WATERTIGHT CLOSURE MAINTENANCE TECHNICIAN TRAINEE …

WATERTIGHT CLOSURE MAINTENANCE TECHNICIAN TRAINEE GUIDE V-702-4405

PROCESS 125.08 Sheet 1 of 21

FOR TRAINING USE ONLY

INFORMATION SHEET 125.08-2

QUICK-ACTING WATERTIGHT DOORS (QAWTD)

A. INTRODUCTION

There are many types of structural closures used on Navy Ships. As Maintenance or Repair

Activity personnel, you will be required to know the function and description of the Quick-

acting Watertight / Airtight Doors.

B. REFERENCE

1. NAVSEA S9086-UF-STM-010, NSTM 600, Volume 1, Structural Closures

C. INFORMATION

1. Introduction.

a. Quick-acting watertight doors (QAWTDs) are installed in high traffic areas where an

individually dogged fitting would be impractical. Due to being installed in high traffic

areas, these doors often see more use, and as a result, receive more wear and tear than

other structural closures. This lesson provides trainees with a working knowledge of

how to effectively inspect, maintain, and repair QAWTDs.

2. Safety precautions.

a. The Navy’s Quick-acting watertight doors and their associated equipment and

components constitute potential safety and health hazards.

b. Technical documents for Navy watertight closure gaskets contain safety sections.

c. All personnel operating, maintaining, or cleaning equipment must be thoroughly

familiar with the safety procedures that govern their respective areas. It is each

person’s responsibility to know, fully understand, and adhere to these precautions to

prevent damage to equipment, personal injury or death.

d. Specific warnings, cautions and notes regarding the system and equipment appear

throughout the technical manuals following paragraph headings and immediately

preceding the text to which they apply.

1) Warning - Used to draw special attention to potential hazardous situations which

if not avoided could result in minor personal injury, serious injury, or death.

2) Caution - Used to draw special attention to anything that could damage equipment

or cause the loss of data and includes what could happen if the caution is ignored.

3) Note - Used to highlight essential procedure(s) by visually distinguishing it from

the rest of the text and can contain any type of information except safety

information.




3. Purpose of watertight closures.

a. Watertight closures provide a means of securing openings in decks and bulkheads that

ordinarily permit passage of personnel and equipment. Quick-acting doors allow ease

of access through bulkheads in locations where increased traffic would make an

individually dogged fitting impractical.

4. Types of Quick-acting doors.

a. Quick-acting doors are known by the number of dogs they have; they can be either 3,

6, 8, 10, or 12 dog doors, as shown in Figure 125.08-2.1.

Figure 125.08-2.1: Types of Quick-acting Doors

1) Doors with only three dogs on the non-hinge side are airtight only; six dogs or

above are watertight, as they provide uniform pressure all the way around the

fitting.

2) Historically, three dog QA airtight doors have proven to be extremely maintenance

intensive due to the extra alignments that must be done on the hinge-side of the

door and are gradually being phased out.

b. Quick-acting doors are constructed of either steel or aluminum and are either water

tight or airtight.

c. Quick-acting doors are fitted with a single operating handle and dog linkages to allow

opening and closing of all dogs in one motion.




5. Components.

a. Frame - Provides the structural integrity for the door to be attached, as shown in

Figure 125.08-2.2. It is welded to the ships bulkhead structure.

Figure 125.08-2.2: Quick-acting Door Components (1 of 4)

b. Connecting rods (conrods) and levers.

1) The Quick-acting door dogs are linked together by connecting rods and levers

operated by the operating handle. The levers are connected to the individual dogs

mounted around the doorframe, as shown in Figure 125.08-2.2.

2) These linkages are made of corrosion resistant steel (CRES) or stainless steel.

3) The conrods and levers are connected via studs and held in place with a brass

collar and stainless-steel cotter pin.

c. Handle holdback clip - Installed to hold the operating handle up to keep the dogs

from prematurely striking the door while opening and closing, as shown in Figure

125.08-2.2.

d. Gasket.




1) Made of flexible silicone rubber, the gasket is inserted into the door panel’s

gasket channel, as shown in Figure 125.08-2.3.


2) When installed correctly, the gasket is compressed against the knife-edge to

obtain the required watertight integrity.

3) MACHALT 444 replaces the older specification gasket MIL-R-900 with ZZ-R-

765. This newer gasket is easier to install using less force in the structural closure

to provide a uniform seal all the way around by bearing against the knife-edge.

4) The newer required gasket is more pliable and less likely to crack.




e. Knife edge.

1) The knife-edge is part of the doorframe and provides the edge where pressure is

applied against from the door panels channel rubber gasket, as shown in Figure

125.08-2.3.

2) The knife-edge combined with the pressure from the door gasket provides the

watertight seal needed for watertight or airtight integrity.

3) A knife-edge that is too high will damage the door gasket from excessive pressure

applied to the gasket.

4) A knife-edge that is too low will damage the door hinges resulting from the over

adjusting of the door to attempt the accomplishment of a watertight seal.

f. Dogs.

1) Dogs are installed on the door panel as shown in Figure 125.08-2.3 and apply

pressure to the door panel’s installed dog wedges.

2) Dogs are operated by the operating handle and door linkages. Applicable

MACHALTs are 444 and 526.

g. Wedges.

1) Dogging wedges are installed on the door to provide a gradually inclined surface

for the dogs to ride up on as the door is being dogged to compress the gasket

against the knife edge for a watertight or airtight seal, as shown in Figure 125.08-

2.4.

2) Wedges may be built into the door (welded) or they may be bolted or riveted on

from within the gasket channel.

3) Wedges may become worn down prematurely due to improper hinge alignment.





h. Hinges.

1) Hinges are installed on the watertight closure frame, as shown in Figure 125.08-

2.4.

2) They support the closure during opening and closing.

3) Regular operation of the closure causes wear and tear of the hinge components,

requiring periodic maintenance for optimal operating conditions.

4) MACHALTs 518 and 538 replaced many hinge components with less

maintenance-intensive versions.

i. Door panel.

1) Constructed of steel or aluminum.

2) Equipped with a hinge blade welded to the hinge side of the door for attachment

to the hinge assembly secured by a hinge pin assembly as shown in Figure

125.08-2.4.

3) Fitted with a channel on the knife-edge side for the gasket to be inserted into.

4) Door panels are impressed with indentations to give them the strength of a thicker

door without the added weight, as shown in Figure 125.08-2.4.




j. Operating handle.

1) This is the mechanism, along with the conrods and levers, that allows the user to

dog and undog multiple dogs at once, as shown in Figure 125.08-2.4.

2) Consists of an inside and outside handle connected through the door frame by a

spindle and various hardware.

3) The operating handle has a protrusion that assists in ensuring the door is closed

completely before the dogs engage the wedges, as shown in Figure 125.08-2.5.

This protrusion also allows firefighting and damage control personnel to crack the

door partially open while maintaining control of the door to check for fire or

flooding on the other side.


4) The door has a raised surface called a striker plate to protect the door itself from

the protrusion on the handle.

6. Locations.

a. The nature of the Quick-acting watertight doors location requires regular interval

inspection and maintenance.




b. Doors must be shut completely before dogging to avoid destruction / wear of door

edge and wedges, as shown in Figure 125.08-2.6.

Figure 125.08-2.6: Worn Dogging Wedge

c. Quick-acting watertight doors are used for routine passage and access / egress into the

superstructure placed in high traffic areas from such areas as:

1) Weather decks.

2) Main passageways.

3) Manned spaces.

4) Combat Information Center (CIC).

5) Radio Central.

6) Machinery Control or Damage Control Central (DCC).

d. The high traffic/high use nature of Quick-acting doors has necessitated promulgation

of several MACHALTs to improve their longevity. When performing preventive or




corrective maintenance on these doors, be sure to check for applicable MACHALTs

as listed on the applicable maintenance requirement cards (MRCs).

7. Inspections.

a. Naval Ship’s Technical Manual 600, Volume 1, contains detailed Quick-acting door

inspection criteria, including the following:

1) Examine the knife-edge and gasket.

2) Accomplish the chalk test.

3) Visual inspection of the door for missing, damaged, or nonstandard components.

4) Visually inspect hinges.

5) Ensure the door hold-open device is intact and workable.

6) Inspect the bottom of the door for rust, which would indicate poor cleaning and

priming of the coaming.

7) Inspect each dog assembly.

8) Verify there are no missing, loose, or worn dog wedges.

8. Periodic maintenance.

a. The Planned Maintenance System (PMS) provides guidance on the required

inspection, cleaning and lubrication maintenance for Quick-acting doors. The

applicable maintenance is organizational level and is found in the Maintenance Index

Page (MIP) 1671 series applicable to the class of ship that door is on.

b. MIP 1671 (series) covers the incorporation of MACHALT configurations for the

installed closures. Installed Quick-acting doors require the identification of the

installed MACHALT’s to ensure the highest level of required maintenance. For

specific procedures, refer to the applicable Maintenance Requirement Card (MRC)

for the Quick-acting door being worked on:

1) MIP 1671/002: PC-1 Class, Watertight Doors and Hatches.

2) MIP 1671/008: Multi-class, Watertight Doors/Airtight, Hatches, and Scuttles

Manually Operated.

3) MIP 1671/009: LCS 1 Sloped Deckhouse, Watertight/Airtight Doors, Hatches

and Scuttles (Quick Acting).

4) MIP 1671/050: INLS, Watertight/Airtight Doors, Hatches, and Scuttles.

c. Each of these MIPs outlines the frequency of accomplishment for the maintenance

requirements listed, but they also authorize more frequent performance if needed due

to harsh weather, operating conditions, corrective maintenance, or in support of

mission requirements.




9. Installation.

a. A watertight closure installation requires a fit-up of the doorframe to the bulkhead.

The frame is welded to the bulkhead.

b. The fit-up should be tight with no spaces between the frame and bulkhead.

c. “C” clamps are used to hold the frame in place where tack welds are placed every six

inches apart on both sides of the bulkhead.

d. During the welding of the frame to the bulkhead it is critical the welds are staggered

to prevent the frame from warping.

e. Warping will prevent the door from obtaining the required watertight and airtight

capabilities. The welding of the installation of the door will be performed by a

qualified welder.

f. As a maintenance person, you may be responsible for assisting during the installation

and final adjustments.

g. Installation of the door to the frame will be accomplished following applicable

Maintenance Requirement Cards (MRCs).

10. Tools and materials.

a. Routine maintenance performed on Quick-acting doors requires common hand tools

and lubricating oil. Applicable MRCs list the required tools and materials for specific

preventive maintenance procedures. Keeping the following commonly used items

available will reduce unnecessary time lost.

1) Rags: used for wiping areas of the doors components.

2) Chalk: used for performing the chalk test described earlier to test the

compression of the gasket.

3) Wood blocks: used to remove paint from gasket material and used in

adjustments.

4) Twine, fibrous: used to determine the door warpage and additional repairs.

5) Gage, thickness: used to determine if the doors knife-edge is acceptable.

6) Rule: Determines the straightness of the knife edge.

7) Magnet: Determines if ferrous or non-ferrous materials are used in the installed

door and attaches the twine to hold in place for the warpage test.

8) 320 Grit abrasive cloth: used in correcting minor deficiencies on the door.

9) Common hand tools: includes wrenches, screwdrivers, key sets, pliers used for

adjustments.

10) Lubricating oils: used for routine lubrication. When using required hazmat,

always follow required safety precautions and doctrines.




11. Pre-maintenance preparations.

a. Preparation of the maintenance location is as important to the maintenance and repair

as the operation of the door itself.

b. Specifying the closure is secured for maintenance notifies personnel of the degraded

travel route and will reduce the maintenance stoppages from unnecessary traffic.

c. Applicable MRCs direct the local manufacture and engraving of warning signs on red

and white plastic with the information shown on the MRC as shown in .

Figure 125.08-2.7: Warning Sign (Typical)

d. The areas of the closure will be roped off preventing access to the door on both sides

of access. The warning sign will be attached to the roped off areas to prevent access.




12. Corrosion inspection criteria.

a. Inspect for corrosion and rust on door panel, bulkhead frame, dog action, sleeves,

connecting rod linkages, and hinge assemblies as shown in .

Figure 125.08-2.8: Corrosion Examples

b. Where dog wedges are mechanically fastened, inspect area on door panel around

wedges for rust. Inspect area around label plates and verify absence of corrosion, rust

trails, bulging plates or white powdery residue (WSA coated doors only).

c. On weather deck doors with WSA coating, inspect door panel for blistered/flaking

paint caused by white powdery residue.

2. Corrosion resistant steel (CRES).

a. A magnet can be used to check proper hardware on weather deck doors; magnets are

not attracted to stainless steel.

b. Dogs, dog spindle nuts and operating handles should be CRES (non-magnetic).

c. As per the maintenance action, the maintenance person will check the entire door and

components with the magnet for CRES material for a satisfactory check.




d. If the check fails, additional action and repair will be required.

13. Greasing locations.

a. On doors not modified by MACHALTs, there are grease fittings known as “Zerk”

fittings for injecting grease with a grease gun.

b. The spindle of individual dogs must be greased inside the dog sleeve where they

penetrate the bulkhead as follows:

1) Inspect the dog spindle for worn dog spindle bushings and operating handle

spindle bushings.

2) Grasp each spindle and attempt to shake it up and down, and side to side. If

movement occurs, then bushings or sleeves indicate that they are worn.

3) When a dogging mechanism or hand lever is observed to refuse to turn, additional

actions require the dog assembly to be completely disassembled and cleaned.

4) The freezing of the operating mechanism is usually due to lack of use, paint, or

extreme environmental conditions. or some combination of these reasons.

Specific procedures for disassembly will be addressed later.

5) For doors equipped with Oilite bronze bushings, string, and string packing, after

cleaning the dog assembly:

a) Replace the string packing which is used to fill space between the coils of the

compression spring on the dog spindle. String packing is the same type of

material used in stick packing but is enclosed in a cotton thread jacket.

b) Lubricate the shafts by applying a light coat of silicone compound. Inspect

threads for damage. If found, chase thread with 7/8-9 UNC2A die nut.

Afterwards, remove all metal particles from spindle threads and shaft.

Lubricate dog lever conrod bushings (Oilite only) with a few drops of oil

(symbol 2190 TEP), as applicable.

6) Reassemble the dog assembly.

c. If MACHALT 526 is incorporated, there will be a spot on the dog for a zerk fitting to

be installed during maintenance to fill the dog sleeve around the spindle with grease,

as shown in Figure 125.08-2.9. This fitting must be removed and replaced with a

setscrew plug after greasing or it will interfere with the operation of the connecting

rods and levers.

WARNING

Prior to lubricating this type of dog assembly, ensure all dogs are adjusted for 1/8-inch gasket compression. If dogs are adjusted after lubrication, the grease will be forced out of the sleeve and onto the deck and other parts of the door. Protect deck area below with rags or drop cloth prior to lubrication.




Figure 125.08-2.9: MACHALT 526 Zerk Fitting Location




d. MACHALT 444 added a zerk fitting to the operating handle to allow greasing of the

operating handle spindle without disassembly, as shown in Figure 125.08-2.10.

Figure 125.08-2.10: MACHALT 444 Zerk Fitting Location

e. MACHALT 444 incorporated the use of self-lubricated bushings. On doors with

MACHALT 444, do not use grease for assembly; silicone compound may be used to

aid in assembly.

14. Hinge adjustments.

a. Doors without MACHALT 518 or 538 installed:

1) With a hammer and chisel, knock the hinge pin collars off the bottom of the hinge

pins.

2) Use a flat tipped drift punch to drive out the hinge pins. If the hinge pins are badly

worn, have another person pick up the door from the bottom and rock it back and

forth while the pins are driven out. The rocking action tends to pull the grooves

that are worn into the shank away from the other steel hinge parts, allowing easier

removal. Set the door panel aside, with the hinge side up.




3) Disassemble the adjusting pin and yoke of each hinge assembly. On Quick-acting

airtight doors, the adjusting yoke has a setscrew and hex nut fitted to the front

side. This yoke is used to push the hinge side of the door and gasket up against

the knife-edge, since there are no dogs on the hinge side of the airtight door for

this purpose.

4) Examine the hinge parts for excessive wear and clean the parts or procure

replacement parts as required. Brass hinge pins are recommended over stainless

steel, and if stainless steel hinge pins are found they should be replaced with brass

hinge pins to avoid undue wear to hinge yokes.

5) Reassemble the adjusting yokes and pins onto the door hinge blades. Be sure to

insert a 1/8-inch thick brass flat washer on top of the bottom adjusting yoke blade

before inserting the adjusting pin and cotter pin.

6) Set the door in the frame.

7) Place three 1/16-inch thick brass flat washers between the top of the hinge blade

and the lower adjusting yoke leaf. Insert the hinge pins.

8) Close and dog the door. Ensure the knife-edge sits in the center three-fifths of the

width of the door gasket at the top and bottom. There should be no contact

between the metal on the door gasket channel and the knife edge. If there is

metal-to-metal contact, shim the door up or down by adding or removing one

1/16-inch washer from each hinge.

9) To lock the hinge pin to the collar, have someone hold a sledge hammer over the

top of each hinge pin while the collar is inserted, bevel side down, over the boss

on the bottom of the hinge pin. Peen over the boss with the rounded end of a ball

peen hammer to lock the collar to the hinge pin. The weight of the sledge

hammer resting on top of the hinge pin keeps the pin from backing out as the boss

is peened over.

b. Doors with MACHALT 518 or 538 installed:

1) Remove cotter pins, spacer washers, hinge pins, and thrust washers. Set the door

panel aside with the hinge side up.

2) Remove cotter pins, yoke pins, hinge yoke, thrust washers, and hinge pin spacer

from each hinge assembly.

3) Clean the hinge parts and examine for excessive wear. Procure replacement parts

as required.

4) Apply a thin film of quick forming adhesive to the outside diameter surface of the

hinge pad bushings, ensuring no adhesive comes in contact with the inside

diameter.

5) Install hinge pad bushings into the upper and lower hinge pads and, if necessary,

gently tap into upper and lower hinge pads.

6) Temporarily install hinge pins while adhesive is forming in order to align hinge

pad bushings. Remove hinge pins after adhesive is formed.




7) Insert yoke pin spacer into the yoke pin hole in the hinge blade. Align cotter pin

holes of the yoke pin spacer with the cotter pin holes of the hinge blades. Position

hinge yoke assembly on hinge blade, and partially insert yoke pin with slotted end

up.

8) Install two thrust washers between the bottom of hinge blades and the hinge yoke

assemblies. Align thrust washers and fully insert yoke pins. Align cotter pin

holes in hinge blades, hinge yoke assemblies, and yoke pins, and install cotter

pins. Ensure hinge yoke assemblies rotate freely around the yoke pins.

9) Position door upright and resting on deck close to hinge pads. Partially rotate

hinge yokes away from hinge pinholes in hinge blades. Insert hinge pin spacers

in holes of hinge blades. Then, rotate hinge yoke assemblies back into position

over the hinge pinholes in the hinge blades, ensuring hinge pin spacers remain in

place and upright.

10) Lift door into position on the hinge pads, and insert hinge pins through the hinge

pads, hinge yokes, and spacer bushings. With one person supporting the door on

the handle side, pry upward on the underside of the hinge blades and lower hinge

pads with a long flat tipped screwdriver. Lift the hinge pins enough to insert two

thrust washers between the hinge yokes and the lower hinge pad bushings. Center

thrust washers, and fully insert hinge pins.

11) Install spacer washers and cotter pins into hinge pins.

12) Close and dog the door. Ensure the knife-edge sits in the center three-fifths of the

width of the door gasket at the top and bottom. There should be no contact

between the metal on the door gasket channel and the knife edge. If there is

metal-to-metal contact, shim the door up or down by adding or removing one

1/16-inch thrust washer from each hinge.

15. Disassembly procedures.

a. Damage to the structure or operability of a watertight door can result from warpage to

the bulkhead in which it is installed. Another factor that contributes to wear on a

watertight door is the weight of the whole door assembly as it swings on its hinges,

particularly in high traffic areas. In order to repair problems such as a warped door

frame or an inoperable Quick-acting dogging assembly, the door must be completely

disassembled. In some cases, removal of the door from its hinge assembly is

necessary to accomplish the repair.

b. When disassembling a watertight closure to accomplish repairs, inspect all wear parts,

such as bushings, and replace as required. If repairing a door to correct for warpage,

expect to replace all wear parts (and possibly non-wear parts) because of the

excessive strain warpage causes to the door assembly. To disassemble a watertight

door, accomplish the following:

1) Disassemble the entire operating handle, spindle, lever, and conrod assemblies.

Procedures on disassembling operating handles and lever / conrod assemblies. To

make reassembly easier, mark each linkage part and its location with a metal

etcher.




2) Flanged bushings on dog assemblies are held in place with Allen head setscrews.

Use an Allen wrench to loosen the setscrews. Gently tap out the flanged and

straight bushings from all spindle sleeves with a brass rod or pipe approximately

5/8 inch in diameter.

3) To inspect bushings for wear, insert on a clean spindle of the proper diameter and

move back and forth. Bushings should have a firm, uniform fit on the spindle,

with no play or wobbling. Replace any bushing that wobbles on the spindle.

4) To inspect springs for wear, compare with a new spring. Replace any spring that

is collapsed or broken, or that has individual coils, which are worn thin. New

springs are machined with the end coils thinner than those in the center. This is

not a sign of wear.

16. Component refurbishment.

a. Operating handle.

1) Work the operating handle back and forth to inspect for excessive tightness or

binding.

2) A handle which cannot be opened and closed with one hand may have dogs which

are out of adjustment or handle nuts which are too tight.

3) If the door handle must be raised in order to close the door, either the hinge pins

are worn, or the hinge pin bracket holes have become enlarged.

4) If a door will not operate from the inside, either the handle has fallen on the

opposite side or the handle is slipping on its spindle.

5) Slipping of the handle indicates excessive wear on the flats of the spindle where

they fit into the hole on the end of the handle.

6) Inspect the lineup of the outer and inner handles. If obstructing the free operation

of the door, the handles must be disassembled and repaired.

7) Operate door handle, inspect for binding in operating linkage.




8) Remove paint from wedges, dogs, spindle threads and nuts, bushings, packing

plungers, set screws, connecting rod studs and nuts, and contact surfaces of

connecting rod linkages as shown in Figure 125.08-2.11 using wire brush,

scraper, or aluminum oxide abrasive cloth, 320 grit. Do not repaint.

Figure 125.08-2.11: Paint on Unauthorized Surfaces / Components

b. Connecting rods and levers (conrods).

1) Visually ensure all brass conrod collars (round nuts) and cotter pins are in place.

2) With the door open, grasp each connecting rod (conrod) in turn with one hand.

Shake the linkage from side to side and note the amount of play.

3) If the linkage is loose or moves more than 1/8 inch, the linkage bushings are worn

and must be replaced.




4) Studs from the factory are swaged in place, as shown in Figure 125.08-2.12. Over

time, these studs may loosen or break completely away.

Figure 125.08-2.12: Conrod Studs

5) To inspect for loose studs, open the door and work the hand lever back and forth.

6) Inspect each stud, one at a time. Failure of even one stud will cause complete

failure of the entire door linkage.

c. Dog wedges.

1) Inspect each dog wedge for wear.

2) If the inspection of a dog wedges reveal that it is less than half its original

thickness of 5/16th inch on the flat portion of the wedge or if the leading edge of

the taper is 1/16th inch will require replacement.

3) Additionally, if deep grooves are carved into it, the wedge must be replaced.

4) When setting the door handle on an individually dogged door, the dog should

come to a stop approximately one-half of the distance across the surface of the

wedge.

5) The dog should never exceed the stop formed into the trailing end of the wedge.

If it does, either the dog is out of adjustment or the wedge is worn away and must

be replaced.

6) If the raised land (sometimes called the ″telltale″) on one side of the wedge is

worn, this could be an indication that the hinge pins are worn.

7) This condition results from the fact that as the hinge pins wear, the door tends to

shift or tilt away from the hinge side toward the lever side.




8) The dog lugs then tend to contact the raised land, wearing it away as the door is

opened and closed. Inspect each dog wedge for tight mounting to the door.

9) Grasp each wedge and try to rattle it back and forth. For riveted wedges, tighten

loose rivets with a ball peen hammer and backup bar or hammer.

10) For bolted and riveted wedges, the gasket must be removed to access the machine

screws or rivets for tightening or replacement.

WATERTIGHT CLOSURE MAINTENANCE TECHNICIAN TRAINEE …

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