u.s.navy underwater ship husbandry manual chapter 27 hydroblast cleaning system

U.S.NAVY UNDERWATER SHIP HUSBANDRY MANUAL

CHAPTER-27

HYDROBLAST CLEANING SYSTEM

TABLE OF CONTENTS

SAFETY SUMMARY

SECTION 1 - INTRODUCTION

27-1.1 PURPOSE

27-1.2 SCOPE

27-1.3 APPLICABILITY

27-1.4 REFERENCES

27-1.5 COMPONENTS

27-1.6 GENERAL INFORMATION

SECTION 2 - WBD-150N JETTING PUMP: DESCRIPTION, SETUP, AND OPERATIONAL PROCEDURES

27-2.1 WBD-150N JETTING PUMP

27-2.2 SETUP PROCEDURE

27-2.3 PRE-OPERATIONAL PROCEDURE

27-2.4 OPERATIONAL PROCEDURE

27-2.5 NORMAL SHUTDOWN PROCEDURE

27-2.6 EMERGENCY SHUTDOWN PROCEDURE

27-2.7 POST-OPERATIONAL PROCEDURE

27-2.8 PREPARATION FOR SHIPMENT OR RETURN TO STORAGE FACILITY

SECTION 3 - Mi-T-M HS-3006-DMKO PRESSURE WASHER: DESCRIPTION, SETUP, AND OPERATIONAL PROCEDURES

27-3.1 MiT-M PRESSURE WASHER







27-3.8 PREPARATION FOR SHIPMENT OR STORAGE

LIST OF ILLUSTRATIONS

Figure 1 - WBD-150N Jetting Pump

Figure 2 - High Pressure Jetting Equipment

Figure 3 - Mi-T-M Pressure Washer

Figure 4 - Low Pressure Jetting Equipment

Figure 5 - Hydroblasting Cleaning Kit (Shipping Configuration)

Figure 6 - Fire and High Pressure Hoses

Figure 7 - Foot Control Valve

Figure 8 - Zero Thrust Gun

Figure 8a - Zero Thrust Gun Nozzle Components

Figure 9 - Flexible Lance Assembly

Figure 10 - Semi Flexible Lance Assembly

Figure 11 - Mini Mole Flexible Lance Assembly

Figure 12 - Rigid Lance w/Shipping Container

Figure 13 - Saf Trol E Pressure Switch

Figure 14 - Manual Dump Valve and Adapter

Figure 15 - WBD-150N Jetting Pump

Figure 16 - Engine Throttle Control Assembly

Figure 17 - WBD-150N Control Gauge Board

Figure 18 - Weatherford Model FE-145 Pump

Figure 19 - Butterworth QU-300M Pump

Figure 20 - Saf Trol E Pressure Switch and Manual Dump Valve Installation on the Weatherford Pump Housing

Figure 21 - Saf Trol E Pressure Switch and Manual Dump Valve Installation on the Butterworth Pump Housing

Figure 22 - Pump Oil Fill and Clutch Lubrication Points

Figure 23 - Schematic of Hydroblasting System Setup

Figure 24 - Power Pump Plunger Cavity

Figure 25 - Engine Speed Control Adjustments

Figure 26 - Mi-T-M Pressure Washer

Figure 27 - Mi-T-M Pressure Washer Controls

Figure 28 - Mi-T-M Pressure Washer Power Pump Assembly

Figure 29 - Mi-T-M Pressure Washer Left Side

Figure 30 - Fuel Filter and Shutoff Valve

Figure 31 - Water Inlet Connection and Filter

Figure 32 - Schematic of Low Pressure Cleaning Equipment

Figure 33 - Mi-T-M Pressure Washer Controls

Figure 34 - Pump Bypass Relief Valve

LIST OF TABLES

Table 1 - Hydroblast Cleaning Tools

Table 2 - Hydroblast Cleaning Kit Supports Components

Table 3 - WBD-150N Installed Safety Devices

Table 4 - WBD-150N Lubricants

Table 5 - Hydroblast Cleaning Kit Component Flow and Pressure

Table 6 - Component Flow vs. Approximate Engine rpm for the WBD-150N Jetting Pump

Table 7 - Mi-T-M Sensors or Controls

Table 8 - Mi-T-M Pressure Washer Engine Lubricants

Table 9 - Low Pressure Cleaning Tool Flow and Pressure

Table 10 - Required Preheat Times

CHAPTER 27HYDROBLAST CLEANING SYSTEM

GENERAL SAFETY NOTICES

The following general safety notices supplement specific warnings and cautions appearing elsewhere in this manual. General and specific precautions must be understood and applied during operation and maintenance. The commanding officer or other authority will issue orders as deemed necessary for any situation not covered in the general and specific safety precautions.

GENERAL AND SPECIFIC SAFETY PRECAUTIONS

Observe the following safety precautions when operating or maintaining the hydroblast equipment.

Personnel who handle high pressure hoses and components shall be thoroughly trained in the use and maintenance of the equipment and the application of safety measures to protect against hazards. Eye and hearing protection and protective clothing shall be worn while operating hydroblast equipment.

Operation of the zero thrust gun and hydroblast lances produces significant noise and hazards. Divers shall not operate lances or zero thrust gun for extended periods of time, nor shall they be exposed to a direct stream of the high pressure water flow. Specific safety precautions are listed in the Warnings and Cautions section of this chapter.

Divers shall wear the Mk21 surface supplied diving helmet while conducting hydroblasting operations.

Inspect the Hydroblast Cleaning System for leaks, defective hoses, improperly adjusted valves, malfunctioning regulators or relief valves, contamination by foreign materials, and corrosion. Do not operate the Hydroblast Cleaning System if any of these defects is present.

Use only the lubricating oils and greases specified by the engine manufacturers. Oils and greases used in incorrect applications can cause damage to internal engine components.

Use only the lubricants specified by the component manufacturers for O-rings, fittings, and quick disconnects. Improper lubricants can cause O-rings to either soften or crack, causing leaks and failure to the hoses and connections.

If, during high pressure operation or maintenance, the operator's skin or eyes are accidentally contaminated with toxic chemicals or solvents, flush with water for fifteen minutes. Immediately seek medical attention.

Check engine exhaust system regularly for leaks. Ensure that exhaust manifolds are secure and not warped.

Make sure all nuts and bolts are secure before operating hydroblast cleaning equipment.

Always obtain first aid or medical attention immediately for any injury, no matter how slight.

WARNING AND CAUTION STATEMENTS

WARNING and CAUTION statements have been strategically placed throughout the text prior to operating or maintenance procedures, practices, or conditions considered essential to protection of personnel (WARNING) or equipment and property (CAUTION). A WARNING, if not strictly observed, could result in injury or death of personnel. A CAUTION, if not strictly observed, could result in damage to or destruction of equipment or loss of mission effectiveness. A WARNING or CAUTION will appear once in an applicable section and apply each time the related step is repeated. Prior to starting any task, the WARNINGS or CAUTIONS included in the text shall be reviewed and complied with.

WARNINGThe jetting pump weighs 8,000 lb. Ensure that all rigging equipment and cargo handling devices used are rated to at least 5 tons. Stand clear of the jetting pump and all other components while they are being handled by a crane or cargo handling equipment.

High pressure leaks can cause personnel injury or death. Ensure that high pressure hoses will be routed clear of personnel and vehicle traffic. Restrict access to only those personnel required for operation of the hydroblasting equipment. Tie off high pressure hoses to prevent hose damage and leaks.

Verify the hydrostatic test dates on all hoses prior to applying pressure. Replace any hose that is out of date or whose tag is missing.

Inspect all high pressure hoses prior to equipment setup and daily, prior to the start of work. Replace any hoses that are damaged or show evidence of swelling or leaks.

The electrical connection from the gauge control panel to the engine throttle control cable must be properly connected. Failure to connect the gauge board cable to the engine throttle control assembly will bypass all safety devices and shutdowns, possibly causing damage to the component or personnel injury.

Do not remove the radiator cap unless the engine is at or near ambient temperature. Severe burns can result from contact with hot coolant.

Electrolyte is extremely corrosive and can cause severe injury and blindness if splashed on skin and eyes. If electrolyte is spilled or comes in contact with the eyes or skin, immediately flush for 15 minutes with fresh water and seek immediate medical attention.

The foot control valve must be connected and manned when using any lance. When laying out high pressure hoses, position the foot control valve so as to provide the diving supervisor constant communication with the diver and the person manning the foot control valve.

Installation and operational verification of the Saf Trol E pressure switch and manual dump valve must be done prior to starting diving operations.

Hearing protection required while operating the jetting pump.

Do not use starting fluid while attempting to start engine.

Diesel exhaust contains carbon monoxide. Do not operate engine in confined space unless adequate ventilation is provided.

Stand clear of rotating parts; do not wear loose clothing while near machinery.

Exhaust system parts can reach 400°F and cause severe burns. Stand clear of all exhaust system components untilthey have cooled to ambient temperature.

Do not attempt to connect or disconnect any high pressure hose, lance, or zero thrust gun while the system is pressurized or the pump clutch is engaged.

While testing, place the lance tip at least 2 feet into an open-ended pipe and secure the lance to the pipe to ensure that the high pressure water flow from the water lance is directed to a safe location. Ensure that the water flow is not pointed at personnel or into easily damaged areas.

Monitor engine rpm while setting maximum operating speed. Do not allow engine to exceed 2150 rpm.

Do not exceed 11,000 psi during operation of the jetting pump.

Only qualified personnel are authorized to operate the jetting pump.

High pressure water can cause severe injuries or death. Do not point the lance at yourself or other personnel. Report any high pressure water-induced injuries and seek immediate medical care for any affected personnel.

Only the Butterworth zero thrust gun has been approved to clean masker belts. No other gun shall be used.

The Butterworth zero thrust gun may only be used in the configuration detailed in NAVSEA Dwg 6699567.

The Butterworth zero thrust gun shall not be operated for more than 85 minutes by one operator in any 24-hour period.

Operators of the Butterworth zero thrust gun shall wear a Mk21 surface supplied diving helmet.

The high pressure jet of water discharging from the Butterworth zero thrust gun is potentially dangerous. Keep water jet trained away from divers.

Diver safety may require instant shutdown of the high pressure water to the lance. Release the foot pedal to confirm instant loss of high pressure water to the lance.

The pressure washer weighs 556 lb. Ensure that all rigging equipment and cargo handling devices used are rated to at least 1/2 ton. Stand clear of the pressure washer and all other components while they are being handled by a crane or cargo handling equipment. Lift the pressure washer only by the lifting point on the upper part of its frame.

CAUTIONThe jetting pump is to be used only with clean fresh water supplied to the unit at a pressure of 75 to 125 psi and 20 gpm available flow. Use of any other water will cause serious damage to the pump.

Ensure that the cable is clear of rotating or reciprocating parts and is secured to prevent damage to the cable.

Do not connect the zero thrust gun or cleaning tool until the hoses have been flushed, as outlined in the operational section of this procedure.

The manual dump valve functions to dump excess water produced by the jetting pump while the unit is at operational rpm. Proper setting of manual dump valve is instrumental in allowing the Saf Trol E pressure switch to activate the throttle control assembly and bring the engine up to operating speed and back to idle when flow is not required. Improper setting of the manual dump valve will cause excessive operating pressure, failure of the Saf Trol E to bring engine rpm up to operating values, or cause the diesel engine to overspeed during operation.

The zero thrust gun and 1/2" O.D. flexible lance are rated at pressures and flows that are higher than the Mi-T-M pressure washer is rated. Do not connect either of these pressure washing tools to the unit.

The pressure washer is to be used only with clean fresh water supplied to the unit at a pressure of 40 to 125 psi and a minimum of 5 gpm. Use of any other water will cause serious damage to pump.

The zero thrust gun (10 gpm) and flexible lance (20 gpm) are rated at pressures and flows that are higher than the Mi-T-M pressure washer is rated. Do not connect either of these pressure washing tools to the unit.

Do not connect the lance until the line has been purged and flushed, as outlined in the operational section of this procedure.

Do not allow the pressure washer to operate in bypass mode (no flow) for more than three minutes without establishing water flow.

HAZARDOUS MATERIALS WARNINGS

Observe and comply with warnings in this manual designed to protect personnel from possible contact with hazardous materials. For each hazardous material used, a Material Safety Data Sheet (MSDS) must be provided. Consult local safety and health staff concerning hazardous chemicals, MSDSs, personal protective equipment requirements, and appropriate handling and emergency procedures.

SECTION 1 - INTRODUCTION

27-1.1 PURPOSE

The purpose of this chapter of the UWSH Manual is to provide operators with instructions for job planning, equipment selection, preparation, setup, and operational procedures for the Hydroblast Cleaning Systems, using the WBD-150N Jetting Pump and the Mi-T-M HS-3006-DMKO Pressure Washer. The jetting pumps and pressure washers and their supporting Hydroblast Cleaning Kits are maintained at various Fleet and contractor facilities.

27-1.2 SCOPE

This chapter provides a brief description of the equipment to assist in planning cleaning tasks. This chapter also provides setup, operational, and shutdown procedures for both the WBN-150N and Mi-T-M pressure supply pumps, utilizing the Hydroblast Cleaning Kit. Required modifications to change the WBN-150N Jetting Pump from the boiler and CHT jetting configuration to the underwater hydroblast cleaning configuration are detailed in section 2 of this chapter, and the necessary parts are contained in the Hydroblast Cleaning Kit. This chapter does not supersede any information contained in equipment technical manuals, the U.S. Navy Diving Manual, or the Naval Ships' Technical Manual. The applicable technical and equipment manuals should be reviewed prior to job planning or the use of any of the hydroblast equipment.

27-1.3 APPLICABILITY

The chapter applies to activities performing cleaning of masker belts and shaft bearing staves on various classes of U.S. Naval vessels and is written to provide divers and equipment operators with clear, concise procedures to assist them in planning and performing setup and operation of the hydroblast equipment.

27-1.4 REFERENCES

The following references apply:

a. Mi-T-M Model HS-3006-DMKO Parts Listing, Mi-T-M publication #EX-9029-101100.

b. Mi-T-M Model HS-3006-DMKO Operator's Manual, Mi-T-M form #37-0492-E/S 06101.

c. Butterworth Jetting Systems Model WBD-150N Replacement Parts and Accessories Manual.

d. Butterworth Jetting Systems Model L-Fluid End Pump Operations and Maintenance Manual.

e. Technical Manual, Operation and Maintenance Instructions, High Pressure Water Jet Cleaning Equipment, NAVSEA 0951-LP-037-5010.

f. Technical Manual, Repair and Overhaul Instructions, High Pressure Water Jet Cleaning Equipment Model No. WBD-150-150N, NAVSEA 0951-LP-037-6010.

g. Underwater Ship Husbandry Manual, S0600-AA-PRO-050, Chapter 5, Masker Emitter Belts.

h. Hydroblast Cleaning Kit, NAVSEA Dwg 6699567.

27-1.5 COMPONENTS

The following components make up the Hydroblast Cleaning System:

a. WBD-150N JETTING PUMP.

b. Mi-T-M HS-3006-DMKO PRESSURE WASHER.

c. HYDROBLAST CLEANING KIT.

27-1.6 GENERAL INFORMATION. Hydroblast equipment is used to provide high or low pressure water jetting to clean marine growth, corrosion products, and foreign material from underwater areas such as maskerbelt emitter belts and bearing staves on Naval vessels. The equipment has two basic configurations that are based on pressure and flow capabilities. They are as follows:

27-1.6.1 WBD-150N JETTING PUMP. The pressure source for high pressure, high flow operations (5,000 to 10,000 psi and up to 20 gpm) is the WBD-150N jetting pump. This self-contained unit is driven by a diesel engine; there are two equivalent functional configurations of the jetting pump, depending upon which pump is installed. In applications where a high pressure (greater than 5,000 psi) and high flow (greater than 5 gpm) is required, the WBD-150N jetting pump should be used (see Figure 1). This provides adequate flow and pressure to clean high volume areas, such as masker emitter belts. Either the zero thrust gun or high pressure lances are used in these applications. A system line diagram (Figure 2) shows a schematic representation of the high pressure jetting equipment set up for operation.

The primary high pressure water source for the Hydroblast Cleaning System is the WBD-150N jetting pump. The pump is a diesel-driven, self-contained, positive displacement pump that is designed to provide up to 20 gpm of pressurized water at up to 10,000 psi. The jetting pump is currently available in two functionally equivalent configurations, both of which share a common engine, but have different high pressure pumps. Following are the specifications for the WBD-150N jetting pump.

WBD-150N JETTING PUMP

Manufacturer Butterworth or Weatherford

Model WBD-150N

Weight 8,000 lb

Capacity 20 gpm @ 10,000 psi

Fuel Diesel

Fuel tank 60 gal.

Fuel consumption 8 gph

Water supply tank 64.5 gal.

Required potable water supply 20 gpm @ 75 to 125 psi

27-1.6.2 Mi-T-M PRESSURE WASHER. The pressure source for low pressure, low flow (3,000 psi and 4.76 gpm) is the Mi-T-M pressure washer. This self-contained unit is driven by a diesel engine and is mounted on a wheeled frame that is easily moved by one person. In applications where a lower pressure (3,000 psi or less), low flow (5 gpm or less) is required, the Mi-T-M HS-3006-DMKO pressure washer (see Figure 3) should be used. This provides adequate flow and pressure to clean low volume areas such as bearing stave water channels. A system line diagram (Figure 4)shows a schematic representation of the low pressure jetting equipment set up for operation.

Mi-T-M Pressure Washer

Manufacturer Mi-T-M Corporation

Model HS-3006-DMKO

Output 4.76 gallons @ 3,000 psi

Fuel Diesel

Fuel tank 12 gal.



27-1.6.3 HYDROBLAST CLEANING KIT. The Hydroblast Cleaning Kit provides the components to perform underwater cleaning, using either the WBD-150N jetting pump or the Mi-T-M pressure washer. In addition, the Hydroblast Cleaning Kit provides the necessary components to convert the WBD-150N jetting pump for use with the appropriate underwater lances and zero thrust gun to conduct hydroblasting operations. The Hydroblast Cleaning Kit contains hoses, a foot control valve, lances, fittings and hardware to configure and operate the Hydroblast Cleaning System. Components of the cleaning kit are used with each of the hydroblast pumps. See Tables 1 and 2 and Figure 5.

27-1.6.3.1 HIGH PRESSURE HOSES. The cleaning kit contains six 50' lengths of 1/2" hose rated at 15,000 psi. This hose is used to connect the foot control valve, zero thrust gun, and lances to the WBD-150N jetting pump and Mi-T-M pressure washer. See Figure 6.

27-1.6.3.2 FIRE HOSES. The cleaning kit contains two 1 1/2" x 50' fire hoses to supply fresh water from the onshore or shipboard water source to the suction side of the WBD-150N jetting pump and Mi-T-M pressure washer. See Figure 6.

27-1.6.3.3 FOOT CONTROL VALVE. The foot control valve is a high pressure control that is placed in-line between the WBD-150 jetting pump or Mi-T-M pressure washer and the high pressure lance used on the job site. The foot control valve controls the flow to the lance by controlling the water flow to the dump water port in the valve assembly. See Figure 7.

27-1.6.3.4. ZERO THRUST GUN. The zero thrust gun is a balanced-flow water jetting device. The zero thrust gun is designed to pressure clean masker belt openings and other underwater surfaces. The zero thrust gun is designed to deliver approximately 10 gpm @ 10,000 psi. See Figures 8 and 8a. The Saf Trol E pressure control switch and manual dump valve must be installed in order for the zero thrust gun to function safely with the high pressure jetting pump. The foot valve is not used, because the zero thrust gun has internal dump ports that will vent the high pressure from the supply line after the trigger is released, thus causing the Saf Trol E switch to lower the engine rpm to idle when high pressure water is not required.

NOTEThe zero thrust gun has two jetting nozzles which must be installed prior to use. See Figure 8a.

27-1.6.3.5. FLEXIBLE LANCE ASSEMBLY. The flexible lance consists of a 37' high pressure hose covered with a braided stainless steel sheath. The flexible lance has an outside diameter of approximately 1/2" and has 3 forward and 6 rear facing openings. The flexible lance is used in applications in which flexibility is required due to the construction of the area to be cleaned. This lance is typically used for cleaning the inside of masker air emitter belts. See Figure 9.

27-1.6.3.6. SEMI FLEXIBLE LANCE ASSEMBLY. The semi flexible lance assembly consists of a stainless steel tube that is .140" in diameter and 15' long. The lance has an end tip with one forward and 5 rear facing openings. This lance is typically used for cleaning propulsion shaft bearings on submarines. See Figure 10.

27-1.6.3.7. MINI MOLE FLEXIBLE LANCE ASSEMBLY. The Mini Mole flexible lance consists of a 25' x 3/16" high pressure hose covered by a stainless steel sheath and has an outside diameter of 0.335". The Mini Mole is used in applications in which flexibility is required due to the construction of the area to be cleaned and is capable of entering small openings. This lance is typically used for cleaning hub masker air passages on rope guards and fairwaters. The lance has an end tip with one forward and 6 rear facing openings. See Figure 11.

27-1.6.3.8. RIGID LANCE. The rigid lance is a 6' long x 1/4" diameter stainless steel tube with a removable nozzle that has 3 forward and 6 rear facing holes. This lance is typically used for cleaning propulsion shaft bearings on mine countermeasures ships. See Figure 12.

27-1.6.3.9. SAF TROL E PRESSURE SWITCH. The Saf Trol E pressure switch is installed on a high pressure port on the pump of the WBD-150N jetting pump. The pressure switch senses pump discharge pressure when flow is initiated or terminated during hydroblasting operations, then sends a signal to the jetting pump control panel to activate the engine throttle control assembly solenoid. The pressure switch is initially set to activate the engine control solenoid to increase engine speed when the sensed pressure reaches approximately 700 to 800 psi. See Figure 13.

27-1.6.3.10. MANUAL DUMP VALVE AND ADAPTER. The manual dump valve and adapter are connected to a port on the high pressure side of the WBD-150N jetting pump. The manual dump valve is a 1/2" needle valve that is set by the operator to dump excess volume and pressure from the system during high speed operation. (Generally, flow to the cleaning tool equals flow from the pump minus flow through the dump valve.) See Figure 14. The manual dump has two functions that are critical to the proper operation of the jetting pump. The first function is to control the low pressure activation of the Saf Trol E pressure switch while establishing flow to the cleaning tool. The second function of the manual dump valve is to bleed off excess water during high speed engine operation, thus controlling pressure during hydroblasting operation. This allows for efficient operation of the engine to provide input power to the high pressure pump. Detailed operating instructions for setting the manual dump valve are given in Setup and Operating Procedures.

NOTEThe zero thrust gun and some of the lances are restricted to flow rates which are less than the output of the WBD-150N jetting pump. The manual dump valve is used to relieve excess flow.

SECTION 2 - WBD-150N JETTING PUMP: DESCRIPTION, SETUP, AND OPERATIONAL PROCEDURES

The following sections give the functional description, setup, pre-operational, operating, normal shutdown, emergency shutdown, and post-operational procedures for the Hydroblast Cleaning System using the WBD-150N jetting pump.

27-2.1 WBD-150N JETTING PUMP. The primary high pressure water source for the Hydroblast Cleaning System is the WBD-150N jetting pump. See Figure 15. The pump is a diesel-driven, self-contained, positive displacement pump that is designed to provide up to 20 gpm of pressurized water at up to 10,000 psi. The jetting pump is currently available in two functionally equivalent configurations, both of which share a common engine, but have different high pressure pumps (Butterworth Model QU-300M and Weatherford Model FE-145). Following are the specifications for the WBD-150N jetting pump.

WBD-150N JETTING PUMP

Manufacturer Butterworth or Weatherford

Model WBD-150N

Weight 8,000 lb

Capacity 20 gpm @ 10,000 psi

Fuel Diesel

Fuel tank 60 gal

Water supply tank 64.5 gal.

Potable water supply 20 gpm @ 75 to 125 psi

DIESEL ENGINE

Manufacturer Detroit Diesel-Allison

Series 4-71

RPM 2200

Horsepower 152 @ 1800 rpm

Starting 12 V dc


27-2.1.1 The two models of power pump are the Butterworth Model QU-300M and the Weatherford Model FE-145. Both pumps are belt-driven, 600 rpm, positive displacement water pumps. The specifications for each follow:

BUTTERWORTH POWER PUMP

WEATHERFORD POWER PUMP

Manufacturer Butterworth Weatherford

Model QU-300M FE-145

No. of cylinders 5 5

Maximum flow 20 gpm @ 600 rpm 20 gpm @ 600 rpm

Maximum pressure 10,000 psi 10,000 psi

27-2.1.2 WBD-150N CONTROL SYSTEM. The Hydroblast Jetting Pump, Model WBD-150N has an installed speed and pressure control system that controls engine speed and pump discharge pressure during normal operation. This system consists of an engine throttle control assembly, alarm controllers (see Table 3 for setpoints), a pressure relief valve, and control switches. Detailed descriptions of each component follow.

a. Engine Throttle Control Assembly. Located behind the engine front cover, the engine throttle control assembly (Figure 16) is attached electrically to the Saf Trol E control system at the unit's gauge board, and mechanically to the engine fuel rack controller. The throttle control system allows the engine to run at idle when the jetting pump is aligned and ready for use but flow is not required. When activated by the component control switch, the throttle control system solenoid activates to pull the fuel rack controller and increase engine speed to an rpm that is preset by the operator. When the component control switch is deactivated, the solenoid is released, causing the fuel rack to return to the idle position. The throttle control assembly is protected by a 10-amp slow-blow fuse.

b. Alarm Controllers. The alarm tattletale indicators are located on the gauge board. These tattletales "pop up" when the parameter that each monitors is sensed to be out of normal range. When activated, the alarm controller cuts power from the control gauge board to the engine throttle control assembly and releases the fuel rack controller, causing the engine to slow down to idle rpm. When the out-of-range condition is corrected, the operator resets the tattletale and the unit is ready to resume normal operation. See Table 3 for alarm setpoints and system responses.

c. Pressure Relief Valve. The pressure relief valve is located on the pump assembly. It lifts at 11,000 psi to protect the pump, hoses, and other components from overpressure. The relief valve vents to ambient pressure.

d. Control Switches. In the boiler and CHT cleaning configuration, the WBD-150N jetting pump Saf Trol E system is controlled and operated using a micro-switch mounted on the cleaning gun. The control switches are manually operated to send an electrical signal through the unit gauge board to the engine throttle control assembly to increase engine rpm. This causes the fuel rack controller to increase engine rpm to allow high pressure hydroblasting operation by the jetting pump. In the underwater configuration, this control switch is replaced with a pressure sensing control switch that monitors discharge pressure at a power unit high pressure port. Upon sensing an increasing pressure (indicating that the foot control valve has been toggled to send water to the high pressure lance or that the zero thrust gun trigger has been depressed), the pressure switch closes and sends an electrical signal to the unit gauge board to the engine throttle control assembly to increase engine rpm. This causes the fuel rack controller to increase engine rpm to allow high pressure hydroblasting operation by the jetting pump.

27-2.1.3 WBD-150N INSTALLED SAFETY DEVICES. The sensors and controls installed on the WBD-150N Hydroblast Jetting Pump are listed in Table 3 .

27-2.1.4 CONTROLS AND INDICATORS. The following controls and indicators are provided to operate the WBD-150N jetting pump. The controls and indicators are located on the engine control panel and the pump assembly (refer to Figure 17, 18, and 19).

a. Ammeter. Displays the generator output to charge the engine battery. Normal reading is in the zero to positive range.

b. Engine Fuel Gauge. Displays the level in the fuel tank.

c. Power Pump Low Oil Level Indicator. The light illuminates when the pump oil level drops below the preset level. In addition, the pump low oil level tattletale pops out to give a visual indication of the low oil level condition.

d. Power Pump Low Suction Pressure Indicator. Causes the engine speed to reduce to idle in the event of a low suction condition. In addition, the pump suction tattletale pops out to give a visual indication of a low level in the water supply tank.

e. Chemical Injection Tank Low Level Indicator. Indicates the level in the chemical injection tank.Normal level is greater than 3 inches. In addition, the chemical tank tattletale pops out to give a visual indication of the low water level in the chemical injection tank.

f. Control Panel Light Switch. When switched to ON position, it causes the control panel lights to illuminate.

g. Chemical Injection Tank Low Level Test Switch. Provides a test function of the low level alarm. Pushing the switch simulates a low level condition and causes the chemical injection tank low level tattletale to activate. The engine speed is then reduced to idle rpm.

h. Power Pump Low Oil Level Test Switch. Provides a test function of the power pump low oil level alarm. Pushing the switch simulates a low level condition and causes the power pump low oil level tattletale to activate. The engine speed is then reduced to idle rpm.

i. Control Power Available Light. Light illuminates when control power is available to the engine control circuits.

j. Engine Tachometer. Displays engine rpm during operation. Normal range is: idle, 600-750 rpm; normal operation, 1800 rpm; maximum, 2150 rpm.

k. Engine Emergency Stop Button. Shuts down engine by engaging engine shutdown solenoid, which tripsthe blower overspeed trip air shutdown flapper.

l. Power Pump Suction Gauge. Indicates the pressure at the suction head of the pump. Normal pressure is 2 to 3 psi.

m. Engine Hourmeter. Displays the running total of engine operating hours.

n. Engine Start Switch. Energizes the engine starting circuit when depressed.

o. Engine Manual Shutdown. Pulling the engine manual shutdown places the fuel rack in the no-fuel position and causes the engine to stop.

p. Engine Overspeed Indicator. Reduces the engine speed to idle in the event of an overspeed condition. In addition, a tattletale pops out to give a visual indication of the engine overspeed condition.

q. Water Tank Low Level Indicator. Lowers engine rpm to idle in the event of a low reservoir water level (approximately 1 1/2"). In addition, a tattletale pops out to give a visual indication of the low water level condition.

r. Engine Coolant Temperature. Indicates engine coolant temperature. Normal range is 160 to 190°F.

s. Engine Oil Pressure Gauge. Indicates engine oil pressure. Normal operating range is greater than 20 psig at engine idle and 40 to 60 psi during normal operation.

t. High Pressure Discharge Connection. This is a threaded, O-ring sealed quick disconnect fitting used to connect the 1/2" high pressure hoses used in the Hydroblast Cleaning System.

u. Discharge Pressure Gauge. Shows pump discharge pressure.

v. High Pressure Relief Valve. Installed on the pump casing, the relief valve is set at 11,000 psi and relieves pressure to the area over the pump.

w. Low Pressure Vent/Drain Valve. Located on the low pressure plenum of the power pump, the vent/drain valve allows the operator to flush, vent, or drain the power pump as required.

x. Saf Trol E Control Cable Connector. Provides an electrical connection point for the Saf Trol E pressure switch.

27-2.1.5 LUBRICANTS. Table 4 lists the lubricants required for operation of the WBD-150N jetting pump:


To set up the Hydroblast Cleaning System using the Hydroblast Jetting Pump, Model WBD-150N, perform the following:

a. Place the jetting pump on-site. Ensure that a suitable source of fresh water is available to the unit for operation.

WARNINGThe jetting pump weighs 8,000 lb. Ensure that all rigging equipment and cargo handling devices used are rated to at least 10,000 lb. Stand clear of the jetting pump and all other components while they are being handled by a crane or cargo handling equipment.

CAUTIONThe jetting pump is to be used only with clean fresh water supplied to the unit at a pressure of 75 to 125 psi and 20 gpm available flow. Use of any other water will cause serious damage to the pump.

WARNINGHigh pressure leaks can cause personnel injury or death. Ensure that high pressure hoses will be routed clear of personnel and vehicle traffic. Restrict access to only those personnel required for operation of the hydroblasting equipment. Tie off high pressure hoses to prevent hose damage and leaks.


Inspect all high pressure hoses prior to equipment setup and daily, prior to the start of work. Replace any hoses that are damaged or show evidence of swelling or leaks.

b. Verify that a clear path is provided for high pressure hoses and supply water hoses.

c. Secure the jetting pump and block the trailer wheels, if required, to prevent shifting during operation.

d. Inspect the jetting pump for structural damage, loose or missing fasteners, and serviceability of components. Replace any missing fasteners and tighten loose or missing fasteners to standard values. Repair any missing or damaged components, as required.

NOTEThe pump has 5 high pressure ports. The manual dump valve may be installed into any unused port without affecting pump operation.

e. Remove one of the high pressure port plugs for installation of the manual dump valve and install the manual dump valve (refer to Figures 20 or 21, as applicable).

f. Verify that the quick disconnect fitting installed on the pump is compatible with the Hydroblast Cleaning Kit high pressure hoses. If required, change the pump quick disconnect fitting with a spare quick disconnect from the cleaning kit.

g. Install the Saf Trol E pressure switch tee connection onto the high pressure water discharge quick disconnect fitting.

WARNINGThe electrical connection from the gauge control panel to the engine throttle control cable must be properly connected. Failure to connect the gauge board cable to the engine throttle control assembly will bypass all safety devices and shutdowns, possibly causing damage to the component or personnel injury.

CAUTIONEnsure that the cable is clear of rotating or reciprocating parts and is secured to prevent damage to the cable.

h. Route the Saf Trol E pressure switch electrical cable from the pressure switch to the gauge control panel, and connect the cable into the Saf Trol E connection on the gauge board.


Perform the following steps daily, prior to operating the Hydroblast Jetting Pump Model WBD-150N.

a. Check the engine sump oil level. Proper oil level is at the normal mark on the dipstick. Replenish, if required, with SAE 30W motor oil.

WARNINGDo not remove the radiator cap unless the engine is at or near ambient temperature. Severe burns can result from contact with hot coolant.

b. Remove the radiator cap and inspect the coolant level. Replenish as required with a mixture of 50% ethylene glycol antifreeze and 50% water to bring the level to within 3/4" of the radiator neck. Reinstall the radiator cap.

c. Check the pump gear case sump oil level. Proper oil level is at the neck of the fill connection located at the engine side of the pump gear case (see Figure 22). Replenish with proper oil for ambient conditions (refer to Table 4).

d. Open the drive belt inspection window (see Figure 22). Inspect the drive belt for wear and proper adjustment. Proper tension can be determined by pushing each belt inward with approximately 15 pounds of force. With this pressure applied the belt deflection at the center point between the two pulleys should be approximately 3/8". If tension is not correct, refer to section 2-1 of reference f. and adjust them accordingly.

e. Lubricate the three grease fittings on the clutch bell housing (see Figure 22) using lithium grease.

f. Verify that the fuel tank drain valve is shut and that the drain valve outlet plug is installed. Inspect the fuel in the jetting pump fuel tank for adequate level. Replenish, as required, using clean No. 2 diesel fuel.

g. Verify that the overspeed trip on the engine air inlet is latched in the run position.

WARNINGElectrolyte is extremely corrosive and can cause severe injury and blindness if splashed on skin and eyes. If electrolyte is spilled or comes in contact with the eyes or skin, immediately flush for 15 minutes with fresh water and seek immediate medical attention.

h. Verify that battery leads are connected to the battery terminals. Inspect the battery for proper electrolyte level in the battery cells. Replenish, if required, with distilled water.

WARNINGVerify the hydrostatic test dates on all hoses prior to applying pressure. Replace any hose that is out of date or whose tag is missing.

i. Lay out the required 50' lengths of high pressure hose needed for the assigned task. Inspect each hose for cuts, abrasions, and tears to the outer cover that expose the inner core, swelling, separation of fittings from the hose, and evidence of leaks. Replace any suspect hose.

WARNINGThe foot control valve must be connected and manned when using any lance. When laying out high pressure hoses, position the foot control valve so as to provide the diving supervisor constant communication with the diver and the person manning the foot control valve.

CAUTIONDo not connect the zero thrust gun or any lances until the hoses have been flushed as outlined in the operational procedure.

NOTEThe foot control valve is not required for the zero thrust gun.

j. Connect the required 50' lengths of high pressure hose to the discharge fitting on the Saf Trol E pressure switch (see Figure 20 or 21, as appropriate). If a lance is used, connect the foot control valve in line.

k. Select and position the appropriate cleaning tool (Figure 23) near the worksite.

NOTEThe zero thrust gun and any of the following lances (Table 5) may be used with the WBD-150N jetting pump as required by the assigned task. Pressure and flow settings must be adjusted by setting the engine rpm and manual dump valve, as required, to accommodate the pressure and flow requirements of assigned job and cleaning tool.


Complete all steps in the setup and pre-operational procedures; then, when ready, start and operate the jetting pump in accordance with the following procedure:

WARNINGInstallation and operational verification of the Saf Trol E pressure switch and manual dump valve must be done prior to starting diving operations.

a. Open the supply water valve; fill the water supply tank.

b. Open the manual dump valve one full turn.

c. Verify that the packing gland cooling water valve is cracked open (see Figure 18 or 19, as appropriate), and that there is water leakage at the plunger packing glands (Figure 24).

d. Verify that the engine clutch is disengaged (pulled away from the engine bell housing).

WARNINGHearing protection required while operating the jetting pump. Do not use starting fluid while attempting to start engine. Diesel exhaust contains carbon monoxide. Do not operate engine in confined space unless adequate ventilation is provided. Stand clear of rotating parts; do not wear loose clothing while near machinery.

Exhaust system parts can reach 400°F and cause severe burns. Stand clear of all exhaust system components until they have cooled to ambient temperature.

e. Depress the engine start switch; release the switch after the engine starts.

f. Allow engine to run at idle for approximately 5 minutes to warm up. While running, inspect the engine for air, fuel, and water leaks; listen for abnormal noises; feel for vibrations; and inspect gauges for signs of abnormal operation. If any abnormal condition is noted, stop the engine and correct.

WARNINGDo not attempt to connect or disconnect any high pressure hose, lance, or zero thrust gun while the system is pressurized or the pump clutch is engaged.

g. With engine at idle, engage clutch (rotate handle towards engine bell housing).

h. While engine is idling, depress foot control valve (if installed) to purge all air and any possible dirt in the pump, hoses, and foot control valve. Observe flow at the hose end and the discharge of the manual dump valve; allow flow to continue until the discharge water is clear and free of any debris.

i. Disengage engine clutch.

j. Connect the appropriate lance or zero thrust gun to the terminal end of the high pressure hose.

WARNINGWhile testing, place the lance tip at least 2 feet into an open ended pipe and secure the lance to the pipe to ensure that the high pressure water flow from the water lance is directed to a safe location. Ensure that the water flow is not pointed at personnel or into easily damaged areas.

NOTEThe pressure and flow rate from the jetting pump available for hydroblasting will be determined by engine speed and the manual dump valve setting.

k. Prepare the lance or zero thrust gun for operational testing and setting of system pressure and flow. Ensure that the lance or zero thrust gun is properly secured and that the water flow is directed into a safe area.

WARNINGMonitor engine rpm while setting maximum operating speed. Do not allow engine to exceed 2150 rpm.

Do not exceed 11,000 psi during operation of the hydroblast jetting pump.


Only qualified personnel are authorized to operate the Hydroblasting System.


CAUTIONThe manual dump valve functions to dump excess water produced by the jetting pump while the unit is at operational rpm. Proper setting of manual dump valve is instrumental in allowing the Saf Trol E pressure switch to activate the throttle control assembly and bring the engine up to operating speed and back to idle when flow is not required. Improper setting of the manual dump valve will cause excessive operating pressure, failure of the Saf Trol E to bring engine rpm up to operating values, or cause the diesel engine to overspeed during operation.

l. Engage engine clutch.

NOTEWhen using the 1/2" diameter flexible lance (20 gpm @10,000 psi) the manual dump valve must be closed.

m. Set the manual dump valve and fuel rack adjustment as follows:

1. Depress the foot control valve or the zero thrust gun trigger, as appropriate. Engine rpm will not change; water flow from the manual dump valve port will stop and flow will start at the lance (or zero thrust gun) nozzle.

CAUTIONIf, during operation, either the maximum engine rpm or pump discharge pressure is exceeded, and releasing the foot control valve or trigger of the zero thrust gun do not return the engine to idle then pull the manual shutdown handle to stop the engine.

2. With engine at idle, slowly throttle the manual dump valve by turning the valve towards the fully closed position. As the valve approaches fully closed (approximately 1/8 turn open), the discharge pressure will start to rise. When the pressure reaches 700 to 800 psi the Saf Trol E pressure switch will activate causing the engine throttle control assembly to increase engine speed.

3. Monitor engine rpm; as engine rpm increases, monitor the pressure. Do not exceed the maximum rpm or the pressure for the attached lance as shown in Table 6. Return the engine to idle by releasing the foot control valve or releasing the zero thrust gun trigger, as appropriate.

4. If the rpm or maximum pressure require adjustment, reset the engine rpm at the fuel rack control arm (refer to Figure 25) as follows:

a. Loosen the locknut on the fuel rack adjustment rod.

b. Adjust the maximum rpm by turning the fuel rack adjustment rod as needed (counterclockwise to raise rpm, clockwise to lower).

c. Reestablish flow through the lance by depressing the foot control valve or zero thrust gun trigger, as appropriate.

d. Repeat steps 3 and 4, as required, to obtain the required engine rpm and hydroblasting pressure.

5. Tighten fuel rack adjustment locknut

6. Cycle the water flow on and off by stopping and starting flow with the foot control valve or zero thrust gun (as installed in the system) to verify that the engine idles when in a no-flow condition and that the pressure returns to the required setpoint when flow is reestablished. Verify that the system pressure remains stable during use.

WARNINGOnly the Butterworth zero thrust gun has been approved to clean masker belts. No other gun shall be used.

The Butterworth zero thrust gun may only be used in the configuration detailed in NAVSEA Dwg 6699567.

The Butterworth zero thrust gun shall not be operated for more than 85 minutes by one operator in any 24-hour period.

Operators of the Butterworth zero thrust gun shall wear a Mk21 surface supplied diving helmet.

The high pressure jet of water discharging from the Butterworth zero thrust gun is potentially dangerous. Keep water jet trained away from divers.

Diver safety may require instant shutdown of the high pressure water to the lance. Release the foot pedal to confirm instant loss of high pressure water to the lance.

The foot control valve must be connected and manned when using any lance. When laying out high pressure hoses, position the foot control valve to provide constant communication with the diving supervisor. If lance jams inside the maskerbelt, ensure that the high pressure water supply is turned off prior to attempting to remove it.

n. The Hydroblast Cleaning System is ready for underwater operation If there will be a delay in starting system operation, disengage the clutch and shut down the jetting pump according to the normal shutdown procedure. When ready to start operations, open the water supply valve and restart the jetting pump.

o. Monitor the jetting pump, hoses, foot control valve, and other components during operation. If an abnormal or hazardous condition emerges, stop the jetting pump, investigate and correct the condition.

p. Operate the system to conduct assigned operations. As required to refuel or for other reasons, disengage the clutch and stop the unit. Restart the jetting pump by returning to step n. above and restarting the engine.


The following procedure lists the steps for a normal shutdown of the jetting pump.

a. Release the foot control valve or zero thrust gun trigger, as appropriate, and allow engine to come to idle.

b. Disengage the engine clutch.

c. Pull the normal shutdown handle OUT. When the engine stops, push the shutdown handle IN.

d. Close the water supply tank inlet valve at the water source.


In the event of an abnormal noise, vibration, ruptured hose, or other casualty, stop the jetting pump as follows:

a. Push the emergency stop button on the control panel.

b. Close the water supply inlet valve at its source.

c. Investigate the cause of the casualty and correct the cause prior to restarting the jetting pump.


After shutdown perform the following:

a. Inspect the jetting pump for loose and damaged fasteners. Replace missing fasteners and tighten loose fasteners to standard values.

b. Inspect each hose for cuts, abrasions, and tears to the outer cover that expose the inner core, swelling, separation of fittings from the hose, and evidence of leaks. Replace any suspect hose.

c. Allow jetting pump to cool. Inspect all fluid levels and replenish as required.

d. If the assigned task is completed, disconnect and drain all hoses, valves, guns, and lances used. Remove the Saf Trol E pressure switch and manual dump valve. Reinstall the high pressure port plugs.

e. If changed in the pre-operational section of the procedure, return the discharge quick disconnect fitting to its original configuration.

f. Using fresh water, rinse the exterior of all hoses, lances, zero thrust gun, and any other components subject to saltwater spray.

g. Drain the freshwater supply tank by removing the drain plug. Replace drain plug when empty. Drain the inlet filter cavity by opening the drain valve on the filter piping. Drain the power pump by opening the low pressure vent/drain valve.

h. Allow all components to air dry. Pack components in the Hydroblast Cleaning Kit.

i. Place plastic plugs over the high pressure water ports and other open hose connections. If the plugs are missing or not serviceable, cover any open fittings with duct tape.

27-2.8 PREPARATION FOR SHIPMENT OR RETURN TO STORAGE FACILITY

After the assigned task is completed and prior to returning the jetting pump and Hydroblast Cleaning Kit to storage or preparing for shipment, complete the following:

a. Disconnect the battery leads from the terminals. Tape the lugs and leads with electrical tape.

b. Drain the fuel from the fuel tank into a suitable container. Dispose of the fuel as required by local instructions.

SECTION 3.0 –Mi-T-M HS-3006-DMKO PRESSURE WASHER: DESCRIPTION, SETUP, AND OPERATIONAL

PROCEDURES

27-3.1 MiT-M PRESSURE WASHER. The low pressure, low flow pressure source for the Hydroblast Cleaning System is the Mi-T-M Model HS-3006-DMKO Pressure Washer. See Figure 26. The pressure washer is mounted on a wheeled, self-contained frame and contains a diesel engine and positive displacement pump that provides up to 4.76 gpm @ 3000 psi. General specifications for the DMKO pressure washer follow:

Mi-T-M Pressure Washer

Manufacturer Mi-T-M Corporation

Model HS-3006-DMKO

Output 4.76 gallons @ 3,000 psi

Fuel tank 12 gal.



Diesel Engine Power End Pump

Manufacturer Kubota Manufacturer Mi-T-M

Model ZB600C-E-B Model CWC

RPM 3500 (maximum) No. cylinders 3

HP 12.5 @ 3200 rpm Maximum flow 4.76 gpm

Starting 12 V dc Maximum pressure 3000 psi

Fuel Diesel Medium Fresh water

Fuel tank 12 gal. Power transfer Belt drive


NOTEThe pressure washer is produced by Mi-T-M Manufacturing of Peosta, Iowa. A contact number for parts and information is 563-556-7484 or 800-553-5053.

27-3.1.1 CONTROLS. The following controls are provided to operate the Mi-T-M pressure washer. The controls arelocated on the engine control panel and the pump assembly (refer to Figures 27 and 28).

a. OFF-PREHEAT-ON-START Switch. Controls the starting functions of the pressure washer.

b. Discharge Pressure Gauge. This is a 0 to 5000-psi gauge. Normal pressure during operation is 3000 psi.

c. High Pressure Discharge Connection. This is a threaded, O-ring-sealed, quick disconnect fitting used to connect the 1/2" high pressure hoses used in the Hydroblast Cleaning System. The pressure control regulator is mounted next to the high pressure discharge connection.

d. Inlet Water Connection and Strainer. This is a standard 3/4" garden hose connection. Normal pressure at the inlet is 40 to 125 psi. A screen filter to remove rust, dirt, and other contaminants from the inlet of the high pressure pump is mounted at the outlet of the hose connection.

e. Control Power Available Light. This light illuminates when the key is in any position except OFF.

f. Glow Plug Indicator. This illuminates after the key has been placed in preheat and the glow plugs have heated.

g. Engine Throttle. The mechanical throttle connects the control to the engine fuel rack by means of a wire cable.

h. Engine Oil Dip Stick and Engine Oil Fill Connection. Located on the side of the engine, these connections are used to measure and replenish the engine oil.

i. Engine Fuel Filter and Shutoff Valve. This filters the engine fuel and shuts off the fuel for maintenance and shutdown periods.

27-3.1.2 Mi-T-M PRESSURE WASHER INSTALLED SAFETY DEVICES. The following sensors or controls (see Table 7) are installed on the Mi-T-M pressure washer.

27-3.1.3 LUBRICANTS. Table 8 lists the lubricants required for operation of the Mi-T-M pressure washer. Use lubricating oil, MIL-PRF-2104 or API CC/CD/CE, in the grades shown.


WARNINGThe pressure washer weighs 556 lb. Ensure that all rigging equipment and cargo handling devices used are rated to at least 1/2 ton. Stand clear of the pressure washer and all other components while they are being handled by a crane or cargo handling equipment. Lift the pressure washer only by the lifting point on the upper part of its frame.

CAUTIONThe pressure washer is to be used only with clean fresh water supplied to the unit at a pressure of 40 to 125 psi and a minimum of 5 gpm Use of any other water will cause serious damage to the power unit pump.

a. Place the pressure washer on-site. Ensure that a suitable source of fresh water is available to the unit for operation.

WARNINGHigh pressure leaks can cause personnel injury or death. Ensure that high pressure hoses will be routed clear of personnel and vehicle traffic. Restrict access to only those personnel required for operation of the hydroblasting equipment. Tie off high pressure hoses to prevent hose damage and leaks.

b. Secure the pressure washer and chock the wheels to prevent shifting during operation.

c. Verify that a clear path is provided for high pressure hoses and supply water hoses.

WARNINGInspect all high pressure hoses prior to equipment setup and daily, prior to the start of work. Replace any hoses that are damaged or show evidence of swelling or leaks.


d. Inspect the high pressure hoses for cracks and tears in the outer cover that expose the inner core, swelling, separation of fittings from hose and evidence of leaks. Repair or replace any suspect hoses.

e. Inspect the pressure washer for structural damage, loose or missing fasteners, and serviceability of components. Replace any missing fasteners and tighten loose or missing fasteners to standard values. Repair any missing or damaged components.


Perform the following steps daily, prior to operating the Mi-T-M pressure washer.

a. Check the engine sump oil level. Proper oil level is at the normal mark on the dipstick. Replenish, if required, with engine lubricating oil. Refer to Table 8 for the lubricating oil viscosity required.

WARNINGDo not remove the radiator cap unless the engine is at or near ambient temperature. Severe burns can result fromcontact with hot coolant.

b. Remove the radiator cap and inspect the coolant level. Replenish, as required, with a mixture of 50% ethylene glycol antifreeze and 50% water to bring the level to within 3/4" of the radiator neck. Reinstall the radiator cap.

c. Check the pressure washer gear case sump oil level. Proper oil level is at the middle of the sight glass located on the side of the pump gear case. Replenish with proper oil for ambient conditions (Mi-T-M pump oil #AW-4085-0016).

WARNINGElectrolyte is extremely corrosive and can cause severe injury and blindness if splashed on skin and eyes. If electrolyte is spilled or comes in contact with the eyes or skin, immediately flush for 15 minutes with fresh water and seek immediate medical attention.

d. Verify that battery leads are connected to the battery terminals. Inspect the battery for proper electrolyte level in the battery cells. Replenish, if required, with distilled water.

e. Remove the secondary drive belt cover (see Figure 29). Inspect the primary and secondary drive belts for proper adjustment. Proper tension can be determined by pushing each belt inward with approximately 15 pounds of force. With this pressure applied, the belt deflection at the center point between the two pulleys should be approximately 1/2". If tension is not correct, consult reference b. and adjust.

f. Inspect the fuel filter bowl and verify that the fuel is free of water and sediment. If any water or sediment is present, close the fuel inlet valve and remove, clean, and reassemble the fuel filter assembly. Verify that the fuel inlet valve at the outlet side of the fuel filter is open after reassembly (see Figure 30).

g. Inspect the fuel level in the pressure washer fuel tank. Replenish, as required, using clean No. 2 diesel fuel.

h. Inspect the inlet water filter screen (see Figure 31). Disassemble and clean if required.

i. Select and position the appropriate cleaning lance (Figure 32) near the worksite. (See Table 9.)

WARNINGVerify the hydrostatic test dates on all hoses prior to applying pressure. Replace any hose that is out of date or whose tag is missing.

j. Lay out the required 50' lengths of high pressure hose needed for the assigned task. Inspect each hose for cuts, abrasions, and tears to the outer cover that expose the inner core, swelling, separation of fittings from the hose, and evidence of leaks. Replace any suspect hose.

WARNINGThe foot control valve must be connected and manned when using any lance. When laying out high pressure hoses, position the foot control valve so as to provide the diving supervisor constant communication with the diver and the person manning the foot control valve.

k. Connect the required 50' lengths of high pressure hose to the foot control valve and the discharge fitting on the pressure washer.

NOTEThe Mi-T-M pressure washer has a maximum flow of 4.76 gpm @ 3000 psi. Only the lances shown in Table 9 and Figure 32 are authorized for use.

CAUTIONThe zero thrust gun (10 gpm) and flexible lance (20 gpm) are rated at pressures and flows that are higher than the Mi-T-M pressure washer is rated. Do not connect either of these tools to the pressure washer.

Do not connect the lance until the line has been purged and flushed as outlined in the operational section of this procedure.

l.m. Connect additional 50' lengths of high pressure hose, as needed for the assigned task, to the outlet side

of the foot valve. Verify that the assigned lance (Table 9) is laid out, but not connected to the high pressure hose.


Complete all steps in the setup and pre-operational procedures. Then, when ready, start and operate the pressure washer in accordance with the following procedure:

a. Lay out the supply water hose, ensuring that all loops and kinks are removed, and connect it to the water inlet connection of the pump.

b. Prime the pump by performing the following:

1. With the supply water turned ON, allow low pressure water to flow through the pump, hoses, and foot control valve. Cycle the foot control valve to purge any air out of the hoses downstream of the valve.

2. After the complete hose assembly is purged, turn off the water supply and connect the high pressure lance to the terminal end of the high pressure hose.

3. Open the water supply valve.

WARNINGHearing protection required while operating the pressure washer.

Do not use starting fluid while attempting to start engine.

Diesel exhaust contains carbon monoxide. Do not operate engine in confined space unless adequate ventilation is provided.

Stand clear of rotating parts; do not wear loose clothing while near machinery.

Exhaust system parts can reach 400°F and cause severe burns. Stand clear of all exhaust system components until they have cooled to ambient temperatures.

Do not attempt to connect or disconnect any high pressure hose while it is pressurized.



c. Move the throttle control to approximately one-half speed (see Figure 33).

d. Turn the OFF-PREHEAT-ON-START switch to the ON position. Verify that the charge light is illuminated. See Table 10.

e. Turn the OFF-PREHEAT-ON-START switch to the PREHEAT position and hold until the glow plug indicator light illuminates.

f. Turn the OFF-PREHEAT-ON-START switch to the START position, and release the key when the engine starts; the key will return to the ON position. Using the engine throttle, reduce engine rpm to idle.

Table 10. Required Preheat Times

Ambient Temperature Preheat Time*

Above 10°C (50°F) Approximately 5 seconds

Below -5°C (23°F) Approximately 10 seconds

* Maximum continuous preheat time is 20 seconds.

CAUTIONDo not allow the pressure washer to operate in bypass mode (no flow) for more than three minutes without establishing water flow.

g. Allow engine to run at idle for approximately 5 minutes to warm up. While running, inspect the engine for air, fuel and water leaks, listen for abnormal noises, and feel for vibrations. Be alert for signs of abnormal operation. Verify that the engine charging light is out. If any abnormal condition is noted, or if the indicator light is lit, stop the engine and correct the problem.

h. While the engine is running at idle, verify that the dump port on the foot valve has a constant flow of water.

WARNINGWhile testing, place the lance tip at least 2 feet into an open-ended pipe and secure the lance to the pipe to ensure that the high pressure water flow is directed to a safe location. Ensure that the water flow is not pointed at personnel or into easily damaged areas.

i. Securely fasten the lance and direct the water flow from the lance and the foot valve vent to safe areas.

j. Increase the speed by moving the throttle control to the RUN position.

NOTEEach cleaning tool requires a different amount of flow to achieve 3,000 psi operating pressure. Therefore, adjustment of the pump bypass relief valve may be required to achieve the required pressure.

k. Operate the foot control valve to establish flow though the water lance. Verify that the pressure is set as required for the assigned task. To adjust pressure, proceed as follows:

1. With the foot valve depressed, loosen the locknut on the bypass relief valve and adjust the bypass relief valve to set the pressure. See Figure 34.

2. Release the foot control valve. Pressure is controlled by the foot control valve dump port.

3. Cycle the foot control valve to verify the setpoint pressure.

4. Tighten the locknut on the bypass relief valve.

l. The hydoblast system is ready for normal use. If there will be a delay in starting underwater operations, slow the pressure washer to idle and stop the unit according to the normal shutdown procedure. When ready to start operations, open the water supply valve and restart the pressure washer.

m. Monitor the pressure washer, hoses, foot control valve, and other components during operation. If an abnormal or hazardous condition emerges, stop the pressure washer, investigate and correct the condition.

n. Operate the system to conduct assigned operations. As required to refuel or for other reasons, stop the unit according to the normal shutdown procedure. Resume pressure washing by returning to step l. above and restarting the engine.


To stop the pressure washer, proceed as follows:

a. Reduce the engine speed to idle.

b. Turn the OFF-PREHEAT-ON-START switch to the OFF position.

c. Close the water supply inlet valve at the water source.


In the event of an abnormal noise, vibration, ruptured hose, or other casualty, stop the pressure washer as follows:

a. Turn the OFF-PREHEAT-ON-START switch to the OFF position.

b. Close the water supply inlet valve at the water source.

c. Investigate the cause of the casualty and correct it prior to restarting the pressure washer.


After shutdown, perform the following:

a. Allow the pressure washer to cool. Inspect all fluid levels and replenish as required.

b. Inspect the pressure washer for loose and damaged fasteners. Replace missing fasteners and tighten loose fasteners to standard values.

c. Inspect each hose for cuts, abrasions, and tears to the outer cover that expose the inner core, swelling, separation of fittings from the hose, and evidence of leaks. Replace any suspect hose.

d. If the assigned task is completed, disconnect and drain all hoses, valves, and lances used.

e. Loosen the spring tension on the bypass relief valve.

f. Using fresh water, rinse the exterior of all hoses, lances, and any other components subject to salt water spray.

g. Allow all components to air dry. Pack components in the Hydroblast Cleaning Kit.

h. Place plastic plug over the high pressure water port and water inlet connection.

i. Install weatherguard cover on the pressure washer.

27-3.8 PREPARATION FOR SHIPMENT OR STORAGE

After the assigned task is completed and prior to returning the pressure washer and Hydroblast Cleaning Kit to storage, or to prepare them for shipment, complete the following:

a. For long-term storage or storage in cold weather conditions, proceed as follows:

1. In a 5-gallon container, mix a solution of 50% antifreeze and 50% water.

2. Connect a 3-foot piece of garden hose to the water inlet of the pressure washer; place the other end into the 5-gallon bucket.

3. Connect one 50-foot length of high pressure hose to the outlet connection of the pressure washer; place the other end into the 5-gallon bucket.

4. Start the pressure washer at idle rpm.

5. Allow the pressure washer to run for 3 minutes to circulate the antifreeze solution through the pump. Ensure that the antifreeze mixture flows out of the 50-foot segment of high pressure hose.

6. Stop the pressure washer.

7. Remove the inlet and outlet hoses. Drain the hoses into the 5-gallon bucket.

8. Install protective plugs on the inlet and outlet of the pressure washer.

9. Dispose of the antifreeze mixture in accordance with local instructions.

b. Disconnect the battery leads from the terminals. Tape the lugs and leads with electrical tape.

c. Drain the fuel from the fuel tank into a suitable container. Dispose of the fuel as required by local instructions.

d. Install weatherguard cover on the pressure washer.

Figure 1. WBD-150N Jetting Pump

Figure 2. High Pressure Jetting Equipment

Figure 3. Mi-T-M Pressure Washer

Figure 4. Low Pressure Jetting Equipment

Figure 5. Hydroblast Cleaning Kit (Shipping Configuration)

Figure 6. Fire and High Pressure Hoses

Figure 7. Foot Control Valve

Figure 8. Zero Thrust Gun

Figure 8a. Zero Thrust Gun Nozzle Components

Figure 9. Flexible Lance Assembly

Figure 10. Semi Flexible Lance Assembly

Figure 11. Mini Mole Flexible Lance Assembly

Figure 12. Rigid Lance w/ Shipping Container

Figure 13. Saf Trol E Pressure Switch

Figure 14. Manual Dump Valve and Adapter

Figure 15. WBD-150N Jetting Pump

Figure 16. Engine Throttle Control Assembly

Figure 17. WBD-150N Control Gauge Board

Figure 18. Weatherford Model FE-145 Pump

Figure 19. Butterworth QU-300M Pump

Figure 20. Saf Trol E Pressure Switch and Manual Dump ValveInstallation on the Weatherforth Pump Housing

Figure 21. Saf Trol E Pressure Switch and Manual Dump ValveInstallation on the Butterworth Pump Housing

Figure 22. Pump Oil Fill and Clutch Lubrication Points

Figure 23. Schematic of Hydroblasting System Setup

Figure 24. Power Pump Plunger Cavity

Figure 25. Engine Speed Control Adjustments

Figure 26. Mi-T-M Pressure Washer

Figure 27. Mi-T-M Pressure Washer Controls

Figure 28. Mi-T-M Pressure Washer Power Pump Assembly

Figure 29. Mi-T-M Pressure Washer Left Side

Figure 30. Fuel Filter and Shutoff Valve

Figure 31. Water Inlet Connection and Filter

Figure 32. Schematic of Low Pressure Cleaning Equipment

Figure 33. Mi-T-M Pressure Washer Controls

Figure 34. Pump Bypass Relief Valve

Table 1. Hydroblast Cleaning Tools

COMPONENTDIAMETER

(INCH)LENGTH(FEET)

RATED PRESS.

(PSI)

FLOW @ 10,000 PSI

(GPM)

FLOW @ 3,000

PSI (GPM)

Zero Thrust Gun

0.30 NA 15,000 10 NA

Flexible Lance 0.50 37 10,000 20 NA

Rigid Lance 0.25 6 10,000 5 2.25

Semi Flexible Lance

0.140 15 3,000 NA 1.25

Mini Mole Flexible Lance

0.335 25 8,000 8 4.5

Table 2. Hydroblast Cleaning Kit Support Components

COMPONENT DIMENSIONSRATED

PRESSURE(PSI)

QUANTITY

Foot Control Value

0.5" 15,000 1

High Pressure Hose

0.5" x 50' 15,000 6

Fire Hose 1.5" x 50' 150 2

Saf Trol E Pressure Switch

0.5" 10,000 1

Manual Dump Valve

0.5" 15,000 1

Table 3. WBD-150N Installed Safety Devices

SENSOR OR CONTROL SETPOINT RESPONSE

Supply water strainer sensor Clogged input strainer, 5" Hg

Idles engine

Supply water tank level sensor

Low water level, less than 17 gal.

Idles engine

Power end oil level sensor 2" or 3" pump oil sump level Idles engine

Engine overspeed sensor Engine speed over 2150 rpm

Idles engine

Engine temperature sensor 195°F to 205°F Idles engine

Engine oil pressure sensor 8 to 12 psiShuts down engine

Low fuel oil pressure sensor 8 to 12 psi Idles engine

Chemical injection tank sensor

2" to 3" chemical tank level Idles engine

Manual shutdown tee handle

Manual shutdownShuts down engine

Table 4. WBD-150N Lubricants

Component Lubricant

EngineEngine oil, SAE 30W (MIL-PRF-2104)

Power pump gear casing

Summer: SAE 30W (MIL-PRF-2104)Winter or Fall: SAE 20 W (MIL-PRF-2104)

Power take-off clutch assembly

Waterproof lithium grease

Table 5. Hydroblast Cleaning Kit Component Flow and Pressure

Assigned Cleaning Tool

Flow (gpm)

Pressure (psi)

Zero Thrust Gun 10 10,000

Rigid Lance 5 10,000

Flexible Lance 20 10,000

Mini Mole 8 8,000

Table 6. Component Flow vs. Approximate Engine rpm for the WBD-150N Jetting Pump


Pressure (psi)Flow (gpm)

Engine rpm (approx)

Zero Thrust Gun 10,000 10 1800

Flexible Lance 10,000 20 1800

Rigid Lance 10,000 5 1500

Mini Mole 8,000 8 1500

Table 7. Mi-T-M Sensors or Controls

Sensor or Control

Setpoint Response

Discharge relief valve

3200 psi Relieve pressure

Engine speed limiter

3500 rpmLimit engine speed

Low flow preventer

Flow less than 1.5 gpm

Vents water

Table 8. Mi-T-M Pressure Washer Engine Lubricants

Component Temperature Range Grade/Viscosity

Kubota Engine

Above 25 °C (77 °F)SAE 30 W, SAE 10W-30 or SAE 10W-40

0 °C (32 °F) to 25 °C (77 °C)

SAE 20 W, SAE 10W-30 or SAE 10W-40

Power end pump sump All rangesMi-T-M pump oil #AW-4085-0016

Table 9. Low Pressure Cleaning Tool Flow and Pressure


Flow (gpm) Pressure (psi)

Rigid Lance 2.25 3,000

Semi Flexible Lance 1.25 3,000

Mini Mole 4.5 3,000

Table 10. Required Preheat Times

Ambient Temperature

Preheat Time*

Above 10°C (50°F) Approximately 5 seconds

Below -5°C (23°F) Approximately 10 seconds

* Maximum continuous preheat time is 20 seconds

u.s.navy underwater ship husbandry manual chapter 27 hydroblast cleaning system

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