0907 - A - Support Thruster 5 Year Overhauls

USNS MARY SEARS
T-AGS 65
Solic. No.: MLL-16-T65-0001

DRYDOCKING & UNDOCKING September 21, 2016
ITEM NO. 0907 CP2 CATEGORY A USMMI/MLL/RCS

Revision X
SUPPORT THRUSTER 5 YEAR OVERHAULS
1.0 Abstract:
1.1 The intent of this item is to provide industrial assistance to the Owner provided service
engineering team to perform UGB (upper Gear Box) and LGB (Lower Gear Box) five year
overhaul to included related work to the stem section and propellers.
1.2 The Starboard gear box was replaced during the last dry dock period and will not be
replaced during this dry dock period but will have regular overhaul and servicing
performed.
2.0 References/Enclosures:
2.1 References:
2.1.1 Technical Manual No. T-AGS60CL034 Titled: Thruster, Stern FS2510-463 Is on

Board Vessel and Available Upon Request.
2.2 Enclosures:
2.2.1 List of Government Furnished Spares (separate file)
2.2.2 Photos Lifting Plate for Lower Gear Box - Disassembled drives and various
components
3.0 Item Location/Description:
3.1 Location: Various
3.2 Description: Z-Drive Thrusters

Mfr: Lips Drunnen - The Netherlands
Model: FS2510 - 463 MNR, Quantity: 2 Each
4.0 USMMI Furnished Equipment/Material/Services:
4.1 USMMI Furnished Services: Wartsila LIPS Service Team to oversee the maintenance
accomplished by the shipyard workers.
4.2 USMMI Furnished materials:
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4.2.1 1600 Gallons of Shell Omala 150 for the Gear Oil Change.
4.2.2 1000 Gallons of Shell Tellus T46 Hydraulic Oil.
4.2.3. Stern UGB Inspection Kit WLP001321-000
4.2.4 Stern Stem Overhaul Kit WLP001473-005
4.2.5 Stern Propeller Install Kit WLP001473-007
4.2.6 One (1) each Port LGB
4.2.7 Eight (8) each hydraulic motors & couplings
4.2.8 All items including the above in enclosure 2.2.1
5.0 Notes:
5.1 The Shipyard shall make necessary arrangements to store all repair parts in covered
storage within the shipyard, as called out in the Specification to handle all USMMIFE.
5.2 The Shipyard shall make necessary arrangements to store all oil that is required to
replenish these drives at the completion of overhaul.
5.3 Weights of Items to Be Worked:
A. UGB: T003001371 2600 kg = 5700# each
B. LGB: T003001660 7600 kg = 16,700# each
C. Stem: T003001393 7400 kg = 16,300# each
D. Propeller: 4000 kg = 8800# each
E. Gear Oil: 3500l = 900G = 6700# each
F. Hydraulic Oil: 800l = 200G = 1500# each
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TOTAL Weight of each Thruster, all inclusive: 55,700# each
5.4 The Contractor and all Sub-Contractors, regardless of tier, must consult the General
Technical Requirements (GTR) to determine applicability to this work item. In
performance of this work item, the Contractor and all Sub-Contractors, regardless of tier,
must comply with the requirements of all applicable GTR's including but not limited to
GTR's 1 through 7 and 21 through 29. GTRs can be retrieved from the Internet at the
following URL: http://www.msc.navy.mil/instructions/pdf/m470016.pdf
5.5 The Contractor and all Sub-Contractors, regardless of tier, are advised to review other
work items under this contract to determine their effect on the work required under this
work item. Many of the definitions relating to performance of this work are found in
Work Item 0001.
6.0 Quality Assurance Requirements:
6.1 All Inspections Shall Be Made Available To The WARTSILA Representative, ABS Surveyor,
and USMMI Port Engineer.
6.2 All Work Shall Be Accomplished In Accordance With The WARTSILA Representative
Requirements.
6.3 All workmanship, materials and testing shall be in accordance with the latest ABS Rules
for Building and Classing Steel Vessels and to the satisfaction of and in presence of the
ABS Surveyor, Manufacturers Representatives, Port Engineer and MSCREP.
6.4 No additional work is to be accomplished without a Condition Report and prior written
approval by the USMMI Port Engineer. The USMMI Port Engineer is the single point of
contact authorized to address technical questions.
7.0 Statement of Work:
7.1 Arrangement/Outfitting:
7.1.1 Provide all labor, material, tools and equipment necessary to accomplish the
work required by this specification.
7.1.2 This work shall commence immediately after docking.
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7.2 Structural:
7.2.1 Temporarily remove all interferences and crop two overhead accesses on the
main deck to facilitate removal of the z-drive upper gearboxes and stem section
7.2.1.1 Prior to making any cut(s) in way of main deck, the contractor shall
submit a sketch to the Port Engineer and the local ABS surveyor which
shows the location and size of proposed cut(s) and the relationship of
the proposed cut(s) to adjacent structural members and weld seams.
ABS approval shall be obtained prior to making the cut(s).
7.2.1.2 Temporarily furnish and install a weather tight covering on main deck in
way of the accesses using " plywood, bordered by lumber and sealed
with either quick cement or silicon sealant. Rope off the areas using
temporary stanchions.
7.2.2 Furnish and install approx. 16 each pad-eyes rated for 15,000 pounds in various
locations in the main motor room, as called out by the Wartsila Service Engineer
in order to lift the upper gear box to re-seal the flange. All pad-eyes are to be
weight tested in the presence of the USMMI Port Engineer or his designee and a
placard installed documenting same. Upon completion of all repairs, crop and
remove pad-eyes welded on the outside hull.
7.3 Mechanical:
7.3.1 Sequence of Events for Thruster Overhaul
7.3.1.1 Temporarily remove upper gear box (UGB)
7.3.1.2 Temporarily remove propeller, drive shaft and seal box.
7.3.1.3 Temporarily remove the port lower gear box (LGB) and shank
7.3.1.4 Temporarily remove the stem/steering section
7.3.1.5 Return each item in the reverse order as listed.
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7.3.2 Intermediate Shaft Removal and Reassembly.
7.3.2.1 Temporarily disassemble and remove the floating shaft

assembly between the propulsion motors and the horizontal
input shaft to the upper gear box.
7.3.2.2 The WARTSILA Service Engineer and Port Engineer shall

inspect the shaft section and its seals. All spline teeth and
components shall be cleaned and inspected. Measurements
shall be recorded per the requirements of Wartsila service
engineer.
7.3.2.3 Upon reassembly of the z-drives, reinstall and grease

the floating shafts as required by the service engineer.
7.3.3 Preparation for inspections of Z-drives
7.3.3.1 Drain all hydraulic oil from the steering system and
dispose of in accordance with all local environmental laws.
Drain reservoir tanks and thoroughly clean using lint free rags.
Clean inlet strainers using dry, compressed air. Renew all in-line
filters.
7.3.3.2 Inspection of the Z-drive steering pump couplings is

covered by another item elsewhere in this specification.
7.3.3.3 Drain all gear oil from the upper, lower gear boxes, and
stem section, and dispose of IAW all local environmental laws.
Oil containers capable of holding at least 800 gallons shall be
required on dry-dock floor in order to drain all gear oil from
EACH thruster. Thoroughly clean surge tanks using lint free rags.
Clean inlet strainers using dry, compressed air. Renew all in-line
filters.
7.3.8 Furnish the necessary slings and chain falls (minimum 16 chain-falls) rated for
15,000 pounds in order to handle the port upper gearbox.
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7.3.9 Erect staging or furnish lifts/JLG to access the propellers and lower gear boxes.
7.3.10 Fabricate mounting flanges to support the lower gearboxes during removal and
reinstallation as called out by the Wartsila Service Engineer and approved by the
USMMI Port Engineer.
7.3.10.1 Minimum 1 thick plate.
7.3.10.2 Pad-eyes shall be rated for 10,000 # each lifting/holding

capacity.
7.3.11 Temporarily provide and install wood planks and other non-slip devices
throughout the main motor room and on top of the removable deck grating.
7.3.12 Upper Gearbox Service
7.3.12.1 Under the direction of the service engineer, perform a gear

tooth contact examination on both leading & trailing edge with
Prussian blue or high-spot red.
7.3.12.2 Allow the Port Engineer and ABS Surveyor to inspect.
7.3.12.3 Take and record the upper gearbox backlash. Provide readings
in Condition Reports to the Port Engineer.
7.3.12.3 Temporarily disconnect the upper gearboxes and lift up

approximately six inches to re-seal the flange between the upper
gear boxes and the stem sections.
7.3.12.4 Perform a non-destructive test of the gear sets and allow for
inspection by the Port Engineer and the ABS surveyor.
7.3.12.5 Upon completion of testing, remount the input flanges and

convey back to ship.
7.3.12.6 Reinstall the port upper gearboxes on the thruster stem sections
and torque down in accordance with the manufacturer
requirements.
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7.3.12.7 Reassemble all piping and electrical connections.
7.3.12.8 Reinstall the overhead in accordance with ABS requirements.
7.3.12.9 Return all fixtures and lagging to their original locations and
paint all new and disturbed areas.
7.3.13 Hydraulic Motor Replacement
7.3.13.1 Disconnect and remove eight (8) azimuth motors from their
foundations.
7.3.13.2 Inspect drive and training gears for wear/ defects. Allow for Port
Engineer and ABS surveyor to inspect.
7.3.13.3 Install Operator furnished spare motors and couplings
7.3.13.4 Box up for transport the original 8 hydraulic motors in wooden

crates, with each motor secured in place.
7.3.13.5 USMMI shall arrange transport of these hydraulic motors

through the Ships Agent.
7.5.13.6 The Ships Supply Officer shall furnish a Government Form

(DD1149) to document removal and shipment to manufacturer
for rebuild.
7.3.14 Upper Gear Box Coil Spring Washers and Bushing Replacement
7.3.14.1 Temporarily disconnect and remove the 16 each coil spring

washer assemblies.
7.3.13.2 Replace the springs, washers, bushings and locknuts as required

using Ship furnished spares.
7.3.13.4 Reassemble the coil springs and reinstall in accordance with

reference. 2.1.1.
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7.3.15 Lower Gearbox Inspections
7.3.15.1 Drain the lower gearbox and stem section of oil. Disconnect the
lower gearbox/ shank and convey to the machine shop.
7.3.15.2 Unbolt the upper shank flange face from the thruster can stem
section. The contractor shall lower the shank, gearbox and drive
shaft as one unit to the dry-dock floor and convey to shop or
another suitable storage area. The entire gearbox shall be
covered with plastic to prevent contaminants from entering the
gearbox.
* Vendor must have 24/7 access to surface grinder (18 x 30) minimum size
7.3.15.3 Prior to commencing the shank installation verify that the shank
is mounted correctly to the lower gearbox (rotation check).
7.3.15.4 Transport port lower gearbox and shank to workshop.
7.3.15.4.1 Remove and clean shank as stated in 7.7.2.1.
7.3.15.4.2 Fit shank and torque to Government Furnished

spare lower gearbox.
7.3.15.4.3 Remove old lower gearbox from lifting plate and

mount new lower gear box with shank to lifting
plate.
7.3.15.4.4 Provide covers and protection to shaft and shank

while stems are overhauled.
7.3.15.4.5 When stems have been installed; transport

lower Gearbox / shank to vessel and install.
7.3.15.4.6 After mounting is complete perform a Prussian

blue tooth contact check and record
measurement.
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7.3.15.4.7 Perform a non-destructive inspection of the

gear sets in the presence of the ABS Surveyor.
7.3.15.4.8 Once the propeller is remounted, perform a

final pressure test in the presence of the ABS
Surveyor and Port Engineer.
7.3.16 Overhaul of Stem Sections
7.3.16.1 After upper gearboxes and port lower gearbox are removed and
the stems are drained:
7.3.16.2 Mark stems locations for alignment.
7.3.16.3 Dismount stems as complete unit. Open mounting bolts.
7.3.16.4 Provide four 5 ton and one 10 ton chain blocks unit.
7.3.16.5 Attach 5 ton chain blocks to the four lifting points on table top
each side.
7.3.16.6 After stems are unbolted attach one 5 ton chain fall to the 10 ton
chain fall creating a single point lift for each side.
7.3.16.7 Heat mounting flanges with 2 large rosebuds while lifting.
7.3.16.8 Expect stems to jump when free.
7.3.16.9 Lift stems and transport to shop.
7.3.16.10 Dismantle and rebuild under direction of technician

representative with GFM.
7.3.16.11 During the reassembling the stem sections, the liner fittings are
to be completed in accordance with work instruction
TCSP0000003. Once the interference fits are accomplished
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where it is heated to 80 degrees C they must be allowed to cool

to ambient temperature before Locktite 290 is applied.
7.3.16.12 Before installation the stem sections are to be air tested and
once the air test are found to be satisfactory the stem sections
are to be filled with new oil and then checked again for any signs
of leakage.
7.3.16.13 Installation is reverse.
7.3.17 Blue fit propellers
7.3.17.1 Provide for propellers to be mounted with Prussian blue on

propeller shafts.
7.3.17.2 Remove high spots with 400/600 grit paper in proper hub.
7.3.17.3 Clean and re-blue shafts, mount properly and recheck. Continue
until 70% or better contact is achieved.
7.3.17.4 American Bureau of Shipping must witness hub blue fit and
propeller drive up.
7.3.17.5 After American Bureau Shipping approval, take a depth

measurement of hub face to shaft dimension and fab plate to
measured thickness and bolt pattern American Bureau of
Shipping must verify and stamp this distance plate with his cross
and thickness. Re: Lips Tech Manual (3.7.1)
7.3.18 Optical Alignment of Stern Thrusters
7.3.18.1 Upon completion of the inspections the z-drives, floating shaft

and main propulsion motors shall be laser aligned.
7.3.18.2 Provide labor and standard alignment equipment/material such

as dowel pins, rods, hydraulic packs and shim stock to properly
align these thrusters to the main propulsion motors.
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7.3.18.3 The stern thruster upper gear boxes shall not be moved to
achieve alignment. All changes shall be in way of the main
motor feet.
7.3.18.4 The contractor shall employ the services of an alignment and

vibration specialist knowledgeable in vibracon chocks to
accomplish this work.
7.3.18.5 The contractor shall accomplish a vibration analysis under

various load conditions.
7.3.18.6 Furnish a service report to the Port Engineer and ABS surveyor
listing conditions found and alignment modifications
accomplished to meet manufacturers recommended
clearances.
7.3.19 Replace Propeller Seals
7.3.19.1 Remove propellers and transport to shop.
7.3.19.2 Polish propellers to Rupert B standard.
7.3.19.3 Replace the propeller seals using GFM under the direction of the
service engineer.
7.4 Electrical
7.4.1 Temporarily disconnect the Motor Room overhead lighting to allow removal of
the overhead in way of the two upper gear boxes.
7.4.2 Reconnect all overhead lighting once all thruster work is completed and the
overhead cutouts have been reinstalled.
7.4.3 Temporarily disconnect all of the electrical cabling to allow UGB units to be
removed for overhaul.
7.5 Electronics: None additional
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7.6 Preparation of Drawings/Documentations:
7.6.1 Reports - Furnish five sets of detailed service reports of all work accomplished.
The reports shall include:
A. Inspections results and readings
B. Replacement parts installed identified by item name, part number and

location
C. Photographs of all non-destructive tests inspections and results. The

report shall identify each item and results
D. Operational tests accomplished and applicable readings
E. Signed copies of all inspections called out in this specification with ABS,
Port Engineer, Wartsila Service Engineer and Shipyard signatures.
7.6.2 The report shall be itemized for each thruster serviced.
7.6.3 Scrap and salvage
7.6.3.1 All used parts shall be removed from the ship and scrapped.
7.6.3.2 Furnish a scrap and salvage report to the Port Engineer

listing all repair parts turned in for scrap. A credit amount shall
be issued, less transportation and labor, for the amount
received.
7.7 Tests/Inspections:
7.7.1 Close-Out, Dock Trial and Sea Trial Testing
7.7.1.1 Upon completion of all repairs, parts renewals, and reassembly

of units or components, replenish all hydraulic and gear oil
systems, grease all applicable areas, and prepare for testing of
stern thrusters.
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7.7.1.2 Check system for external leaks while in dry-dock. Check for
internal leaks in the Motor Room after all work is completed.
Repair as required.
7.7.1.3 When the ship is waterborne and clear of dry-dock,

operationally test each thruster in accordance with reference
2.1. Tests shall be accomplished at all control stations.
7.7.1.4 Check for any abnormal noises
7.8 Painting:
7.8.1 After completion of all thruster work the thrusters and disturbed areas of the
hull and Motor Room overhead are to be painted using the Underway Hull
Painting guidance in specification 0902 and GTR 7.
7.9 Markings: None additional
7.10 Manufacturers Representative: None additional
8.0 General requirements: None
Enclosure 2.2.1
2 STEM OVERHAUL KITS EA TAGS 1940-017

2 BEARING, DBL ROW SPHERICAL ROLLER W006210920
2 FITTED SLEEVE T002051796
O RING W/ VULCANIZED JOINT, ID 990.00X7.00 NBR 70
2 SHORE W007000360
2 CORD RING W/ VULCANIZED JOINT W007000355
2 O RING W007054300
2 O RING W007000356
2 RING, CORD W007000348
2 RING, CORD W007001422
2 V RING M730030050
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2 O RING W007001295
2 RING, CORD W007001438
4 O RING W007050001
10 HEXAGON NUT M20 LD.0016 ST.KL.8 M714040039
10 OIL SEAL T002010288
20 BOLT 8.8 M20 X 40 M713000582
SCREW, HEX M16X40 1.4401 X5CRNIMO17 12 2 DIN 933 A4-
32 80 W007100386
36 BOLT, M14 X 45 W007100408
36 SCREW M712045346
40 NUT, HEX, M24 LD.0016 ST.KL.8 M714040041
40 WASHER, SQUARE M716100041
46 FITTED SLEEVE T002051308
48 NUT, HEXAGON M36 M714040050
48 SCREW, HEX SOCKET HEAD CAP M712045447
48 STUD 1.25 M36X110 ST KL 8.8 DIN 939 M711050591
72 NUT, HEX W007210054
72 STUD 1.25 M14X80 ST KL 8.8 DIN 939 W007265029
120 BOLT, HEXAGON M24 X 110 W007110152
2 PLUG, HEX HEAD SCREW M710380243
2 THRUSTER, O'RING VULC JOINT W007001398
4 SCREW, HEX HEAD M713000370
8 BEARING, CYLINDER ROLLER W006220027
10 STUD M20 2.5 90MM M711050439
8 DOWEL SPRING M718500379
40 STUD 1.25L M24X70 ST KL 8.8 DIN 939 M711050487
56 HSHCS, M16 X 35 FULL THREAD LD.0010 ST.KL.12.9 DIN 912 M712040381
2 LINER T002051221
10 SPRING WASHER, SINGLE COIL M716100039
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4 SEALING RING, COPPER W007385035

2 O RING W007031007
52 STUD M20X110 DIN 939 8.8 W007260032
62 HEXAGON NUT M20 LD.0016 ST.KL.8 M714040039
62 SPRING WASHER, SINGLE COIL M716100039
2 LINER, UPPER STEM EA T003001374
2 PROPELLER INSTALLATION / OVERHAUL KIT EA TAGS 1940-012

2 O RING EA W007000909
2 RING, CORD W/VULCANIZED JOINT 1017990#9 EA W007000575
16 HEX BOLT, M24 X 80 EA M713005638
16 HEXAGON HEAD SCREW EA W007100391
16 WASHER, PLAIN EA M716000436
24 HEXAGON HEAD SCREW, M20 X 50 1.4401 X5CRNIMO17 12 2 EA W007100387
24 WASHER, PLAIN 21/37X3 EA W007375026
6 PLUG, PROPELLER HUB EA W006564007
6 COPPER SEALING RING EA M731000290
2 GLAND EA T001016055
2 SEAL WIPER KIT EA PAAI033228
2 O-RING EA W007001259
2 O-RING EA W007001218
2 SEAMLESS ORING SEAL EA W007031011
2 O-RING EA W007030700
24 HEX. SOCKET HEAD CAP SCREW EA W007281058

24 HEX. HEAD SCREW EA M713001580
2 RETAINING RING EA M716600039
2 SHANK OVERHAUL KIT EA TAGS 1940-016

44 BOLT, SHOULDER T001016091
60 SCREW, STUD M36-4.0X120MM 431 SSHHCS W007265034
2 O'RING SEAMLESS W007000249
4 O'RING DIA 44X3.0MM NBR 90 SHORE W007035092
60 NUT, HEX W007210132
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7 LOCKING WIRE MT W007550008
2 UPPER GEAR BOX O/H KIT EA TAGS 1940-013

2 BEARING, DBL ROW SPHERICAL ROLLER W006200201
2 BEARING, CYLINDER ROLLER W006220030
2 BEARING, SPHERICAL ROLLER THRUST W006260033
2 BEARING, DBL SPHERICAL ROLLER W006210001
2 BUSH, DISTANCE T001019950
2 BUSH, DISTANCE T001019857
2 CORD RING, W/VULCANIZED JOINT W007000647
2 DISTANCE BUSH T001019853
2 KEY T001010581
2 O RING W007001069
2 O RING W007000977
2 O RING W007001062
2 O RING W007000653
2 O RING, SEAMLESS W084813333
2 O RING W/VULCANIZED JOINT W007001423
2 O'RING W007000641
2 OIL SEAL, TAGS T001010605
2 RING, ADJUSTING T003001361
2 RING, ADJUSTING T001019851
2 RING, ADJUSTING (SET) T003001360
2 SCREW W007355084
4 O RING W007035270
4 O'RING W007001277
4 OIL SEAL W007065070
4 COPPER SEALING RING M731000261
6 CUP SPRING, DISC T001067975
8 BOT, HEX M713005489
10 SEALING RING, COPPER M731000302
12 NUT, HEX M714040036
20 RING, COPPER SEALING FOR PLUGS M731000290
20 SEALING RING, COPPER M731000340
48 SCREW, HEX SOCKET CAP M712045389
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50 NUT, HEX, M24 LD.0016 ST.KL.8 M714040041

76 WASHER, SPRING SINGLE COIL ID 12.2/21.1X2.5 1.1248 CK75 M716100033
68 BOLT, HEX HEAD M12X30 M713000480
36 SCREW, HEX M713000532
96 WASHER, SPRING SINGLE COIL M716100036
2 RACE BALL T001019941
2 LINER T001019942
2 RING T003001372
2 PIN, HARDENED CYL T001017984
8 THRUSTER O SPRING T001003859
2 ROLLER BEARING, SPHERICAL W006210906
2 BEARING, SHPERICAL ROLLER THRUST W006200174
2 RETAINING RING FOR SHAFT M718700420
2 RETAINING RING FOR SHAFT M718700422
12 BOLT, M16 X 45 M712040383
2 O RING W007050001
40 STUD 1.25L M24X70 ST KL 8.8 DIN 939 M711050487
40 NUT, HEX, M24 LD.0016 ST.KL.8 M714040041
2 O RING W007001004
2 O RING W007000712
4 O RING W007035511
48 NUT, HEX LOCKING + NYLON RING W007255507
4 RING, DUO T973004178
16 O RING M730000144
96 SQUARE WASHER M716100031
96 SCREW, HEX HEAD M713000431
40 STUD SCREW M711050488
6 COUNTERSUNK SCREW W/ HEX SOCKET M712060431
6 HEX SOCKET COUNTERSUNK HD CAP EA M712060431
40 STUD, SCREW EA M711050488
16 SPLIT PIN EA M71770382
32 HEXAGON NUT EA W007210124
32 WASHER EA T003001702
28 CUP SRING EA W004020008
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8
96 HEXAGON SCREW EA M713000431
96 SINGLE COIL SPRING WASHER EA M716100031
16 O-RING EA M730000144
1 BOW THRUSTER PROP SHAFT OH KIT EA TAGS 1940-010

1 SEAL RING MK2 190 FR AFT KIT KT SRRMK2190FRAFT
1 SHEET PACKING MK2 190 AFT SET EA SSHPKMK2190AFT
6 PLUG (G 1/8 SUS304 WIRE) EA PLGHG18SUS304W
4 SUS WIRE M WIRE1.0SUS304
8 HEXAGON SCREW EA W007100521
8 HEX HEAD BOLT EA W007100547
8 HEAD SCREW EA M712046288
8 WASHER, SPRING EA M716200031
6 COPPER SEALING RING EA M731000200
1 O RING EA W005905862
1 BOW THRUSTER PROP INSPECTION KIT EA TAGS 1940-019

1 O RING EA W007000627
8 HEXAGON BOLT EA M713005587
3 PLUG, HEX SOCKET PIPE EA W006575029
1 SEALING RING, COPPER EA W007385035
1 BOW THRUSTER NOZZLE INSPECTION KIT EA TAGS 1940-020

1 O RING EA W007001205
1 SEAL, BONDED EA W006580044
2 DUBO RING EA M716600036
3 LOCKING WIRE M W007550008
4 BOLT, HEX EA W007110141
4 DUBO RING EA M716600036
8 HEXAGON SCREW EA W007100411
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T-AGS 65


Revision X
10 HEXAGON HEAD SCREW, M20 X 50 1.4401 X5CRNIMO17 12 2 EA W007100387

1 PLUG, SCREW, HEXAGONAL HEAD EA W006552115
6 SCREW, HEX EA M713001480
1 SEALING RING, COPPER EA W007385035
1 O'RING EA W007001022
Enclosure 2.2.2
Below: Removal of Port LGB and Shank Note Pad eye requirements and the plate fabricated to facilitate
removal
VR16-0094 0907- 19
USNS MARY SEARS
T-AGS 65


Revision X
Below: Contractor Fabricated Plate to Remove and Reinstall the Port LGB and Shank Sections
VR16-0094 0907- 20
USNS MARY SEARS
T-AGS 65


Revision X
VR16-0094 0907- 21

0907 - A - Support Thruster 5 Year Overhauls

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0907 - A - Support Thruster 5 Year Overhauls

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USNS MARY SEARS

Solic. No.: MLL-16-T65-0001

ITEM NO. 0907 CP2 CATEGORY A USMMI/MLL/RCS

SUPPORT THRUSTER 5 YEAR OVERHAULS

2.1.1 Technical Manual No. T-AGS60CL034 Titled: Thruster, Stern FS2510-463 Is on

2.2.1 List of Government Furnished Spares (separate file)

3.0 Item Location/Description:

3.1 Location: Various

3.2 Description: Z-Drive Thrusters

4.0 USMMI Furnished Equipment/Material/Services:

4.2 USMMI Furnished materials:

Solic. No.: MLL-16-T65-0001

ITEM NO. 0907 CP2 CATEGORY A USMMI/MLL/RCS

SUPPORT THRUSTER 5 YEAR OVERHAULS

4.2.2 1000 Gallons of Shell Tellus T46 Hydraulic Oil.

4.2.3. Stern UGB Inspection Kit WLP001321-000

4.2.4 Stern Stem Overhaul Kit WLP001473-005

4.2.5 Stern Propeller Install Kit WLP001473-007

4.2.6 One (1) each Port LGB

4.2.7 Eight (8) each hydraulic motors & couplings

4.2.8 All items including the above in enclosure 2.2.1

5.3 Weights of Items to Be Worked:

A. UGB: T003001371 2600 kg = 5700# each

B. LGB: T003001660 7600 kg = 16,700# each

C. Stem: T003001393 7400 kg = 16,300# each

D. Propeller: 4000 kg = 8800# each

E. Gear Oil: 3500l = 900G = 6700# each

F. Hydraulic Oil: 800l = 200G = 1500# each

Solic. No.: MLL-16-T65-0001

ITEM NO. 0907 CP2 CATEGORY A USMMI/MLL/RCS

SUPPORT THRUSTER 5 YEAR OVERHAULS

TOTAL Weight of each Thruster, all inclusive: 55,700# each

6.0 Quality Assurance Requirements:

7.0 Statement of Work:

7.1.2 This work shall commence immediately after docking.

Solic. No.: MLL-16-T65-0001

ITEM NO. 0907 CP2 CATEGORY A USMMI/MLL/RCS

SUPPORT THRUSTER 5 YEAR OVERHAULS

7.3.1 Sequence of Events for Thruster Overhaul

7.3.1.1 Temporarily remove upper gear box (UGB)

7.3.1.2 Temporarily remove propeller, drive shaft and seal box.

7.3.1.4 Temporarily remove the stem/steering section

7.3.1.5 Return each item in the reverse order as listed.

Solic. No.: MLL-16-T65-0001

ITEM NO. 0907 CP2 CATEGORY A USMMI/MLL/RCS

SUPPORT THRUSTER 5 YEAR OVERHAULS

7.3.2 Intermediate Shaft Removal and Reassembly.

7.3.2.1 Temporarily disassemble and remove the floating shaft

7.3.2.2 The WARTSILA Service Engineer and Port Engineer shall

7.3.2.3 Upon reassembly of the z-drives, reinstall and grease

7.3.3 Preparation for inspections of Z-drives

7.3.3.2 Inspection of the Z-drive steering pump couplings is

Solic. No.: MLL-16-T65-0001

ITEM NO. 0907 CP2 CATEGORY A USMMI/MLL/RCS

SUPPORT THRUSTER 5 YEAR OVERHAULS

7.3.10.1 Minimum 1 thick plate.

7.3.10.2 Pad-eyes shall be rated for 10,000 # each lifting/holding

7.3.12 Upper Gearbox Service

7.3.12.1 Under the direction of the service engineer, perform a gear

7.3.12.2 Allow the Port Engineer and ABS Surveyor to inspect.

7.3.12.3 Temporarily disconnect the upper gearboxes and lift up

7.3.12.5 Upon completion of testing, remount the input flanges and