10 4320 303 13 CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS Subject Index Page SECTION REPAIR PARTS TOOLS SPECIAL TOOLS TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT TMDE AND SUPPORT EQUIPMENT Common Tools and Special Tools TMDE and Support Equipment sss seen d Repair Pats PRENNE MNT S NUUR SECTION Il SERVICE UPON RECEIPT cccscscscesssssseseseses nennen nennen nennen 4 2 Service Upon Receipt of Materiel s essen nennen Installation sese enne nennen enne
184. hoseline segment Figure 2 58 7 using grooved end pipe quick 10 para 2 3 3 2 disconnect coupling ara 2 3 3 2 aa Repeat steps a through z for each downline hoseline segment Move air compressor down two hose lengths Evacuate trailing hose then lead hose length to minimize number of times air compressor is to be moved ab When a hoseline length has been evacuated collapsed and capped it is ready for packing in a flaking box ac When a swivel joint is removed return it and one grooved end pipe quick disconnect coupling clamp to lead pumping station installation site 2 8 2 3 Repacking Hoseline Segments in Flaking Box Assemblies CAUTION Clear sharp objects out of flaking box before packing Any object pressed against hose during packing could puncture it a Clean empty flaking box assembly Figure 2 59 1 Figure 2 59 Flaking Box Assembly Preparation b Perform steps and b or c oi paragraph 2 3 8 4 to load empty flaking box on truck c Transport empty flaking box and packing kit to leading end of first hoseline length 2 94 10 4320 303 13 Figure 2 60 Pullboard Flange and Coupling Sleeve Installation d Remove the following from packing kit 2 hose retaining clamps 2 pullboard halves 2 pullboard flanges 1 coupling sleeve 14 hex nuts 14 flat washers 8 square neck bolts 6 cap screws 14 self locking nuts 1 chain hoist 2 eyebolts 4 nuts and 4 flat washers 1 Remove screws on fro
185. ications and Blank Forms Recommended Changes to Equipment Technical Publications Depreservation Guide for Vehicles and Equipment Equipment Inspection and Maintenance Worksheet Report of Discrepancy Product Quality Deficiency Report FIELD MANUALS NBC Contamination Avoidance NBC Protection 0 Fixed Site 7 4 241 NBC 00 2 Field Behavior of NBC Chemical Reference Handbook First Aid for Soldiers eee eene A 4 TECHNICAL MANUAL Operator s Manual for Welding Theory and Applications Procedures for Destruction of Equipment to Prevent Enemy Use Mobility Equipment Command Operator s and Unit Maintenance Manual for 20 000 Gallon Collapsible Fabric sene Operator s Unit Intermediate Direct Support and Intermediate General Support Maintenance Including Repair Parts and Special Tools List Compressor Rotary Air DED 250 CFM 100 PSI Trailer MOUnted RR Rn Organizational Direct Support and General Support Repair Parts and Special Tools List for Tactical Water Distribution Equipment System TWDS Set 10 Mile Segment Models 06749 0183 81 110 00 0000 10 5 cerco 5 MISCELLANEOUS PUBLICATIONS Abbrevi
186. ifies the item item size item quantity contained in the crate and an inspection to be performed on each item Refer to applicable technical manual for inspection and unpacking of the 600 GPM pumping assemblies 20 000 gallon pillow storage tanks and 125 GPM 4 3 4 4 3 Checking Unpacked Equipment Continued TM 10 4320 303 13 pumping assemblies Check the equipment against the packing slip to see if the shipment is complete Report all discrepancies missing components or damage in accordan ce with the instructions of DA Pam 738 750 Report any deficiencies found while unpacking on SF 364 Report of Deficiency Table 4 1 Pumping Station Crate 18 6 inch Butterfly valve Check valve 6 inch 6 6inchx10 foot 6 inch x 20 foot assembly Discharge hose assembly 6 inch x 75 Discharge hose foot assembly 6 inch Grooved pipe coupling 12 6 inch Lateral grooved pipe fitting 6 inch Pressure relief valve and nipple Inspection operation Ensure disc operates freely Ensure assembly is tight Check for loose missing or damaged nuts scrapes Ensure bands that secure adapters are tight Inspect hose for punctures cuts or scrapes Ensure bands that secure adapters are tight Inspect hose for punctures cuts or scrapes Ensure bands that secure adapters are tight Check for damaged or missing gasket Check for damaged or missing components Check for damaged to sealing surfaces Check for cra
187. ii DETAIL B i ste 4 Q BOOST PUMPING STATIONS DETAIL G LEAD PUMPING STATION STORAGE ASSEMBLY DISTR DOTON POINT DETAIL A DETAIL H BOOST PUMPING STATIONS DETAIL G FLAKING BOX ASSEMBLY DETAIL F 9068 44 REDUCING ROAD CROSSING GUARD VALVE DETAIL D 10 MILE ASSEMBLY HOSELINE DETAIL E SEGMENT DETAIL B Figure 2 7 Operator PMCS Routing Diagram Sheet 1 of 5 2 10 10 4320 303 13 DETAIL DETAIL B DETAIL C Figure 2 7 Operator PMCS Routing Diagram Sheet 2 of 5 2 11 10 4320 303 13 Figure 2 7 Operator PMCS Routing Diagram Sheet 3 of 5 2 12 10 4320 303 13 DETAIL I Figure 2 7 Operator PMCS Routing Diagram Sheet 4 of 5 2 13 10 4320 303 13 22 41 DETAIL I continued Figure 2 7 Operator PMCS Routing Diagram Sheet 5 of 5 2 14 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Item Interval Item to Procedure Not Fully No Check Service Mission Capable if LEAD PUMPING STATION 1 Before Suction Hose Inspect for damage leaks and loose Hose is damaged or collapsed Assembly connections Tighten loose Class Ill leak Connection is connections If hose is damaged or loose Class Ill leaks are present notify supervisor 2 Before 6 Inch Butterfly Ensure butterfly valves on hose Valve on suction and discharge Valve assemblies are in open pos
188. ination unit A 506131 reference applicable technical manual 2 6 4 125 GPM Pumping Assembly For decals and instruction plates reference applicable technical manual 2 7 OPERATION OF AUXILIARY EQUIPMENT Refer to TM 5 4310 452 14 amp P for operation of Compressor Rotary Air DED 250 CFM 100 PSI Trailer Mounted Item 1 Appendix D 2 88 10 4320 303 13 2 8 PREPARATION FOR MOVEMENT 2 8 1 Procedures for Preparation for Movement of TWDS This paragraph provides general information for movement of TWDS equipment Detailed instructions for the movement of each major component will be provided in paragraphs 2 8 2 through 2 8 6 a Preparing TWDS for movement requires the following 1 Removing water from system 2 Shutting down and disassembling major components 8 Repacking major components b Remove water at lead pumping station first then move down the line to the last boost pumping station After hoseline water has been removed empty storage tanks and begin to disassemble major components c To begin emptying hoseline reference applicable technical manual and shut down lead pump Close butterfly valves on suction and discharge ports of lead pump Run boost pumping stations in manual mode until suction pressure drops to 10 psi Shut down boost pumping stations CAUTION Do not operate 600 gpm pumping assemblies below 10 psi Damage to 600 gpm pumping assemblies may result if they are operated below 10 psi d
189. inch Grooved end pipe quick disconnect coupling clamp 0 375 16 UNC 2B Hex nut 6 inch x 6 inch Reducing tee 2 3 6 2 Assembly and Installation Procedures CAUTION e To prevent damage to storage assembly DO NOT choose site subject to flooding or high water To prevent damage to storage tank DO NOT walk on tank unless you must DO NOT drop sharp objects on tank e After removing components from boxes be sure to protect them from sand and grit a Place gasket Figure 2 21 14 on male flanged coupling half 18 Place 4 inch gate valve 12 on male flanged coupling half 18 Align holes of 4 inch gate valve 12 gasket 14 and male flanged coupling half 18 b Place eight flat washers 17 on eight bolts 19 Insert bolts through openings on male flanged coupling half 18 gasket 14 and 4 inch gate valve 12 2 48 10 4320 303 13 Figure 2 21 Storage Assembly Connection Components Assembly c Install eight flat washers 16 lock washers 15 and nuts 13 on eight bolts 19 d Tighten nuts 13 until lock washers 15 engage and parts are firmly together Place gasket 10 4 inch female coupling half 5 Place 4 inch gate valve 12 4 inch female coupling half 5 Align holes in 4 inch female coupling half 5 gasket 10 and 4 inch gate valve 12 Place eight flat washers 7 on eight bolts 6 Insert eight bolts 6 through openings in 4 inch female coupling half 5 ga
190. ine 6 BYPASS 6 inch x 75 foot collapsible hose assembly Directs flow of ASSEMBLY water around boost pumping station to hoseline 7 CHECK VALVE Retards water from flowing into pumping assembly through discharge elbow Figure 1 5 Location of Major Components for TWDS Storage Assembly Table 1 5 Description of Major Components for TWDS Storage Assembly Item Item Name Description and Purpose No 1 6 INCH X 6 INCH X 4 INCH Used to connect storage assembly to hoseline PIPE TEE 2 4 INCH GATE VALVE Used to control water flow into storage assembly ASSEMBLY 3 4 INCH X 10 FOOT HOSE Directs water flow from 4 inch gate valve to filler fitting on ASSEMBLY water storage tank 1 7 10 4320 303 13 1 15 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED Table 1 5 Description of Major Components for TWDS Storage Assembly Continued STORAGE TANK 20 000 gallon collapsible rubberized nylon pillow tank Used to supply TWDS distribution point or water storage Refer to applicable technical manual for detailed information concerning the 20 000 gallon pillow tank Figure 1 6 Location of Major Components for TWDS Distribution Point 1 8 Item 10 11 12 13 TM 10 4320 303 13 Table 1 6 Description of Major Components for TWDS Distribution Point Item Name HOSE ASSEMBLY 125 GPM ASSEMBLY PUMPING HOSE ASSEMBLY HYPOCHLORINATION UNIT HOSE ASSEMBLY 2 INCH VALVE AS
191. ine route c At left hand edge of ground profile graph mark a point that represents lead pumping station elevation d Continuing across ground profile graph mark points where significant changes in elevation occur along hoseline route e To complete ground profile join the points marked on the ground profile graph with a straight line 2 3 1 6 2 Pump Spacing Triangle Construction To construct a spacing triangle obtain a piece of paper transparent sheet or cardboard thick enough to be used as a straightedge Then prepare the pump spacing triangle as follows a Divide horizontal base of pump spacing triangle Figure 2 9 into spaces on the same uniform scale used to divide the ground profile graph base Mark off spaces along pump spacing triangle base to at least 39 000 feet 2 32 10 4320 303 13 0123 45 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 FEET X 1000 Figure 2 9 Pump spacing Triangle b Divide vertical left hand edge of pump spacing triangle into spaces on the same uniform scale used to represent elevation changes on ground profile graph Mark off spaces along vertical side of pump spacing triangle as follows 1 Zero represents pumping station elevation 2 The upper left hand corner represents 300 feet above pumping station 3 The lower left hand corner represents 600 feet below pumping station c Draw a straight diagonal line from the 300 feet mark
192. ine tripod 5 e Install bolts 2 through saddles 3 and shackles 4 f Install nut 1 on bolt 2 Tighten nut 1 g Repeat steps d through f for each saddle assembly to outside of downline tripod 6 h Remove three or more U bolt clamps used to secure end shackles to wire rope i Pull hose 7 across span Saddles 3 should drag with hose 7 along wire rope 8 j As saddles 3 arrive at pulley block 9 on tripod tower 5 perform steps d through f k After all saddles 3 have been removed and hose 7 has been retrieved loosen turnbuckles 10 to release tension on wire rope 8 Remove turnbuckles 10 from ends of wire rope 8 m Remove turnbuckles 10 from stakes 11 and remove stakes 11 n Pull wire rope 8 across span and coil it o Remove two nuts Figure 2 39 4 clamps 5 U bolts 6 and thimble 3 from each end of wire rope Figure 2 65 8 p Install one clamp Figure 2 39 5 and two nuts 4 on each U bolt 6 q Remove pulley blocks Figure 2 65 9 from tripods 5 and 6 Disassemble tripods 5 and 6 S Locate chests for suspension kits and remove any contents t Wipe out inside of chest and clean kit items u Using loading diagram on chest lid pack kit items as indicated v Transport suspension kit chest to lead pumping station installation site for final packing 2 8 2 5 Preparation for Movement of Road Crossing Guards NOTE Road crossing guards should be removed
193. ing grinding riveting straightening facing machining and or resurfacing B 2 10 4320 303 13 location time and quality assurance 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 levels are as follows essit etie ed en bns Operator or crew maintenance om HI Unit maintenance DOSE ROMS MEA Direct Support maintenance Ra E Specialized Repair Activity 5 In T General support maintenance D REDE MNA Depot maintenance B 3 5 Column 5 Tools and Test Equipment Reference Code Column 5 specifies by code those common tool sets not individual tools common TMDE and special tools special TMDE and special support equipment required to perform the designated function Codes are keyed to tools and test equipment in Section Ill B 3 6 Column 6 Remarks When applicable this column contains a letter code in alphabetic order which is keyed to the remarks contained in Section IV B 4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS SECTION III B 4 1 Column 1 Reference Code The tool and test equipment reference code correlates with a code used in the MAC Section Il Column 5 B 4 2 Column 2 Maintenance Level The lowest level of maintenance authorized to use the tool or test equipment
194. ing paragraphs will provide operating procedures for operating the remaining TWDS components under unusual environmental weather conditions 2 9 5 1 Operation in Extreme Heat Pressure Reducing Valve Assembly Cover unit with moistened burlap tarpaulin or suitable cover to shade it from sun 2 9 5 2 Operation in Cold Weather The TWDS is not intended for use at temperatures below 32 F 0 C 2 9 5 3 Operation in Salt Water Area Pressure Reducing Valve Assembly Notify organizational maintenance if rust or aluminum oxide formations are present 2 9 5 4 Operation in Dusty or Sandy Conditions Hypochlorination Units Protect unit from sand or dust as much as possible Be careful when mixing chlorine solution to prevent introduction of sand or grit in solution 2 5 5 4 2 5 5 4 2 9 5 5 Operation in High Winds 10 Mile Hoseline Segment Pack hoseline as soon as possible 2 5 1 2 10 NUCLEAR BIOLOGICAL AND CHEMICAL NBC DECONTAMINATION Refer to FM 3 3 FM 3 4 FM 3 4 1 FM 3 5 FM 3 6 and FM 3 8 for decontamination procedures 2 11 FORDING Reference applicable technical manual for fording procedures on the vehicle used to transport TWDS components Reference the applicable technical manual for fording procedures for the 600 GPM pumping assemblies and the model 1955 3 and model A 506131 hypochlorination units Reference the applicable technical manual for fording procedures for the 125 GPM pumping assembly 2 12 EMERGENCY
195. is procedure is applicable to both the right and left hose retaining bracket a Remove nul Figure 4 21 1 and flat washer 2 b Remove bolt 3 flat washer 4 and nut 5 4 16 1 2 Inspection a Inspect hose retaining bracket 6 for separation of welds cracks damaged or missing toggle Notify direct support maintenance if hose retaining bracket 6 is damaged b Inspect nuts 1 and 5 flat washers 2 and 4 and bolt 3 for damage 4 65 10 4320 303 13 4 16 1 Hose Retaining Bracket Maintenance Continued 4 16 1 3 Repair Repair of hose retaining bracket assembly consists of replacing defective or damaged components 4 16 1 4 Assembly a Install nut 5 and flat washer 4 on bolt 3 b Install bolt 3 on hose retaining bracket 6 c Install flat washer 2 and nut 1 Tighten nut 1 d Place hose retaining bracket in packing kit 4 16 2 Pull Board Assembly Repair Pull board assembly repair consists of replacing damaged or defective components 4 66 10 4320 303 13 4 17 REPAIR KIT MAINTENANCE This task covers 4 17 1 Inspect 4 17 3 Replace 4 17 2 Repair INITIAL SETUP Tools General Safety Instructions Tool Kit General Mechanic s Do not work on equipment without following Automotive Section Ill Item 1 standard shop safety precautions Figure 4 28 Repair Kit Components 4 67 10 4320 303 13 4 17 REPAIR KIT MAINTENANCE Continued 4 17 1 Inspect a Inspe
196. ition If hoses will not fully open Valve valve will not open notify supervisor on bypass hose assembly is Ensure butterfly valve on bypass hose open assembly is closed when not in use If valve will not close notify supervisor 3 Before Check Valve Ensure check valve is Check valve is installed properly Arrow on not installed body casing must point in properly direction of water flow If Connection is valve is not installed loose Class correctly notify supervisor Ill leak Inspect for leakage and loose connections Tighten loose connections If Class Ill leak is present notify supervisor 4 Before Discharge Hose Inspect for damage leaks Hose is damaged Assembly and loose connections or collapsed Tighten loose connections Class III leak If hose is damaged or Class Connection is leak is present notify loose supervisor 2 15 Item Interval No 5 TM 10 4320 303 13 Table 2 7 perat on e M Preventive Maintenance Checks and Services for TWDS Continued Before Location Item to Check Service 10 MILE HOSELINE STATION 6 Inch x 500 Foot Hose Assembly Procedure Inspect for damage leaks kinks twists and loose connections Tighten loose connections If hose is damaged or Class III leaks are present notify supervisor Inspect for rubbing or chafing against trees rocks Suspension device tripods or other objects that might damage hoseline Reposition hose as required
197. jecting solution into water No discharge of water at manual disbursing stations No discharge of water at pressure reducing valve Pressure Relief Valve activates sss esses eee nemen nnne nnns 5 Table 3 1 Operator Troubleshooting Table MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1 20 000 GALLON PILLOW TANK IS NOT BEING FILLED Step 1 Check 4 inch gate valve to see if it is closed or damaged a Open 4 inch gate valve b Notify supervisor if 4 inch gate valve is damaged or Class Ill leak is present 3 2 10 4320 303 13 Table 3 1 Operator Troubleshooting Table Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2 a b Step 3 Step 4 a b Step 5 a Check to see if valve on drain assembly is open or damaged Close valve Refer to applicable technical manual for 20 000 gallon pillow tank and replace damaged valve Check to see if tank fabric is punctured torn or damaged Refer to applicable technical manual and repair damaged 20 000 gallon pillow tank Check hose assembly for leaks Close 4 inch gate valve refer to paragraph 2 3 6 2 Hisconnect and reconnect hose if hose connections have a Class Ill leak open 4 inch gate valve If hose assembly is damaged notify unit maintenance Check to see if pressure reducing valve assembly is damaged Notify unit maintenance if pressure reducing valve assembly is damaged 2 HYPOCHLOR
198. l Figure 3 7 1 over buckle 2 releasing tension by turning banding tool handle 3 clockwise throughout entire course of roll Figure 3 8 Removing Banding Tool t Pull cutting handle 1 cut strapping 2 and remove banding tool 4 Figure 3 9 Securing Buckle and Strapping u Clinch strapping stub Figure 3 9 1 by hammering down stub then ears of buckle 2 3 10 10 4320 303 13 3 4 1 6 Inch Hose Assembly Repair Continued Figure 3 10 Spacing of Buckles on Repaired 6 Inch Hose Assembly CAUTION To avoid leaks at adaptor shoulder buckles must use alternately positioned as shown in figure 3 10 v Repeating steps i through u install second third and fourth strapping and buckle in an offset as shown in figure 3 10 w Repeat step h and install male quick disconnect coupling half 1 on second hose end Figure 3 11 Repaired Hose Connection x Refer to paragraph 2 3 3 1 connect hose ends Figure 3 11 1 with grooved end pipe quick disconnect coupling clamp 2 y Release hose clamp Figure 3 1 and inspect repaired section for leaks 3 11 10 4320 303 13 3 4 1 2 Hose Repair Using Double Ended Adapter Repair a e f NOTE If leak is caused by a small puncture cut hose at puncture Refer tq paragraph 3 4 1 1 and perform steps a through g 1 Figure 3 12 Double Ended Adapter Installation Insert one end of double ended adapter Figure 3 12 1 into
199. l TWDS performance 2 3 1 6 Ground Profile and Pump Spacing Triangle A ground profile drawn on graph paper and a pump spacing triangle can be utilized to determine the location of each boost pumping station Proper construction and use of the ground profile and pump spacing triangle will ensure that the installed TWDS will perform within its optimal range 2 31 10 4320 303 13 2 3 1 6 1 Ground Profile Construction To construct a ground profile first obtain a topographical map or other source material providing accurate information concerning terrain along projected hoseline route Then using this information draw a ground profile of the hoseline route on graph paper as follows ALLLLLLLLELLLELLEELELEELLELLETLLLALELETIT hr E BENIN HAHAH ATTIN L ELEVATION FEET LII LIT LI ELE EE Ee PT TT Tt FEET X 1000 Figure 2 8 Ground Profile a Divide horizontal base of ground profile graph Figure 2 8 into spaces that represent uniform distances such as 1 000 foot intervals However any suitable scale can be used The ground profile base represents the horizontal distance the hoseline will cross b Divide vertical left hand edge of ground profile graph into spaces that represent uniform changes in elevation such as 100 feet intervals Again any suitable scale can be used However the scale must include at least the highest and lowest elevations along the hosel
200. l manual for the assembly installation and preparation for use of the model 600 gpm pumping assembly supplied with your TWDS 2 40 10 4320 303 13 Figure 2 14 Lead Pumping Station Suction Port and Butterfly Valve Assembly Model 609 A shown Ensure plastic cap has been removed from suction port Figure 2 14 1 on 600 gpm pumping a assembly reference applicable technical manual for suction port location on 600 gpm pumping assemblies not shown If plastic cap has not been removed remove cap and retain for movement or storage b Install 6 inch butterfly valve clamp 3 para 2 3 3 2 2 on suction port 1 with grooved end pipe quick disconnect coupling Figure 2 15 Lead Pumping Station Discharge Port and TWDS Components Assembly 2 41 10 4320 303 13 2 3 4 Lead Pumping Station Assembly Continued c Remove plastic cap from discharge port Figure 2 15 1 on 600 pumping assembly reference applicable technical manual for discharge port location on 600 gpm pumping assemblies not shown If plastic cap has not been removed remove it and retain for use later CAUTION To prevent damage to pump make sure arrow on check valve points away from pump d Install 6 inch check valve 3 on discharge port 1 with grooved end pipe quick disconnect coupling clamp 2 para 2 3 3 2 Install check valve 3 with arrow pointing away from pumping assembly 1 e Install 6 inch x 20 foot discharge h
201. le Hoseline Segment Continued Figure 2 41 Hoseline Installation x When hoseline 1 is in place use three or more U bolt clamps to secure end shackles to wire rope 4 2 3 8 8 Assembly and Installation of Pressure Reducing Valve Assembly a Remove 6 inch grooved pipe couplings Figure 2 44 1 and 2 2 3 5 1 connecting hoseline lengths 7 and 8 where pressure reducing valve assembly 3 is to be installed b Locate pressure relief valve 4 with attached grooved end pipe quick disconnect coupling 5 Remove grooved end pipe quick disconnect coupling 5 para 2 3 3 1 Figure 2 42 Pressure Reducing Valve Assembly Installation 2 74 10 4320 303 13 WARNING Ensure opening of pressure relief valve assembly 4 faces downline from pressure reducing valve assembly 3 Failure to do so may result in personal injury NOTE Inlet connection can be determined by observing the diaphragm rod c Install pressure relief valve 4 on inlet connection 6 of pressure reducing valve assembly 3 using grooved end pipe quick disconnect coupling AERE as shown in figure 2 34 d Connect upline hoseline length 7 to pressure relief valve 4 with 6 inch grooved pipe coupling 1 para 2 3 2 2 e Connect downline hoseline length 8 to outlet connection 9 on pressure reducing valve assembly 3 with grooved end pipe quick disconnect coupling 2 f Place all isolation cock valves 10 to open po
202. le quick disconnect coupling half 1 on inlet port of hypochlorination unit 3 af Remove female quick disconnect coupling half 1 from hypochlorination unit 3 inlet port 2 113 10 4320 303 13 2 8 6 Preparation for Movement of Distribution Points Continued ag Push cam arms on inlet port reducer 5 forward to open Remove hose assembly 2 from reducer 5 ah Push cam arms on female quick disconnect coupling half 6 forward to open Remove reducer 5 from female quick disconnect coupling half 6 ai Remove female quick disconnect coupling half 6 from nipple 7 aj Remove nipple 7 from hypochlorination unit 8 ak Install plastic dust caps 4 on hypochlorination unit 3 inlet and outlet ports al Refer to applicable technical manual and restart 125 GPM pumping assembly 9 am Drain storage tank as much as possible When storage tank is drained refer to applicable technical manual and shut down 125 GPM pumping assembly 9 Continue disconnecting distribution point an Push cam arms on hose assembly 2 forward to open Remove hose from male quick disconnect coupling half 10 on outlet port of 125 GPM pumping assembly 9 ao Unscrew and remove male quick disconnect coupling half 10 from 125 GPM pumping assembly 9 outlet port ap Push cam arms on inlet female quick disconnect coupling half 11 forward to open Remove end of hose assembly 12 from female quick disconnect
203. leaks 2 inch gate and turns freely If valve valve is is leaking damaged or not damaged Class operating properly notify Ill leak Valve supervisor does not rotate freely 18 Before Elbow Valve Inspect for damage leaks Elbow valve is and improper operation damaged or not Inspect for damaged or operating missing gasket If valve is properly Class damaged not operating Ill leak properly or Class III leaks Damaged or are present notify missing gasket supervisor 19 Before Nozzle Inspect for damage and leaks Nozzle is Ensure triggers work damaged Class properly Ill leak Trigger is not properly operating 20 Before Distribution Inspect for damage and leaks Connection is Point Hose If hose is damaged or Class loose Hose is Assemblies Ill leaks are present notify damaged Class supervisor Ill leak 2 20 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Item Interval Item to Check Service Procedure Not Fully No Mission Capable if DISTRIBUTION POINT CONT 21 Before Water Storage Bag Inspect bag and faucets for Water storage damage and leaks Ensure bag bag or faucet is has adequate support damaged Class Ill leak Water storage bag does not have enough support HYPOCHLORINATION UNIT MODEL 1955 1 22 Before Pipes and Tubes Inspect pipes tubes and Pipe s connections for damage and tube s or leaks connection s are damage
204. led by adjusting in line valves After controls are initially set no further adjustment is usually required A proper chlorine dosage will be injected into the water regardless of water flow rate through the hypochlorination unit The operator is required to periodically fill the five gallon chlorine solution reservoir Water is periodically tested at the manual disbursing stations for chlorine content using a color comparator Refer to applicable technical manual for a functional description of hypochlorination units model 1955 3 and model A 506131 1 19 4 3 Hose Network and Manual Dispersing Stations The hose network is used to transport water from the 20 000 gallon water storage assembly to the 125 GPM pumping assembly hypochlorination unit and manual dispersing stations A 2 inch x 20 foot rigid walled hose assembly directs water flow from the 20 000 gallon pillow tank to the 125 GPM pumping assembly A 2 inch x 10 foot collapsible hose assembly directs water flow from the 125 GPM pumping assembly to the hypochlorination unit Water flow from the hypochlorination unit to the manual dispersing stations is directed by a series of 2 inch x 20 foot hose assemblies Water flow to each of the manual disbursing stations is controlled by a 2 inch gate valve The hose network ends at four manual dispersing stations Two manual dispersing stations are equipped with nozzles and two with elbow valves The nozzles and elbow valves are stored on a nozzle stand as
205. lf removed refer to paragraph 2 8 5 2 Flange Adapter removed refer to paragraph 2 8 5 2 General Safety Instructions Do not work on equipment without folowing standard shop safety precautions applicable technical manual 4 12 1 1 Removal Placing the 4 inch gate valve assembly Figure 4 13 1 in the equipment conditions specified above will remove the 4 inch gate valve assembly 1 from the storage assembly 4 12 1 2 Disassembly a Remove nut 2 and handwheel 3 b Remove packing nut 4 c Remove packing gland 5 packing 6 and spring 7 Discard packing 6 d Remove eight screws 8 and lock washers 9 Discard lock washers 9 e Remove bonnet 10 and gasket 11 from valve body 12 Discard gasket 11 Unscrew valve stem 13 and remove from bonnet 10 g Remove disc assembly 14 from valve stem 13 h Remove two screws 15 i Separate two discs 15 and 16 from pull nut 17 4 12 1 3 Inspection a Inspect handwheel 3 bonnet 9 valve body 11 bonnet stem 12 disc stem 13 discs 14 and 15 and two seat rings 16 for corrosion cracks holes bends or damage b Inspect nut 2 packing nut 4 packing gland 5 eight screws 7 and lock washers 8 for corrosion or damage 4 12 1 4 Repair Repair consists of replacing defective or damaged components 4 35 10 4320 303 13 NN 15 4 SN 7 R N 2 gt 1 7
206. long hoseline route An excessive drop in elevation will significantly increase water pressure as water flows downhill CAUTION To prevent damage to TWDS components do not allow water pressure to exceed 225 psig If pressure builds to 225 psig hoseline can rupture and equipment failure will result Therefore when a sharp elevation drop along hoseline route is indicated by the ground profile graph a pressure reducing valve assembly must be installed in the hoseline To determine pressure reducing valve assembly location refer to ground profile graph and proceed as follows 2 34 10 4320 303 13 CREST OF HILL PUMPING STATION VERTICAL LINE PRESSURE REDUCING VALVE HORIZONTAL LINE Figure 2 11 Pressure Reducing Valve Assembly Location a Mark crest of hill on ground profile graph b Draw a vertical line downward from hill crest c Determine location of pumping station closest to hill crest on uphill side d Draw a horizontal line outward from pumping station until it intersects the vertical line drawn in step b above e Measure footage of horizontal line and footage of vertical line f Using formula provided below determine total hoseline footage between pumping station and hill crest Total hoseline footage Ya b where a horizontal line footage b vertical line footage g Using formula provided below determine friction loss of total hoseline footage in terms of vertical feet
207. ls such as rubber and plastic Unusual cracking softening swelling or breaking of these materials may be a corrosion problem If a corrosion problem is identified it can be reported using Standard Form 368 Product Quality Deficiency Report Use of key words such as corrosion rust deterioration or cracking will ensure that the information is identified as a CPC problem The form should be submitted to the address specified in DA PAM 738 750 1 11 CALIBRATION The TWDS does not contain equipment which requires calibration 1 2 TM 10 4320 303 13 1 12 LIST OF ABBREVIATIONS All abbreviations acronyms signs and symbols used in this manual and not listed in MIL STD 12 are listed in the Glossary located in the back of the manual 1 13 GLOSSARY All terms used in this manual that are not defined in the text or listed in the Army Dictionary AR 310 25 are defined in the glossary located in the back of the manual SECTION Il EQUIPMENT DESCRIPTION 1 14 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES 1 14 1 Characteristics The TWDS consists of five or six pumping stations a 10 mile hoseline segment two storage assemblies and two distribution points The number of pumping stations is dependent on the terrain and distance over which the water must be transported Smooth terrain requires five pumping stations with the sixth pumping station used as a spare Rough terrain requires six pumping stations Each pumping
208. ls 06794 0183 81 NSN 4320 01 122 3547 110 00 0000 NSN 4320 01 168 0591 919 NSN 4320 01 0590 and 10 NSN 4320 01 221 6006 All four models of the TWDS perform the same function The TWDS is depicted Feu IE This manual covers general information needed by the operator descriptions of the TWDS functional descriptions of how the TWDS works operating instructions operator maintenance instructions unit maintenance instructions direct support maintenance instructions and general support maintenance instructions for the equipment The TWDS receives water from large storage and distribution units water purification units host nation support or additional TWDS The TWDS transports this water to small distribution points additional TWDS or large storage and distribution units The TWDS is capable of transporting up to 720 000 seven hundred twenty thousand gallons of water in a 24 hour period The TWDS is not intended for use with brackish or contaminated water or at temperatures below 320 F 0 C 1 2 MAINTENANCE FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by as applicable DA Pam 738 750 The Army Maintenance Management System TAMMS Maintenance Management Update DA Pam 738 751 Functional Users Manual for the Army Maintenance Management System Aviation TAMMS A or AR 700 138 Army Logistics Readiness and Sustainability 1 3 DESTRUCTION OF ARMY M
209. lve stem 5 with wire brush before removing stem nut 6 Remove stem nut 6 g Remove diaphragm washer 7 diaphragm 8 disc ring retainer 9 and disc ring 10 from valve stem 5 h Pry disc ring 10 from disc ring retainer 9 Remove disc 11 from disc ring retainer 9 i Remove disc guide 12 from valve body 3 5 5 2 2 Repair a Inspect valve stem 5 for corrosion and scale If required use sandpaper moistened with water to clean valve stem 5 NOTE If new disc ring is unavailable flip old disc ring over b Inspect diaphragm 8 and disc 11 for signs of wear corrosion and damage c Inspect remaining parts for signs of cracks holes wear corrosion and damage d Replace all defective components 5 5 2 3 Assembly a Install disc guide 12 in valve body 3 b Install disc ring 10 in disc ring retainer 9 c Install disc ring retainer 9 diaphragm 8 and diaphragm washer 7 on valve stem 5 5 8 10 4320 303 13 If new disc is installed a different number of spacers may be required to obtain right amount of grip on disc d Install valve stem 5 in disc guide 12 CAUTION e When installing stem nut tighten nut until diaphragm cannot be twisted If nut is loose diaphragm could pull loose and tear under pressure e When tightened make sure disc is not compressed too much Disc should be compressed only very slightly by disc guide If needed remove or inser
210. m arms at the same time e Donotstrike cam arms to close Damage to couplings may result aj Connect female quick disconnect coupling half 4 on 2 inch gate valve 5 to male adapter on Y connection 1 Close cam arms ak Push cam arms on discharge hose 7 forward to open position CAUTION e To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result al Connect discharge hose 7 to male quick disconnect coupling half 6 on 2 inch gate valve 5 Close cam arms am Push cam arms on Y connection 8 forward to open position CAUTION e To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result an Connect female adapter on Y connection 8 to discharge hose 7 Close cam arms ao Push cam arms on two discharge hoses 9 forward to open position CAUTION e To prevent leakage close both cam arms at the same time e Donotstrike cam arms to close Damage to couplings may result ap Connect two discharge hoses 9 to male adapters on Y connection 8 Close cam arms aq Repeat steps ag through ap to connect female quick disconnect coupling half 10 2 inch gate valve 11 male quick disconnect coupling half 12 discharge hose 13 Y connection 14 and discharge hoses 15 2 58 at au av aw ax ay TM 10 4320 303 13 NOTE e f tank trucks are to be filled
211. manual for maintenance procedures for the 20 000 Gallon Water Storage Tank 10 4320 303 13 APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS SECTION I INTRODUCTION C 1 SCOPE This appendix lists components of the end item and basic issue items for the pump to help you inventory the items for safe and efficient operation of the equipment C 2 GENERAL The Components of End Item and Basic Issue Items BII Lists are divided into the following sections C 2 1 Section Il Components of End ltem This listing is for information purposes only and is not authority to requisition replacements These items are part of the TWDS As part of the end item these items must be with the end item whenever it is issued or transferred between property accounts Items of COEI are removed and separately packaged for transportation or shipment only when necessary Illustrations are furnished to help you find and identify the items C 2 2 Section Ill Basic Issue Items These essential items are required to place the TWDS in operation operate it and to do emergency repairs Although shipped separately packaged BII must be with TWDS during operation and when it is transferred between property accounts This list is your authority to request requisition them for replacement based on authorization of the end item by the TOE MTOE Illustrations are furnished to help you find and identify the items C 3 EXPLANATION OF COLUMNS C 3 1 Col
212. ments E 1 10 4320 303 13 SECTION Il EXPENDABLE AND DURABLE ITEMS LIST 3 4 Item National Stock Number Number Description 8415 01 333 4158 APRON CHEMICAL 63531 96 074 6810 00 255 0472 CALCIUM HYPOCHLORITE POWDER 81348 O C 114 6550 01 285 0796 CHLORINE TEST REAGENT 4E712 R OOOC 1C 8415 01 112 1885 GLOVES CHEMICAL 79371 36 124 LUBRICANT GASKET POTABLE WATER SYSTEM 19853 18225E9192 6810 00 664 1622 pH INDICATOR SOLUTION 81349 MIL T 17412 7920 00 205 1711 RAGS WIPING 58536 A A 2522 6850 00 664 5685 SOLVENT DRYCLEANING TYPE I 58536 8030 00 889 3535 TAPE ANTISEIZING 81349 E 2 10 4320 303 13 APPENDIX F ILLUSTRATED LIST OF MANUFACTURED ITEMS F 1 INTRODUCTION This appendix includes complete instructions for making items authorized to be manufactured or fabricated at unit maintenance level and direct support maintenance level A part number index in alphanumeric order is provided for cross referencing the part number of the item to be manufactured to the figure which covers fabrication criteria All bulk materials needed for manufacture of an item are listed by part number or specification number in a tabular list on the illustration F 2 MANUFACTURED ITEMS PART NUMBER INDEX Part Number of Manufactured Item Applicable Figure 100 56 001 F 1 RR C 271 F 2 10 4320 303 13 Figure F 1 Hose Material MATERIALS ITEM NO DESC
213. mping assemblies are protected by plywood caps which rest on the trailer rails and are fastened to the unit by banding straps All other components necessary to complete the assembly of the six pumping stations are in a crate marked PUMPING STATIONS Load this crate on the back of the truck used to tow the first trailer mounted pumping assembly to the lead pumping station installation site Tow crate and pump to installation site for lead pumping station Transport remaining trailer mounted pumping assemblies boost pumping stations to their respective installation sites 4 4 2 3 Storage Assemblies Components for the storage assemblies are packed in three crates Two crates are marked TANK FABRIC COLLAPSIBLE 20K GALLON Each of these two crates contains one 20 000 gallon pillow tank along with valves and fittings required for tank installation The third crate is marked STORAGE ASSEMBLY This crate contains all other components for two storage assemblies Transport these three crates to the first storage assembly site 4 4 2 4 Distribution Points Components for distribution points are packed in three crates Two of these crates contain a 125 GPM pumping assembly and are marked PUMP CENTRIFUGAL 125 GPM The third crate is marked DISTRIBUTION POINT This crate contains all other components necessary to complete assembly of two distribution points Transport the three distribution point crates to the first storage assembly site 4 4 2 5 10
214. n Spacing 2 3 1 1 Terrain Survey Prior to installing TWDS equipment a thorough study of the terrain is required A general route for hoseline and general locations for the pumping stations storage assemblies and distribution points can be determined from examination and comparison of maps photographs and charts Some elements to be considered in selecting a route and installation sites for TWDS are e Whether TWDS will operate independently or as part of a large system e TWDS assigned mission i e dispensing storing or transferring water e Expected length of time TWDS will be required to operate e Elevation differences and distances TWDS will encounter along its route 2 3 1 2 Pumping Station Storage Assembly and Distribution Point Location Reconnaissance Organize a ground reconnaissance prior to installation of TWDS to determine exact locations for pumping stations storage assemblies and distribution points If possible site locations should be near or parallel to 2 30 10 4320 303 13 existing roads to ease transportation assembly inspection maintenance and disassembly of TWDS Avoid routes along the banks of streams marshes ponds gullies ravines or other areas subject to flooding Whenever possible the hoseline should be laid out on firm dry level ground that allows easy access and is not subject to flooding 2 3 1 3 Minimum Route Selection Requirements Ensure minimum requirements necessary for rou
215. n discharge hose 5 forward to open position CAUTION ac To prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result ad Connect discharge hose 5 to male quick disconnect coupling half 4 on hypochlorination unit 2 Close cam arms Push cam arms on female quick disconnect adapter on Y connection_ Figure 2 25 1 forward to ae open position 2 56 10 4320 303 13 Figure 2 25 Distribution Point Assembly CAUTION e prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result af Connect female adapter on Y connection 1 to discharge hose 2 attached to hypochlorination unit 3 Close cam arms NOTE Wrap antiseize tape in direction of threads ag Wrap antiseize tape item 9 appendix E around threads of female quick disconnect coupling half 4 and screw female quick disconnect coupling half 4 into one end of 2 inch gate valve 5 2 57 10 4320 303 13 2 3 7 Assembly of Distribution Points Continued NOTE Wrap antiseize tape in direction of threads ah Wrap antiseize tape item 9 appendix E around threads of male quick disconnect coupling half 6 and screw male quick disconnect coupling half 6 into end of 2 inch gate valve 5 ai Push cam arms on female quick disconnect coupling half 4 forward to open position CAUTION e To prevent leakage close both ca
216. n storage tank CAUTION After removing components from boxes be sure to protect them from sand and grit b Push cam arms on female end of reducer 2 forward to open position CAUTION e prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result c Connect female end of reducer 2 to male filler discharge elbow 1 Close cam arms d Push cam arms on rigid walled suction hose 3 forward to open position CAUTION e prevent leakage close both cam arms at the same time e Do not strike cam arms to close Damage to couplings may result e Connect rigid walled 2 inch X 20 foot suction hose 3 to reducer 2 attached to male filler discharge elbow 1 Close cam arms f Locate suction port 4 and discharge port 5 on 125 GPM pumping assembly 6 Reference applicable technical manual for preparation for use of the 125 GPM pumping assembly 6 2 52 10 4320 303 13 Figure 2 23 Hypochlorination Unit and 125 GPM Pump Installation 2 53 10 4320 303 13 2 3 7 Assembly of Distribution Points Continued NOTE Wrap antiseize tape in direction of threads g Wrap antiseize tape item 9 appendix E around threads on female quick disconnect coupling half 7 Screw female quick disconnect coupling half 7 into suction port 4 of 125 GPM pumping assembly 6 h Push cam arms on female quick disconnect coupling half 7 forward to open position CAU
217. nance a Loosen jam nut Figure 5 6 1 b Remove setscrew 2 and jam nut 1 from pressure valve cap 3 c Remove six nuts 4 and bolts 5 5 20 10 4320 303 13 WARNING Pressure regulating valve spring is under pressure Slowly remove pressure valve cap to prevent flying components Failure to obey this warning may result in personal injury or injury to personnel Slowly remove pressure valve cap 3 seat 6 and spring 7 Remove valve piston 8 valve diaphragm 9 valve retainer disk 10 and connecting link 11 from pressure valve retainer 12 Remove nut 13 from connecting link 11 Separate valve piston 8 valve diaphragm 9 valve retainer disk 10 and connecting link 11 Remove pressure valve retainer 12 from body 14 Remove flat washer 15 disc guide 16 gasket 17 and valve disk 18 from body 14 Discard old gasket 17 5 6 4 2 Inspection a b C Inspect pressure valve cap 3 pressure valve retainer 12 and body 14 for corrosion cracks holes or damage Inspect all other components for corrosion or damage Replace all defective components 5 6 4 3 Assembly j Install valve disc 18 new gasket 17 disc guide 16 and flat washer 15 in body 14 Place pressure valve retainer 12 on body 14 Assemble valve retainer disc 10 valve diaphragm 9 and valve piston 8 on connecting
218. nch grooved pipe coupling 8 2 3 2 1 connecting hose assembly 7 to suction port 9 on pumping assembly refer to applicable technical manual for location of suction ports on 600 GPM pumping assemblies not shown Remove hose assembly 7 e Install 6 inch grooved pipe coupling 8 para 2 3 2 2 on end of hose assembly 7 2 105 10 4320 303 13 2 8 4 Preparation for Movement of Boost Pumping Stations Continued Figure 2 71 Disassembly of Boost Pump Station Discharge Port f Remove 6 inch grooved pipe coupling Figure 2 71 1 para 2 3 2 1 connecting pressure relief valve assembly 2 to downline hoseline segment 3 Remove downline hoseline segment 3 g Install 6 inch grooved pipe coupling 1 para 2 3 2 2 on end of downline hoseline segment 3 h Remove grooved end quick disconnect coupling clamp 4 pa ra 2 3 3 1 connecting pressure relief valve assembly 2 to lateral grooved pipe fitting b Remove pressure relief valve assembly 2 i Remove grooved end quick disconnect coupling clamp 6 pa ra 2 3 3 1 connecting lateral grooved pipe fitting b to 6 inch butterfly valve assembly 7 j Remove grooved end quick disconnect coupling clamp 8 para 2 3 3 1 connecting 6 inch butterfly valve assembly 7 to hose assembly 9 Remove 6 inch butterfly valve assembly 7 k Remove 6 inch grooved pipe coupling 10 para 2 3 2 1 connecting hose assembly 9 to check valve 11 Remove h
219. nhill side of the hoseline route para 2 3 1 9 f Other components contained in the 10 MILE HOSELINE SEGMENT crate are used for various purposes The lifting sling is used when a forklift is not available to load flaking boxes onto trucks para 2 3 8 2 3 The end cap is used when dead end service is required end of hoseline route does not connect to a storage and or distribution assembly The repair kit is used to repair damaged hoseline The displacement and evacuation kit along with the packing kits are used to recover and pack hoseline in flaking boxes 2 63 10 4320 303 13 2 3 8 Assembly of 10 Mile Hoseline Segment Continued g Listed below are the total number size and type of components packed in the 10 MILE HOSELINE SEGMENT crate Remove the components needed to complete the assigned mission Perform inspection of each part for damage and operability Table 2 13 Components Required from 10 Mile Segment Crate for Assembly of 10 Mile Hoseline Segment Displacement and evacuation kit End cap Grooved pipe coupling Lifting sling Packing kit Pressure reducing valve skid mounted 6 inch Pressure relief valve and nipple Repair Kit 5 foot Road crossing guard 1 1 4 inch Socket wrench Socket wrench handle Suspension kit 6 inch Swivel joint and coupling Figure 2 30 Loading and Securing Flaking Boxes 2 3 8 4 Preparation for Hose Laying To prepare for hose laying flaking boxes Figure 2 30 1 are first loaded
220. nical manual for operation of hypochlorination unit model A 506131 2 83 10 4320 303 13 2 5 5 7 Performing Chlorine Residual Tests a Locate color comparator kit Figure 2 49 Install Chlorine Color Disc CAUTION e f wrong disc is used chlorine residual test results will be incorrect e sure tag on disc reads either DPD CHLORINE or CHLORINE b Remove two screws Figure 2 4 1 and front cover 2 from comparator body 3 c Place chlorine color disc 4 in comparator body 3 with numbers 5 facing outward Place front cover 2 over chlorine color disc 4 Ensure that number display window 6 is at top of comparator body 3 Install and tighten screws 1 Figure 2 50 Installation of Prism Eyepiece d Place prism eyepiece Figure 2 5 1 over sample cell windows 2 on comparator front cover 3 2 84 10 4320 303 13 Figure 2 51 Preparation of Sample Cells e Rinse and fill two clean 15 ml sample Figure 2 51 1 to 15 ml mark 2 with water from manual disbursing station f Hold the comparator with the prism Figure 2 50 1 facing you and insert one of the water filled sample cells Figure 2 51 1 into the right hand sample space 3 Insert the second water filled sample cell 4 into the left hand sample space 5 g Fill the droppers in the arsenite and orthotolidine bottles and let the dropper caps sit loosely in the bottles Do not screw the c
221. nical manual for a functional description on the operation of the pumping assembly and location of discharge elbow 1 19 1 2 Boost Pumping Stations Receives water from up line hose segments Pumps water down line to next boost pumping station or to storage assembly Manual operation of 6 inch butterfly valves on the hose assemblies controls water flow into away from or around each boost pumping assembly A check valve is installed on the discharge elbow of the pumping assembly to restrict reverse water flow into the pumping assembly s discharge elbow A pressure relief valve is installed between the boost pumping station and the down line hose segment to reduce water pressure when water pressure exceeds 200 pounds per square inch psi when leaving the boost pumping station Refer to applicable technical manual for a functional description on the operation of the pumping assembly and location of discharge elbow 1 19 2 Storage Assembly The storage assembly is connected to the main TWDS hoseline by a 6 inch x 6 inch x 4 inch tee pipe A series of couplers 4 inch gate valve and a 4 inch x 10 foot hose assembly connect the 20 000 gallon pillow tank to the tee pipe Each storage assembly can collect up to 20 000 gallons of water tapped from the main TWDS hoseline The storage assembly water fill rate is controlled by manual operation of the 4 inch gate valve Water can be stored in the storage assembly for later use or can be supplied to distribution
222. nnecting 6 inch butterfly valve assembly 5b to suction port 8 on pumping assembly 9 Remove 6 inch butterfly valve assembly 5 g Reference applicable technical manual and install plastic cap on suction port 8 of 600 GPM pumping assembly Reference applicable technical manual for suction port location on 600 GPM pumping assemblies not shown Figure 2 69 Disassembly of Lead Pumping Station Discharge Port h Remove 6 inch grooved pipe coupling Figure 2 69 1 para 2 3 2 1 connecting pressure relief valve assembly to 2 downline hoseline 3 Remove downline hoseline segment 3 i Install 6 inch grooved pipe coupling 1 para 2 3 2 2 on end of downline hoseline segment 3 Remove grooved end quick disconnect coupling clamp 4 para 2 3 3 1 connecting pressure relief valve assembly 2 to 6 inch butterfly valve assembly 5 on discharge hose assembly 6 Remove pressure relief valve assembly 2 Remove grooved end quick disconnect coupling clamp 7 para 2 3 3 1 connecting 6 inch butterfly valve assembly 5 to discharge hose assembly 6 Remove 6 inch butterfly valve assembly 5 Remove grooved end quick disconnect coupling clamp 8 para 2 3 3 1 connecting discharge hose assembly 6 to check valve 9 Remove discharge hose assembly 6 m Install grooved end quick disconnect coupling clamp 8 para 2 3 3 2 on end of discharge hose assembly 6 2 104 10 4320 303 13 n Remove g
223. no general lubrication procedures required for the TWDS Refer to applicable technical manual for lubrication procedures for 600 GPM pumping assemblies 125 GPM pumping assembly and hypochlorination units models A 506131 and 1955 3 SECTION Il OPERATOR TROUBLESHOOTING PROCEDURES 3 2 TROUBLESHOOTING The malfunction index lists faults that may be observed by the operator The faults are then cross referenced to the troubleshooting Table 3 1 Table 3 t contains information useful in diagnosing and correcting unsatisfactory conditions which may be encountered during operation or maintenance of the TWDS Use the malfunction index to locate specific troubleshooting procedures contained in After locating the troubleshooting procedure perform the test inspections and corrective actions in the order listed The malfunction index 3 1 cannot list all of the malfunctions that may occur all the test and inspections needed to find the fault or all the corrective actions needed to correct the fault If the equipment malfunction is not listed or actions listed do not correct the fault notify your supervisor Refer to applicable technical manual for troubleshooting procedures for 600 GPM pumping assemblies 125 GPM pumping assembly and hypochlorination units models A 506131 and 1955 3 OPERATOR MALFUNCTION INDEX Malfunction Number in Table 3 1 20 000 Gallon Pillow Tank is not being filled Hypochlorination Unit Model 1955 1 is not in
224. nob 13 k Insert stroke adjust knob 13 into diaphragm cap 14 Turn stroke adjustment knob 13 right one full turn 4 13 6 6 Installation a Align mounting slots of hypochlorinator frame 12 with mounting holes on hypochlorination unit b Install three bolts 11 flat washers 10 new lock washers 9 and nuts 8 Tighten nuts 8 c Insert washer 7 and check valve 6 into liquid head 2 d Install suction tube 5 into liquid head 2 e Install discharge tube 1 on hypochlorination unit Insert washer 4 and check valve 3 into liquid head 2 g Install discharge tube 1 into liquid head 2 4 49 10 4320 303 13 4 13 7 Manifold Assembly Maintenance And Pressure Regulator Valve Replacement This task covers 4 13 7 1 Removal 4 13 7 4 Repair 4 13 7 2 Disassembly 4 13 7 5 Assembly 4 13 7 3 Inspection 4 13 7 6 Installation INITIAL SETUP Tools Equipment Conditions Continued Tool Kit General Mechanic s Pressure Hose Assembly removed refer to Automotive Section Ill Item 1 paragraph 4 13 2 Pressure Gauge and Fill Assembly removed Material Parts refer to paragraph 4 13 3 Antiseize Tape Item 9 Appendix E Water Meter and Gear Box Assembly disconnected from unions refer to paragraph Lock washers TM 10 4320 303 23P 4 13 5 Equipment Conditions General Safety Instructions Hypochlorination Unit Model 1955 1 Do not work on equipment without following removed refer to pa
225. nspect Retaining Replace Repair Repair Kit Inspect Replace Repair Sling Assembly Inspect Replace Repair SECTION Ill TOOL AND TEST EQUIPMENT REQUIREMENTS FOR TACTICAL WATER DISTRIBUTION EQUIPMENT SYSTEM TWDS SET 10 MILE SEGMENT 1 2 3 4 5 TOOL OR TEST MAINTENANCE NOMENCLATURE NATIONAL NATO TOOL EQUIPMENT LEVEL STOCK NUMBER NUMBER REF CODE Tool Kit General Mechanic s 5180 00 177 7033 Automotive Shop Equipment Automotive 4910 00 754 0654 Maintenance and Repair Organizational Maintenance Common No 1 10 4320 303 13 SECTION IV REMARKS FOR TACTICAL WATER DISTRIBUTION EQUIPMENT SYSTEM TWDS 10 MILE SEGMENT 1 2 REFERENCE CODE REMARKS A Repair Kit Hoseline 6 inches Item 124 of Appendix C 5 used for repair replacement of hoses of the Tactical Water Distribution Equipment System TWDS 10 Mile Segment Refer to applicable technical manual for maintenance procedures for the 600 Gallons Per Minute Pump Direct Support Maintenance repair consists of welding damaged components Refer to applicable technical manual for maintenance procedures for the125 Gallons Per Minute Pump Refer to applicable technical manual for maintenance procedures for the Hypochlorination Unit Model 1955 3 and applicable technical manual for the Hypochlorination Unit Model A 506131 Repair of this kit is limited to the replacement of damaged missing or expended items Refer to applicable technical
226. nt of flaking box that secure tie bar to box 2 Lift and remove tie bar from box NOTE Steps e through m are for pullboard assembly e Align holes on left pullboard flange Figure 2 60 1 with holes on pullboard half 2 2 95 10 4320 303 13 2 8 2 Preparation for Movement of 10 Mile Hoseline Continued f Install four square neck bolts 3 flat washers 4 and self locking nuts 5 in holes g Tighten each nut 5 until heads on bolts 3 are flush with surface of pullboard half 2 h Repeat steps e through g to install right pullboard flange 6 on second pullboard half 7 i Place pullboard halves 2 and 7 in coupling sleeve 8 Align holes in pullboard halves 2 and 7 with holes in coupling sleeve 8 j Install six cap screws 9 flat washers 10 and self locking nuts 11 in holes k Tighten each self locking nut 11 until pullboard halves 2 and 7 are firmly secured in coupling sleeve 8 Install nut 12 and flat washer 13 on eyebolt 14 NOTE When installing eyebolt through coupling sleeve make sure eyebolt and flanges are on opposite sides of pullboard m Place eyebolt 14 through hole in top of coupling sleeve 8 Install flat washer 15 and nut 16 5 Figure 2 61 Start Hoseline Packing n Install nut Figure 2 61 1 on eyebolt 2 Turn nut 1 to its limit of travel 2 96 10 4320 303 13 Place eyebolt 2 through hole in permanent end wall 3 of flaking box
227. o maintain or regulate within prescribed limits by bringing into proper or exact position or by setting the operating characteristics to specified parameters B 2 5 Align To adjust specified variable elements of an item to bring about optimum or desired performance B 2 6 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 B 1 10 4320 303 13 B 2 7 Remove Install To remove and install the same item when required to perform service or other maintenance 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 B 2 8 Replace To remove an unserviceable item and install a serviceable counterpart in its place Replace is authorized by the MAC and assigned maintenance level is shown as the 3d position code of the SMR code B 2 9 Repair The application of maintenance services including fault location troubleshooting removal installation and disassembly assembly procedures and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage fault mal
228. o on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines A HREFzhttp www liberatedmanuals com Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
229. o screws 5 and remove mounting plate 4 from upper housing 6 Remove two nuts 7 and bolts 8 Carefully separate upper housing 6 and lower housing 9 Remove lower stem 10 and preformed packing 11 from lower housing 9 Discard preformed packing 11 f Remove body 12 from upper housing 6 g Remove disc 13 from body 12 h Remove washer 14 and preformed packing 15 from upper stem 16 Discard preformed packing 15 i Remove upper stem 16 from upper housing 6 4 10 2 3 Inspection a Inspect handle assembly 3 for cracks damage and smooth operation of handle b Inspect mounting plate 4 upper housing 6 and lower housing 9 for cracks holes or damage c Inspect lower stem 10 body 12 disc 13 and upper stem 16 for corrosion cracks holes or damage 4 17 10 4320 303 13 4 10 2 6 Inch Butterfly Valve Assembly Maintenance Continued d Inspect all mounting hardware for corrosion or damage 4 10 2 4 Repair Repair consists of replacing all damaged or defective components 4 10 2 5 Assembly a Install upper stem 16 in upper housing 6 b Install new preformed packing 15 and washer 14 on upper stem 16 c Install disc 13 in body 12 Ensure holes in top and bottom of disc 13 are aligned with holes in top and bottom of body 12 d Install body 12 in upper housing 6 Ensure upper stem 16 is inserted through body 12 and installed
230. odel 1955 1 Ensure all hoses and unit pipes are not damaged or cracked all meters are not damaged or cracked solution reservoir and tool box are present skid frame is not damaged or broken and all valves operate freely Refer to applicable technical manuals for inspection of Hypochlorination unit model 1955 3 and model A 506131 2 inch x 20 Suction hose Inspect hose for punctures cuts or foot assembly scrapes Ensure cam arms move freely Check for damaged or missing gasket 4 Nozzle Check for stripped or worn threads Ensure trigger mechanism operates smoothly Nozzle stand Inspect assembly for bent or damaged assembly legs Check for missing broken or unconnected chains Inspect chain attachment and hook welds for cracks or separation IE inch x 1 5 Reducer quick Ensure cam arms move freely Check for NE disconnect damaged or missing gasket Check for threaded stripped or worn threads inch disconnect damaged or missing gasket inch disconnect damaged or missing gasket inch disconnect damaged or missing gasket inch disconnect damaged or missing gasket e Rl inch x 2 inch quick disconnect damaged or missing gasket Table 4 4 10 Mile Segment Crate Qty Sze Mspetin 2 1 6 inch Coupling half Check for stripped or worn threads quick disconnect Ensure cam arms move freely Check for female damaged or missing gasket 10 4320 303 13 Table 4 4 10 Mile Segment Crate Continued
231. of Distribution Points 2 8 6 Preparation for Movement of Lead Pumping Station 2 8 3 Preparation for Movement of Storage Assemblies 2 8 5 Preparation for Movement of TWDS Procedures for 2 8 1 Preparation for Storage or 2 22 02 1 4 Preservation Procedures 4 19 Pressure Gauge Assembly Replacement 4 13 3 Pressure Reducing Control eee 5 5 1 Pressure Reducing Valve Assembly Maintenance Direct 5 5 Pressure Reducing Valve Assembly Maintenance Unite ied Dota ee 4 11 5 Pressure Reducing Valve Assembly Replacement 4 11 4 Pressure Reducing Valve Assembly Skid Assembly Repar eds 5 5 3 Pressure Regulating Valve Repair 5 6 4 Pressure Regulator Hose Assembly Maintenance 4 13 2 Pressure Regulator Valve Replacement 4 13 7 INDEX 3 P Continued Pressure Relief Valve Assembly 4 11 6 Procedures for Preparation for Movement of TWDS 2 8 1 Procedures Operating 2 5 Pillow Tank 20 000 Gallon Equipment Data for 1 17 2 Pull Board Assembly Repair
232. oir cover Figure 2 76 1 2 Remove suction hose 2 and reservoir fill hose 3 from reservoir 4 3 Remove and empty reservoir 4 on hypochlorination unit 5 Rinse reservoir 4 and install on hypochlorination unit 5 2 110 10 4320 303 13 4 Place suction hose 2 and reservoir fill hose 3 Install cover 1 on reservoir 4 g Refer to applicable technical manual and clean plastic reservoir if the Hypochlorination Unit model A 506131 was used with the distribution point h Refer to applicable technical manual and clean plastic reservoir if Hypochlorination Unit model 1955 3 was used with the distribution point 17 gt Bate 6 B 18 Figure 2 77 Disassembly of Distribution Point NOTE If disconnecting Hypochlorination Unit model 1955 1 or model A 506131 perform steps i and If disconnecting Hypochlorination Unit model 1955 3 perform steps through m i Push cam arms on discharge hose assembly Figure 2 77 1 forward to open Remove hose assembly 1 attached to male quick disconnect coupling half 2 on hypochlorination unit 3 outlet port 2 111 10 4320 303 13 2 8 6 Preparation for Movement of Distribution Points Continued j Unscrew and remove male quick disconnect coupling half 2 from hypochlorination unit 3 outlet port k 1 m n o Push cam arms on hose assembly 1 forward to open Remove hose assembly 1 attached to reducer 4 Pu
233. on Number in 20 000 Gallon Pillow Tank is not being filled Pressure reducing valve assembly will not open or will not close drip tight Hypochlorination unit model 1955 1 pressure gauge shows high pressure Hypochlorination unit model 1955 1 camshaft is turning but spring is not moving Little or no water flow at distribution points 4 10 10 4320 303 13 Table 4 7 Unit Troubleshooting Table MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1 20 000 GALLON PILLOW TANK IS NOT BEING FILLED Step 1 Check to see if pressure reducing valve assembly is damaged Refer to replace pressure reducing valve assembly Step 2 Refer to applicable technical manual and troubleshoot 20 000 gallon pillow tank 2 PRESSURE REDUCING VALVE ASSEMBLY WILL NOT ALLOW WATER TO FLOW WARNING Assembly may be pressurized Personal injury may result if pressure is not reduced before performing maintenance on pressure reducing valve assembly Step 1 Check isolation tubing for obstructions a If found remove obstructions Step 2 Close inlet isolation cock valve a If valve opens replace regulator control b If valve remains closed notify direct support maintenance 3 PRESSURE REDUCING VALVE IS NOT REDUCING PRESSURE WARNING Assembly may be pressurized Personal injury may result if pressure is not reduced before performing maintenance on pressure reducing valve assembly Step 1 Check isolation tubing for obstruction
234. on Unit Model A 506131 X 1 17 EQUIPMENT DATA 1 17 1 Trailer Mounted Pumping Assemblies Refer to applicable technical manual for installation and operation procedures for Trailer Mounted Pumping Assemblies Models 609 A 609 C and US636HCCD 1 The performance and equipment data for the Trailer Mounted Pumping Assemblies are provided below 1 17 1 1 Pumping Assembly Model 609 Weight dry Length Width Height Pump Type Output volume Designed working pressure Designed suction pressure Suction and discharge size Engine Type Bore Stroke Piston displacement Compression ratio Weight Power output Speed maximum Idle speed minimum Fuel Lubrication Valve clearance cold Crankcase capacity Fuel tank capacity Radiator capacity Weight dry Length Width Height 3 052 Ib 1 384 kg 139 in 353 cm 70 in 178 cm 90 in 229 cm Self priming centrifugal direct coupled to diesel engine 600 gpm at 350 ft tdh 150 5 psi 1 034 34 kPa 30 to 200 psi 138 to 1 034 kPa 6 in 15 cm 4 stroke 6 cylinder liquid cooled turbocharged diesel 4 in 10 cm 4 5 in 11 cm 339 cu in 5 555 cu cm 16 1 1 050 Ib 476 kg 120 hp at 2 400 rpm 2 500 rpm 1 000 rpm diesel forced lubrication 0 015 in 0 381 mm 6 qt 5 7 L 12 gal 45 42 L 7 gal 26 50 L 4 600 Ib 2 088 kg 158 19 in 402 cm 84 in 214 cm 72 in 183 cm 1 17 1 2 Pumping Assembly Model 609 C Pump Type
235. onents from the PUMPING STATION crate Perform inspections of each part for damage and operability 2 3 5 1 Assembly Requirements Tools Used To Rubber Mallet and Clamping Tool Items Install 6 inch grooved end pipe quick 157 and 3 disconnect coupling clamps Personnel Two required Components Table 2 10 Components Required From Pumping Station Crate for Assembly of Boost Pumping Station 6 inch Butterfly valve 6 inch Check valve 6 inch x 10 foot Hose assembly 6 inch x 20 foot Hose assembly 6 inch x 75 foot Hose assembly 6 inch Grooved end pipe quick disconnect coupling clamp 6 inch Lateral grooved pipe fitting 6 inch Pressure relief valve and nipple 2 3 5 2 Assembly and Installation Procedures Refer to applicable technical manual for assembly installation and preparation for use of the model 600 gpm pumping assembly supplied with your TWDS 2 44 10 4320 303 13 Figure 2 18 Boost Pumping Station Suction Components Assembly Remove plastic cap from suction Figure 2 18 1 on 600 pumping assembly reference applicable technical manual for suction port location on 600 pumping assemblies not shown If plastic cap has not been removed remove it and retain cap for movement or storage CAUTION After removing components from boxes be sure to protect them from sand and grit Sand and grit in components may cause damage to components themselves and 600 GPM pumping assembly
236. onnect 4 inch x 10 foot hose assembly Figure 2 22 3 to female to female elbow 2 on 20 000 gallon pillow tank 1 Close cam arms Connect additional 4 inch X 10 foot hose assemblies 3 as necessary to reach reducing tee gate valve assembly 2 50 10 4320 303 13 CAUTION e To prevent leakage close both cam arms at the same time e Donotstrike cam arms to close Damage to couplings could result p Connect female flanged coupling half 4 on the last 4 inch x 10 inch discharge hose assembly 3 with male flanged coupling half attached to 4 inch gate valve assembly 5 Close cam arms NOTE Hose laying crew should provide enough slack in hoseline to allow for connection of reducing tee gate valve assembly q Move reducing tee 4 inch gate valve assembly 5 to a location that will be out of the way of hose laying crews 2 3 7 Assembly of Distribution Points Assembly of a distribution point requires the tools personnel and components listed below Remove the required components from the DISTRIBUTION POINT crate Perform inspection of each part for damage and operability Reference applicable technical manual for assembly installation and preparation for use of the 125 GPM pumping assembly Reference applicable technical manuals for the assembly and preparation for use of hypochlorination unit models 1955 3 and A 506131 2 3 7 1 Assembly Requirements Tools Used To Pipe wrench 1 inch minimum Install components with thre
237. ors for 2 1 1 Lead Pumping Station Preparation for Movement of 2 8 3 Leakage Definitions PMCS 2 2 5 List of Abbreviations 1 12 Location Siting 4 4 1 Location and Description of Major Components 1 15 EubriCatlOn 3 1 Lubrication 4 7 Major Components Location and Description 1 15 Main Valve Assembly Repair 5 5 2 Maintenance 10 Mile Segment sss 4 11 Maintenance Butterfly Valve Assembly 6 Inch 4 10 2 Maintenance Color 4 13 10 Maintenance Displacement and Evacuation 4 15 Maintenance Distribution 4 13 Maintenance Drain Hose 4 13 2 Maintenance Fill Hose Assembly See 4 13 2 Maintenance Flaking Box 4 11 2 Maintenance Forms Records and 1 2 Maintenance Gate Valve Assembly 4 Inch 4 12 1 Maintenance Gear Box 5 6 2 INDEX 2 M Continued Maintenance Hose Retaining Bracket cerea 4 16 1 M
238. ose assembly 5 on end of check valve 3 with grooved end pipe quick disconnect coupling clamp 4 2 3 3 2 f Install 6 inch butterfly valve 7 on end of 6 inch x 20 foot discharge hose assembly 5 with grooved end pipe quick disconnect coupling clamp 6 para 2 3 3 2 Figure 2 16 Pressure Relief Valve Installation WARNING Personal injury may result from high pressure water if pressure relieve valve faces butterfly valve Ensure pressure relief valve is installed as shown in figure 2 16 to avoid personal injury g Install 6 inch pressure relief valve Figure 2 15 9 on end of butterfly valve 7 as shown in figure 2 para 2 3 3 2 16 with grooved end pipe quick disconnect coupling clamp 8 h Set butterfly valves attached to suction port Figure 2 14 2 and discharge hose assembly Figure 2 15 7 to fully open position 2 42 10 4320 303 13 Figure 2 17 TWDS Water Source Connection Components Assembly NOTE To prevent leakage make sure coupling pipe fitting is tightly fitted to coupling half e Suction hose lengths coupling pipe fitting coupling half and Y connection reducer are packed in crate marked 10 MILE SEGMENT e Wrap antiseize tape in direction of threads i Wrap antiseize tape item 9 appendix E around threads on 6 inch coupling pipe fitting Figure 2 17 3 Screw 6 inch coupling pipe fitting 3 into 6 inch coupling half 4 j Install 6 inch coupling pipe fitting
239. ose assembly 9 Install 6 inch grooved pipe coupling 10 2 3 2 2 end of hose assembly 9 m Remove 6 inch pipe coupling 12 para 2 3 5 1 connecting check valve 11 to discharge port 13 on pumping assembly refer to applicable technical manual for location of discharge ports on pumping assemblies not shown Remove check valve 11 n Remove grooved end quick disconnect coupling clamp Figure 2 72 1 para 2 3 3 1 connecting lateral grooved pipe fitting 2 to 6 inch butterfly valve assembly 3 Remove lateral grooved pipe fitting 2 2 106 10 4320 303 13 WC Figure 2 72 Disassembly of Bypass Hose o Remove grooved end quick disconnect coupling clamp 4 para 2 3 31 connecting 6 inch butterfly valve 3 to hose assembly 5 Remove 6 inch butterfly valve assembly 3 p Install 6 inch grooved pipe coupling 4 para 2 3 2 2 on end of hose assembly 5 q Remove 6 inch grooved pipe coupling 6 para 2 3 2 1 connecting hose assembly 5 to lateral grooved pipe fitting 7 Remove hose assembly 5 and lateral grooved pipe fitting 7 2 8 5 Preparation for Movement of Storage Assemblies This is a general procedure for the moving of storage assemblies For additional information pertaining to moving the 20 000 gallon pillow tank reference applicable technical manual 2 8 5 1 Disassembly Requirements Disassembly of a storage assembly requires the tools and personnel referenced in p
240. oseline during startup will damage equipment e Ensure bends twists or kinks in hoseline are removed when hose is flaked Failure to remove bends twists or kinks may result in damaged equipment 2 3 8 2 4 As truck moves forward along route hose flakes out of boxes and is manually laid out behind the truck Any bends twists or kinks in hoseline must be straightened Figure 2 29 10 Mile Hoseline Segment Installation 2 3 8 2 5 A minimum of two trucks with crews of five men each is recommended for hose laying operations Crews alternate between laying hose and reloading trucks Individual task assignments for each crew member are as follows a Supervisor Figure 2 29 1 One supervisor 1 is needed per truck 2 to oversee hose laying operations Should a problem develop during hose laying operations the supervisor 1 is responsible for contacting operators at pumping stations who are packing the hoseline b Driver 3 One driver 3 is needed to operate each truck 2 c Assistant Driver 4 An assistant driver 4 is needed to observe hose laying operation tell driver 3 to speed up slow down or stop truck 2 depending on needs of the line walkers 5 who are straightening and 2 62 10 4320 303 13 repositioning hoseline 6 He must also observe hose for catching or binding as it flakes out of box d Linewalkers 5 A minimum of two linewalkers 5 are needed to follow behind each truck 2 and perform the
241. oving the lead pumping station For information pertaining to moving the 600 GPM pumping assembly reference applicable technical manuals 2 8 3 1 Disassembly Requirements Disassembly of the lead pumping station requires the tools and personnel referenced ir paragraph 2 3 4 1 Pack the components listed in tables 2 8 and 2 9 in the PUMPING STATION CRATE and the 10 MILE SEGMENT CRATE after removing them from the lead pumping station 2 8 3 2 Disassembly Procedures Figure 2 68 Disassembly of Lead Pumping Station Suction Port 1 NOTE e Set aside all removed components for repacking e Notify unit maintenance for removal of threaded fittings a Push cam arms on Y connection red icer Figure 2 68 1 forward to open position Remove Y connection reducer 1 from water source b Push cam arms on suction hose assembly 2 forward to open position Remove Y connection reducer 1 from hose assembly 2 c Disconnect additional suction hose assembly lengths 2 as required d Remove grooved end quick disconnect coupling clamp 3 para 2 3 3 1 connecting coupling pipe fitting 4 to 6 inch butterfly valve assembly 5 Remove coupling pipe fitting 4 with attached coupling half 6 2 103 10 4320 303 13 2 8 3 Preparation for Movement of Lead Pumping Station Continued e Remove coupling half 6 from coupling pipe fitting 4 f Remove grooved end quick disconnect coupling clamp 7 para 2 3 3 1 co
242. ox Assembly Breakaway Installation p Grooved Pipe Coupling and Swivel Joint Connection to Lead Pumping Swivel Joint Connection sese Road Crossing Guard Installation sess Tripods and Wire Rope Installation ssseessseeeeeeeeee nennen Securing Wire ROp datu ba o sex Meat Me dU AME D EM MM MM OM DI UU Saddle 2 0 nnern ennt rers sint rmr sint 2 41 Hoseline nennen 2 42 Pressure Reducing Valve Assembly 2 43 20 000 Gallon Pillow Tank Sandbag AU AON RD DD Hypochlorination Unit Model 1955 1 Controls and Suction Foot Hypochlorination Unit Model 1955 1 Control and Water Meter Stroke Adjust Thimble ODGfFatlQEi sacks shank li ain tz Ga idit ok kl ttd nm ani dan Correcting Air Bound Unit After Startup tentent 49 Install Chlorine Color iv TM 10 4320 303 13 LIST OF ILLUSTRATIONS CONTINUED Title Page Installation of Prism Eyepiece nennen nnn nennen nnns Preparation of Sample Viewing Water
243. p item 16 If storage assembly contains item 16 it will also contain one 1 spanner wrench item 17 TWDS storage assemblies may contain one 1 6 inch pipe coupling clamp item 18 or one 1 6 inch coupling clamp item 19 If storage assembly contains item 19 it will also contain one 1 spanner wrench item 17 TWDS 10 mile hoseline segment may contain either 128 2 Way Flaking Boxes item 66 or 54 Flaking Box Assemblies item 67 TWDS 10 mile hoseline segment may contain fifteen 15 6 inch pipe coupling clamps item 68 or fifteen 15 6 inch coupling clamps item 69 If 10 mile hoseline item 69 it will also contain one 1 spanner wrench item 70 TWDS displacement and evacuation kit may contain eight 8 6 inch pipe coupling clamps item 99 or eight 8 6 inch coupling clamps item 100 If displacement and evacuation kit contains item 100 it will also contain one 1 spanner wrench item 101 C 34 10 4320 303 13 7 TWDS hoseline repair kit may contain three 3 6 inch pipe coupling clamps item 137 or three 3 6 inch coupling clamps item 138 If hoseline repair kit contains item 138 it will also contain one 1 spanner wrench item 139 SECTION Ill BASIC ISSUE ITEMS 10 4320 303 13 Part Number On Code MANUAL OPERATOR S UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR TACTICAL WATER DISTRIBUTION EQUIPMENT SYSTEM TWDS SET 10 MILE SEGMENT MODELS 06749 0183
244. pace in flaking box assembly 4 2 98 10 4320 303 13 ah Push down on two toggle levers 5 and remove two hose retaining brackets 1 installed in step ad ai Install two hose retaining brackets 1 one or two folds in front of pullboard assembly 2 aj Push up on two toggle levers 5 and lock hose retaining brackets 1 against metal rim 3 on inside of flaking box assembly 4 ak Release chain 6 on hoist 7 Remove pullboard assembly 2 from hoist 7 Set pullboard assembly 2 and hoist aside 7 al Remove 6 inch grooved pipe coupling 9 para 2 3 2 1 on leading end of hoseline 8 Remove end cap 10 am Place plastic cap on leading end of hoseline 8 an Repeat steps al and am for trailing end of hoseline 8 ao Install 6 inch grooved pipe coupling 9 para 2 3 2 2 on end of trailing end of hoseline 8 ap Deliver end caps and grooved pipe coupling removed in step al to crews evacuating hoseline Figure 2 64 Tailgate Assembly Installation aq Fold endg Figure 2 64 1 of hoseline 2 into flaking box assembly 3 ar Insert tailgate assembly 4 into cleats on lower frame of flaking box assembly 3 as Install tie bar 5 on flaking box assembly 3 so that tailgate assembly 4 fits into cleats on tie bar 5 at Install two screws 6 on rear of flaking box assembly 3 Tighten two screws 6 until tie bar 5 is securely fastened to flaking box assembly 3 2 99
245. ployed When the TWDS is deployed over smooth terrain five pumping stations are required When the TWDS is deployed over rough terrain six pumping stations are required During rough terrain deployment if there is a decrease in elevation of 75 feet or greater between two pumping stations a pressure reducing valve assembly can be installed in the main hose line to reduce water pressure and protect down line equipment from damage When the TWDS is deployed for transporting water from a source to a large storage or distribution unit only the pumping stations and 10 mile hose line segment are required For water distribution to personnel or storage three configurations can be employed First one storage assembly and distribution point can be installed in the TWDS Second two storage assemblies and distribution points can be installed in the TWDS Third if only transporting and water storage capabilities are required the TWDS can be deployed without the distribution points SECTION Ill PRINCIPLES OF OPERATION 1 19 FUNCTIONAL DESCRIPTION The TWDS is used to transport potable water across level terrain for distances up to 10 miles Five or six pumping assemblies are used to transport water from a source desalination units wells or large storage and distribution units to two 20 000 gallon storage assemblies additional TWDS units or larger storage and distribution units The water stored in the two 20 000 gallon pillow tanks can be supplied to large
246. point Used to dispense water in small volumes with a pistol like action Two are used with each distribution point Used to dispense water in large volumes with the user controlling water flow volume Two are used with each distribution point Collapsible tripod Used to support nozzle and elbow valve when not in use 36 gallon capacity cotton duck water storage bag Faucets at bottom of bag used to distribute water to personnel Used to reduce water volume from the filler discharge elbow to the rigid walled hose assembly Two are used with each distribution point Connects threaded ends of hypochlorination unit and 125 GPM pump to rigid walled hose assembly Used to direct Change 1 1 9 10 4320 303 13 1 15 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED Figure 1 7 Major Support Components for TWDS Table 1 7 Description of Major Support Components for TPWDS Item Item Name Description and Purpose No 1 FLAKING BOX Newer model flaking box holds two 500 foot hose assemblies Older model flaking box holds one 500 foot hose assembly Allows hose to be flaked from back of vehicle During flaking of hoses the flaking boxes are stacked four high Adapted for either forklift or sling lift 2 LIFTING SLING Used for lifting flaking boxes when a forklift is not available 3 ROAD CROSSING GUARD Used to protect hoseline buried beneath road from damage 05 GOVERNMENT PRINTING OFFICE 1996 7554 025 40188 1 10
247. pping Preparation 3 7 10 4320 303 13 3 4 1 6 Inch Hose Assembly Repair Continued NOTE Double bands must be used to secure adapters on hoseline lengths m Continue long end of strapping Figure 3 4 1 around hose 2 and through buckle 3 once more forming a double band n Position buckle 3 so that it is on top of hose 2 CAUTION To avoid cutting or weakening hose wall when bands are tightened install bands between quick disconnect coupling halves Position strapping 1 in groove farthest from adapter 5 Figure 3 5 Preparing Banding Tool for Use p Install strapping 1 through open slot of banding tool nose 2 Ensure ears of buckle 3 are facing away from banding tool 4 and band gripper lever 5 is facing up 10 4320 303 13 Figure 3 6 Tightening Strapping NOTE After tension is created it is not necessary to hold band gripper lever since it locks itself under tension With thumb on band gripper lever Figure 3 6 1 apply tension by turning banding tool handle 2 clockwise Continue to turn banding tool handle 2 clockwise until strapping 3 stops moving stop turning banding tool handle 2 Figure 3 7 Rolling of Banding Tool 3 9 10 4320 303 13 3 4 1 6 Inch Hose Assembly Repair Continued NOTE To prevent breaking strapping release tension by turning banding tool handle counterclockwise while rolling banding tool over buckle s Roll banding too
248. ragraph 4 13 1 standard shop safety precautions 4 13 7 1 Removal Figure 4 20 Manifold Assembly Maintenance 4 50 4 13 7 2 gt o Qa o pn 4 13 7 w 10 4320 303 13 Remove two Figure 4 20 1 lock washers 2 bolts 3 and flat washers 4 from outlet support coupling b Discard lock washers 2 Remove two nuts 6 lock washers 7 bolts 8 and flat washers 9 from inlet support coupling 10 Discard lock washers 7 Remove manifold assembly 11 from hypochlorination unit Disassembly Unscrew and remove union 12 from inlet nipple 13 Unscrew and remove union 14 from outlet nipple 15 Remove inlet support coupling 10 from inlet nipple 13 Remove inlet nipple 13 from 2 inch globe valve assembly 16 Remove 2 inch globe valve assembly 16 from outlet nipple 15 Remove outlet nipple 15 from pressure regulating valve 17 Remove pressure regulating valve 17 from pipe nipple 18 Remove pipe nipple 18 from outlet support coupling 5 Inspection Inspect outlet support coupling 5 inlet support coupling 10 unions 12 and 14 inlet nipple 13 outlet nipple 15 and pipe nipple 18 for corrosion cracks holes or damage Inspect 2 inch globe valve 16 and pressure regulating valve 17 for leaks cracks holes missing components or damage Notify direct support if pressure regulator valve 17 i
249. ration by packing hoseline As soon as lead pumping station and first boost pumping station are installed and connected by hoseline perform the following steps 1 Refer to applicable technical manual for location of pump suction and pump discharge gauges for the 600 GPM pumping assemblies Turn petcock on boost pump discharge elbow to the left until fully opened This will 2 75 10 4320 303 13 2 5 1 TWDS General Operating Procedures Continued allow air trapped inside hoseline to be vented as water column moves forward S Notify operator s on lead pumping station to begin pump operation Observe hoseline for visual indications of approaching water Listen for air escaping from petcock Close petcock on discharge elbow when water begins to flow out of petcock G Notify operator s on lead pumping station to shut down pump operation 9 Close butterfly valve on boost pump discharge hose to contain water column c Begin moving water again when next downline station is installed and connected by hoseline Open butterfly valve on boost pump discharge hose and repeat applicable steps above Refer to applicable technical manual and start up lead pump and first boost pump When water column reaches second boost pumping station refer to applicable technical manual and close petcock on discharge elbow shut down pumps and cease operation of system Close butterfly valve on second boost pump discharge hose to con
250. ressure inside main valve assembly 2 b Remove tubing 3 c Remove reducer 4 from isolation cock valve 5 4 29 10 4320 303 13 4 11 5 Pressure Reducing Valve Assembly Maintenance Continued d e o Remove isolation cock valve 5 Remove elbow 6 from reducer 7 Remove reducer 7 from body of main valve assembly 2 Remove tubing 8 Remove elbow 9 from isolation cock valve 10 Remove isolation cock valve 10 from reducer 11 Remove reducer 11 from cover of main valve assembly 2 Remove reducer 12 and elbow 13 from pipe tee 14 Remove pipe tee 14 from main valve assembly 15 Remove pressure reducing control assembly 15 Remove pipe nipple 16 from isolation cock valve 17 Remove isolation cock valve 17 Remove pipe nipple 18 from elbow 19 Remove elbow 19 from reducer 20 Remove reducer 20 from body of main valve assembly 2 Inspection Inspect main valve assembly Figure 4 10 2 for evidence of leaks cracks holes missing components or damage Inspect mounting brackets 3 and skid assembly 7 for cracks bends holes or damage Return damaged or defective main valve assembly 2 and skid assembly 7 to direct support maintenance Replace all damaged mounting hardware and mounting brackets 3 Inspect all tubing Figure 4 11 3 and 8 reducers 4 7 11 12 and 20 elbows 6 9 13 and 1
251. rooved end quick disconnect coupling clamp 10 para 2 3 3 1 connecting check valve 9 to discharge port 11 on 600 GPM pumping assembly refer to applicable technical manual for location of discharge port on 600 GPM pumping assemblies not shown Remove check valve 9 2 8 4 Preparation for Movement of Boost Pumping Stations This is a general procedure for moving boost pumping stations For information pertaining to moving the 600 GPM pumping assemblies reference applicable technical manuals 2 8 41 Disassembly Requirements Disassembly of each boost pumping station requires the tools and personnel referenced in paragraph 2 3 5 1 Pack the components listed in table 2 10 in the PUMPING STATION crate after removing them from the boost pumping station 2 8 4 2 Disassembly Procedures Figure 2 17 Disassembly of Boost Pumping Station Suction Port NOTE Set aside all removed components for repacking a Remove 6 inch grooved pipe coupling Figure 2 70 1 para 2 3 2 1 connecting lateral grooved pipe fitting 2 to hoseline segment 3 Remove upline hoseline segment 3 b Remove grooved end quick disconnect coupling clamp 4 para 2 3 3 1 connecting lateral grooved pipe fitting 2 to 6 inch butterfly valve 5 c Remove grooved end quick disconnect coupling clamp 6 para 2 3 3 1 connecting 6 inch butterfly valve assembly 5 to discharge hose assembly 7 Remove 6 inch butterfly valve assembly 5 d Remove 6 i
252. s 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 Liquid Measure lcentiliter 10 milliters 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 lkiloliter 10 hectoliters 264 18 gallons Square Measure TM 10 4320 303 13 1 sq centimeter 100 sq millimeters 155 sq inch 1 aq decimeter 100 sq centimeters 15 5 sq inches 1 sq meter centare 100 sq decimeters 10 76 sq feet 1 eq dekameter 100 sq meters 1 076 4 sq feet 1 sq hectometer hectate 100 sq dekameters 2 47 acres 1 sq kilometer 100 sq hectometers 386 sq mile leu 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 Te 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 F Fahrenheit temperature Multiply by 2 540 305 914 1 609 6 451 093 836 2 590 405 028 165 29
253. s and damaged thimbles CAUTION To avoid damage to wire rope make sure lubricant is free of acids and alkalies c Clean 3 4 inch 1 9 cm wire rope assembly 4 and two 1 2 inch 1 3 cm wire rope assemblies 5 of dirt sand and other abrasives Using clean rag swab rope with lubricant d Inspect eight nuts 1 four flat washers 2 spreader bar 6 for damage 4 18 3 Repair Repair consists of replacing damaged or defective components 4 18 4 Assembly a Insert two U bolts 3 through thimbles on each end of 3 4 inch 1 9 cm wire rope assembly 4 b Install two wire rope assemblies 5 on each end of spreader bar 6 c Position two wire rope assemblies 5 between two holes on each end of spreader bar 6 Insert two U bolts 3 through holes on each end of spreader bar 6 securing two wire rope assemblies 5 to spreader bar 6 e Install two flat washers 2 and four nuts 1 on each U bolt 3 Tighten nuts 1 4 70 10 4320 303 13 SECTION VI PREPARATION FOR SHIPMENT AND STORAGE 4 19 PRESERVATION PROCEDURES Preservation procedures for the TWDS are contained in paragraphs 4 19 1 through 4 19 7 4 19 1 TWDS Components Preservation a Clean all dirt sand and debris from exterior surfaces of all TWDS components b Ensure all TWDS components are thoroughly dry prior to packing 4 19 2 600 GPM Pumping Assemblies Preservation Refer to applicable technical manual for preservation procedures for the 6
254. s not overhang grooved fittings Place gasket 8 over grooved fitting 6 on first component being sure that gasket 8 does not overhang end of grooved fitting 6 Align end of second grooved fitting 7 with first grooved fitting 6 Slide gasket 8 to center position between grooves No portion of gasket 8 should overhang grooves of grooved fittings 6 and 7 Open and place grooved end pipe quick disconnect coupling clamp 3 under gasket 8 and into grooved fittings 6 and 7 Ensure that grooved end pipe quick disconnect coupling clamp 3 is in grooves of grooved fittings 6 and 7 and close grooved end pipe quick disconnect coupling clamp 3 around gasket 8 Position lower portion of grooved end pipe quick disconnect coupling clamp tool 1 under cradles 2 on lower side of grooved end pipe quick disconnect coupling clamp 3 Position top portion of grooved end pipe quick disconnect coupling clamp tool 1 over cradles 4 on upper side of grooved end pipe quick disconnect coupling clamp 3 Pull handle of grooved end pipe quick disconnect coupling clamp tool 1 over grooved end pipe quick disconnect coupling clamp 3 and insert pin 5 into grooved end pipe quick disconnect coupling clamp 3 Remove grooved end pipe quick disconnect coupling clamp tool 1 from grooved end pipe quick disconnect coupling clamp 3 2 3 4 Lead Pumping Station Assembly Lead pumping station assembly requires one trailer mounte
255. s damaged or defective Inspect all mounting hardware for damage 4 13 7 4 Repair Repair of manifold assembly 11 consists of replacing damaged or defective components 4 13 7 5 Assembly a b NOTE e Wrap all threaded portions of pressure gauge and fill assembly components with antiseize tape prior to installation e Wrap antiseize tape in direction of threads Install pipe nipple 18 in outlet coupling support 5 Install pressure regulating valve 17 on pipe nipple 18 Install outlet nipple 15 in pressure regulating valve 17 Install union 14 on outlet nipple 15 Install 2 inch globe valve assembly 16 on outlet nipple 15 Install inlet nipple 13 in 2 inch globe valve assembly 16 Install union 12 on inlet nipple 13 Install inlet support coupling 10 on inlet nipple 13 4 51 10 4320 303 13 4 13 7 Manifold Assembly Maintenance And Pressure Regulator Valve Replacement Continued 4 13 7 6 Installation a Place manifold assembly 11 in hypochlorination unit and align mounting holes of manifold assembly 11 with mounting holes of hypochlorination unit b Install two flat washers 9 bolts 8 new lock washers 7 and nuts 6 on inlet support coupling 10 Tighten nuts 6 c Install two flat washers 4 bolts 3 new lock washers 2 and nuts 1 on outlet support coupling 5 Tighten nuts 1 4 52 10 4320 303 13 4 13 8 Frame Assembly
256. sembly when not in use All hoses in the hose network are equipped with quick disconnect fittings to allow for rapid installation and disassembly of the distribution point Up to four 36 gallon water storage bags suspended on tripods and fitted with faucets are used to disperse water to personnel for canteens and other small containers Operator is required to refill water storage bags periodically 1 19 5 TWDS Support and Supply Kits The TWDS is supplied with metal chests containing materials required to construct suspension devices repair 6 inch hoseline segments and prepare 6 inch by 500 foot hoseline segments for storage The kits are detailed below functional description of each support and supply kit is provided in the following 1 19 5 1 Suspension Kit The suspension kit is comprised of five metal chests containing kits of materials for constructing suspensions across streams ponds or gullies Each kit contains enough rope cable saddles sheeve blocks shackles turnbuckles and pickets to construct one suspension spanning 200 feet or two shorter spans Materials suitable for constructing tripods are not included in the kit and must be procured or fabricated locally 1 19 5 2 Displacement and Evacuation Kit The displacement and evacuation kit is used to remove water and air from the hoseline prior to packing An air compressor is required to operate the kit Using compressed air as a propellent a polyurethane ball which fits snugly
257. sh cam arms on reducer 4 forward to open Remove reducer 4 from male coupling half 5 Remove male coupling half 5 from hypochlorination unit 6 Start 125 GPM pumping assembly Figure 2 78 Flushing of Hypochlorination Unit Model 1955 1 Shown Open hypochlorination unit reservoir fill valve Figure 2 78 1 Fill reservoir 2 with water When reservoir 2 is full close reservoir fill valve 1 of hypochlorination unit 3 If model 1955 1 is used perform steps c through i of paragraph 2 5 5 4 For disassembly of hypochlorination unit model 1955 3 and model A 506131 reference applicable technical manual Allow hypochlorination unit to operate for 10 minutes to flush solution from hypochlorination unit parts and tubes At the same time continue to disconnect hoseline network Push cam arms of two reducers Figure 2 77 7 forward to open Remove two nozzles 8 with attached hose swivels 9 and reducers 7 from ends of hose assemblies 10 Unscrew and remove two reducers 7 from ends of hose swivels 9 Unscrew and remove two hose swivels 9 from ends of nozzles 8 Push cam arms on hose assemblies 10 forward to open Remove hose assemblies 10 from end of Y connection 11 Push cam arms on Y connection 11 forward to open Remove Y connection 11 from end of hose assembly 12 Push cam arms on discharge hose 12 forward to open Remove hose from male quick disconnect coupling half 1
258. sition 2 4 INITIAL ADJUSTMENTS CHECKS AND SELF TEST There are no initial adjustments checks or self tests other than the BEFORE B PMCS Perform all BEFORE B PMCS prior to operating the TWDS 2 5 OPERATING PROCEDURES The operating procedures for the TWDS are provided in paragraphs 2 5 1 through 2 5 5 2 5 1 TWDS General Operating Procedures This paragraph provides general instructions for operation of the entire TWDS under usual conditions Detailed instructions for operation of each major component will be provided in paragraphs 2 5 2 through 2 5 5 CAUTION If suction pressure falls below 10 psi or if discharge pressure rises above 150 psi damage can result to pump a When packing hoseline monitor suction and discharge pressures on pumps refer to applicable technical manual for location of pump suction and pump discharge gauges for the 600 GPM pumping assembly lf pressure is to low or too high IMMEDIATELY shut down pumps refer to applicable technical manual for procedures to shut down 600 GPM pumping assembly Notify supervisors on hose laying crews and operators at other pumping stations who are packing hoseline Cease operation until problem is corrected CAUTION e Trapped air can cause hoseline to collapse and pressure at downline pumping stations to fall below 10 psi e prevent damage to pump take precautions to vent air from hoseline b As hose laying crews connect major components prepare TWDS for ope
259. sket 10 and 4 inch gate valve 12 g Place eight flat washers 8 lock washers 9 and nuts 11 on eight bolts 6 2 Tighten nuts 11 until lock washers 9 engage and parts are firmly together NOTE Wrap anti seize tape in direction of threads i Wrap anti seize tape item 9 appendix E around threads of 4 inch coupling pipe fitting 3 Screw 4 inch coupling pipe fitting 3 into male coupling half 4 j Connect 6 inch x 6 inch x 4 inch reducing tee 1 to coupling pipe fitting 3 with 4 inch grooved end pipe quick disconnect coupling clamp 2 2 3 3 2 2 49 10 4320 303 13 2 3 6 Assembly of Storage Assemblies Continued k Push cam arms on 4 inch female coupling half 5 attached to gate valve forward to open position CAUTION To prevent leakage close both cam arms at the same time Do not strike cam arms to close Damage to couplings could result NOTE When installing gate valve on reducing tee make sure two 6 inch ends on tee are at right angles to stem on gate valve Connect 4 inch female coupling half 5 attached to 4 inch gate valve to male coupling half 4 Close cam arms m Place reducing tee gate valve assembly at point where junction with 10 mile hoseline segment is expected Figure 2 22 Final Assembly of Storage Assembly CAUTION To prevent leakage close both cam arms at the same time Do not strike cam arms to close Damage to couplings could result C
260. ssembly Maintenance a Loosen two hose clamps Figure 4 15 1 and slide them back from hose connectors 2 and 3 b Remove outlet hose 4 from hose connectors 2 and 3 c Remove two hose clamps 1 from outlet hose 4 d Remove hose connectors 2 and 3 4 39 10 4320 303 13 4 13 2 Outlet Pressure Regulator Inlet Drain and Fill Hose Assemblies Maintenance Continued 4 13 2 2 Inspection a Inspect two hose clamps 1 for corrosion damage and missing components b Inspect hose connectors 2 and 3 for corrosion 6cracks or damage c Inspect outlet hose 4 for holes cracks slices tears or damage 4 13 2 3 Repair a Replace defective outlet hose 4 length b Replace defective or damaged hose clamps 1 and hose connectors 2 and 3 4 13 2 4 Installation NOTE Wrap antiseize tape in direction of threads a Wrap antiseize tape around threads of hose connectors 2 and 3 and install hose connectors 2 and 3 b Place two hose clamps 1 on replacement piece of outlet hose 4 c Install outlet hose 4 on hose connectors 2 and 3 d Slide two hose clamps 1 over outlet hose 4 and hose connectors 2 and 3 interface Tighten hose clamps 1 4 40 10 4320 303 13 4 13 3 Pressure Gauge Fill Assembly Replacement This task covers 4 13 3 1 Removal 4 13 3 2 Inspection 4 13 3 3 Installation INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s Hypochlorination
261. station consists of a 600 gallons per minute gpm pumping assembly hose assemblies 6 inch butterfly valves check valve and coupling clamps One of three different 600 GPM pumping assemblies may be supplied with the TWDS se P Refer to applicable technical manual for a description of 600 GPM pumping assembly characteristics The 10 mile hoseline segment is constructed of 6 inch by 500 foot hose assemblies At intervals of every 1 000 feet a swivel joint is installed to prevent hoseline damage or chinking during hoseline packing A pressure reducing valve assembly can be installed to reduce water pressure between two pumping stations The storage assemblies store water tapped from the main TWDS hose line which can be dispensed at the distribution points or pumped further down line as required The storage assembly is a 20 000 gallon pillow tank For a description of the 20 000 gallon pillow tank reference 7M 55430 22612 Each distribution point consists of a 125 GPM pumping assembly a hypochlorination unit a network of hoses and 2 inch gate valves and three types of water dispensing equipment Refer to applicable technical manual for a description of the characteristics of the 125 GPM pumping assembly One of three different hypochlorination units may be supplied with the TWDS Refer to applicable technical manuals for a description of the characteristics of the model 1955 3 and model A 506131 hypochlorination units The model 1955 1 hypoc
262. stribution 1 7 Major Support Components for 5 1 8 Suspension Kit and Displacement and Evacuation Packing Kit and Repair 2 0 0 1 1 00 rnn nitri Operator s Controls and Indicators for TWDS Lead Pumping Station Operator s Controls and Indicators for TWDS 10 Mile Hoseline Segrment dae Operator s Controls and Indicators for TWDS Boost Pumping Station Operator s Controls and Indicators for TWDS Storage Operator s Controls and Indicators for TWDS Distribution Operator s Controls and Indicators for Hypochlorination Unit Model io oto PT Operator PMCS Routing Diagram Ground drole Pump Spacing Triangle sssessssssssssssssesseeeeeeeeennnnnn nnne nennen nnne nnne First Boost Pumping Station Pressure Reducing Valve Assembly 2 4 4 Pipe Grooved End Pipe Quick Disconnect Coupling Clamp Lead Pumping Station Suction Port and Butterfly Valve Assembly Model 609 A Le
263. t enough spacers to obtain proper disc compression e Install stem nut 6 Tighten stem nut 6 f Align holes in diaphragm 8 with studs in valve body 3 Stretch diaphragm 8 over studs in valve body 3 g Install spring 4 over valve stem 5 CAUTION When installing cover make sure diaphragm is lying smooth under cover If diaphragm is not smooth valve will not work properly h Align holes in cover 2 with studs in valve body 3 Carefully install cover 2 over studs on valve body 3 i Install twelve hex nuts 1 on studs of valve body 4 5 9 10 4320 303 13 5 5 3 Pressure Reducing Valve Assembly Skid Assembly Repair This task covers 5 5 3 1 Repair INITIAL SETUP Equipment Conditions General Safety Instructions Skid Assembly removed paragraph Do not work on equipment that is not secure 4 11 5 ly stabilized to prevent sliding Do not work on equipment without following standard shop safety precautions 5 5 3 1 Repair WARNING Do not work on equipment that is not securely stabilized to prevent sliding Failure to do so may result in personal injury a Repair of pressure reducing valve assembly skid consists of welding cracked seams and frame members in accordance with MIL STD 1261 and TM 9 237 5 10 10 4320 303 13 5 6 HYPOCHLORINATION UNIT MODEL 1955 1 MAINTENANCE 5 6 1 Pilot Valve Assembly Maintenance This task covers 5 6 1 1 Removal 5 6 1 3 Repair 5 6 1
264. t notify Class Ill leak supervisor 2 27 Item No Interval 39 40 41 TM 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued During During During Item to Check Service DISTRIBUTION POINT CONT Distribution Point Hose Assemblies Procedure Inspect for loose connections Disconnect and reconnect loose connections Inspect for damage and leaks If hose is damaged or Class Ill leaks are present notify supervisor Water Storage Bag HYPOCHLORINATION UNIT MODEL 1955 1 Pipes and Tubes Inspect bag and faucets for damage and leaks If bag or faucet is damaged or Class lll leak is present notify supervisor Ensure bag has adequate support Inspect pipes tubes and connections for damage and leaks If pipes tubes or connections are damaged or Class 1 leak is present notify supervisor 2 28 Not Fully Mission Capable if Connection is loose Hose is damaged Class Ill leak Water storage bag or faucet is damaged Water storage bag does not have enough support Class Ill leak Pipe s tube s or connection s are damaged Class III leak Item No Interval 42 43 44 TM 10 4320 303 13 Table 2 7 Operator Preventive Maintenance Checks and Services for TWDS Continued Not Fully Mission Capable Procedure if During During After Location Item to Check Service DISTRI
265. t Equipment Direct Support Maintenance 10 Mile Segment Equipment Maintenance Unit Tank Pillow 20 000 Gallon Equipment Data Trailer Mounted Pumping Assemblies Equipment Data Troubleshooting Operator Troubleshooting Unit TWDS Distribution Point Controls and Indicators for TWDS General Operating TWDS Lubrication TWDS Preparation for Movement Procedures 2 2 TWDS Site Location and Pumping Station Spacing TWDS Storage Assembly Controls and Indicators for TWDS Supply Connection Items Maintenance TWDS Support and Supply Kits Functional Description TWDS 10 Mile Hoseline Segment Operator s Control and Indicators U Unit PMCS Table Introduction lO cce b ate Re dto Unpacking neioii ianei Unusual Weather Operation in Use Assembly and Preparation TOM E EI W Warranty Information Water Meter Maintenance Water Meter and Gear Box Assembly Replacement 2 1 4
266. t washers 6 on two U bolts 8 Install two u bolts 8 through hypochlorination unit 10 securing water meter and gear box assembly 9 to hypochlorination unit 10 Install four new lock washers 4 and nuts 3 on two u bolts 8 Tighten nuts 3 and 7 g Insert two close nipples 2 in two unions 1 Tighten unions 1 until water meter and gear box assembly 9 is firmly secured to hypochlorination unit 10 4 46 10 4320 303 13 4 13 6 Hypochlorinator Assembly Maintenance This task covers 4 13 6 1 Removal 4 13 6 4 Repair 4 13 6 2 Disassembly 4 13 6 5 Assembly 4 13 6 3 Inspection 4 13 6 6 Installation INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s Hypochlorination Unit Model 1955 1 removed Automotive Section Ill Item 1 refer to paragraph 4 13 1 Outlet Hose Assembly removed refer to Material Parts paragraph 4 13 2 Lock washers TM 10 4320 303 23P General Safety Instructions Preformed packing TM 10 4320 303 23P Do not work on equipment without following standard shop safety precautions 4 13 6 1 gt o o n 4 13 6 2 gt o Removal Unscrew and remove discharge tub Figure 4 19 1 from liquid head 2 Remove check valve 3 and washer 4 Unscrew other end of discharge tube 1 and remove from hypochlorination unit Unscrew and remove suction tube 5 from liquid head 2 Remove check valve 6 and washer 7 Remov
267. tain enough water to allow a normal discharge ratel para 288 Pumping rates during operation will vary depending on amount of water being discharged at either distribution points large storage and distribution units or both Pumping stations operate at intervals long enough to refill 20 000 gallon pillow tanks if discharge rate is minimal When water is pumped on a continual basis and boost pumping stations are operating in electric automatic mode perform DURING D PMCS on trailer mounted pump assemblies at a minimum of every 3 hours 2 76 10 4320 303 13 j During all phases of operation operators at pumping stations and storage assemblies must be in communication with each other Any unusual situations or difficulties must be reported immediately 1 Since pumps are operated in manual or electric manual modes during startup operators must monitor suction and discharge pressures on pumps They must report low suction pressure or high discharge pressure and take corrective action immediately 2 Storage assembly operators should report beginning and completion of tank filling operations 3 Operators at lead pumping station should track status of advancing water column during packing operation During startup they should monitor overall performance of system 4 Once operation of complete system begins operators on each pumping station must continue to monitor suction and discharge pressures They must report low suction pressur
268. tain water column d Continue packing hoseline as each boost pumping station is installed and connected NOTE Before storage tanks are filled or complete operation of system begins flush hoseline of sediment and debris e To protect hose from damage in high winds do not begin filling storage tanks until hoseline is packed When system is ready for operation reference paragraph 2 5 4 for instructions on filling storage tanks f Complete operation of TWDS can begin as soon as all pumping stations storage assemblies and distribution points have been installed and connected g During startup of the complete system run all pumps in manual or electric mode reference applicable technical manual After startup boost pumping stations can be operated in electric automatic mode reference applicable technical manual However the lead pump should always be operated in manual mode reference applicable technical manual for operation of 600 GPM pumping assemblies h When 20 000 gallon pillow tanks are approaching maximum holding capacity reduce speed on lead pump to decrease rate of downline water flow reference applicable technical manual If operating in electric mode rate of boost pumps should decrease automatically When 20 000 gallon pillow tanks are filled to maximum capacity height of tank reaches 5 1 2 feet close 4 inch gate valve on each storage assembly i Operation of distribution points can begin when storage tanks con
269. tall reducer 7 in body of main valve assembly 2 n Install elbow 6 in reducer 7 Install isolation cock valve 5 on elbow 6 p Install reducer 4 on isolation cock valve 5 q Install tubing 3 on reducer 4 and reducer 12 r Place all cock valves 1 in open position 4 31 10 4320 303 13 4 11 5 Pressure Reducing Valve Assembly Maintenance Continued 4 11 5 4 Installation WARNING Two personnel are required for lifting main valve assembly Failure to obey this warning may result in personnel injury CAUTION When installing main valve assembly ensure that tubing does not become damaged a Install main valve assembly Figure 4 10 2 on skid assembly 7 Ensure valve inlet and outlet ports rest securely on skid assembly mounting brackets 8 b Install mounting brackets 3 on main valve assembly 2 and align holes in mounting brackets 3 with mounting holes on skid assembly 7 c Install two mounting bolts 6 new lock washers 5 and nuts 4 in each mounting bracket 3 Tighten nuts 4 d Install four nuts 1 Tighten nuts 1 4 32 10 4320 303 13 4 11 6 Pressure Relief Valve Assembly Maintenance This task covers 4 11 6 1 Disassembly 4 11 6 3 Repair 4 11 6 2 Inspection 4 11 6 4 Assembly INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s Pumping station shutdown refer to Automotive Section Ill Item 1 applicable technical manual Pressure
270. te selection are available when selecting a route for the TWDS The minimum requirements for selecting the route are as follows A sketch of the proposed hoseline route Odometer distances e Enough topographic information surveying altimeter elevations to establish relative altitude at various points along the hoseline route 2 3 1 4 TWDS Installation and Operation Guidelines The following guidelines should be utilized to gain maximum effectiveness for installation and operation of TWDS The route should be direct and present a minimum number of obstacles and obstructions A route parallel to a secondary all weather road is preferable to one along a heavily traveled road e f roadways do not exist or cannot be utilized select a route that is accessible to vehicles required for laying the hoseline e Plan to locate junction of two hoseline lengths at installation sites for each boost pumping station and storage assembly Keep security precautions in mind Utilize natural camouflage wherever possible and avoid routing hoseline through populated areas 2 3 1 5 Pumping Station Installation Sight Selection When selecting pumping station installation sites the location of the lead or first pumping station will be determined by location of the water source Boost pumping stations are intended to be spaced at approximately two mile intervals assuming that the route is reasonably direct and the terrain is level However a su
271. ten screws 10 h Attach valve rod 8 to link spring coupling 9 i Tighten rod lock nut 7 j Grasp end of valve rod 8 Slowly move valve rod 8 back and forth to test for smooth operation If valve rod 8 sticks or movement is rough foreign matter is in valve sleeve 15 area Repeat steps 5 6 1 1 k through m and inspect parts for cleanliness Refer to paragraph 5 6 1 2 and clean all items as appropriate Repeat steps 5 6 1 4 a through j until valve rod movement is smooth CAUTION Do not over tighten thumbscrew or it may break k Install yoke cover 5 on gear box 6 Install thumbscrew 4 Tighten thumbscrew 4 m Install end cap 2 on lock spring cap 3 n Insert two screws 1 Tighten screws 1 5 13 10 4320 303 13 5 6 2 Gear Box Maintenance This task covers 5 6 2 1 Disassembly 5 6 2 3 Repair 5 6 2 2 Inspection 5 6 2 4 Assembl INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s 125 GPM pumping assembly shutdown refer to Automotive Section Ill Item 1 applicable technical manual Water Meter and Gear Box Assembly removed Materials Parts paragraph 4 13 5 Gasket TM 10 4320 303 23P Pilot Valve Assembly removed paragraph Cotter Pin TM 10 4320 303 23P 5 6 1 General Safety Instructions Do not work on equipment without following standard shop safety precautions 5 6 2 1 Disassembly a Remove two cap screws Figure 5 4 1 b Remove valve cap 2 from
272. tion Strength NOTE e confuse the terms dosage and residual e Dosage refers to amount of chlorine added to the water e Residual refers to amount of chlorine remaining in the waterafter 10 minutes a Determine desired chlorine dosage or solution strength b Check listing on table 2 19 Read across for required quantity of calcium hypochlorite powder needed If chlorine requirement is unknown start with a 1 0 percent solution strength Adjust in accordance with chlorine residual tests NOTE Table 2 19 is based on strength of calcium hypochlorite at 7096 strength Table 2 14 Hypochlorite Solution Strength Index Required Quantity of Calcium Hypochlorite 02 20 2 00 600 Figures table 2 19 based on the following 1 Model 1955 1 100 gpm maximum flow rate through unit at 24 spm with 50 percent stroke setting 2 Model A 506131 100 gpm maximum flow rate through unit at 12 spm with 100 percent stroke setting 2 79 10 4320 303 13 2 5 5 4 Operation of Hypochlorination Unit Model 1955 1 Figure 2 45 Hypochlorination Unit Model 1955 1 Controls and Suction Foot WARNING To keep dirt sand and grit from contaminating the solution make sure reservoir is covered by lid a Open water reservoir fill valve Figure 2 45 1 and fill reservoir 2 Close water reservoir fill valve 1 when water reaches FULL mark on reservoir 2 2 80 10 4320 303 13
273. tive Section Ill Item 1 applicable technical manual Material Parts General Safety Instructions Do not work on equipment without following standard shop safety precautions Antiseize Tape Item 9 Appendix E Silicon Lubricant Item 5 Appendix E Gasket TM 10 4320 303 23P 4 10 1 1 Removal Figure 4 1 Reducer Y Connection Removal a Open cam arms and disconnect reducer Y connection Figure 4 1 1 from water source 4 13 10 4320 303 13 4 10 1 Reducer Y Connection Maintenance Continued b Open cam arms on 6 inch x 10 foot suction hose assembly 2 and remove reducer Y connection 1 from 6 inch x 10 foot suction hose assembly 2 4 10 1 2 Disassembly om Figure 4 2 Reducer Y Connection Disassembly Remove quick disconnect male coupling half Figure 432 1 from grooved pipe coupling fitting 2 Remove two female quick disconnect couplings 3 from reducer pipe fittings 4 Discard gaskets of female quick disconnect couplings 3 Remove three grooved end pipe quick disconnect coupling clamps 5 paragraph 2 3 3 1 Remove two reducer pipe fittings 4 from Y fitting 6 Remove Y fitting 6 from grooved pipe coupling fitting 2 10 1 3 Inspection Inspect grooved end pipe quick disconnect coupling clamps 6 for cracks bends damage or ripped torn sliced or damaged gasket Inspect two female quick disconnect couplings 3 for cracks holes
274. to reservoir Figure 2 48 5 2 82 10 4320 303 13 Figure 2 48 Correcting Air Bound Unit After Startup 4 Run unit for 10 minutes and take residual test para 2 5 5 7 b Continue adding water and repeating tests until desired residual is obtained 1 If residual reading is low 1 Turn stroke adjust thimble Figure 2 47 1 setting to 7 5 on micrometer bar scale 2 2 Run unit for 10 minutes and repeat residual test para 2 5 5 7 3 If reading remains low continue to adjust stroke setting up and perform residual tests until desired residual is obtained m When residual test para 2 5 5 7 gives desired reading no adjustments to unit are required Check level of solution in reservoir every 30 minutes When level drops within 2 or 3 inches of foot valve Figure 2 45 4 prepare new batch of solution in reservoir 2 n Make residual tests para 2 5 5 7 at frequent intervals to see if desired residual is being maintained Over an extended period of time unit requires some adjustment steps k or 1 above to keep residual at desired level o To stop unit close range adjusting valve Figure 2 46 1 Hypochlorination unit will not operate when there is no flow through water meter 2 5 5 5 Operation of Hypochlorination Unit Model 1955 3 Reference applicable technical manual for operation of hypochlorination unit model 1955 3 2 5 5 6 Operation of Hypochlorination Unit Model A 506131 Reference applicable tech
275. tool box 3 for smooth operation of top corrosion cracks holes or damage d Inspect mounting hardware for damage 4 13 8 4 Repair a Replace damaged or defective chlorine reservoir 1 or tool box 3 b Notify direct support if frame 2 is damaged or defective 4 53 10 4320 303 13 4 13 8 Frame Assembly Replacement Continued Figure 4 21 Chlorine Reservoir and Tool Box Heplacement c Replace all damaged mounting hardware 4 13 8 5 Assembly a Align mounting holes of tool box 3 and frame 2 b Install four screws 6 new lock washers 5 and nuts 4 Tighten nuts 4 c Close top of tool box 3 d Insert chlorine reservoir 1 in frame 2 4 54 10 4320 303 13 4 13 9 Stand Assembly Maintenance This task covers 4 13 9 1 Disassembly 4 13 9 3 Repair 4 13 9 2 Inspection 4 13 9 4 Assembly INITIAL SETUP Tools Equipment Conditions Tool Kit General Mechanic s Nozzles and Elbow Coupler Valves removed Automotive Section Ill Item 1 from stand General Safety Instructions Material Parts Do not work on equipment without following Cotter Pins standard shop safety precautions 4 13 9 1 Disassembly 12 777 F Figure 4 22 Stand Assembly Maintenance a Remove three S hooks Figure 4 22 1 b Remove three chains 2 from three S hooks 1 c Remove two cotter pins 3 from two straight pins 4 Discard cotter pins 3 4 55 10 4
276. towing unused accessories and other routine procedures such as equipment inventory cleaning components and touch up painting are not listed in the table These are things you should do any time you see that they need to be done If a routine check is listed in the PMCS Table it is because experience has shown that problems may occur with this item Take along tools and cleaning cloths needed to perform the required checks and services 2 2 5 Leakage Definitions Leakage definitions operator crew PMCS are classified as follows 55 Seepage of fluid indicated by wetness or discoloration not great enough to form drops Class Il Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked Class Ill Leakage of fluid great enough to cause drops to drip from item being checked NOTE The TWDS can be operated with Class and Class Ill leaks When in doubt notify supervisor of leak Do operate TWDS with a Class Ill leak Class Ill leaks must be reported to your supervisors or to Unit Level Maintenance for corrective action f the equipment must be kept in continuous operation do only the procedures that can be done without disturbing operation Make the complete checks and services when the equipment can be shutdown 2 9 10 4320 303 13 STORAGE ASSEMBLY DETAIL H DISTRIBUTION POINT DETAIL 1 SUSPENSION DEVICE Se 5 10 MILE DETAIL C A HOSELINE SEGMENT
277. ult b Close cam arms on 6 inch x 10 foot suction hose assembly 2 10 4320 303 13 4 10 2 6 Inch Butterfly Valve Assembly Maintenance This task covers 4 10 2 1 Removal 4 10 2 2 Disassembly 4 10 2 3 Inspection INITIAL SETUP Tools Tool Kit General Mechanic s Automotive Section Item 1 Equipment Conditions Pumping station shutdown refer to applicable technical manual 4 10 2 1 Removal 4 10 2 4 Repair 4 10 2 5 Assembly 4 10 2 6 Installation Materiel Parts Lock washers TM 10 4320 303 23P Preformed packing TM 10 4320 303 23P General Safety Instructions Do not work on equipment without following standard shop safety precautions NOTE There are 3 versions of the 6 Inch Butterfly Valve assembly used with TWDS These procedures cover the 6 Inch Butterfly Valve shown The maintenance procedures for the others are similar Figure 4 3 6 Inch Butterfly Valve Assembly Removal a Remove two grooved end pipe quick disconnect coupling clamps Figure 413 1 securing 6 inch butterfly valve assembly 2 to 6 inch X 20 foot hose assembly 3 and lateral grooved pipe fitting 4 b Remove 6 inch butterfly valve assembly 2 4 10 2 2 Disassembly a Remove two bolts Figure 4 4 1 lock washers 2 and remove handle assembly 3 from mounting plate 4 Discard lock washers 2 4 16 10 4320 303 13 Figure 4 4 6 Inch Butterfly Valve Assembly Disassembly Remove tw
278. umn 1 The first column Illus Number gives you the number of the item illustrated C 3 2 Column 2 The second column National Stock Number identifies the stock number of the item to be used for requisitioning purposes C 3 3 Column 3 The third column Description and Usable On Code identifies the Federal item name in all capital letters followed by a minimum description when needed The last line below the description is the Commercial and Government Entity Code CAGEC in parentheses and the part number If the item you need is not the same for different models of the equipment a Usable On Code will appear on the right side of the description column on the same line as the part number These codes are identified below CODE USED ON DTC Model 06749 0183 81 DTQ Model 110 00 0000 DTR Model 919 EAM Model 10 C 3 4 Column 4 The fourth column U I unit of issue indicates how the item is issued for the National Stock Number shown in column two C 3 5 Column 5 The fifth column Qty Rad indicates the quantity required C 1 10 4320 303 13 SECTION Il COMPONENTS OF END ITEM 1 2 3 4 NATIONAL STOCK DESCRIPTION Usable U M NUMBER NUMBER CAGEC and Part Number On Code ILLUS PUMPING STATION 1 4730 01 176 5772 COUPLING CLAMP PIPE 6 INCH EA 81349 M10387 1 D 11 2 4730 01 270 6555 COUPLING CLAMP 6 INCH EA x 79154 6 791 A 3 5120 01 270 7428 WRENCH SPANNER EA 79154 792 4 472
279. ump Close to shut off pump from water source 4 6 INCH BUTTERFLY Used to control water flow down line from lead DISCHARGE VALVE pumping assembly Open to route water flow down line Close to shut off down line water flow 5 PRESSURE RELIEF Releases pressure when boost pumping station discharge VALVE pressure exceeds 200 psi 2 4 10 4320 303 13 2 1 4 TWDS Storage Assembly S e figure 2 4 and table 2 4 Figure 2 4 Operator s Controls and Indicators for TWDS Storage Assembly Table 2 4 Description of Operator s Controls and Indicators for TWDS Storage Assembly Item Item Name Description and Purpose No 1 STORAGE TANK 20 000 gallon collapsible rubberized nylon pillow tank Reference applicable technical manual for a description of the operators controls and indicators for the 20 000 gallon pillow tank 2 4 INCH GATE VALVE Used to control water flow into storage assembly ASSEMBLY 10 4320 303 13 2 1 5 TWDS Distribution Point See figure 2 4 and table 2 5 Figure 2 5 Operator s Controls and Indicators for TWDS Distribution Point Table 2 5 Description of Operator s Controls and Indicators for TWDS Distribution Point Description and Purpose 2 INCH GATE VALVE Used to control water flow to manual dispersing stations ASSEMBLY NOZZLE Used to control flow of water at manual dispersing stations when attached to hose end ELBOW Used to control flow of water at manual dispersing stations ASSEMBLY
280. using a grooved end pipe quick disconnect coupling clamp to connect two TWDS components 2 3 3 1 Removal Figure 2 13 Grooved End Pipe Quick Disconnect Coupling Clamp a Position lower portion of grooved end pipe quick disconnect coupling clamp tool Figure 2 13 1 under cradles 2 on lower side of grooved end pipe quick disconnect coupling clamp 3 b Position top portion of grooved end pipe quick disconnect coupling clamp tool 1 over cradles 4 on upper side of grooved end pipe quick disconnect coupling clamp 3 c Pull handle of grooved end pipe quick disconnect coupling clamp tool 1 over grooved end pipe quick disconnect coupling clamp 3 and push pin 5 from grooved end pipe quick disconnect coupling clamp 3 d Remove grooved end pipe quick disconnect coupling clamp tool 1 from grooved end pipe quick disconnect coupling clamp 3 2 38 f 9 2 3 3 2 b h TM 10 4320 303 13 Open and remove grooved end pipe quick disconnect coupling clamp 3 from grooved fittings 6 and 7 Remove gasket 8 from grooved fittings 6 and 7 Check gasket 8 for damage If gasket 8 is damaged replace it Installation Apply thin coat of non petroleum silicone lubricant item 5 appendix E to gasket lips and outside of gasket 8 CAUTION Overhanging of gasket on grooved fittings may result in damage to gasket when securing grooved end pipe quick disconnect coupling clamp Ensure gasket doe
281. valve 3 with grooved end pipe quick disconnect coupling clamp 4 2 3 3 2 i Install 6 inch butterfly valve 7 on end of 6 inch x 20 foot hose assembly 5 with grooved end pipe quick disconnect coupling clamp 6 2 3 3 2 j Install 6 inch lateral grooved pipe fitting 9 on end quick disconnect coupling clamp 8 2 3 3 2 of 6 inch butterfly valve 7 with grooved end pipe WARNING Personal injury may result from high pressure water if pressure relieve valve faces butterfly valve Ensure pressure relief valve is installed as shown figure 2 16 to avoid personal injury k Install 6 inch pressure relief valve 11 on end of lateral grooved pipe fitting 9 with grooved end pipe quick disconnect coupling clamp 10 para 2 3 3 2 2 46 10 4320 303 13 Figure 2 20 Boost Pumping Station and Bypass Components Assembly l Install 6 inch butterfly valve Figure 2 20 2 on end of lateral grooved pipe fitting 4 on suction line of boost pumping station with grooved end pipe quick disconnect coupling clamp 3 para 2 3 3 2 m Install 6 inch x 75 foot discharge hose assembly 7 on end of 6 inch butterfly valve 2 with grooved end pipe quick disconnect coupling clamp 2 3 3 2 n Install 6 inch x 75 foot discharge hose assembly 7 on end of lateral grooved pipe fitting 5 on discharge line of boost pumping station with grooved end
282. vement Operation in Unusual Nuclear Biological and Chemical NBC geo EE Emergency Procedures 2 1 10 4320 303 13 SECTION DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS 2 1 OPERATOR S CONTROLS AND INDICATORS 2 1 1 Lead Pumping Station Sde figure 2 1 and table 2 1 Figure 2 1 Operator s Controls and Indicators for TWDS Lead Pumping Station Table 2 1 Description of Operator s Controls and Indicators for TADS Lead Pumping Station Item Item Name Description and Purpose No 1 LEAD PUMPING STATION 600 gpm pumping assembly Reference applicable technical manual for a description of the operator s controls and indicators for the 600 gpm pumping assemblies 2 6 INCH BUTTERFLY Used to control water flow into lead pumping assembly Open VALVE SUCTION to route water flow from water source through pump Close to shut off pump from water source 3 6 INCH BUTTERFLY Used to control water flow down line from lead pumping VALVE DISCHARGE assembly Open to route water flow down line Close to shut off down line water flow 4 PRESSURE RELIEF Releases pressure in 10 mile hoseline segment when pressure VALVE exceeds 200 pounds per square inch psi 2 2 10 4320 303 13 2 1 2 TWDS 10 Mile Hoseline Segment S6e figure 2 and table 2 2 Figure 2 2 Operator s Controls and Indicators for TWDS 10 Mile Hoseline Segment Table 2 2 Description

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