Tuck San’s Reefer Workshop

Featuring

I cannot recall the particulars of this case as it

occurred over 1 year ago already. Definitely salt water

entering gang box either through bad or missing gasket

or a warped frame.

Break it down

The circuit breaker lugs were all frozen

So the wires had to be cut

Remove retaining ring from its groove with a flat

screwdriver

Spring compression retaining ring for interlock release

Pull down on on/off plunger to remove spring,

interlock mechanism and plunger

Remove the 4 screws securing breaker handle

actuator unit, top plate and breaker to frame. Lift off

breaker with actuator unit and ground pin.

Observe alignment with circuit breaker handle as it is

removed. Be careful not to disturb cam positioning

inside actuator. The plastic housing can separate.

Remove brass receptacle housing

And remove receptacle from brass housing

Stainless steel and brass clean up nicely. The brass is a

little more work but is necessary for the new receptacle

to slide into the bore. Wire brush and medium grain

crocus cloth work well. Some brass housings have a

groove at base end for a retaining ring which needs to

be scraped and brushed clean.

Once brass housings are polished clean a thick coating

of LPS 3 left to dry overnight will keep the creeping

corrosion at bay.

Reassemble The top 1/3 at flange end of the brass housing internal

bore needs to be super clean for an easy fitting of new

receptacle so only apply a light coat of LPS 3 if any here.

Below the receptacle resting ledge a thick layer will be

good.

Dow Corning 111 valve lubricant and sealant works

well on internal bore as well as Molykote 55 o-ring

grease around receptacle o-ring. This will extend the life

of your module and reduce your maintenance load.

To prepare the receptacle wires for a quick and

smooth installation into the circuit breaker lugs they

must be shaped for a compressible helical spiral. The

wires are thick stranded gauge so a 3/8 closed end

wrench can be slipped over for bending leverage.

Do not try to cut the wires to length because

the circuit breaker lugs are not in direct

alignment with receptacle.

Install receptacle into brass housing aligning tab at

base of receptacle with notch in brass housing flange.

This prevents rotation of receptacle within housing.

After shaping the wires, the ends will need to be

trimmed flat or the contact surface between wire and

lug will be reduced. Poor contact area will result in

overheating and reduced life of circuit breaker and

receptacle.

Reassemble circuit breaker actuator to circuit

breaker.

With circuit breaker switch in off position align circuit

breaker switch handle with actuator mechanism.

Install circuit breaker and secure to frame with the 4

screws.

Lightly lubricate receptacle mating gasket with 111

and place over housing flange.

While guiding actuator ground plunger into bore of

receptacle ground pin insert wires into circuit breaker

lugs being careful not to bend any wire strands.

Tighten lugs. Bend the B phase wire to the side to

allow free movement of ground pin plunger.

Tighten the 4 receptacle housing screws evenly until

gasket touches frame plus ¼ turn or so being careful not

to squeeze out the gasket.

With circuit breaker and receptacle secured, bench test

for smooth operation.

To reassemble on/off plunger first place interlock

release mechanism in position on its actuator.

The sliding cam actuated block mounted on circuit

breaker is aligned with plunger in interlock release

mechanism.

With o-ring and shaft greased, insert on/off plunger

through faceplate and interlock release.

The cam actuated release plunger will interact with

deep groove in on/off plunger shaft.

Place spring into position into guides above interlock

release

Push on/off plunger up through interlock release, spring

and guides until groove for retaining ring is visible

above interlock release mechanism.

And insert ring between release mechanism and spring

The module is now complete and is ready for testing

in same manner as shown in 480V version with ohm

and meggar meter test equipment before installation

for use.