TECHNICAL MANUAL OPERATION AND MAINTENANCE MANUAL WITH ILLUSTRATED PARTS BREAKDOWN ORGANIZATIONAL LEVEL FIREFIGHTER LADDER SAFETY SYSTEM (LSS)

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1 REVISION 3 TECHNICAL MANUAL OPERATION AND MAINTENANCE MANUAL WITH ILLUSTRATED PARTS BREAKDOWN ORGANIZATIONAL LEVEL FIREFIGHTER LADDER SAFETY SYSTEM (LSS) 0910-LP THIS PUBLICATION SUPERSEDES REVISION 2 OF NAVSEA S9623-AE-MMO-010, DATED 12 OCTOBER DISTRIBUTION STATEMENT A. APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED. PUBLISHED BY DIRECTION OF THE COMMANDER, NAVAL SEA SYSTEMS COMMAND 0910LP

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3 REVISION 3 TECHNICAL MANUAL OPERATION AND MAINTENANCE MANUAL WITH ILLUSTRATED PARTS BREAKDOWN ORGANIZATIONAL LEVEL FIREFIGHTER LADDER SAFETY SYSTEM (LSS) 0910-LP THIS PUBLICATION SUPERSEDES REVISION 2 OF NAVSEA S9623-AE-MMO-010, DATED 12 OCTOBER DISTRIBUTION STATEMENT A. APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED. PUBLISHED BY DIRECTION OF THE COMMANDER, NAVAL SEA SYSTEMS COMMAND 14 FEBRUARY 2005

4 LIST OF EFFECTIVE PAGES INSERT LATEST CHANGE PAGES. DESTROY SUPERSEDED PAGES. Date of issue for original pages is: Revision February 2005 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 60, CONSISTING OF THE FOLLOWING: Page No. * Change No. Page No. * Change No. Title A blank... 0 i - iii iv blank blank... 0 v vi blank blank... 0 vii - ix x blank A-1 - A * Zero in this column indicates an original page A Revision 3

5 RECORD OF CHANGES CHANGE NO. DATE TITLE OR BRIEF DESCRIPTION ENTERED BY Revision 3

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7 TABLE OF CONTENTS Section Page LIST OF EFFECTIVE PAGES...A TABLE OF CONTENTS...i LIST OF FIGURES... iii LIST OF TABLES... iii FOREWORD...v ABBREVIATIONS AND ACRONYMS...vii SAFETY SUMMARY...ix CHAPTER 1 INTRODUCTION AND SAFETY PRECAUTIONS INTRODUCTION Purpose Scope SYSTEM DESCRIPTION SPECIFICATIONS COMPLIANCE SAFETY PRECAUTIONS Standard Safety Precautions General Safety Instructions Special Precautions EQUIPMENT AND ACCESSORIES SUPPLIED REFERENCE PUBLICATIONS NOT SUPPLIED CHAPTER 2 OPERATION INTRODUCTION COMPONENTS UTILIZED DURING OPERATION OPERATING PROCEDURES Visual Inspection and Extension Assembly Installation Ladder Descent Ladder Ascent POST-OPERATING PROCEDURES Stowage CHAPTER 3 FUNCTIONAL DESCRIPTION INTRODUCTION FUNCTIONAL DESCRIPTION Carrier Rail Rung Clamp Assemblies Male Extension Extension Assembly Extension Lanyard Carrier Sleeve Waist Belt Revision 3 i

8 CHAPTER 4 SCHEDULED MAINTENANCE INTRODUCTION SCOPE SAFETY REQUIREMENTS MAINTENANCE CONCEPTS Scheduled Maintenance Unscheduled Maintenance PLANNED MAINTENANCE SYSTEM USN MAINTENANCE AND MATERIAL MANAGEMENT (3-M) SYSTEM COVERAGE AND PROBLEM REPORTING GENERAL MAINTENANCE INSTRUCTIONS Parts Replacement General Cleaning Procedure Lubricants Inspection Pre-operational Inspection Post-operational Inspection CHAPTER 5 TROUBLESHOOTING INTRODUCTION GENERAL TROUBLESHOOTING INSTRUCTIONS CHAPTER 6 CORRECTIVE MAINTENANCE INTRODUCTION Scope Safety Requirements ADJUSTMENTS AND ALIGNMENTS GENERAL MAINTENANCE INFORMATION TEST EQUIPMENT AND TOOLS MATERIALS CORRECTIVE MAINTENANCE Carrier Rail with Offset Rung Clamp Assemblies Removal and Installation Carrier Rail with Regular or Square Rung Clamp Assemblies Removal and Installation CHAPTER 7 ILLUSTRATED PARTS BREAKDOWN INTRODUCTION PARTS LISTS AND ILLUSTRATIONS LIST OF MANUFACTURERS APPENDIX A OPERATIONAL CHECKLIST...A-1 ii Revision 3

9 LIST OF FIGURES Figure Page 1-1 Firefighter Ladder Safety System Carrier Rail, Carrier Sleeve, and Waist Belt Carrier Rail with Extension Assembly Inspect Carrier Sleeve, Carrier Rail, and Waist Belt Extension Assembly with Keeper Pin Proper Carrier Sleeve Orientation Carrier Rail and Extension Assembly Equipment Carrier Sleeve Waist Belt Firefighter Ladder Safety System with Offset Rung Clamp Assemblies Remove Splice Install Splice Firefighter Ladder Safety System with Regular Rung Clamp Assemblies Firefighter Ladder Safety System with Square Rung Clamp Assemblies Remove Splice Install Splice Firefighter Ladder Safety System Parts (Sheet 1 of 2) LIST OF TABLES Table Page 1-1 LSS Portable Equipment Specifications Equipment and Accessories Supplied Reference Publications Not Supplied Components Utilized During Operation LSS Planned Maintenance Troubleshooting Guidelines Materials Required Firefighter Ladder Safety System Parts List Revision 3 iii/(iv blank)

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11 FOREWORD This technical manual contains procedures for operation and maintenance of the Firefighter Ladder Safety System (LSS). The information in this manual is presented in seven chapters and one appendix, as follows: Chapter 1 - Introduction and Safety Precautions Chapter 2 - Operation Chapter 3 - Functional Description Chapter 4 - Scheduled Maintenance Chapter 5 - Troubleshooting Chapter 6 - Corrective Maintenance Chapter 7 - Illustrated Parts Breakdown Appendix A - Operational Checklist Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of Naval Sea Systems Command (NAVSEA) technical manuals. Should the need arise, the In-Service Engineering Agent (ISEA) may be contacted at Commanding Officer, Naval Surface Warfare Center Panama City, Attn: Code E53, 110 Vernon Avenue, Panama City, FL All errors, omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be forwarded to: Naval System Data Support Activity (NSDSA), Code 310, Port Hueneme Division, Naval Surface Warfare Center. Technical Manual Deficiency/Evaluation Report (TMDER) (formerly Form NAVSEA 4160/1) can now be accessed, completed, and transmitted electronically to NSDSA. To access this form from the Internet, enter: At the Home Page, click on the TMDER icon. Complete the form and transmit as directed. All comments shall be thoroughly investigated and originators will be advised of action resulting from those comments. Revision 3 v/(vi blank)

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13 ABBREVIATIONS AND ACRONYMS A ANSI ASSE American National Standards Institute American Society of Safety Engineers C CAGE CFR COSAL COTS Commercial and Government Entity Code of Federal Regulations Coordinated Shipboard Allowance List Commercial Off-The-Shelf D DC Damage Control F FEDLOG FFE Federal Logistics Record Fire Fighting Ensemble I IPB ISEA Illustrated Parts Breakdown In-Service Engineering Agent L LSS Ladder Safety System MDS Maintenance Data System MIP Maintenance Index Page 3-M Maintenance and Material Management MRC Maintenance Requirement Card M N NAVOSH NAVSEA NSDSA Navy Occupational Safety and Health Naval Sea Systems Command Naval System Data Support Activity O OPNAVINST OSHA Office of the Chief of Naval Operations Instruction Occupational Safety and Health Administration P PMS Planned Maintenance System Revision 3 vii

14 ABBREVIATIONS AND ACRONYMS (Continued) S SPMIG Standard PMS Materials Identification Guide T TMDER Technical Manual Deficiency/Evaluation Report U USN United States Navy viii Revision 3

15 SAFETY SUMMARY 1. GENERAL SAFETY NOTICES. The following general safety notices supplement specific warnings and cautions appearing in this manual. All general safety notices and specific warnings and cautions must be understood and applied during all Firefighter Ladder Safety System (LSS) operation and maintenance functions. Should situations arise that are not covered in the general or specific safety precautions, the commanding officer, or other authority, will issue orders as deemed necessary to cover the specific situation. In addition, refer to Office of the Chief of Naval Operations Instruction (OPNAVINST) , Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, Vol I/II/III or OPNAVINST , Navy Occupational Safety and Health (NAVOSH) Program Manual for any situation not covered in the general or specific safety precautions. 2. S, CAUTIONS, AND NOTES. The warnings, cautions, and notes appearing throughout this technical manual must be followed to prevent hazards to personnel and damage to equipment. The following notations define warnings, cautions, and notes as they are used in the text of this manual: Warnings highlight an essential operating or maintenance procedure, practice, condition, or statement, which, if not strictly observed, may result in injury to, or death of, personnel. CAUTION Cautions refer to an operating or maintenance procedure, practice, condition, or statement, which, if not strictly observed, may result in damage to, or destruction of, equipment, or loss of mission effectiveness. NOTE Notes refer to an operating or maintenance procedure, practice, condition, or statement that is essential, but not of a known hazardous nature. Revision 3 ix/(x blank)

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17 CHAPTER 1 INTRODUCTION AND SAFETY PRECAUTIONS 1.1 INTRODUCTION Purpose. This manual contains technical information necessary to install, operate, troubleshoot, and maintain the Firefighter Ladder Safety System (LSS) (Figure 1-1). Reference to additional publications is given if auxiliary manuals exist or if lengthy procedures are required. Figure 1-1. Firefighter Ladder Safety System Scope. Information in this manual is presented in seven chapters and one appendix as follows: Chapter 1, Introduction and Safety Precautions, presents a system description and specifications; introduces safety precautions; provides reference data and publications; provides lists of equipment, accessories, and documents supplied; provides equipment acceptance and initial installation procedures; and storage requirements. Chapter 2, Operation, provides a description of the equipment utilized during operation and operating procedures. Chapter 3, Functional Description, provides a detailed description of the function for each major component of the LSS. Chapter 4, Scheduled Maintenance, provides information required to perform scheduled and general maintenance procedures. Chapter 5, Troubleshooting, provides a table to isolate equipment malfunctions and will direct the user to related maintenance procedures. Chapter 6, Corrective Maintenance, provides procedures required to perform corrective maintenance. Revision 3 1-1

18 Chapter 7, Illustrated Parts Breakdown, provides an Illustrated Parts Breakdown (IPB) for major components of the LSS. Appendix A, Operational Checklist, provides reproducible copy of checklist for operating, postoperating, and stowage procedures. 1.2 SYSTEM DESCRIPTION. The LSS provides fall protection for firefighters while climbing or descending escape trunk ladders during vertical entry firefighting or during training exercises. The system consists of commercial off-the-shelf (COTS) equipment. The fixed components consist of a bolt-on alteration installed on existing ladder rungs in the main and auxiliary machinery space escape trunks. The portable components may be stowed in a stowage case close to the escape trunk area. 1.3 SPECIFICATIONS. The LSS portable equipment specifications are provided in Table 1-1. Table 1-1. LSS Portable Equipment Specifications. Equipment Sleeve, Carrier Belt, Waist Case, Stowage Specification Weight: 2.8 lbs Material: Machined aluminum Designed Working Load: 350 lbs (individual use) Stopping Distance: less than one inch Static Load Testing: 1,000 lbs Width: 3 inches Material: Nylon Web Sizes: S, M, L, and XL Maximum Storage Capacity: o 8 carrier sleeves o 12 waist belts 1-4. COMPLIANCE. The LSS complies with the following standards: Naval Ships Technical Manual, Surface Ship Firefighting, NAVSEA S9086-S3-STM-010, Rev. 11, 01 October 2004, Chapter 555V1, paragraph Occupational Safety and Health Administration (OSHA) 29 Code of Federal Regulations (CFR), Part , Fixed Ladder, and Part , Ladders American National Standards Institute (ANSI) A , American National Standard for Ladders - Fixed - Safety Requirements ANSI/American Society of Safety Engineers (ASSE) A , American National Standard for Construction and Demolition Operations - Requirements for Safety Belts, Harnesses, Lanyards, and Lifelines for Construction and Demolition Use 1-2 Revision 3

19 1.5 SAFETY PRECAUTIONS. While using the LSS, personnel shall comply with the safety precautions and instructions listed in paragraphs and Safety precautions must be understood and followed by all personnel during operation and maintenance procedures Standard Safety Precautions. The LSS shall be used only after personnel have been properly instructed in its use. Use of the LSS equipment shall be in accordance with (IAW) posted instructions, labels, and limitations. Personnel must be thoroughly familiar with all safety practices and understand the potential hazards associated with the use and maintenance of the LSS equipment General Safety Instructions. Standard operational and maintenance safety precautions contained in the following documents apply to the LSS: Forces afloat must comply with OPNAVINST , Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, Vol I/II/III Shore activities must comply with OPNAVINST , Navy Occupational Safety and Health (NAVOSH) Program Manual Special Precautions. The warnings, cautions, and notes appearing throughout this technical manual must be followed to prevent hazards to personnel and damage to equipment. 1.6 EQUIPMENT AND ACCESSORIES SUPPLIED. Table 1-2 provides a listing of the equipment and accessories supplied with each LSS. Table 1-2. Equipment and Accessories Supplied. Item LSS Components: o Carrier Sleeve 1 o Waist Belt 1 o Carrier Rail 1, 2 o Extension Assembly 1 Planned Maintenance System (PMS) for Firefighter Ladder Safety System (LSS) Reference Number 2000-DEVN , -3, -4, SR316N 9200-SLERE316N MIP 6641/023 1 Quantity is ship-class dependent 2 Fixed component not installed by O-level personnel Revision 3 1-3

20 1.7 REFERENCE PUBLICATIONS NOT SUPPLIED. Table 1-3 lists reference publications that are not supplied with each LSS. Table 1-3. Reference Publications Not Supplied. Publication Title Publication Number Application NAVSEA Damage Control News Damage control/firefighting information Navy Occupational Safety and Health (NAVOSH) Program Manual Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, Vol I/II/III Ships Maintenance and Material Management (3-M) Manual Naval Ships Technical Manual, Surface Ship Firefighting OPNAVINST OPNAVINST OPNAVINST (Series) NAVSEA S9086-STM-010, Rev. 11, 01 October 2004, Chapter 555V1, paragraph Operation and maintenance safety Operation and maintenance safety Failure analysis reporting United States Navy (USN) firefighting doctrine 1-4 Revision 3

21 CHAPTER 2 OPERATION 2.1 INTRODUCTION. This chapter contains the following information: A description and illustration of the Firefighter Ladder Safety System (LSS) equipment utilized during operation. Operating Procedures providing visual inspection and extension assembly installation, LSS descent, LSS ascent, and post-operating instructions. The checklist for these procedures is in Appendix A, Operational Checklist. Proper short-term stowage procedures. 2.2 COMPONENTS UTILIZED DURING OPERATION. The LSS components utilized during operation are described in Table 2-1 and illustrated in Figures 2-1, 2-2, and 2-4. The following information is provided for each item illustrated: Figure No. - figure number to reference for an illustration of item Nomenclature - item name Function - brief description of function of item Normal Operating Condition - position of item during operational use Table 2-1. Components Utilized During Operation. Figure No. Nomenclature Function Normal Operating Condition 2-1, 2-2 Carrier Sleeve Slides along the carrier rail during ladder descent and ascent. Prevents free-fall to bottom of escape trunk should user slip during ladder descent or ascent. Functions as the braking system for the LSS. On carrier rail 2-1 Waist Belt Attaches user to the carrier sleeve. Worn around the waist 2-1 Snap Hook Secures carrier sleeve to waist belt. Bottom of carrier sleeve 2-1 Carrier Rail Provides track for carrier sleeve. Installed on ladder rungs 2-2 Extension Assembly Allows access to the LSS through hatch or scuttle opening. Installed (if applicable) Revision 3 2-1

22 Table 2-1. Components Utilized During Operation (Continued). Figure No. Nomenclature Function Normal Operating Condition 2-2 Extension Lanyard Prevents extension assembly from falling to the bottom of the escape trunk if dropped during removal or installation procedures. 2-4, Item 4 Keeper Pin Secures extension assembly in place during ladder descent and ascent. 2-2 Male Extension Top offset on uppermost section of carrier rail below Damage Control (DC) deck level in escape trunks with a watertight hatch at the DC deck level. During operational use, the male extension provides an attachment point for the extension assembly. Attached to ladder rung Installed (if applicable) Installed (if applicable) CARRIER RAIL CARRIER SLEEVE SNAP HOOK WAIST BELT Figure 2-1. Carrier Rail, Carrier Sleeve, and Waist Belt. 2-2 Revision 3

23 EXTENSION LANYARD EXTENSION ASSEMBLY CARRIER RAIL MALE EXTENSION 2.3 OPERATING PROCEDURES. Figure 2-2. Carrier Rail with Extension Assembly. Paragraphs 2.3 and 2.4 address operating procedures providing visual inspection, LSS descent, LSS ascent, and post-operating procedures. Appendix A, Operational Checklist, provides corresponding checklist to be copied and used as needed. Post-operating and stowage procedures are addressed in paragraphs 2.4 and Visual Inspection and Extension Assembly Installation. A quick-check visual inspection is necessary prior to operation. The Operational Checklist (Table A-1) should be completed. a. Remove carrier sleeve (1, Figure 2-3) from stowage case and inspect for deformed sliding surfaces and broken or missing rollers. b. Ensure carrier sleeve D-ring and snap hook (3) are not deformed. c. Ensure snap hook gate (2) is operable. Revision 3 2-3

24 Figure 2-3. Inspect Carrier Sleeve, Carrier Rail, and Waist Belt. d. Remove waist belt (5) from stowage case and inspect for deformed D-rings, a broken or inoperable buckle, and frayed or damaged webbing. Extra care should be taken to avoid falling through the hatch when inspecting the carrier rail. Failure to observe this warning may result in injury or death to personnel. NOTE Uppermost portion of carrier rail on escape trunks with a hatch is referred to as the male extension. e. Ensure section of carrier rail (4) closest to escape trunk entrance is not bent or deformed. f. If escape trunk has a hatch at the Damage Control (DC) deck level continue with extension assembly installation. Otherwise, proceed to paragraph Revision 3

25 Extra care should be taken to avoid falling through hatch when inspecting, removing, or installing keeper pin. Failure to observe this warning may result in injury or death to personnel. g. Ensure keeper pin (4, Figure 2-4) is not broken or missing. Figure 2-4. Extension Assembly with Keeper Pin. Extension lanyard must remain attached to a ladder rung above the hatch at all times. Failure to observe this warning may result in injury or death to personnel. h. Inspect extension lanyard (2) for fraying or slippage at swaged ends (1) while attached to a ladder rung above the hatch. i. Carefully pull extension assembly away from ladder rung to release spring clamp (3) while ensuring extension lanyard remains in place. j. Pull extension assembly up and away from ladder rung to remove hook from ladder rung. k. Slide female end of extension assembly over male extension. Revision 3 2-5

26 Extra care should be taken to avoid falling through hatch while inspecting, removing, or installing keeper pin. Failure to observe this warning may result in injury or death to personnel. l. Align a hole in the female extension assembly with a hole in the male end of the male extension, and insert keeper pin Ladder Descent. Only waist belts with side D-rings may be used with the LSS. Failure to observe this warning may result in injury or death to personnel. a. Don waist belt over Fire Fighting Ensemble (FFE) coveralls; adjust waist belt for snug fit. To operate properly, carrier sleeve must be attached with snap hook at bottom of carrier sleeve and green label must be visible. Failure to observe this warning may result in injury or death to personnel. b. Hold carrier sleeve in hand with snap hook at bottom of carrier sleeve as shown in Figure 2-5. UP CARRIER SLEEVE SNAP HOOK GATE CARRIER RAIL SNAP HOOK Figure 2-5. Proper Carrier Sleeve Orientation. 2-6 Revision 3

27 c. Open snap hook gate and secure carrier sleeve to a D-ring on waist belt. Ensure proper closure of snap hook gate. d. Verify proper orientation of carrier sleeve as illustrated in Figure 2-5. Check for proper fit of waist belt and closure of waist belt buckle and snap hook. e. Enter escape trunk and stand adjacent to carrier rail (or extension assembly, if applicable). f. Attach carrier sleeve to carrier rail (or extension assembly, if applicable). Maintain adequate separation, of approximately 5 feet, from other firefighters to avoid collision during descent. Failure to observe this warning may result in injury or death to personnel. g. Descend escape trunk ladder while maintaining tension on carrier sleeve by leaning slightly away from carrier rail. If carrier sleeve catches on carrier rail, grasp and slide carrier sleeve down carrier rail several inches to disengage and continue descent. h. Upon reaching bottom of escape trunk, disengage from carrier rail using one of the following methods: Waist belts must be removed and left in the escape trunk. Failure to observe this warning may result in injury or death to personnel. NOTE Carrier sleeves and waist belts will stack on lower portion of carrier rail. (1) With carrier sleeve and waist belt still attached to carrier rail, remove waist belt. (2) Remove carrier sleeve from carrier rail and remove waist belt. Temporarily stow carrier sleeve with waist belt attached, inside escape trunk. i. Exit escape trunk and proceed to fire space Ladder Ascent. a. Locate carrier sleeve and waist belt to be used for ascent. Don waist belt over FFE coveralls; adjust waist belt for a snug fit. b. Verify proper orientation of carrier sleeve. Ensure proper closure of waist belt buckle and snap hook to waist belt D-ring. Revision 3 2-7

28 Maintain adequate separation, of approximately 5 feet, from other firefighters to avoid collision during ascent. Failure to observe this warning may result in injury or death to personnel. c. Ascend escape trunk ladder while maintaining tension on carrier sleeve by leaning slightly away from carrier rail. If carrier sleeve catches on carrier rail, grasp and slide carrier sleeve up carrier rail several inches to disengage and continue ascent. d. Ascend through escape trunk scuttle or hatch. e. Remove carrier sleeve from carrier rail or extension assembly. Step away from ladder and remove waist belt. 2.4 POST-OPERATING PROCEDURES. a. If escape trunk has a hatch at the DC deck level continue with extension assembly disassembly. Otherwise, proceed to paragraph Extra care should be taken to avoid falling through hatch when inserting or removing the keeper pin. Failure to observe this warning may result in injury or death to personnel. Ensure extension lanyard remains attached to a ladder rung above the hatch at all times. Failure to observe this warning may result in damage to equipment and injury or death to personnel. b. Remove keeper pin from bottom of extension assembly, and remove extension assembly from male extension without removing extension lanyard. c. Return extension assembly to stowage area above hatch by placing extension assembly hook over appropriate climbing rung. d. Slide extension assembly and extension lanyard to one end or corner of escape trunk ladder and press extension assembly spring clip onto appropriate ladder rung Stowage. a. Ensure waist belts and carrier sleeves are in good repair, clean and thoroughly dry, then place in stowage case. b. Store stowage case IAW ship policy. 2-8 Revision 3

29 CHAPTER 3 FUNCTIONAL DESCRIPTION 3.1 INTRODUCTION. This chapter provides a description of the major components of the Firefighter Ladder Safety System (LSS). The descriptions are intended to provide personnel with a basic understanding of how each component achieves the desired purpose. 3.2 FUNCTIONAL DESCRIPTION. The LSS provides fall protection for firefighters while ascending or descending escape trunk ladders during vertical entry firefighting or during training exercises. The LSS may be safely used by multiple firefighters simultaneously as long as adequate separation is maintained to avoid interference. The system consists of commercial off-the-shelf (COTS) equipment. The fixed components consist of a bolt-on alteration installed on existing ladder rungs in the main and auxiliary machinery space escape trunks. The portable components may be stowed in a stowage case close to the escape trunk area Carrier Rail. To allow maximum clearance for the firefighter, the carrier rail (Figure 3-1) is bolted along one side of the escape trunk ladder, or near the corner of ladders with L-shaped rungs and provides fall protection should a user slip during ladder descent or ascent. Individual carrier rail sections are held together with splices and are attached to ladder rungs with rung clamp assemblies. EXTENSION LANYARD EXTENSION ASSEMBLY CARRIER RAIL MALE EXTENSION Figure 3-1. Carrier Rail and Extension Assembly Equipment. Revision 3 3-1

30 Rung Clamp Assemblies. Rung clamp assemblies attach the carrier rail to the ladder rungs and come in two variations: regular rung clamp assemblies and square rung clamp assemblies. Offsets of 1.5 inches or 4.0 inches are installed in escape trunks having projections that the carrier rail and carrier sleeve must not interfere with during ladder descent or ascent Male Extension. For escape trunks with hatches at the Damage Control (DC) deck level, the top offset on the uppermost section of the carrier rail below the hatch is the male extension (Figure 3-1). The extension assembly is installed over the male extension and allows firefighters easy access to the LSS above and below the hatch during ladder descent and ascent Extension Assembly. The extension assembly (Figure 3-1) is installed in escape trunks that have a watertight hatch at the DC deck level. The extension assembly is stowed above the hatch, is easily removed without tools, and is installed on top of the male extension during operation. The keeper pin is attached with a lanyard to the extension assembly to ensure the keeper pin does not fall to the bottom of the escape trunk if dropped during removal or installation Extension Lanyard. The extension lanyard (Figure 3-1) is a wire rope that must always be attached to a ladder rung above the hatch and to the extension assembly at all times. This is necessary to ensure the extension assembly does not fall to the bottom of the escape trunk if dropped during removal or installation Carrier Sleeve. The carrier sleeve (Figure 3-2) is equipped with a snap hook that is secured through the D-ring of the waist belt. The carrier sleeve will grip the carrier rail to prevent a fall to the bottom of the escape trunk in the event a user slips during ladder descent or ascent. To ensure proper function, the carrier sleeve must be installed with the snap hook at the bottom of the carrier sleeve. UP CARRIER SLEEVE SNAP HOOK GATE CARRIER RAIL SNAP HOOK Figure 3-2. Carrier Sleeve. 3-2 Revision 3

31 3.2.3 Waist Belt. The waist belt (Figure 3-3) has a tongue and buckle closure and two D-rings that are on each side of the waist when worn. The waist belt is worn on the outside of the Fire Fighting Ensemble (FFE) coveralls and can be attached to the carrier sleeve on either D-ring of the waist belt. Care must be taken not to expose the waist belt to heat or flames which will weaken and damage the material. Figure 3-3. Waist Belt. Revision 3 3-3/(3-4 blank)

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33 CHAPTER 4 SCHEDULED MAINTENANCE 4.1 INTRODUCTION. Omission or negligent performance of prescribed maintenance procedures for this equipment may result in equipment failure and serious injury or death to personnel. Proper scheduling and performance of preventive maintenance actions reduces equipment failures and ensures sufficient performance of the Firefighter Ladder Safety System (LSS). This chapter outlines safety requirements, defines the maintenance concept, references the LSS Planned Maintenance System (PMS), discusses reporting requirements, and provides general maintenance instructions relating to both scheduled and unscheduled (corrective) maintenance actions. 4.2 SCOPE. The preventive maintenance requirements for the LSS are addressed in this chapter to assist supervisors and maintenance personnel in planning, scheduling, and documenting maintenance actions. The information in this chapter supplements the LSS PMS (paragraph 4.5) and is presented in the following sequence: Safety Requirements Maintenance Concepts PMS United States Navy (USN) Maintenance and Material Management (3-M) System Coverage and Problem Reporting General Maintenance Instructions 4.3 SAFETY REQUIREMENTS. Maintenance personnel shall read and thoroughly understand the safety precautions contained in this manual and the Maintenance Requirement Card (MRC) contained in the LSS PMS before performing any maintenance on the LSS. Forces afloat should also comply with the Office of Naval Operations Instruction (OPNAVINST) , Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, Vol I/II/III. Shore activities should comply with OPNAVINST , Navy Occupational Safety and Health (NAVOSH) Program Manual. 4.4 MAINTENANCE CONCEPTS. The LSS maintenance concept is based on the USN PMS, which classifies maintenance into two categories - scheduled and unscheduled. Revision 3 4-1

34 4.4.1 Scheduled Maintenance. Scheduled maintenance primarily involves actions required to ensure reliable system operation and includes such actions as inspection, cleaning, lubrication, and operational testing. Scheduled maintenance requirements are provided in the LSS PMS (see paragraph 4.5) Unscheduled Maintenance. Unscheduled (corrective) maintenance includes actions required to locate equipment faults and to correct failures or performance degradations. Unscheduled maintenance is covered in Chapter 5, Troubleshooting, and in Chapter 6, Corrective Maintenance. 4.5 PLANNED MAINTENANCE SYSTEM. Table 4-1 lists the MRCs that govern the LSS PMS. The MRCs are indexed and referenced on MIP 6641/023, Firefighter Ladder Safety System (LSS). MIP 6641/023 provides a summary of the maintenance actions found on the MRC, periodicity codes, personnel requirements, man-hours, and related maintenance. Table 4-1. LSS Planned Maintenance. Periodicity A-1R A-2R A-3R A-4R Maintenance Requirement Card Description Clean and inspect carrier sleeve Inspect waist belts Clean and inspect carrier rail Clean and inspect extension assembly 4.6 USN MAINTENANCE AND MATERIAL MANAGEMENT (3-M) SYSTEM COVERAGE AND PROBLEM REPORTING. The provisions of the OPNAVINST series, Ships Maintenance and Material Management (3-M) Manual, apply to the LSS. Accordingly, any problems or need for corrective maintenance arising from performance of the maintenance actions contained in the LSS MRC should be properly reported using OPNAV Form 4790/2K to ensure timely and accurate Maintenance Data System (MDS) documentation of LSS performance in the Fleet. In addition to Fleet requirements, MDS input from Fleet units is used by the In-Service Engineering Agent (ISEA) to identify and correct problems within the system itself or the related documentation and provisioning, including Coordinated Shipboard Allowance List (COSAL) support. The ISEA can be contacted at Commanding Officer, Naval Surface Warfare Center Panama City, Attn: Code E53, 110 Vernon Avenue, Panama City, FL Revision 3

35 4.7 GENERAL MAINTENANCE INSTRUCTIONS. If in doubt about the serviceability of a part, replace it immediately. Worn or damaged parts shall be replaced with authorized replacement parts only. Component failure during operations may result in serious injury or death to personnel Parts Replacement. If any component fails inspection, replace the worn or damaged part with authorized replacement parts only (see parts lists in Chapter 7, Illustrated Parts Breakdown). All the tools, parts, and materials used for maintenance are listed on the MRC General Cleaning Procedure. Clean is defined as free of all loose scale, rust, grit, filings, dirt, oil, grease, and other foreign substances when viewed by the unaided eye. Clean LSS Components IAW applicable MRCs Lubricants. There are no lubrication requirements for the LSS Inspection Pre-operational Inspection. Perform a visual inspection of LSS components before use as directed in Chapter 2, Operation Post-operational Inspection. Perform post-operational inspection procedures IAW applicable MRCs. Revision 3 4-3/(4-4 blank)

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37 CHAPTER 5 TROUBLESHOOTING 5.1 INTRODUCTION. This chapter contains the troubleshooting procedures and data necessary to assist personnel in locating the source of equipment malfunction or performance degradation in the Firefighter Ladder Safety System (LSS). 5.2 GENERAL TROUBLESHOOTING INSTRUCTIONS. Troubleshooting is based on locating potential faults in the equipment and taking timely corrective action. Table 5-1 does not list all of the malfunctions that may occur, or all the possible causes for the malfunction that may apply. If a malfunction is not listed or is not remedied by the suggested corrective action(s) notify the supervisor. References to additional maintenance procedures located elsewhere in this manual are included where applicable. Table 5-1. Troubleshooting Guidelines. Symptom Possible Cause(s) Corrective Action(s) Carrier sleeve slips during braking action. Carrier sleeve intermittently sticks when sliding up and down carrier rail. Carrier rail, splices, rung clamp assemblies, and attaching hardware are loose. a. Carrier sleeve is upside down. a. Ensure snap hook is on bottom of carrier sleeve as illustrated in Figure 2-5. b. Excessively worn gripping b. Remove carrier sleeve from service. plates. a. Carrier rail edges are burred. a. File carrier rail edges smooth. b. Cam action of carrier sleeve is tight. c. Carrier rail, splices, or rung clamp assemblies are worn or misaligned. d. Ladder, splices, or rung clamp assemblies are blocking carrier sleeve. e. Section(s) of carrier rail is buckled or damaged. b. Remove from service and install new carrier sleeve. c. Remove worn or misaligned component and install new component IAW paragraph 6.6. d. Ensure ladder, splices, rung clamp assemblies, and attaching hardware are installed correctly IAW paragraph 6.6. e. Remove damaged section(s) of carrier rail and install new carrier rail section(s) IAW paragraph 6.6. f. Build-up of dirt or corrosion. f. Clean IAW MRC A-1R. System is improperly installed or needs corrective maintenance actions performed. Ensure carrier rail, splices, rung clamp assemblies, and attaching hardware are installed properly IAW paragraph 6.6. Revision 3 5-1/(5-2 blank)

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39 CHAPTER 6 CORRECTIVE MAINTENANCE 6.1 INTRODUCTION. Omission or negligent performance of corrective maintenance procedures on this equipment may result in equipment failure and serious injury or death to personnel Scope. The corrective maintenance information presented in this chapter includes the actions and procedures required to restore the Firefighter Ladder Safety System (LSS) to a fully operable condition. The corrective maintenance procedures identify maintenance actions; provide safety precautions; list tools, parts, and materials; and present step-by-step instructions. The procedures included in this chapter are prescribed in the interest of safety and optimum service life of the LSS equipment. Equipment requiring corrective maintenance beyond the limits described in this document must be removed from service and replaced. The information in the remainder of this chapter is arranged in the following sequence: Adjustments and Alignments General Maintenance Information Test Equipment and Tools Materials General Maintenance Procedures LSS Corrective Maintenance Safety Requirements. Before performing corrective maintenance on the LSS, replacement procedures, along with the associated warnings and cautions, shall be read in full. 6.2 ADJUSTMENTS AND ALIGNMENTS. There are no adjustments or alignments required. Revision 3 6-1

40 6.3 GENERAL MAINTENANCE INFORMATION. If in doubt about the serviceability of a part, replace it immediately. Worn or damaged parts shall be replaced with authorized replacement parts only. Component failure during operations may result in serious injury or death to personnel. Only approved replacement parts listed in Chapter 7, Illustrated Parts Breakdown, shall be used on the LSS. 6.4 TEST EQUIPMENT AND TOOLS. No special test equipment is required for corrective maintenance on the LSS. The tools required to perform corrective maintenance procedures on the LSS are as follows: Bandsaw, portable Driver, socket, 9/16-inch File, flat, 12-inch bastard Wrench, open-end, 9/16-inch 6.5 MATERIALS. Table 6-1 lists the nomenclature and purpose for the materials necessary to perform corrective maintenance on the LSS. Table 6-1. Materials Required. Nomenclature Line, Nylon Marker, Permanent Purpose Haul carrier rail section out of escape trunk Mark ladder rung and carrier rail 6.6 CORRECTIVE MAINTENANCE. Before attempting corrective maintenance, visually identify the LSS configuration installed. The rung clamp assembly may be installed with regular or square rung clamps. The type and quantity of rung clamp assemblies used may vary depending upon the escape trunk configuration. The rung clamp assembly configuration will determine the corrective maintenance procedures to follow. Depending upon the number and position of carrier rail sections in need of corrective maintenance, splices may not need to be completely removed. 6-2 Revision 3

41 6.6.1 Carrier Rail with Offset Rung Clamp Assemblies Removal and Installation. When performing removal and installation procedures on the LSS, an OSHA-approved safety system shall be utilized. Failure to observe this warning may result in injury or death to personnel. a. Tools, Parts, Materials. (1) Driver, socket, 9/16-inch (2) File, flat, 12-inch bastard (3) Line, nylon (4) Wrench, open-end, 9/16-inch b. Removal. Ensure extension lanyard is attached to a ladder rung before removing extension assembly from escape trunk. Failure to observe this warning may result in injury or death to personnel. (1) If extension assembly requires corrective maintenance, remove from escape trunk as follows. Otherwise, proceed to step 2. (a) Pull extension assembly away from escape trunk ladder to release spring clamp. (b) Remove extension assembly hook from ladder rung. (c) With extension lanyard still attached, move extension assembly to deck area. (d) Remove extension lanyard from ladder rung, and move extension assembly a safe distance from escape trunk. CAUTION Remove only one carrier rail section with nylon line at a time. Failure to observe this warning may result in damage to equipment. (2) Secure top of carrier rail section (2, Figure 6-1) requiring corrective maintenance with nylon line. Secure other end of nylon line at Damage Control (DC) deck level and maintain slight tension in nylon line. Revision 3 6-3

42 DETAIL A SEE DETAIL B SEE DETAIL A SEE DETAIL B 10 2 DETAIL B 14 SEE DETAIL B SEE DETAIL B WITH HATCH WITHOUT HATCH Figure 6-1. Firefighter Ladder Safety System with Offset Rung Clamp Assemblies. 6-4 Revision 3

43 (3) Remove top splice (14, Figure 6-2) on carrier rail section as follows: NOTE Figure 6-1 illustrates location of splice (14). Top and bottom carrier rail sections in escape trunk only have one splice attached. Figure 6-2. Remove Splice. (a) Using 9/16-inch socket driver and 9/16-inch open-end wrench, loosen and remove elastic stop nuts (8) and washers (5) from splice (14). (b) Remove hex head bolts (16), washers (5), and splice bar (15). (4) If second splice is attached, repeat step 3 (a) and (b). (5) Working from bottom of carrier rail section, disassemble rung clamp assembly as follows: NOTE During LSS installation, extra washers may have been inserted between the rung clamp and 4-inch offset. (a) Using 9/16-inch socket driver and 9/16-inch open-end wrench, remove bottom nut (8, Figure 6-1, Detail B) and washer (5). Remove bolt (10) and washer (5). (b) Remove top nut (8) and washer(s) (5). Remove bolt (10), washer (5), 4-inch offset (17), and 1.5-inch offset (18) or male extension (19). (c) Mark ladder rung with permanent marker next to rung clamp assembly to be removed. (d) Remove rung clamp (7) from ladder rung. Revision 3 6-5

44 (6) Repeat steps 5 (a) - (d) until all rung clamp assemblies attached to secured carrier rail section have been removed. (7) Haul carrier rail section up to deck area. Move carrier rail section a safe distance away and remove nylon line. (8) Repeat steps 2-7 until all carrier rail sections in need of corrective maintenance have been safely removed. c. Installation. (1) If male extension was removed, insert bolt (10, Figure 6-1, Detail A) with washer (5) through top holes of carrier rail (2), male extension (19), and 4-inch offset (17). Otherwise, proceed to step 5. (2) Slide rung clamp (7) over the second ladder rung below the DC deck level. Insert bolt (10) through rung clamp (7). CAUTION The threads on the nut (8) may become galled or stripped if the nut is installed at an angle. Ensure that the nut is not tightened to the point of galling. Galling is evident when a nut becomes locked on the bolt threads during the tightening process. Failure to observe this caution may result in loss of structural integrity. (3) Place washer (5) on bolt (10) and secure with nut (8). Using a 9/16-inch socket driver and a 9/16-inch open-end wrench, tighten nut (8) until sides of rung clamp (7) are parallel or slightly beyond parallel. Visually inspect nut to ensure threads are not galled or stripped. (4) Using the bottom holes of male extension (19) and 4-inch offset (17), repeat steps 1-3 on the next ladder rung downward to fully secure carrier rail (2) and male extension (19). CAUTION Ensure rung clamps assemblies are installed every three feet. Failure to observe this caution may result in loss of structural integrity. (5) Working from top of carrier rail section down, locate ladder rung with permanent marker marking and align carrier rail section for installation. (6) Insert bolt (10, Figure 6-1, Detail B) with washer (5) through corresponding hole of carrier rail (2) and top holes of 1.5-inch offset (18) and 4-inch offset (17). (7) Slide rung clamp (7) over ladder rung and insert bolt (10) through rung clamp. 6-6 Revision 3

45 CAUTION The threads on the nut (8) may become galled or stripped if the nut is installed at an angle. Ensure that the nut is not tightened to the point of galling. Galling is evident when a nut becomes locked on the bolt threads during the tightening process. Failure to observe this caution may result in loss of structural integrity. (8) Place washer (5) and nut (8) on bolt (10). Using 9/16-inch socket driver and 9/16-inch openend wrench, tighten nut (8) until sides of rung clamp (7) are parallel or slightly beyond parallel. Visually inspect nut to ensure threads are not galled or stripped. (9) Using bottom holes of 1.5-inch offset (18) and 4-inch offset (17), repeat steps 5-8 to fully secure carrier rail (2). (10) Install splices (14, Figure 6-3) to connect carrier rail sections, as follows: NOTE Figure 6-1 illustrates location of splice (14). Top and bottom carrier rail sections in escape trunk only have one splice attached. Figure 6-3. Install Splice. (a) With carrier rail sections touching end-to-end, place splice bar (15) behind carrier rail sections, matching four holes in splice bar to two holes in each carrier rail section. (b) Insert one hex head bolt (16) with washer (5) through splice bar (15) and carrier rail section. Revision 3 6-7

46 (c) Secure in place with washer (5) and elastic stop nut (8). Repeat for three remaining holes. (d) Using 9/16-inch socket driver and 9/16-inch open-end wrench, tighten connections until carrier rail sections are aligned. (11) If applicable, repeat steps 10 (a) - (d) to install second splice on carrier rail section. (12) Repeat steps 5-11 until all removed carrier rails have been installed. (13) If new carrier rail is being installed, terminate carrier rail 24 to 36 inches above lowest deck by cutting with a portable bandsaw, or an appropriate portable cutting tool, as needed. Otherwise, proceed to step 15. (14) Use 12-inch flat bastard file to smooth bottom edges of carrier rail. (15) Visually inspect newly installed and adjacent carrier rail sections from the top down, to ensure carrier rail sections are straight and not bowed. If corrective action is required, resolve as follows. Otherwise, proceed to step 16. (a) Using 9/16-inch socket driver and 9/16-inch open-end wrench, remove nut (8, Figure 6-1, Detail B) and washer (5). (b) Remove bolt (10) from rung clamp (7) but not from 4-inch offset. Insert one or more washers (5) until carrier rail is parallel to ladder rung. (c) Reinsert bolt (10) through rung clamp assembly (7). CAUTION The threads on the nut (8) may become galled or stripped if the nut is installed at an angle. Ensure that the nut is not tightened to the point of galling. Galling is evident when a nut becomes locked on the bolt threads during the tightening process. Failure to observe this caution may result in loss of structural integrity. (d) Place washer (5) and nut (8) on bolt (10). Using 9/16-inch socket driver and 9/16-inch open-end wrench, tighten nut (8) until sides of rung clamp (7) are parallel or slightly beyond parallel. Visually inspect nut (8) to ensure threads are not galled or stripped. (16) If escape trunk has a water-tight hatch at DC deck level, proceed as follows. Otherwise, proceed to step 17. (a) Attach extension lanyard to a ladder rung above the DC deck level that allows enough leeway for stowing and installation. (b) Slide female end of extension assembly over male extension (19). 6-8 Revision 3

47 Extra care should be taken to avoid falling through hatch while inserting or removing keeper pin. Failure to observe this warning may result in injury or death to personnel. (c) Insert keeper pin in appropriate hole. (17) Attach a carrier sleeve to carrier rail, ensuring that the carrier sleeve is oriented correctly (snap hook at bottom of carrier sleeve). (18) Ensure that carrier sleeve slides smoothly along entire length of carrier rail (extension assembly and carrier rail). Mark any problem areas with permanent marker. (19) Remove carrier sleeve. (20) File edges of any problem areas noted in step 18. (21) Repeat steps after filing the carrier rail section edges. Extra care should be taken to avoid falling through hatch when inserting or removing keeper pin. Failure to observe this warning may result in injury or death to personnel. Ensure extension assembly lanyard remains attached to a ladder rung above the hatch at all times. Failure to observe this warning may result in damage to equipment and injury or death to personnel. (22) If escape trunk has a water-tight hatch at DC deck level, stow extension assembly as follows: (a) Remove keeper pin from bottom of extension assembly and remove extension assembly from male extension. Do not remove lanyard. (b) Working at DC deck level, place extension assembly against ladder rungs to determine which ladder rung will allow sufficient height for stowage. Place hook at top end of extension assembly over ladder rung. (c) Slide extension assembly and lanyard to one end or corner of escape trunk ladder. Press extension assembly spring clip onto appropriate ladder rung. Revision 3 6-9

48 6.6.2 Carrier Rail with Regular or Square Rung Clamp Assemblies Removal and Installation. Corrective maintenance procedures for regular and square rung clamp assemblies are identical and utilize most of the same parts. When different parts are required during removal and installation procedures, the following format has been employed when introducing figures and callouts in the text: ( ) refers to regular rung clamp assemblies illustrated in Figure 6-4, and [ ] refers to square rung clamp assemblies illustrated in Figure 6-5. When performing removal and installation procedures on the LSS an OSHA-approved safety system shall be utilized. Failure to observe this warning may result in injury or death to personnel. a. Tools, Parts, Materials. (1) Driver, socket, 9/16-inch (2) File, flat, 12-inch bastard (3) Line, nylon (4) Wrench, open end 9/16-inch b. Removal. Ensure extension lanyard is attached to a ladder rung before removing extension assembly from escape trunk. Failure to observe this warning may result in injury or death to personnel. (1) If extension assembly requires corrective maintenance, remove from escape trunk as follows. Otherwise, proceed to step 2. (a) Pull extension assembly away from escape trunk ladder to release spring clamp. (b) Remove extension assembly hook from ladder rung. (c) With extension lanyard still attached, move extension assembly to deck area. (d) Remove extension lanyard from ladder rung, and move extension assembly a safe distance from escape trunk. CAUTION Remove only one carrier rail section with nylon line at a time. Failure to observe this caution may result in damage to equipment. (2) Secure top of carrier rail section (2, Figure 6-4 and 6-5) requiring corrective maintenance with nylon line. Secure other end of nylon line at DC deck level and maintain slight tension in nylon line Revision 3

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