» $9593- BE-MMM- 010/19190- MSD-MKI a es amma em Om ~ TECHNICAL MANUAL ARS : OPERATION AND MAINTENANCE INSTRUCTIONS ~ WITH PARTS BREAKDOWN SEWAGE SYSTEM, GATX DUPLICATE MANUFACTURED BY GARD, INC, subsidiary of GATX Corporation Contract: N00024-81-C-2022 “DISTRIBUTION LIMITED TO U.S. GOVERNMENT AGENCIES ONLY; (TEST AND EVALUATION) (DATE STATEMENT APPLIED). REQUESTS FOR THIS DOCUMENT MUST BE REFERRED TO THE COMMANDER, NAVAL SEA SYSTEMS COMMAND’’ | zs 15 DECEMBER 1982 ® PROPERTY OF SUPSHIP LIBRARY x, age | SHELF NO: - | v3¥ oa COPY NO: hig te See } : "6G 4 S9593-BE-MMM-010/19190-MSD-MKIl ~ TECHNICAL MANUAL ARS : OPERATION AND MAINTENANCE INSTRUCTIONS WITH PARTS BREAKDOWN SEWAGE SYSTEM, GATX MANUFACTURED BY GARD, INC, subsidiary of GATX Corporation Contract: N00024-81-C-2022 ‘(DISTRIBUTION LIMITED TO U.S. GOVERNMENT AGENCIES ONLY; (TEST AND EVALUATION) (DATE STATEMENT APPLIED). REQUESTS FOR THIS DOCUMENT MUST BE REFERRED TO THE COMMANDER, NAVAL SEA SYSTEMS COMMAND”’ 15 DECEMBER 1982 $9593-BE-MMM-010 INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGES NOTE: The portion of the text affected by the changes is indicated by a vertical line in q the outer margin of the page. rd 9 pag TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 72 CON SISTING OF THE FOLLOWING: Page Page 4-1 5-2 (Blank) 5-3 5-4 (Blank) 5-6 (Blank) 5-7 5-8 (Blank) 6-1 — 6-3 6-4 (Blank) 6-6 (Blank) 1-6 (Blank) aL 2m. 7-16 (Blank) 2-6 (Blank) 8-1 — 8-8 3-6 (Blank) *Zero in this column indicates an original page. $9593-BE-MMM-010 RECORD OF CHANGES TITLE OR BRIEF DESCRIPTION ENTERED BY $9593-BE-MMM-010 je APPROVAL AND PROCUREMENT RECORD PAGE APPROVAL DATA FOR: S9593-BE-MMM-010/19190-MSD-MKII TITLE OF MANUAL: SEWAGE SYSTEM, GATX APPROVAL AUTHORITY: PMS383.123-2:SBC086.01/ARS-50 SER: 6108 CONTRACT SHIP QUANTITY QUANTITY BUILDING NUMBER APPLICABILITY OF OF YARD eho ee eee oc ar i enmceoe.” 6.8274 Eames 81 Shi” |. i ee eee N00024-81-C-2202 “ARS-50, 51, 52, 53 1 CRC 1 PER SHIPSET PETERSON BUILDERS, INC. STURGEON BAY, WI 54235 DATE:__1 MAY 1983 CERTIFICATION: It is hereby certified that NAVSEA S9593-BE-MMM- 010/19190-MSD-MKII to be provided under contract number N00024-81-C-2022 has been approved by the approval data shown above. GARD INC. 7449 N. Natchez Ave. Niles, IL 60648 FMC 19190 $9593-BE-MMM-010 FOREWORD This technical manual describes Marine Sanitation Device MK II (MSD-MK II). The technical manual includes reference data, parts identification, and procedures for installation, operation, and maintenance of the complete system. The MSD-MK II is specifically designed to prevent discharge of shipboard sewage into lakes and navigable waters. The system, as installed on U.S. Navy boats or service craft, collects sanitary waste in reduced- volume-flush water closets, holds the sewage in a special holding tank during operations in navigable waters, and pumps the sewage to proper shore facilities or into waters outside those restricted from such discharge. This manual is divided into 8 chapters as follows: CHAPTER 1. GENERAL INFORMATION AND SAFETY PRECAUTION. This chapter provides an overall view of the Marine Sanitation device and includes Safety Precautions that must be observed when performing maintenance on the equipment. CHAPTER 2. OPERATION. This chapter provides user instructions for operation of the Commode and overall system operations. This includes identification of the Control and indicators associated with the equipment. CHAPTER 3. FUNCTIONAL DESCRIPTION. This chapter provides a detailed look at the overall operation. Included are explanations of all electrical circuit operations and the waste collection system. CHAPTER 4. SCHEDULED MAINTENANCE. This chapter provides detailed coverage of all required Preventive Maintenance procedures. CHAPTER 5. TROUBLESHOOTING. This chapter contains information to aid the technician in quickly locating a faulty component. Troubleshooting is based on the use of fault logic diagram. CHAPTER 6. CORRECTIVE MAINTENANCE. This chapter contains the recommended procedure for performing repairs on components of the system. CHAPTER 7. PARTS LIST. This chapter provides illustration identifying all replaceable parts and includes parts lists identifying the parts by part number and listing the FSCM for the manufacture of the parts. CHAPTER 8. INSTALLATION. This chapter provides information to aid in properly installing the components of the equipment. Included is information on Site Selection, Installation of each component and Installation Checkout Procedure. ‘‘Ships, training activities, supply points, depots, naval shipyards, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be reported to the Naval Sea Data Support Activity (NSDA), Naval Ship Weapon Systems Engineering Station (Code 5700), Port Hueneme, California 93043, on NAVSEA Technical Manual Deficiency/Evaluation Report, Form NAVSEA 5600/2. To facilitate such reporting, three copies of Form NAVSEA 5600/2 are included at the end of each bound part of each newly published unclassified technical manual. FOREWORD-1/(FOREWORD-2 BLANK) TABLE OF CONTENTS Page Paragraph ® Paragraph g g 2 CHAPTER | — GENERAL INFORMATION AND —__ 3-12. Emergency Collection SAFETY PRECAUTIONS 3-13. Normal Discharge to Pierside Facilities SECTION I. GENERAL INFORMATION 3-14, Normal Discharge Overboard 1-1. Introduction 3-15. Emergency Discharge 1-2. | Equipment Description 3-16. Normal/Emergency Off-Loading-Hose 1-3. User Option Flushing 1-4. Reference Data CHAPTER 4 — SCHEDULED MAINTENANCE .4-1 SECTION II. SAFETY PRECAUTIONS 4-1. Introduction 4-1 1-5. 4-2. 1-6. Sewage Handling 4-3. Preventive Maintenance Checks and Services 1-7. Electrical Equipment 1-8. Disinfectants 4-4. Maintenance Plan 1-9. Decontamination of Personnel and 4-5. Equipment 1-10. Equipment Required 4-7. Personal Decontamination After Working 4-8. in Contaminated Space 4-9. 1-12. Laundry Procedure 4-10. Annual 1-13. CHAPTER 5 — TROUBLESHOOTING 1-14. Certifications of Space Suitability 5-1. 1-15. Additional Procedures §-2. Arrangement of Data CHAPTER 2 — OPERATION 5-3. Troubleshooting Charts SECTION I. USER INSTRUCTIONS CHAPTER 6 — CORRECTIVE MAINTENANCE 2-1. Introduction 6-1. Introduction 2-2. Operating Modes SECTION I. ADJUSTMENT AND ALIGNMENT 2-3. ‘‘Dry’’ Bowl 6-2. 2-4. ‘‘Wet’’ Bowl SECTION II. REPAIR 2-5. 6-3. |. Commode Assembly SECTION II. SYSTEM OPERATION 6-4. 2-6. Controls and Indicators 6-5. Flush Valve 2-7. Operating Modes 6-6. Urinal Assembly 2-8. Valve Operation Settings 6-7. Macerator/Transfer Pump Assembly 2-9. Normal Collection Servicing Procedure 2-10. Emergency Collection 6-8. Cleaning Volute Case and/or Replacing Grinder 2-11. Discharge to Pierside Facility 2-12. Discharge Overboard 6-9. Replacing Seals 2-13. Flushing Sewage Holding Tank 6-10. Adjustment of Cutter Mechanism 2-14. Normal/Emergency Off-Loading Hose 6-11. Electrical Controls Servicing Procedure .... Flushing CHAPTER 7 — PARTS LIST CHAPTER 3 — FUNCTIONAL DESCRIPTION SECTION I. INTRODUCTION 3-1. 7-1. Introduction 3-2. 7-2. List of Major Components 3-3. 7-3. Parts List 3-4. 7-4. Figure and Index Number 3-5. High Level Alarm 7.5. Nameand Part Number 3-6. Macerator/Transfer Pump Control 7-6. 3-7. General 7-7. Federal Supply Code 3-8. Auto Operation 7-8. Manufacturers Part Number 3-9. Manual Operation SECTION II. PARTS LIST 3-10. Waste Processing Components (Refer to List of Illustrations) 3-11. Normal Collection $9593-BE-MMM-010 CHAPTER 8 — INSTALLATION 8-1. Site Information 8-18. Impellar Rotation Check @ 8-2. Controlled Volumne Flush Commode 8-19. Mounting : way 8-3. Flush Valve Assembly 8-20. Interface 8-4. Electrical Connection of Water Closet 8-21. Electrical Connection of Macerator Pump 8-5. Controlled Volumne Flush Urinal Assembly 8-6. Macerator/Transfer Pump Assembly 8-22. Electrical Controls Installation 8-7. Electrical Connection of Macerator/Transfer 8-23. Component Location 8-24. Cabling 8-8. Electrical Controls 8-25. Installation Checkout 8-9. Tools and Materials Required 8-26. Preenergizing Procedure 8-10. Input Requirements 8-27. Initial Turn-On 8-11. Unpacking and Repacking 8-28. Commode Installation Verification 8-12. Commode Assembly Installation 8-29. Switch Adjustment 8-13. Mounting and Outlet Connection 8-30. 8-14. Flush Valve 8-31. Stopper Disc Assembly 8-15. Flush Water 8-32. Stopper Disc Seal 8-16. Electrical 8-33. Macerator/Transfer Pump Assembly 8-17. Macerator/Transfer Pump Assembly Installation Verification Installation 8-34. Electrical Controls Installation Verification . .8-8 LIST OF ILLUSTRATIONS Figure Page Figure 1.1 Figure 1-1. Marine Situation Device MK II Unit 7 Timing and Control Panel Assembly ES Relationship 7-3. Printed Circuit Board Assembly : 2-1. Commode and Urinal Operator Controls . .. .2- 7-4. Macerator/Transfer Pump Assembly 2-2. Controls and Indicators 7-5. Macerator/Transfer Pump 2-3. Valve Identification with Interconnection 7-6. Commode Assembly (Sheet 1 of 2) Plumbing 7-44. Commode Assembly (Sheet 2 of 2) MSD—MkK II, Functional Diagram 7-7. Remote Control Lever : MSK MK II Schematic Diagram 7-8. Spring/Bracket Assembly Waste Processing Diagram 7-9. Flush Valve Cable Assembly Commode Adjustment Parts Location 7-10. Hopper Stopper Assembly Marine Sanitation Device Fault Logic. 7-11. Urinal Assembly 8-1. Commode Installation Detail Commode Fault Logic Diagram 8-2. Piping Detail Macerator/Transfer Pump Fault Logic 8-3. Platform—Commode Shock Mount 8-4. Flush Valve Cable Installation Electrical System Fault Logic Diagram 8-5. Macerator/Transfer Pump, Outline Drawing 8-6 Commode and Urinal Flush Valve 8-6. Wiring Diagram Macerator/Transfer Pump , 8-7. Printed Circuit Board Assembly Timing and Control Enclosure Assembly .... LIST OF TABLES Number Title Page Number Title 1-1. Water Data and Electrical Power 2-2. Valve Operation Setting Requirements 8-1. “Commode Macerator/Transfer Pump 1-2. Dimensions and Weights Assembly Wiring & 2-1. Controls and Indicators $9593-BE-MMM-010 SAFETY SUMMARY Operator and Maintenance personnel working on Marine Sanitation Equipment must follow all safety precautions to minimize possible contamination. Section II has been added to chapter 1 to cover these precautions. All personnel should review this section before servicing the components of this equipment. CHAPTER 1 GENERAL INFORMATION AND SAFETY PRECAUTIONS Section |. GENERAL INFORMATION 1-1. INTRODUCTION. This technical manual describes Marine Sanitation Device MK II (MSD-MkK II). The technical manual includes reference data, parts identification, and procedures for installation, operation, and maintenance of the complete system including the sewage holding tank and its associated parts. 1-2. EQUIPMENT DESCRIPTION. The MSD-MK II is specifically designed to prevent discharge of shipboard sewage into lakes and navigable waters. The system, collects sanitary waste in reduced-volume-flush water closets, holds the sewage in a special holding tank during operations in navigable waters, and pumps the sewage to proper shore facilities or into waters outside those restricted from such discharge. Refer to figure 1-1 to identify the major components of the MSD-MK II. Each complete system includes the components listed in table 1-1. ce] TIMING AND a CONTROL ASSEMBLY ® Qe AIRED OC AES ee Ra i ETE ae ate = = | NOT SUPPLIED | MSD-MKI SYSTEM Y FLUSH VENT | COMMODE URINAL SEWAGE ASSEMBLY HOLDING TANK HIGH LEVEL SENSOR (OPTIONAL) Ose same ee LOW LEVEL eee: SENSOR MACERATOR a TRANSFER | PUMP : as nont| | | | | | | (OPTIONAL) | | | | | ——d Figure 1-1. Marine Sanitation Device, Unit Relationship $9593-BE-MMM-010 Table 1-1. Dimensions and Weights ie ince ITEM NAME OR NOMENCLATURE Commode Assy 10168200200 (2-28-14679) Urinals 10168200300 (2-28-14837) Macerator/Transfer Pump Assy A3-11-100 (2-28-16776) Timing and Control Assy AC 10169500102-1 (2-22-16771 1-3. USER OPTION. The audible alarm is a user option. If an aiidibie alarm is not installed, disregard any reference to the alarm in this publication. 1-4. REFERENCE DATA. Refer to table 1-2 for water data and electrical requirements for the MSD-MK II. Table 1-3 provides dimensional data for each of the components. Table 1-2. Water Data and Electrical Power Requirements. Water Data Pressure per Commode (psig) Volume per Commode Discharging Liquids (pint) Discharging Solids (pint) Holding Tank Capacity (gal.) Power Requirements Input Macerator Pump (KYA) oo 500 ieee cs cee s cen ce cn het came seeks the ee Cab onan ty eter es tenees 2.8 Timing and Control Assembly (KVA)........ 00. ccc cece eee tenet eee t eee e eee n ne nenne aes 0.7 1-2 $9593-BE-MMM-010 Section ll. SAFETY PRECAUTIONS 1-5. SCOPE. This section contains the precautions which must be observed by operators and maintenance personnel of Marine Sanitation Systems. Some of the precautions are descriptions of how to perform certain procedures, and some of the precautions are procedures that must be performed before or after contact with any part of the system. Super- visory personnel should become familiar with all health and safety precautions and should ensure that only qualified operators and maintenance personnel are permitted to operate and maintain this system. 1-6. SEWAGE HANDLING. Contact with raw sewage can be a health hazard unless good personal hygiene is practiced. The following precautions should be obeyed when operating or maintaining sewage handling equipment: e Wear protective rubber gloves, rubber boots, and overalls while working with sewage handling equipment. e Thoroughly wash face and hands with soap and water before eating, drinking, and/or smoking. e Drain and flush soil drains before servicing any sewage handling equipment. @ Wash sewage spills and solids found on sewage hose connections and the exterior of sewage handling equipment with warm water containing a stock detergent. WARNING Disconnecting sewage hose or pipe while it is pressurized is hazardous. System should be depressurized prior to any disconnection. . Personnel engaged in sewage transfer hose operations shall not connect or disconnect potable water hoses. 1-7. ELECTRICAL EQUIPMENT. WARNING Arcing in electrical systems can cause eye injury or severe burns. Mishandling electrical equipment or connections can cause electrical shock or other injuries. NOTE Refer to NAVSEA Technical Manual 0901-LP-300-0000, Chapter 300 for additional information on handling electrical equipment. Keep unauthorized personnel away from electrical equipment; set up warning signs, barricades, or watch personnel in the area where equipment is to be opened or exposed. De-energize circuit at fuse or circuit breaker; remove fuse or secure circuit breaker in the OFF position, and attach warning tag(s) when working on electrical equipment. Test the circuit to make sure voltage has been removed. Discharge capacitors by shorting across the capacitors. NOTE Equipment may have more than one source of power. Check that all possible sources of power have been de-energized before handling electrical equipment. Use only authorized portable electrical equipment. Wear rubber gloves when handling electrical equipment. Use insulated tools when possible, and avoid wearing or using such electrically conductive objects such as watches, rings, metal pens, and pencils. When required to work on energized equipment, obtain permission from the officer/P.O. responsible and follow special precautions noted in NAVSEA Technical Manual 0901-LP-300-0000, Chapter 200. 1-3 $9593-BE-MMM-010 1-8. DISINFECTANTS. 7 In the event equipment or personnel are contaminated with sewage to an extent that disinfection is required, the referenced items are included in the Federal stock system and are recommended for shipboard use. Solids must be removed from the equipment or surface before using a disinfectant. Care must be exercised in the storage, mixing, and use of all of these items and all of the manufacturer’s instructions must be followed explicitly. While other disinfectants presently in the stock system may perform equally as well, substitutions should not be made unless interchangeability has been verified. NOTE If in doubt concerning the use of disinfectants, a Medical Officer should be consulted. Decks - Bulkheads and Equipment. (1) Phenol Base. Germicidal and fungicidal concentrate phenolic, dry type NSN 9G840-00-753-4797: 1 ounce packet per 4 gallons water. (2) Combined. Disinfectant and fungicidal concentrate (i.e. pine oil) NSN 9G6840-00-530-7109: 1 gallon jug. (3) Iodine Base. Disinfectant, germicidal, and fungicidal concentrate (i.e. Wesodyne G tamed iodine) NSN 9G6840-00-526-1192: 1 ounce of concentrate per gallon of water. Hands. (1) Iodine Base. Detergent, surgical antiseptic sudsing skin cleanser. Predodyne surgical scrub (use like liquid hand soap - full strength with water and lather). NSN 9P7930-00-282-9699: 1 gallon, NSN 9P7930-00-985-6911: 5 gallons, NSN 9P7930-00-282-9700: 50 gallons. WARNING Surgical soap can injure or damage the face or eyes. (2) Surgical Soap. Betadine NSN 9G6505-00-914-3593. 1-9. DECONTAMINATION OF PERSONNEL AND EQUIPMENT. The following information is presented as a decontamination guide for personnel and equipment which may have been exposed to raw sewage: 1-10. EQUIPMENT REQUIRED. (1) Coveralls (one set for each individual). (2) Goggles (one set for each individual). (3) Hood-type hats (one for each individual). (4) Rubber boots having pants integral with boots (one pair for each individual). (5) Dissolvable laundry bags (NSN 8465-00-436-9652). (6) Canvas laundry bags. (7) Respirators. 1-11. PERSONNEL DECONTAMINATION AFTER WORKING IN CONTAMINATED SPACES. (1) Remove protective clothing and equipment. NOTE Neither dissolvable nor canvas laundry bags shall enter contaminated space; pass all clothing through entry way. (2) Place clothing in dissolvable laundry bags stored outside of the contaminated space; use caution not to contaminate the outside of the bag. (3) Secure dissolvable bag, insert (top down) in canvas laundry bag, and secure canvas bag. $9593-BE-MMM-010 (4) Disinfect boots, goggles, and respirators. (5) Disassemble equipment for complete cleaning. (6) Place disinfected equipment outside contaminated space as it is cleaned. (7) Disinfect entire contaminated space. (8) Place paper towels or other remaining waste or cleaning materials in plastic trash can liners and discard with trash. (9) Personnel may then exit space and don personal clothing. (10) Immediately transfer canvas bag with enclosed dissolvable laundry bag and contaminated clothing to the laundry for washing. 1-12 LAUNDRY PROCEDURE. (1) Dump dissolvable laundry bag with clothing directly into washer. (2) Place canvas bag in washer and wash in accordance with standard procedures. 4-13. FOLLOW UP. Resanitize contaminated areas (decks, bulkheads, overheads, etc.) several hours after the first treatment. Use the same procedures that were used for the first treatment. 1-14. CERTIFICATION OF SPACE SUITABILITY. Upon completion of sanitization of a contaminated space, a senior medical department representative must inspect the space and certify, in writing to the OIC/POIC, that it has been adequately decontaminated. Until certification is obtained, the space shall be considered contaminated and all personnel entering shall follow the decontamination safety procedures outlined previously. 1-15. ADDITIONAL PROCEDURES. (1) Provide for acquisition, maintenance and storage of all protective clothing and equipment. (2) Conduct an inspection of holding tank, pumping systems, and piping to insure watertight integrity and the absence of contamination leaks, overflow, or spillage once each watch. These inspections shall be logged and any discrepancies noted shall be reported immediately to the OIC/POIC. (3) Provide for instruction and training in the procedures for decontamination of personnel and spaces in the event of contamination by raw sewage. In addition, any personnel who in the line of duty, occupy or transit spaces susceptible to contamination shall receive the above training. Provide for certification of satisfactory sanitization of contaminated spaces. 1-5 (1-6 Blank) $9593-BE-MMM-010 CHAPTER 2 OPERATION 2-1. INTRODUCTION. This chapter is divided into two sections. Section I provides all information needed by the actual on board users of the Marine Sanitation System. The commode and urinal are similar to those found in domestic or industrial applications except that their use demands certain concessions to water conservation. Section II details the procedures that system operating personnel must follow to accommodate pier side and open sea conditions. Operation of the MSD-MK II beyond its collection of wastes, is accomplished automatically by its electrical controls. Section |. USER INSTRUCTIONS | 2-2. OPERATING MODES. 2-3. “DRY” BOWL. The commode is used ‘‘dry’’ bowl for urination. The lower section of the commode bowl normally contains a small amout of water in the ‘‘dry’’ bowl mode, and is ready to be used at any time for urination. After urination, the manual control level (foot pedal), which opens a valve to drain the commode, is depressed. Then, releasing the pedal allows the lower action to be refilled with water (see figure 2-1). 2-4. “WET’ BOWL. The commode is used ‘‘wet’’ bowl for defecation. When the commode is used for defecation, it is necessary that the user add an additional amount of water to fill the bowl, both to provide aesthetic acceptability and to minimize the possibility of soiling the bowl surface. Filling is accomplished by actuating the valve flush handle (see figure 2-1). Actuating this handle allows water, under pressure from the supply line, to flow into the bowl. The volume of water in each operation mode is automatically determined by a control chamber within the flush valve. 2-5. URINAL. The wall mounted urinal (see figure 2-1) is flushed by actuating the flush handle. Each flush operation releases approximately one pint of water into the urinal. The volume of water in each operation is automatically determined by a control chamber within the flush valve. FLUSH HANOLE Figure 2-1. Commode and Urinal Operator Controls $9593-BE-MMM-010 Section Il. SYSTEM OPERATION fo 2-6. CONTROLS AND INDICATORS. Cig” Table 2-1 and figure 2-2 list and identify the operator controls and indicators. Table 2-1. Controls and Indicators FUNCTION POWER ON Green lamp assy Indicates that the equipment is energized. HIGH LEVEL Amber lamp assy Indicates that the holding tank contents (User Option) should be discharged. LOW LEVEL Amber lamp assy Indicates that the holding tank contents (User Option) are low. ALARM SILENCE Pushbutton actuator Turns off the audible alarm which (User Option) indicated that the holding tank was discharged sufficiently to resume normal operation. HAND/OFF/AUTO Selector Switch Selects function of Macerator/Transfer (M/T) pump. HAND START Pushbutton actuator Starts M/T pump in hand mode. WASTE COLLECTION YSTEM (O) ape S io GATX MKIL HAND /EN\ AUTO (AN (Hy 4 HAND OFF HAND ApS AUTO (ES (Ws HAND OFF HAND , 7 AUTO HAND (HD) WY START Figure 2-2. Controls and Indicators $9593-BE-MMM-010 2:7. OPERATING MODES. 2-8. VALVE OPERATION SETTINGS. Refer to table 2-2 for proper valve operation settings for the various operating modes. Figure 2-3 shows the interconnection plumbing and identifies the functional location of each of the valves. 2-9. NORMAL COLLECTION. Set the valves as indicated in table 2-2. 9-10. EMERGENCY COLLECTION. In the unlikely event that all macerator/transfer pump assemblies fail, the system allows for manual flushing of at least one commode discharge line. This will allow temporary use of at least one commode until the macerator/transfer pump assemblies can be repaired. The following procedure details this manual flush mechanism (refer to figure 2-3). (1) Set valves for emergency disposal as shown in table 2-2. (2) Attach a fire hose to the vent-line connection located outside the deck house near the applicable commode. (3) Employ the normal commode flushing techniques when using the commode for urination and defecation. (4) Apply water pressure to the fire hose at the vent-line connection in order to drain sewage from the line below the commode. (5) Reset the system’s valves for normal collection. 2-11. DISCHARGE TO PIERSIDE FACILITY. When the sewage holding tank has been filled to 80 percent of its capacity, the HIGH LEVEL lamp glows and the audible alarm in the tank area signals an alert to the need for emptying the holding tank. The following procedure is for discharge to pierside facilities. (1) Connect the sewage transfer hose between the pier connection and the vessel’s topside sewage discharge connection, and cap the opposite discharge connection. (2) Refer to table 2-2 and set each of the valves to proper position for discharge pierside facility. (3) Silence the audible alarm by pressing the ALARM SILENCE switch. (4) Open the holding tank flushing valve (figure 2-3), and flush the tank, piping, and hoses. Close the flushing valve when finished. (5) Reset the valves for normal sewage collection. (6) Remove the sewage transfer hose, recap the vessel’s topside sewage discharge and uncap the opposite discharge connection before getting underway. 2:12. DISCHARGE OVERBOARD. Discharge of tank contents directly overboard into washers not prohibited from such discharge is accomplished by use of the following procedure (refer to figure 2-3). (1) Set the valves for overboard disposal as shown in table 2-2. (2) Silence the audible alarm by pressing the ALARM SILENCE switch. (3) Open the holding tank flushing valve, and flush the tank, piping, and hoses. Close the flushing valve when finished. (4) Reset the system’s valves for normal sewage collection. 2-13. FLUSHING SEWAGE HOLDING TANK. During periods of limited usage the volume of sewage collected may be insufficient to activate the alarm system, but may cause accumulation of gas. Pump down and flush the holding tank at least once every four days according to the following procedures. WARNING Accumulation of gas in the holding tank is a health and safety hazard. (1) Reset valves for shore or overboard discharge as described in table 2-2. (2) Pump the tank down to the low water level. $9593-BE-MMM-010 Open the tank flushing valve (figure 2-3). Run pump as the salt water sprays inside of the tank. Continue flushing for five minutes. Close the tank flushing valve. Pump the tank down to the low water level. NOTE If the LOW LEVEL lamp lights, stop the pump until the indicator lamp goes out. If the HIGH LEVEL lamp lights, close the tank flushing valve and start over at step (2). NOTE In the event that the water level does not rise to the high water level sensor during the flushing, check the sensor by stopping the pump long enough for the HIGH LEVEL lamp to operate. As soon as the HIGH LEVEL lamp comes on immediately shut the tank flushing valve, and repeat step (7). (8) Reset the system’s valves for normal sewage collection. & 2-14. NORMALIEMERGENCY OFF-LOADING-HOSE FLUSHING. After the holding tank has been pumped down, set the valves as shown in Table 2-2 for Flush Discharge Line & Hose. Flush out the off-loading-hose with sea water. Table 2-2. Valve Operation Setting Emergency — Pierside Facility Emergency — Overboard Flush Discharge Line & hose a Code: Valve A Code: Valve B through M A Macerator/Transfer Pump setting © Open setting X Overboard setting @ Closed setting (yue1g 9-Z) S-Z SEWAGE HOLDING TANK VENT FLUSHING VENT EMERGENCY (PORT) FLUSHING OECK CONNECTION DISCHARGE - CONNECTION COMMODE > ASSEMBLY HOLDING TANK FLUSHING VALVE MACERATOR/ TRANSFER PUMP ASSEMBLY ><) HOSE VALVE b& PLUG VALVE sania ba Ol 3-WAY PLUG VALVE 1 CHECK VALVE 1 MANUAL SHUTOFF CHECK VALVE SEWAGE EXISTING OVERBOARD HOLDING TANK DISCHARGE SESS eee PUMP 3 oS Cio i) Figure 2-3. Valve Identification with Interconnection Plumbing FLUSHING VENT (STARBOARD) DECK DISCHARGE CONNECTION ——COMMODE ASSEMBLY MACERATOR/ TRANSFER # FOR SOME INSTALLATIONS A 2-WAY, 3-PORT PLUG VALVE IS SUBSTITUTED FOR VALVES E &F. ## ADDITIONAL MACERATING PUMPS AND COMMODE ASSEMBLIES ARE CONNECTED AT THIS POINT. OLO-WWIW-38-€6S6S $9593-BE-MMM-010 CHAPTER 3 @ FUNCTIONAL DESCRIPTION 3-1. INTRODUCTION. This chapter describes the operation of an MSD-MK II. Paragraph 3-2 describes the electrical controls that form the machine-operator interface while paragraph 3-3 covers the balance of the system. 3-2. FUNCTIONAL ANALYSIS. Both the water closets (commodes) and the urinal (figure 3-1) receive flush water through a flush valve. The valves limit the water to 1 pint for each flush. For urination only the flush valves are operated by the operator. This washes the urinal or the commode and transfers the liquid to the line connected to the macerator/transfer pump. After the commode is used for defecation the flush pedal is depressed by the user. The flush pedal is mechanically linked to the flush valve. This causes the flush valve to operate releasing about | pint of water into the commode. At the same time the flush pedal closes a microswitch on the commode which activates a circuit in the timing and control assembly. This circuit turns on the macerator/transfer pump for about 10 seconds. The macerator/transfer pump pulverizes the waste material and transfers it to the sewage holding tank. The sewage holding tank has both a high level and low level sensing circuit. The high level sensing circuit causes a HIGH LEVEL indicator lamp on the timing and control assembly to light indicating that the tank is 80% full. The low level sensor indicates when the liquid level in the holding tank is near the empty condition. This sensor activates an audible alarm indicating the tank has been emptied. NOTE The Low Level and High Level Alarm and indicator circuit may not be externally connected depending on the specific installation. €& TIMING AND CONTROL ASSEMBLY | : NOT SUPPLIED a AS PART OF MSO- MKIT SYSTEM | FLUSH VENT LINE | = 3 3 SEWAGE HOLDING | TANK HIGH LEVEL SENSOR 1 2 (OPTIONAL) KA | | | | SENSOR | (OPTIONAL) | | | | | _— | MACERATOR | TRANSFER | PUMP | | \ cf] [ Figure 3-1. Functional Diagram ~ §9593-BE-MMM-010 3-3. ELECTRICAL CONTROLS and INDICATORS, (Refer to Figure 3-2). ® 3-4. LOW LEVEL ALARM (USER OPTION). When the holding tank water level is below the low level sensor, the low level switch (line 3) opens, deenergizing CR2. The normally closed contacts of CR2-B (line 4) energize the LOW LEVEL lamp (LT3) and the normally closed contacts of CR2-A (line 5) sound the audible alarm. Momentarily closing ALARM SILENCE switch S1 (line 7) energizes alarm silence relay CR1 and silences the audible alarm by opening contacts (R1-A1 line 5). When the normally closed contacts of CR1-A open, the audible alarm circuit is deenergized. When the ALARM SILENCE switch is released and opens, relay CRI (line 7) is held operated by its own contacts CR1-B (line 6). As the water level rises, the low level sensor switch closes, energizing low level relay CR2 (line 3). When relay CR2 operates, contacts CR2-B (line 4) open, deenergizing the LOW LEVEL lamp (LT3) circuit and contacts CR2-A (line 5) open to deenergize alarm silence relay CR1 permitting it to restore. 3-5. HIGH LEVEL ALARM (USER OPTION). When the water level rises to close the high level switch, CR3 (line 2) energizes. HIGH LEVEL lamp (LT2) (line 8) and the audible alarm (line 5) become energized through relay contacts CR3-A (line 8). The audible alarm may be silenced as described in the previous paragraph. Pumping the tank down will cause the high level switch to open deenergizing relay CR3 (line 2). Relay contacts CR3-A (line 8) open to deenergize HIGH LEVEL lamp (LT2) and also to reset alarm silence relay CRI (line 7). When the tank level reaches a level below the low level switch actuating point, then the audible alarm will sound and the LOW LEVEL lamp will light as described earlier. 3-6. MACERATOR TRANSFER PUMP CONTROL. 3-7. General. The macerator/transfer pumps can be operated automatically or manually. A three position MANUAL-OFF-AUTO switch is used to select the type of operation. In the OFF position of the MANUAL-OFF- AUTO switch the macerator/transfer pumps starter solenoids (MS1, MS2 and MS3) (lines 12, 16, and 19) are disconnected from operating voltage. This prevents either the manual or auto from energizing the starter solenoids. Refer to paragraph 3-8 for auto operation and paragraph 3-9 for manual operation. 3-8. AUTO Operation. When the MANUAL-OFF-AUTO switch is in the AUTO position and a commode is flushed, a microswitch (line 9, 10, 13, 14 or 17) closes and completes the circuit between an associated motor starter (line 12, 15, or 19) and an associated time delay (delay on operate) relay (TR) (line 11, 15, or 18). The coil of the motor starter becomes energized and its holding contacs (line 12, 15, or 19) close. This set of contacts maintains power on the coils of the motor starter and the time delay relay after the micros witch opens. Other motor starter contacts (line 20 through 28) start the macerator/transfer pump motors. When the time delay relay completes its timing cycle, normally closed contacts (line 12, 16, or 19) open and interrupt the power to the coil of the magnetic motor starter and the time delay relay turning off the macerator/transfer pump. The length of the operating cycle is controlled by a resistor in the time delay relay circuit. For a 10-second cycle the required resistance is 220k ohms. 3-9. MANUAL Operation. When the MANUAL-OFF-AUTO switches are in the MANUAL position the macerator/transfer pump starter solenoids MS1, MS2 and MS3 (lines 12, 16 and 19) are connected to pushbutton switches S5, S6 and S7 (lines 11, 15, and 18) respectively. Thus if pushbutton S5 is pressed motor starter solenoid MSI is energized closing the circuits at lines 20, 21 and 22 energizing macerator pump number |. The pump & remains energized until the switch is released. Operation of pump number 2 by switch S6 and operation of pump 3 by switch S7 is identical to operation of pump | by switch SS. 3-2 $9593-BE-MMM-010 440 ae 36 Tel-) TBl-2-TBl-3 ul L2 L3 10 VAC 110 VAC “ TOR" TB2-2 pree-s SF A be > SAMP pA PCTB-40 PCTB-41 PCTB-45 HIGH LEVEL PCTB-48 SWITCH PCTB-49 LOW LEVEL SWITCH pcTB-46 3 CR2-8 PCTB-38 a 5 6 7 8 20 F3 fu: T3l 5 AMP CR3-A % E & 21 Fat T2! ee 9 PCTB 32 a 3 SAMP | | Pump 10 PCTS-30 - PCI8-29 22 Fs tu 4 Z Sami 6p 2 5] PCTB-86 " = © MANUAL, OFF] 35 |OFF auTO /PCTB-56 és a Ae 131 es 4 OL! PCTe-54 5 AMP| . (ss?) MOTOR a 7? Tp)! 24 ST ptt ral A2M/T PCTB-24 PCTB-23 iS on TAI 5 AMP | PUMP 13 a ra ky T PCTB-22 PCTB8-21 #1 M/T PUMP 25 é\s 14 : ‘ Sauer lo 3 ae MS2 pcTe-se le 3 i = c MANUAL OFF 's6”lorF . . inl hs 13 ° Baro mamma} ecre-5e PUMP FAILS TO DELIVER CAPACITY (MOTOR RUNS). PUMP FAILS TO DELIVER CAPACITY (MOTOR DOES NOT RUN.) PUMP EMITS NOISE WHEN OPERATING. FLUID LEAKS FROM MACERATOR/ TRANSFER PUMP ASSEMBLY, is impeller clogged with solids? Is power correct at motor starter? Check and verify that power is applied to the motor starter. Is noise “rattling” sound accompanied by shaking of the macerator pump assembly? Mounting bolts are loose. Tighten See para 4-9. Is fluid leaking from pump part of assmbly? Is grinder ring clogged with solids? Check for and remove solids. See para 6-4. Is pump volute case jammed? is motor starter satisfactory? Clean pump volute Check reset on starter case. Refer to 6-3a. Is noise high-pitched “singing” caused by impeller rubbing against cutter ring? Adjust impeller. See para 6-4. Is fluid from motor area lubricant? Faulty plumbing connection. Locate and repair. —_ on a= ese os ewe oe ce sas ee ome Check for and remove solids. See para 6-4. Is pump impeller jammed? Clear away obstruc- tions. See para 6-3a, Is condition of grinder unit ball bearing satisfactory? Check ball bearing condition. See para 6-5. Seals must be replaced. See para 6-5. i Check rotaticn of pump impeiier. Is pump impeller faulty? ls condition of motor bearing satisfactory? Sewage leaking from faulty connection or part. Locate and © repair or replace. See chapter 6. . $9593-BE-MMM-010 Replace pump impeller. Refer to para. 6-4. Check motor bearing condition. Figure 5-3. Macerator/Transfer Pump Fault Logic Diagram _ §-7/(5-8 blank) ACTUATION OF FLUSH PEDAL FAILS TO ENERGIZE Pump, MOTOR STARTER ACTIVATES, PUMP HUMS BUT DOES NOT PUMP. PUMP OPERATES BUT FAILS TO SHUT OFF AFTER 10 SECONDS OF OPERATION. Is 110V as specified supplied to timing and control assembly? Are fuses F1 and F2 faulty? Malfunction in ship's power supply maintenance per- Pump probably is jammed. Refer to fig. 5-3 for macerator/transfer pump. Is time delay relay operative? install replacement System. Alert proper fuse(s). Does motor starter operate when S5, $-6, or $8 (lines 11, 15, or 18) on printed circuit board inside control enclosure is momentarily pushed? Does motor starter operate when reset switch button also is pressed? Check motor starter coil and replace motor starter. Is fuse on motor starter intact? Is time delay period approximately 10 seconds? Remove faulty component and install replacement. is 110V present between CR2-A pin and PCTB-41? Is high level sensor in sewage holding tank operative? Replace or correct faulty component or condition. Install replacement fuse. Resistor is faulty. Install replacement 220KQ resistor. 's 110V present between PCTB-32 and PCTB-41, or PCTB-24 and PCTB-44 or PTCB-16 and PTCB-44? Are relay contact CR-3 (line 8) and associated coil CR3 (line 2) operative? Replace or correct faulty component or condition. ts motor or wiring faulty? Correct faulty condition. Check commode switch. Is low resistance or short present? Are microswitches operative and micro- switch wiring intact? Check and/or replace relays contacts TR1, Is holding tank high level switch oper- ative? Replace faulty component. Does pump operate only when micro- switch is actuated? Holding contact of motor starter is not holding. Replace motor starter. Switch is faulty. Remove switch and install replacement. $9593-BE-MMM-010 Replace faulty microswitch and/or correct faulty wiring. e Figure 5-4. Electrical Syster: ih Fault Logic Diagram $-9/(5-10 blank) CHAPTER 6 CORRECTIVE MAINTENANCE 6-1. INTRODUCTION. This chapter contains procedures recommended for repairing the MSD-MK II. For efficiency, this material is presented with the system broken down into its major components: a commode assembly, urinal assembly and macerator/transfer pump assembly. Section | ADJUSTMENT AND ALIGNMENT 6-2. GENERAL. No electrical adjustments are required for the system. The length of time the macerator/transfer pump operates when activated is determined by the value of the resistor connected across the associated time delay relay. This is normally set for about 10 seconds using a 220K resistor. Mechanical alignment of the cutter blades in the macerator/transfer pump is described in the repair procedures for the pump paragraph 6-8. Procedures for adjusting the flush valve flush volume are described in the repair procedures for the commode, paragraph 6-5. The adjustment procedure for the flush valve cable asembly is described in paragraph 8-11 of the Installation Section. Section Il REPAIR 6-4. COMMODE. The replacement of parts on the s pa eg ADJUSTING commode is obvious upon inspection and requires no special instructions. Refer to the illustration in the COVER parts list section for identification of replacement parts. PISTON 6-5. FLUSH VALVE If a decrease in commode assembly flush valve output is noticed, it may be necessary to clean the inside of the flush valve. To accomplish this, follow these steps: 1. Remove the cover as shown in VALVE BODY figure 6-1. 2. Remove the piston, and use water to rinse all parts that are dirty. 3. Check that the flush volume is adequate after cleaning. 4. Readjust flush volume, if necessary, by turning the adjusting screw clockwise to reduce the volume of flush water or tur- ning the same screw counterclockwise to increase volume. MAIN SEAT FLUSH HANOLE | ] VACUUM BREAKER AY Ld] Figure 6-1. Commode and Urinal Flush Valve S$9593-BE-MMM-010 $9593-BE-MMM-010 6-6. URINAL ASSEMBLY The urinal assembly flush valve in the same as the commode. Refer to paragraph 6-5. il” 6-7. MACERATOR/TRANSFER PUMP ASSEMBLY SERVICING PROCEDURE. Refer to Figure 6-2 for identification of parts listed in the following procedures. 6-8. CLEANING VOLUTE CASE AND/OR REPLACING GRINDER PARTS. WARNING Never work on pump or control panel with power on. Tag ‘SOUT OF SERVICE.”’ 1. Remove power cable for pump from timing and control enclosure assembly. 2. Remove pump from soil line. 3. Unscrew screws (38) and remove inlet flange and suction castings (1). 4. Unscrew screws (31) and remove pump volute case (2). Cutter ring (6) can now be removed from case (2). Keep shims (21) for reassembly. NOTE Lower radial cutter (4) and upper axial cutter (5) are now exposed. If checking for clogging, these parts can now be cleaned without removing from shaft. 5. If necessary to replace lower radial cutter, remove screw (32) and unscrew cutter (4) from shaft (thread is right hand). 6. Bump cutter (4) with plastic hammer if necessary to loosen. Cutter (5) lifts off of shaft and is held . from rotating by pin (19). Be sure pin (19) is in place when reassembling. If necessary to replace pump impeller (3), unscrew from shaft. Thread is right hand. If new impeller (3) is used, face clearance may have to be adjusted from top bearing. Replace impeller (3), cutter (5), and cutter (4) and replace case (2) but do not replace stationary cutter (6) at this point. Release screws (40) on top bearing cap and tighten screws (29) until pump impeller (3) just drags on volute case (2). . Now back off on screws (29) 1/8 turn and tighten on screws (40) to lift impeller (3) for proper face clearance. : Now replace cutter (6) and inlet flange (1). Turn cutter (4) with fingers; it must run free. If it is not free and some rubbing exists, remove cutter (6) and add extra shims (21). These are stainless steel shims and must be obtained from the factory. It may be necessary to loosen screws (31) in volute case (2) and tap with hammer to get proper clearance on O.D. of cutter (4). 14. Reconnect power and operate pump. Run pump for a few seconds only to be sure parts are not rubbing. 15. Be sure all parts are thoroughly clean before any replacement operations are begun. 6-9. REPLACING SEALS. 1. Remove plugs (13) from motor and from seal chamber and drain out all oil. 2. Remove cutter and pump parts as described in previous procedure. 3. Remove screws (33) in seal plate (10) and use two of the screws in the tapped back off holes to force plate (10) from bearing frame (7). Pushing this plate (10) off will also force seal (18) from shaft. 4. — Remove retaining ring (39) and pull ball bearing (16) from shaft. & 5. Remove locknut (15). 6. Remove oil seal (25). $9593-BE-MMM-010 CAUTION Do not use any old seal parts. Replace all parts with new parts combining old with new seal parts during repair can cause immediate seal failure. 7. Thoroughly clean all parts before replacing, checking to be sure ball bearing or shaft is not worn. Be sure all O rings are in good condition without cuts or nicks. Replace if defective. 8. After all parts are replaced and before final assembly of pump and grinder parts refill seal chamber and motor chamber with oil. Lay pump on side to fill seal chamber. Do not fill completely, allow about 1/2 inch below fill plug so that there will be an air space for expansion. Set pump upright to fill motor chamber. Again fill so that oil level is just over the top of winding to allow air space for expansion. Use only Hydr-O-Matic submersible oil in motor chamber and seal chamber. A high grade transformer oil can be used in the motor chamber and No. 20 non-detergent automobile oil can be used in the seal chamber. 6-10. ADJUSTMENT OF CUTTER MECHANISM 1. Lay pump on side so that pump inlet is exposed and can easily be reached by hand. 2. Using thumb and forefinger, turn radial cutter (4) to be sure shaft turns freely. NOTE Remember that the allen screws raise the shaft while the hex screws push the shaft downward. 3. Loosen jam nuts (35) on allen screws (40) located on top bearing cap. CAUTION The cap screws mentioned herein, both hex (29) and allen (40) varieties, must be tightened and/or loosened approximately the same amount. 4. Using proper size allen wrench, loosen allen screws (40). 5. Using proper size wrench, tighten hex screws (29) until axial cutter (5) just drags on cutter ring. 6. Back off hex screws (29) 1/8 turn. 7 Tighten allen screws (40) to lift impeller for proper clearance. 8 Tighten jam nuts (35) on allen screws (40). 9. Again turn radial cutter (4) with thumb and forefinger to determine if shaft has any drag. 10. If there is still some drag, repeat above steps and back off hex screws (29) further. 6-11. ELECTRICAL CONTROLS SERVICING PROCEDURE. Refer to Fold-out 5-4, Electrical Controls Troubleshooting, for aid in pinpointing malfunctions. Proceed as follows when replacing the faulty components. WARNING Electrical circuits can be hazardous. Use extreme care when working on the electrical controls system of a Marine Sanitation Device. 1. Check that circuits to be serviced have been de-energized. 2. Label all wires that are to be disconnected during removal of a faulty component to aid in reassembly. 3. Remove faulty component(s). Install a replacement part(s) with the same part number(s) or equivalent(s) in its place (refer to Chapter 7, Parts List). 6-3/(6-4 blank) $9593-BE-MMM-010 1 FLANGE, THREE-INCH, INLET 2 CASE, VOLUTE (MPELLER, PUMP CUTVER, RADIAL, LOWER, CUTTER, AXIAL, UPPER CUTTER, STATIONARY FRAME, BEARING HOUSING CAVITY * DELETED . PLATE AND BUSHING, SEAL 42 (SUCTION @5) -GASKET (PERMATEX) 12 WASHER 13. PLUG, PIPE 14 SHAFT 15 LOCKNUT 16 BEARING, BALL 17. SEAL HEAD 18 SEAL SEAT 19 PIN 20 PLATE, NAME, DESCRIPTIVE 21 SHIM 22 DELETED 23 DELETED 24 O-RING 25 SEAL, OIL 26 KEY, 3/16 X 3/16 X 7/8 IN. 27 O-RING 28 COUPLING, SHAFT 29 SCREW, CAP, 1/4 X 1 IN. 30 DELETED 31 SCREW, CAP, 5/16 X 1-1/2 IN. 32 SCREW, MACHINE, 1/4 X 5/8 IN. 33 SCREW, CAP, 1/4 X 5/8 IN. 34 COUPLING, SLEEVE 35 NUT, 1/4 NOTE: 36 SCREW, DRIVE la laa etge nce VIEW A-A 33 Seaewuar tes x1 DELETED. 39 RING, RETAINING & 40 SET SCREW, 1/4 X 3/4 = : -- ie 41 O-RING . Figure 6-2. Macerator/Transfer Pump | 4 WASHER t | 6-5/(6-6 blank) $9593-BE-MMM-010 CHAPTER 7 PARTS LIST 7-1. INTRODUCTION This chapter contains parts location illustrations and identifies the parts used for each component listed in paragraph 7-2. The original manufacturer and part number are provided. 7-2. LIST OF MAJOR COMPONENTS. The following table lists the major components covered in the following parts lists. The quantity is for one shipset. Table 7-1. List of Major Components NAME OR QUANTITY NOMENCLATURE PAGE NO Figure 7-1. Timing and Control Enclosure Assembly 7-2 Figure 7-2. Timing and Control Panel Assembly © 7-3 Figure 7-3. Printed Circuit Board Assembly 7-4 Figure 7-4. Macerator/Transfer Pump Assembly 7-5 Figure 7-5. Macerator Transfer Pump 7-6 Figure 7-6. Commode Assembly (Sheet 1 of 2) 7-8 Figure 7-6. Commode Assembly (Sheet 2 of 2) 7-9 Figure 7-7. Remote Control Lever 7-11 Figure 7-8. Spring Bracket Assembly 7-12 Figure 7-9. Flush Valve Cable Assembly 7-13 Figure 7-10. Hopper Stopper Assembly 7-13 Figure 7-11. Urinal Assembly 7-14 7-3. PARTS LIST. The parts list identifies all the parts used in the components. These parts are crossreferenced to an illustration to identify the exact location of the part. AJl new military parts are identified by the FSCM number and manufacturers part numbers. The parts list is divided into the following columns. 7-4. FIGURE AND INDEX NUMBER. This column contains the figure number and index number, thus locating the part on the corresponding illustration. 7-5. NAME AND DESCRIPTION. This column contains the designated names of the parts with brief descriptions indicating their use. Following the description of military part in the military identification number. 7-6. QUANTITY. This column identifies the quantity of parts used in a component. 7-7. FEDERAL SUPPLY CODE. This column lists the government assigned federal manufacturer code identification number for the parts. 7-8. MANUFACTURERS PART NUMBER. This column lists the acutal manufacturers part number. S$9593-BE-MMM-010 WASTE COLLECTION SYSTEM Figure 7-1. Timing and Control Enclosure Assembly & FIGURE AND NAME AND FEDERAL MFR INDEX NO. DESCRIPTION SUPPLY CODE PART NO. TIMING AND CONTROL ENCLOSURE ASSMEBLY: 2-22-16771 ENCLOSURE, MODIFIED: 2-22-16770 PANEL ASSEMBLY: (See Figure 7-2 for Breakdown) 2-22-16769 LAMP ASSEMBLY: Green 104-3227-0212-403 LAMP ASSEMBLY: Amber 104-3227-0213-403 SWITCH, PUSHBUTTON: KR-3U SWITCH, ROTARY: 3-position KS-43B LAMP: 10C7/5 DC CONTACT BLOCK: KA-2 CONTACT BLOCK: KA-1 LEGEND PLATE: KN-360 LEGEND PLATE: _ | KN-301 ' tier i eee WN = i i | ee ce EE ee t SoOraurda ak tT eed pee eet ete Corte | ts me NO —_— © $9593-BE-MMM-010 x ny F 723. ‘@ % fai 748! \ / Figure 7-2. Timing and Control Panel Assembly S FIGURE AND NAME AND QTY | FEDERAL MFR INDEX NO. DESCRIPTION SUPPLY CODE PART NO. 7-2 PANEL ASSEMBLY: Timing and Control l 2-22-16769 7-2-1 PANEL: 2-22-16764 7-2-2 STARTER, MOTOR: 3 14CF32AA 7-2-3 PRINTED CIRCUIT BOARD: (See Figure 7-3 for Breakdown) 2-17-16763 7-2-4 STANDOFF: 6-32 x 3/4 in. 8517-8-0632 7-2-5 FUSE BLOCK: 2-pole 2808 7-2-6 FUSE: 3 Ampere KTK-3 7-2-7 TERMINAL BLOCK: 3-pole 16021-3 7-2-8 COVER: Power Terminal Block 2-22-16026 7-2-9 TERMINAL BLOCK: 3-Pole 3-140 7-2-10 FUSE BLOCK: 3-Pole 2809 7-2-11 FUSE: 5-Ampere KTK-S5 7-2-12 SCREW, RD. HD: 8-32 x 3/4 in. 1-26-12235 7-2-13 NUT, HEX: 8-32 1-26-10862 7-2-14 WASHER, LOCK: #8 1-26-10858 7-2-15 SCREW, RD. HD: 10-32 x 1 in. 1-26-12291 7-2-16 NUT, HEX: 10-32 1-26-10860 7-2-17 WASHER, LOCK: #10 1-26-10497 7-2-18 SCREW, RD. HD: 10-32 x 1/2 in. 1-26-15915 7-2-19 SCREW, RD. HD: 6-32 x 3/8 in. 1-26-11037 7-2-20 WASHER, LOCK: #6 1-26-11454 7-2-21 HEATER: Overload 1-19-16780 $9593-BE-MMM-010 40 41 A ll Soe 58 59 6 6I 62 63 & 65 0 2) Figure 7-3. Printed Circuit Board Assembly FEDERAL SUPPLY CODE NAME AND DESCRIPTION FIGURE AND INDEX NO. PRINTED CIRCUIT BOARD ASSEMBLY l 2-17-16763 PRINTED CIRCUIT BOARD: | 2-23-15937 TERMINAL BLOCK: 26 Terminals 2 GBPC-26 TERMINAL BLOCK: 13 Terminals l GBPC-13 SOCKET, RELAY: 1 27E046 CLIP: Relay Holddown 7 20C228 RELAY: 110 Vac 3 KUP11A15 RELAY: Time Delay, 110 Vac 3 CUF41-70120 SCREW, RD. HD: 6-32 x 1/2 in. 14 1-26-10234 NUT, HEX: 6-32 14 1-26-10773 WASHER, LOCK: #6 14 1-26-11454 RESISTOR, FIXED COMPOSITION: 220K, 1/2W 4 RCR20GF221J 29593-BE-MMM-010 Figure 7-4. Macerator/Transfer Pump Assembly INDEX NO. DESCRIPTION SUPPLY CODE PART NO. 74 MACERATOR/TRANSFER PUMP ASSEMBLY: 2-28-16776 7-4-1 PUMP ASSEMBLY: (See figure 7-4 for Breakdown) NPG-200M 7-4-2 MOTOR, AC: 2 HP, 440 V, 30 356731X454 7-4-3 SCREW, HEX HEAD: 3/8-16 x 1 in. 1-26-15909 FIGURE AND NAME AND FEDERAL MFR $9593-BE-MMM-010 | 37) a an 66) 40 . ? i), Wii aa BSH a Se gem SX (28) @) 4 DISCHARGE ea G6) C/PQMLLLLLE Ly ay ie t:-4* =) a ' ’ x, 4 G) WN \" # IISSSS 5 Yn. Sect eee a OS! ®) SS OA N NN N N a Ny A Trip net wes GLI ZL LALYELLL WZ] bale 4 yy ZAR GIG.G. WU BD NOTE: ITEMS 9, 22,23 AND 30 DELETED. VIEW A-A Figure 7-5. Macerator/Transfer Pump $9593-BE-MMM-010 FIGURE AND NAME AND FEDERAL MFR INDEX NO. DESCRIPTION SUPPLY CODE PART NO. 7-5 MACERATOR/TRANSFER PUMP: NPG-200M 7-5-1 FLANGE: 3 inch inlet 10152-010-2 7-5-2 7-5-3 7-5-4 7-5-5 7-5-6 7-5-7 7-5-8 7-5-9 7-5-10 7-5-11 7-5-12 7-5-13 7-5-14 7-5-15 7-5-16 7-5-17 7-5-18 7-5-19 7-5-20 7-5-21 7-5-22 7-5-23 7-5-24 7-5-25 7-5-26 7-5-27 7-5-28 7-5-29 7-5-30 7-5-31 7-5-32 7-5-33 7-5-34 7-5-35 7-5-36 7-5-37 7-5-38 7-5-39 7-5-40 7-5-41 7-5-42 CASE, VOLUTE: IMPELLER: CUTTER, RADIAL, Lower CUTTER, AXIAL, Upper CUTTER, STATIONARY: FRAME, BEARING: HOUSING, CAVITY: Not Used PLATE AND BUSHING, SEAL: GASKET: (Permatex No Gasket) WASHER, BEVEL: PLUG, PIPE: SHAFT: NUT, LOCKS: BEARING, BALL: SEAL HEAD: SEAL SEAT: PIN: PLATE, NAME: Descriptive SHIM: Not Used Not Used O-RING: SEAL, OIL: KEY: 3/16 x 3/16 x 7/8 in. O-RING: COUPLING, SHAFT: SCREW, CAP: 1/4x 1 in. Not Used SCREW, CAP: 5/16 x 1-1/2 in. SCREW, MACHINE: 1/4 x 5/8 in. SCREW, CAP: 1/4x 5/8 in. COUPLING, SLEEVE: NUT: 1/4 SCREW, DRIVE: CAP, BEARING: SCREW, CAP: 5/16x 1 RING RETAINING: SET SCREW: 1/4 x 3/4 O-RING: WASHER: 5402-010-2 7033-002-2 5405-002-2 5506-001-2 5407-001-2 9803-000-2 5409-012-2 5404-010-5 5413-001-1 $570-001-3 119-002-1 9802-001-3 9855-001-1 7167-001-1 4917-000-1 4918-000-1 5419-001-1 7173-000-1 628-013-1-1 150-013-1 1090-007-1 9831-001-1 150-029-1 8349-025-1 517-007-1 101-010-1 1130-001-1 517-004-1 8348-007-1 112-008-1 4580-001-1 9801-000-2 101-007-1 974-008-1 11-009-1 834-018-1 156-025-1 $9593-BE-MMM-010 COMMODE PLAT POR SHE F/G. 8-S Figure 7-6. Commode Assembly (Sheet 1 of 2) FIGURE AND , NAME AND QTY | FEDERAL MFR INDEX NO. DESCRIPTION SUPPLY CODE PART NO. COMMODE ASSEMBLY: 2-28-14679 BRACKET: Manual Control Lever Mounting 2-23-10551 LEVER: Manual Control 2-23-10550 PIN, GROOVED: Straight, 1-19/32 in. lg., 1/2 in. dia. 2-26-10597 SCREW, CAP, HEX: MS35307-343 NUT, SELF-LOCKING, HEXAGON: T9NE0S8 WASHER, FLAT: AN960C 516 WASHER: Neoprene, 3/8 I.D., 3/4 O.D. by 1/8 in. Thk. 1-39-10729 NUT, PLAIN, HEXAGON: MS519171-5 WASHER, FLAT: MS5795-819 PIN, GROOVED: Straight, 29/32 in. Lg., 1/2 in. dia. MS15795-819 BOWL, PORCELAIN, COMMODE: White 2-39-10557 PAD: Rubber, 1/16 in. Thk. 1-9/16 in. by 15/16 in. 2-36-13957 CUSHION: Rubber, Mounting 2511 FLUSH VALVE ASSY: 3942604 GASKET: Oil-Paper, 0.15 Thk. 2.12 by 1.75 in. 2-31-14089 SEAT, COMMODE: 1SORBS SCREW, CAP, HEXAGON HEAD: MS35307-368 BRACKET, MOUNTING, VALVE: J312A3-41N @ FIGURE AND INDEX NO. 7-6-19 7-6-20 7-6-21 7-6-22 7-6-23 7-6-24 7-6-25 7-6-26 7-6-27 7-6-28 7-6-29 7-6-30 7-6-31 7-6-32 7-6-33 7-6-34 7-6-35 76-36 MOTE: ITEMS 20, 36, 39-47, 64, ANDO EO MOT UMD NAME AND DESCRIPTION POST, HINGE, SEAT ASSY: NOT USED WASHER: Rubber, 3/32 in. Thk., 1-1/4 in. O.D., 7/16 I.D. SWITCH PUSH: Enclosed, SPDT, Flange Mount HOSE: Rubber 15 in. lg. CLAMP, HOSE: Screw-Type LEVER, REMOTE CONTROL: (See Figure 7-6 for Breakdown CRANKSHAFT, COMMODE: Brass SLEEVE: Brass, Tubular, 1-3/4 In. Lg., 19/32 In. I.D., 47/64 In. O.D. LINK, HOPPER CONNECTING: Curved, Slotted and Drilled RING, RETAINING: LINK, CONNECTING: Rigid, 1/4 in. Thk., 3-3/4 in. Lg., Drilled, 507 In., 2-3/4 In. Centers WASHER, FLAT: 3/8 I.D. x 1 O.D. x 1/16 In. Thk. SCREW, CAP HEX HEAD: PIN, GROOVED: 1/2 In. Dia., 1-3/32 In Lg. SCREW, MACHINE: WASHER, FLAT: NOT USED FEDERAL SUPPLY CODE $9593-BE-MMM-010 MFR PART NO. 2-39-10600 2-36-13474 BZV6-2RN All12 3-4 IN 6316 2-23-10558 2-23-16080 2-26-10543 2-23-13320 5133-50 2-23-13321 1-26-14086 MS35307-308 2-26-13475 MS51957-30 MS-15795-806 INDEX NO. @ - - 4.6.97 16-38 16-39 7-6-40 1-6-41 1-6-42 16-43 1-6-44 16-45 1-6-46 16-41 1-6-48 16-49 7-6-50 76-51 1-6-52 7-6-53 7-6-54 7-6-55 7-6-56 7-6-57 ®@ 7-6-58 7-6-59 7-6-60 7-6-61 7-6-62 7-6-63 7-6-64 7-6-65 7-6-66 7-6-67 7-6-68 7-6-69 7-6-70 76-71 7-6-72 7-6-73 $9593-BE-MMM-010 FIGURE AND FEDERAL MFR SUPPLY NAME AND DESCRIPTION CODE PART NO. NUT, SELF-LOCKING, HEXAGON: 79NM62 PAD: Rubber, Rectangular 2-31-13351 NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED BRACKET: Brass SCREW, FLAT HEAD: 1/4-20 x 1/2 In. SST. SCREW, FILLISTER HEAD: PIPE, FLUSH: Bent Steel WASHER, FLAT: 1/8 In. Thk. Karropak, 1-7/8 In. by 2 In. INSERT, COMMODE, BOWL: Abf, .100 In. JAM NUT, HEX: Brass, 3/4 In. NPSC WASHER: Rubber, 3/16 In. Thk., 1 In. I.D. 1-7/8 In. O.D. COLLAR: Remote Control Lever, Brass SPRING/BRACKET ASSEMBLY: (See Figure 7-7 for Breakdown) GASKET: 1/8 Thk. Asphalted Paper LUG, INSERT RETAINING: Brass, Drilled and Tapped PAD: Karropak, 1/32 In. Thk., Drilled 1/2 In. Dia. SCREW, CAP, SOCKET HEAD: NUT, PLAIN: Square CLAMP, LOOP: NOT USED CABLE ASSEMBLY: Flush Valve (See Figure 7-8 for Breakdown) NUT, SELF-LOCKING, HEX: SCREW, CAP, SOCKET HEAD: NOT USED SCREW, CAP, SOCKET HEAD: STOPPER ASSEMBLY, HOPPER: (See Figure 7-9 for Breakdown) : BRACKET, MOUNTING, SHAFT: COLLAR, ACTUATOR: SCREW, SQAURE HEAD: 5/16- 2-23-16050 2-26-16052 MS35276-311 2-23-10555 2-31-10599 2-41-14091 2-26-10590 2-31-10601 2-23-13322 2-28-14090 2-31-10733 2-39-10592 2-31-10593 MS16995-81 1-26-11007 2-22-10658 2-28-13517 7T9NM02 MS16996-9 MS16995-55 2-28-13338 2-24-16076 2-24-16077 1-26-16079 18 x 1/2 SST tt, = FIGURE AND INDEX NO. Figure 7-7. Remote Control Lever NAME AND DESCRIPTION LEVER, REMOTE CONTROL: ROD: 10-7/8 in. lg. x 0.628 in. minor dia., PIN, RETAINING: ARM: PIN, GROOVED: Brass FEDERAL SUPPLY CODE 2-23-10558 2-23-16055 2-23-16058 2-23-16056 2-23-16057 $9593-BE-MMM-010 Figure 7-8. Spring/Bracket Assembly FIGURE AND NAME AND QTY | FEDERAL MFR INDEX NO. DESCRIPTION SUPPLY CODE PART NO. 7-8 SPRING/BRACKET ASSEMBLY: 2-28-14090 7-8-1 ROD: Brass, 5/16 in. dia., 5/16-24 thk. 2-28-16042 7-8-2 NUT, JAM HEX: Brass, 5/16-24 1-26-16044 7-8-3 YOKE, ANGLE: 2-23-16043 7-8-4 RIVET: Solid, 1/4 in. x 3/4 in., 2 in. plate 1-26-16040 7-8-5 LINK: 1/4 in. thk., 2-1/2 in. lg., drilled 0.257 in., 1-3/4 in. centers 2-23-16045 7-8-6 ARM, PIVOT: Brass 2-23-16041 7-8-7 SCREW, SET: 3/8-16 x 1, Socket head Screw SST 1-26-16048 7-8-8 LOCKWASHER, INTERNAL TOOTH: SST, 3/8 in. 1-26-16047 7-8-9 NUT, JAM HEX: SST, 3/8-16 1-26-16046 7-8-10 SPRING: 43 Coil, RH, SST, 0.55 in., 6-9/16 in. 2-39-16049 7-8-11 WASHER, FLAT: SST 1-26-13312 $9593-BE-MMM-010 FIGURE AND NAME AND FEDERAL INDEX NO. | DESCRIPTION SUPPLY CODE CABLE ASSEMBLY, FLUSH VALVE: 2-28-13517 CLEVIS, ROD END: 2-22-13516 ROPE ASSEMBLY: Wire, 36 in. lg. 2-18-13521 NOT USED — RETAINER ASSEMBLY, RETAINER: 2-28-13515 TUBE, COPPER ALLOY: 1-21-13514 COLLAR, SHAFT: 0.50 in. dia. by 0.66 in. lg. 2-23-13513 SETSCREW: MSS51021 SECTION A-A Figure 7-10. Hopper Stopper Assembly FIGURE AND NAME AND FEDERAL MFR INDEX NO. DESCRIPTION SUPPLY CODE PART NO. STOPPER ASSEMBLY HOPPER: 2-28-13338 STOPPER, HOPPER: Neoprene 2-33-10648 CUP, STOPPER: — 2-33-10649 WASHER, FLAT: AN960C416 WASHER, LOCK: MS35339-139 NUT, PLAIN HEX: MS35649-2254 BRACKET, MOUNTING, STOPPER: SST, 1/8 in. thk. 2-22-13337 $9593-BE-MMM-010 — 3,50 ner =— BULKHEAD OR SUPPORT L FLUSH WATER INLET 3/a NPT FEMALE C3) Ri 2A (0X 9 (Ol eas Om ioe a Ss 2 P's : (293 OF Jas COKIXT) & ©} 3 PUS Figure 7-11. Urinal Assembly $9593-BE:-MMM-010 FIGURE AND NAME AND QTY | FEDERAL MFR INDEX NO. DESCRIPTION SUPPLY CODE PART NO. 7-11 7-11-1 7-11-2 7-11-3 7-11-4 7-11-5 7-11-6 7-11-7 7-11-8 7-11-9 7-11-10 7-11-11 7-11-12 7-11-13 7-11-14 7-11-15 7-11-16 7-11-17 7-11-18 7-11-19 7-11-20 7-11-21 7-11-22 7-11-23 7-11-24 7-11-25 7-11-26 7-11-27 7-11-28 7-11-29 7-11-30 7-11-31 URINAL ASSEMBLY: MOUNT, RESILIENT: SPACER, SLEEVE: INSULATOR, WASHER: SCREW, CAP, HEXAGON HEAD: WASHER, FLAT: NUT, SLEEVE: SCREW, CAP, HEXAGON HEAD: WASHER, FLAT: NUT, PLAIN, HEXAGON: WASHER, LOCK: MOUNT, RESILIENT: SCREW, MACHINE: WASHER, FLAT: NUT, PLAIN, HEXAGON: WASHER, LOCK: VALVE ASSEMBLY, FLUSH: HOSE: Rubber 7 in. lg. CLAMP, HOSE: TAILPIECE, UNION: NUT, UNION: NOT USED GASKET: HOSE: Rubber CLAMP, HOSE: TAILPIECE, WASTE DRAIN: NUT, UNION: NOT USED GASKET: RUBBER STRIP: URINAL, STATIONARY: BRACKET, MOUNTING, VALVE: | 2 4 4 4 4 4 6 6 6 6 2 4 4 4 4 l l 2 l 1 l l 2 1 l L 2 l 1 10168200300 PA2403 PB16321 PB16320 PB16323 PB18414 PB16327 MS35307-309 1-26-10100 MSS51971-1 MS35338-139 PB16511 MS51957-67 MS15795-842 MS35649-204 MS35338-138 185 16350 QS200M12S PB18386 B21358 PB18389 PB16348 QS200M24S PB16346 PB8880 PB6821 PB18211 PB1904 J312A3-41N 7-15/(7-16 blank) $9593-BE-MMM-010 CHAPTER 8 INSTALLATION Section |. REQUIREMENTS 8-1. SITE INFORMATION. The components of the Marine Sanitation Device all have special requirements that must be considered during the selection of suitable mounting sites. These include the water, water pressure, electric power and space needs as follows. 8-2. CONTROLLED VOLUME FLUSH WATER CLOSETS. The CVF water closets supplied are vitreous china bowl units equipped with foot pedal operated waste flapper valves and controlled volume flush water valves. Refer to Commode Piping Detail (figure 8-2). The units are designed to be shock mounted on the deck surface and to interface with a standard 4-inch soil line. The soil pipe (or sump pipe) is brought through the deck water closet mounting plate so that the upper end of the soil pipe protrudes approximately 1/4-inch above the deck plate surface. Seating between the soil pipe and the water closet outlet is normally accomplished by using a standard wax seal ring available at plumbing supply houses. Mechanical anchoring of the commode assembly requires four bolts or studs welded to the deck plate for hold down. 8-3. Flush Valve Assembly. The controlled volume flush valve is provided with a manual valve handle actuated by a cable attached between the valve handle and the collar extension on the water closet. The valve unit is preassembled and calibrated to provide ine proper volume of water at each flush. The deatils for mechanical mounting of the valve and valve bracket and interfacing of the valve with the ship’s flush water line and the water closet are left to the discretion of the ship’s outfitters. However, it is recommended that the valve handle be — located high enough (approximately 24 inches) and in a line to permit a favorable angle for the valve actuating cable connected between the valve handle and the collar assembly on the water closet. 8-4. Electrical Connection of the Water Cioset. The water closet is provided with a switch assembly mounted on a plate at the rear of the water closet. This switch is interconnected with the control system, as shown on the Cable Diagram (figure 8-6). 8-5. CONTROLLED VOLUME FLUSH URINAL. The CVF urinal supplied with the system is a vitreous china unit equipped with a controlled volume fiush water valve. The unit is designed to be shock mounted on a bulkhead; typical mounting height to the bottom of the urinal is 20 inches. Plumbing interface consists of a flush water line from the ship’s service line to the valve input and a soil line from the urinal tailpiece to the soil line. 8-6. MACERATOR/TRANSFER PUMP ASSEMBLY. The macerator/transfer pump assembly needs gravity’s assistance for utmost efficiency and so should be located below and as close as possible to the bottoms of the commodes they serve. If at all possible, avoid horizontal runs greater than 4 feet and never exceed horizontal runs of 6 feet. Also, to ease future maintenance, the location should provide access for unhindered removal of the macerator/transfer pump assembly from the soil line. 8-7. Electrical Connection of Macerztor’Transfer Pump. Electrical power to operate the pump is provided by the ship’s service (440 VAC, 3-phase, 60 Hz) through the fused disconnect and magnetic starter; the starter relay is controlled by 115 VAC, 1-phase, 60 Hz power. 8-8. ELECTRICAL CONTROLS. The electrical control box is designed for bulkhead mounting utilizing the four mounting legs located at the top and bottom of the box. The control box should be located in a reasonably accessible area. 8-9. TOOLS AND MATERIALS REQUIRED. Installation of the Marine Sanitation Device requires the use of welding, plumbing, electrical wiring and mechanical assembly tools and equipmer.. [he operation, however, can be accomplished without any need for specially-designed material. OLO-WWW-38-C6S6S : NOTE: MUT, WASHER 6 BUSMIN/G _-- PAO (FURAIISHEO FULNW/ISHEO WITH COMAMOOE ~ : , _ WITH Commove) site 5 Sau : _ ENN AAS SS SS Sy | Bs >>,’ apy > - PLATFORM SENG MEN np A — SLEEVE - 309 SST 5.00 0.0.*.€47 WALL, LEMGTH VARIES WITH SPECIFIC INSTALLATION SECTION B-B {Yh pe He SILVER BRAZE ALL AROUVA/D SECTION A-A WASTE CONNECTION - CUPRO MICKEL 4.50 QQ4.1/O9 WALL, LEAGTH ‘VARIES WITH SPECIFIC INSTALL y) TION Figure 8-1. Commode Installation Detail $9593-BE-MMM-010 8-10. INPUT REQUIREMENTS. Installation of the Marine Sanitation Device requires inputs of water at 30 psig and 110 VAC 60 Hz and 440 VAC, 60 Hz electrical power. 8-11. UNPACKING AND REPACKING. Each component is supplied ready for installation and connection to a ship’s holding tank, piping, and discharge connections. No special unpacking and repacking procedures are required. Care must be exercised in handling the urinal and commode to prevent breakage since these components are made of vitreous china. 8-12. COMMODE ASSEMBLY INSTALLATION. 8-13. MOUNTING AND OUTLET CONNECTION. The commodes are designed to interface with standard 4-inch soil line (4.5” OD) as shown in Figure 8-1, Commode Installation Detail and Figure 8-2, Piping Detail. The soil pipe should be brought through the commode mounting platform so that the upper end of the soil pipe protrudes approximately 3/8 inch above the surface of the platform. The platform normally is constructed by the shipyard installing the sanitary system. Overall dimensions are shown in Figure 8-3, Platform-Commode Shock Mount. The height of the platform should be such that its top surface is from 1/2 to 1 inch above the finished surface (title etc.) of the deck. Due to variations of the finished ceramic commode, the location of the mounting studs are not shown on the above referenced drawing. These dimensions should be taken from the supplied commodes. Both the base of the platforms and its studs should be fabricated from 300 series stainless steel. 1. The commode should be located at a sufficient distance from the rear bulkhead to afford easy access to flush valve plumbing and mounting. A distance of approximately 16 to 18 inches between the bulkhead and the center of the discharge soil pipe is recommended. 2. Install a 1-inch vent line directly beneath the 4-inch soil line that penetrates the deck as shown in figure 8-2. The purpose of this vent is to prevent air from forming a large bubble that would cause & water to splash out of the commode during the flush operation. = 3. Before the commode is put in place, insert a wax ring between the commode and the shock mount. The wax ring assures a leak-proof seal. 4. | When the platform is not constructed during installation (i.e. the ship deck serves as the commode platform) then the commode mounting bolts should be welded to the deck as shown in figure 8-3. yt 8-14. FLUSH VALVE. Position and mount flush valve as follows. 1. Position the furnished flush valve bracket at least 25 inches above the deck. 2. Mount the flush valve to the bulkhead with the mounting bracket, making sure the flush valve handle is on the left and the water inlet on the right when facing the valve. The valve has a 3/4-inch NPT female thread at its inlet. NOTE A wire rope assembly (flush cable), connects the flush valve handle to the actuator collar on the remote control lever. 3. Adjust the actuator collar (figure 8-4), so it rests in a position roughly parallel to the deck by loosening the square head set screw, rotating the actuator collar into place and then tightening the set screw. 4. Feed the flush cable, unfinished end first, through the exposed hole of the rod end clevis and then through the hole in the lever portion of the actuator collar. 5. Attach the rod end clevis to the flush valve handle. 6. Feed the free end of the wire rope assembly through the shaft collar. 7. Slide the shaft collar up the wire rope assembly against the lever portion of the actuator collar and tighten the two set screws. Final adjustment should allow minimal free play in the cable without pulling on the flush valve handle. Excess cable may be cut off and discarded. FLUSH VALVE »® V4 NPT (FEMALE) VALVE /A/L ET OXF REDUCER SWEEP TEE PREFERRED L° PIPE VENT LIME j Se ee 3°03 72 ACTUML QD.) SO1L PIPE OUTLET 3” FLANGE AT PUMP INLET Figure 8-2. Piping Detail 4,25 DIR OR THRU s~EIBUNC 4@%'s LOCATED TO MATCH — MOLE PATTERN OF COMMODE —.30 FRONT EDGE OF COMMIODE. ze. Figure 8-3. Platform-Commode Shock Mount $9593-BE-MMM-010 ACTUATOR COLLAR SHAFT COLLAR Figure 8-4. Flush Valve Cable Installation 8-15. FLUSH WATER. Connect flush water supply at 30 psig to the inlet of the flush valve. 8-16. Electrical. Check microswitch operation as follow. 1. Wires from the microswitch at the rear of the commode assembly will be connected later to terminals in the control enclosure. 2. Check that the remote control lever falls away from the microswitch sufficiently when the flush pedal is pressed to actuate the microswitch. 8-17. MACERATOR/TRANSFER PUMP ASSEMBLY INSTALLATION. 8-18. IMPELLER ROTATION CHECK. Prior to installation of the pumps, the rotation of the impellers must be checked. The impeller rotation must be counterclockwise when viewed from the suction (input) end of the pump or the unit will not function properly. Reversal of pump rotation can be attained by reversing any two of the three input power lines to the pump. It should be noted that pump rotation should not be determined by ‘‘feeling”’ the outward air flow from the pump since some air flow will be sensed irrespective of the direction of rotation. 8-19. MOUNTING. In laying out the plumbing system, it is important that the suction end of the pump be located below and as close as possible to the bottom of the water closets it serves; distances greater than 6 feet should be avoided. Urinal location is not critical since urinal wastes are entirely liquid and their flow to the pump will be adequate as long as the urinal outlet is reasonably above the pump level. Mount the macerator/transfer $9593-BE-MMM-010 pump assembly to a convenient ceiling, hull, bulkhead, deckplate, or other permanent structural member with the S mounting feet provided, as shown in figure 8-2. Mounting dimensions are shown in figure 8-5. _ 8-20. INTERFACE. Connect pump to soil line as follows. 1. Connect the 3-inch pump inlet flange to the soil pipe as shown in figure 8-4, in order to allow the pump to be readily removed for cleaning or servicing. : 2. Install a check valve at the 1-1/4-inch female connector of the pump outlet to prevent backflow from the pump. 8-21. ELECTRICAL CONNECTION OF MACERATOR/TRANSFER PUMP ASSEMBLY. Refer to the wiring diagram figure 8-6 for pump connections to the control enclosure. NOTE Electrical power from the ship’s service to operate the pump motor must be connected through the magnetic starter. 8-22. ELECTRICAL CONTROLS INSTALLATION. 8-23. COMPONENT LOCATION. Installation of controls consists of mounting the control enclosure and providing prime power from the ships’s source. 115 VAC single phase is used for control circuitry and 440 VAC three phase is used to operate the pumps. 8-24. CABLING. In installations in which more than one commode flows to a single macerator/transfer pump assembly, all connects microswitches are wired in parallel. Typical system configuration, wiring diagram, and electrical schematics are shown in figures 8-6 and 3-2 respectively. Table 8-1 identifies all the terminals that may & be used in conjunction with commode wiring and macerator/transfer pump assembly operation. + MACERATOR/ TRANSFER PuadP 2 MeTeR, Ac 3S Ste Figure 8-5. Macerator/Transfer Pump, Outline Drawing $9593-BE-MMM-010 PCTB-32 PCTB-31 #1M/T pcta-so | | : CUSTOMER FURNISHED PCTB-29 TIMING AND EQUIPMENT CONTROL CABINET in VAC,1¢ | 440 VAC, 3¢ #1 M/T #2 M/T #3 M/T PUMP PUMP PUMP Figure 8-6. Wiring Diagram Table 8-1. Commode Macerator/Transfer Pump Assembly Wiring PTCB 32 & 31 30 & 29 PTCB 24 & 23 22 & 21 PTCB 16 & 15 *These terminals are on the terminal strip on the printed circuit board, figure 8-7, inside the timing and control enclosure assembly. 8-25. INSTALLATION CHECKOUT. 8-26. PREENERGIZING PROCEDURE. 1. Set all control valves for normal operation of the Marine Sanitation System. 2. Check that water and drain line for possible leaks. 3. Check that all electrical connections have been completed. 8-27. INITIAL TURN-ON. 1. Place HAND-OFF-AUTO switches (total 3) in OFF position. 2. Apply ships power to system. 3. Place all three HAND-OFF-AUTO switches in AUTO position. 8-28. COMMODE INSTALLATION VERIFICATION. After the commode and flush valve are installed the following check should be made: $9593-BE-MMM-010 8-29. Switch Adjustment. Push the flush pedal and observe that (1) the flush cable pulls the flush valve handle and operates the flush valve, (2) the microswitch (foot pedal switch) lever pulls away from the switch and starts the macerator/transfer pump or if the pump is not ROBRECLES a ‘‘click’’ can be heard within the switch each time the foot-pedal is pressed and released. 8-30. Output. Check the volumetric output of the flush valve by adding 1 pint (16 fluid ounces) of water to an empty commode. Mark the level of water in the commode with a crayon or suitable marker. Empty the water by pressing the flush pedal and holding it down until the flush valve has completed its operation. Release the flush pedal and add a single flush from the flush valve by pushing the handle once. The amount of water added to the bowl should be approximately the same as when one pint was added to the bowl. Refer to pargraph 6-2 if an adjustment is necessary. 8-31. Stopper Disc Assembly. The operation of the commode stopper disc assembly should be checked by pushing the foot pedal all the way to its stop. This action should cause the stopper disc assembly to swing open until it is almost in a vertical position. 8-32. Stopper Disc Seal. The stopper disc seal should be checked by adding 1 or 2 pints of water to the bowl with the flush valve. The water level should be marked and no noticeable decrease i in water level should occur within a 15-minute period of time. 8-33. MACERATOR/TRANSFER PUMP ASSEMBLY INSTALLATION VERIFICATION. To check ‘that the factory-sealed macerator/transfer pump assembly is installed and functioning correctly, follow these steps: 1. | Check that the assembly is securely attached to the mounting surface. 2. Check that the motor on each unit runs smoothly with no unusual noises. 3. | Check that no leaks are present at any pipe junction. 8-34. ELECTRICAL CONTROLS INSTALLATION VERIFICATION. Installation checkout for the electrical controls should include the following steps: 1. Place all three HAND-OFF-AUTO switches in HAND position. Press each of the three START push buttons and check that macerator/transfer pumps operate. 2. Place all three HAND-OFF-AUTO switch in AUTO position. Flush each commode using the foot pedal and check that macerator/transfer pumps operate. Allow pump to stop before flushing next commode. Place all three HAND-OFF-AUTO switch in OFF position. Verify that macerator/transfer pump does not operate either from pushbutton or by flushing commode with foot pedal. 26-25. 24-23, 22.2) 20. 19 Sia es or leblefloleel ele! eloletol Figure 8-7. Printed Circuit Board Assembly