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Tm-55-1925-204-12

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TM 55-1925-204-12 DEPARTMENT OF THE ARMY TECHNICAL MANUAL TECHNICAL MANUAL OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL TUG, HARBOR, DIESEL, STEEL, 1,200 HP, 100 FOOT DESIGN 3006, FLIGHT ONE FSN 1925-375-3003 This copy is a reprint which includes current pages from Changes 1 through 5. HEADQUARTERS, DEPA RTMENT OF THE ARMY FEBRUARY 1975 WARNING DANGEROUS CHEMICALS are used in this equipment. SERIOUS INJURY OR DEATH may result if personnel fail to observe these safety precautions. Avoid contact with the battery electrolyte. If the solution comes in contact with the skin, rinse the area immediately with clear water to avoid skin burns. Be sure all equipment and supplies are secure, especially during rough seas. WARNING FIRE OR EXPLOSION HAZARD SERIOUS INJURY OR DEATH may result if personnel fail to observe these safety precautions. Hatches must be open before energizing any electrical circuits or starting engines. Do not smoke or use an open flame in the vicinity when servicing batteries as hydrogen gas, an explosive is generated. Use only distilled water to maintain battery electrolyte level. When refueling tug, provide metallic contact between the fuel hose and fuel tank to prevent a static spark from igniting fuel. Wipe or flush any spillage. Volatile materials will not be brought aboard; electrical circuits will not be energized; fuel tanks will not be topped off; and engines will not be started before CO2 fire fighting equipment is available and operative. Observe NO SMOKING rules when refueling. Do not work on live circuits. Tag circuit and warn other personnel not to energize the circuit. Never use a blow torch or other similar means for heating fuel or oil lines. WARNING ASPHYXIATION DANGER Be sure engine room ventilators are open when operating the engine(s). \ TM 55-1925-204-12 C7 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 10 OCTOBER 1996 NO. 7 Operator and Organizational Maintenance Manual TUG, HARBOR, DIESEL, STEEL, 1,200 HP, 100 FOOT DESIGN 3006, FLIGHT ONE NSN 1925-00-375-3003 DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited TM 55-1925-204-12, 10 February 1975, is changed as follows: 1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand. Remove pages 1-1 and 1-2 B-7 through B-10 ---B-11 and B-12 Insert pages 1-1 and 1-2 B-7 through B-10 B-10.1 through B-10.8 B-11 and B-12 2. Retain this sheet in front of manual for reference purposes. TM 55-1925-204-12 C7 By Order of the Secretary of the Army DENNIS J. REIMER General, United States Army Chief of Staff Official: JOEL B. HUDSON Administrative Assistant to the Secretary of the Army 02516 DISTRIBUTION: To be distributed in accordance with DA Form 12-25-E, block no. 1981, requirements for TM 55-1925-204-12. TM 55-1925-204-12 C6 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 3 JULY 1992 NO. 6 Operator and Organizational Maintenance Manual TUG, HARBOR, DIESEL, STEEL, 1,200 HP, 100 FOOT DESIGN 3006, FLIGHT ONE NSN 1925-00-375-3003 Approved for public release; distribution is unlimited TM 55-1925-204-12, 10 February 1975, is changed as follows: 1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand. Remove pages Insert pages B-1 through B-13/B-14 B-1 through B-13/B-14 2. Retain this sheet in front of manual for reference purposes. By Order of the Secretary of the Army: GORDON R. SULLIVAN General, United States Army Chief of Staff Official: MILTON H. HAMILTON Administrative Assistant to the Secretary of the Army 01872 DISTRIBUTION: To be distributed in accordance with DA Form 12-25E, qty rqr block no. 1981. TM 55-1925-204-12 C5 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 5 October 1989 NO. 5 Operator and Organizational Maintenance Manual TUG, HARBOR, DIESEL, STEEL 1,200 HP, 100 FOOT DESIGN 3006, FLIGHT ONE NSN 1925-00-375-3003 Approved for public release; distribution is unlimited TM 55-1925-204-12, 10 February 1975, is changed as follows: 1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand. Remove pages Insert pages B-1 and B-2 B-1 and B-2 2. Retain this sheet in front of manual for reference purposes. By Order of the Secretary of the Army: CARL E. VUONO General United States Army Chief of Staff Official: WILLIAM J. MEEHAN, II Brigadier General United States Army The Adjutant General DISTRIBUTION: To be distributed in accordance with DA Form 12-25A, Operator and Unit Maintenance Requirements for Tug, Harbor, Diesel, Steel, Flight 1, 1200 HP, 100 FT (Design 3006). TM 55-1925-204-12 C4 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 17 June 1988 NO. 4 Operator and Organizational Maintenance Manual TUG, HARBOR, DIESEL, STEEL, 1,200 HP, 100 FOOT DESIGN 3006, FLIGHT ONE NSN 1925-00-375-3003 TM 55-1925-204-12, 10 February 1975, is changed as follows: 1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand. Remove pages Insert pages B-1 through B-10 B-1 through B-13/B-14 2. Retain this sheet in front of manual for reference purposes. By Order of the Secretary of the Army: CARL E. VUONO General, United States Army Chief of Staff Official: R. L. DILWORTH Brigadier General, United States Army The Adjutant General DISTRIBUTION: To he distributed in accordance with DA Form 12-25A, Operator, and Unit Maintenance requirements for Tug, Harbor, Diesel, Steel, Flight 1, 1200 HP, 100 FT (Design 3006). TM 55-1925-204-12 C3 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 21 July 1986 No. 3 Operator and Organizational Maintenance Manual TUG, HARBOR, DIESEL, STEEL, 1,200 HP, 100 FOOT DESIGN 3006, FLIGHT ONE FSN 1925-375-3003 TM 55-1925-204-12, 10 February 1975, is changed as follows: 1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand. Remove pages 3-7 and 3-8 Insert Pages 3-7 and 3-8 2. Retain this sheet in front of manual for reference purposes. By Order of the Secretary of the Army: JOHN A. WICKHAM, JR. General, United States Army Chief of Staff Official: R. L. DILWORTH Brigadier General, United States Army The Adjutant General DISTRIBUTION: To be distributed in accordance with DA Form 12-25A, Operator and Organizational Maintenance requirements for Tug, Harbor, Diesel, Steel, Flight 1, 1200 HP, 100 FT (Design 3006). TM 55-1925-204-12 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 28 February 1986 NO. 2 Operator and Organizational Maintenance Manual TUG, HARBOR, DIESEL, STEEL, 1,200 HP, 100 FOOT DESIGN 3006, FLIGHT ONE, NSN 1925-375-3003 TM 55-1925-204-12, 10 February 1975, is changed as follows: 1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand. Remove pages Insert pages i and ii B-1 through B-20 i and ii B-1 through B-10 2. Retain this sheet in front of manual for reference purposes. By Order of the Secretary of the Army: JOHN A. WICKHAM, JR. General, United States Army Chief of Staff MILDRED E. HEDBERG Brigadier General, United States Army The Adjutant General DISTRIBUTION: To be distributed in accordance with DA Form 12-25A, Operator and Organizational maintenance Requirements for Tug, Harbor, Diesel, Steel, Flight 2, 1200 HP, 100 FT (Design 3006) (TM 55-1925-205 Series) TM 55-1925-204-12 C1 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 7 0ctober1982 No. 1 Operator's and Organizational Maintenance Manual TUG; HARBOR; DIESEL; STEEL; 1,200 HP; 100 FOOT; DESIGN 3006; FLIGHT ONE; NSN 1925-00-375-3003 TM 55-1925-204-12, 10 February 1975, is changed as follows: 1. Title is changed as shown above. 2. Remove and insert pages as indicated below: Remove Table of Contents Chapter 1 Chapter 3 3-9 and 3-10 Chapter 5 Appendix B Appendix C pages i and ii 1-1 and 1-2 3-1 thru 3-8 3-9 and 3-10 5-91 and 5-92 B-1 thru B-20 C-11 and C-12 Insert pages i and ii 1-1 and 1-2 3-1 thru 3-8.14 5-91 and 5-92 B-1 thru B-23/B-24 C-11 and C-12 3. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand. 4. Retain this sheet in front of manual for reference purposes. By Order of the Secretary of the Army: E. C. MEYER General, United States Army Chief of Staff Official: ROBERT M. JOYCE Major General, United States Army The Adjutant General DISTRIBUTION: To be distributed in accordance with DA Form 12-25D, Operator Maintenance requirements for Marine Equipment, All. TM 55-1925-204-12 TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D. C., 10 February 1975 No, 55-1925-204-12 OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL TUG, HARBOR, DIESEL, STEEL, 1,200 HP, 100 FOOT DESIGN 3006, FLIGHT ONE, NSN1925-00-375-3003 ___________ Paragraph Page Chapter Section 1. I. II. INTRODUCTION General .................................................................................................... Description an data .................................................................................. 1-1 1-8 1-1 1-2 Chapter Section 2. I. II. III. OPERATING INSTRUCTIONS Operating procedures ............................................................................... Operation of Auxiliary Equipment ............................................................. Operation under unusual conditions .......................................................... 2-1 2-10 2-33 2-1 2-23 2-66 Chapter Section 3. I. II. III. IV. OPERATOR/CREW MAINTENANCE INSTRUCTIONS Lubrication Instructions ............................................................................. Preventive Maintenance Checks and Services .......................................... Troubleshooting ....................................................................................... Maintenance Procedures .......................................................................... 3-1 3-1 3-1 3-9 320 4. I. II. III. IV. V. VI. VII. ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Service upon receipt of equipment ............................................................ Repair Parts, Special Tools and Equipment............................................... Lubrication Instructions ............................................................................ Preventive Maintenance Checks and Services .......................................... Troubleshooting ....................................................................................... Radio Interference Suppression ................................................................ Maintenance of the Propulsion Engine ...................................................... 4-6 4-8 4-12 4-1 4-3 4-6 4-5 4-5 4-6 4-8 Chapter Section 5. I. II. III. IV. V. VI. VII. VIII. IX. X. XI. XII. XIII. XIV. XV. XVI. MATERIEL USED IN CONJUNCTION WITH THE TUG Auxiliary Set.............................................................................................. Pumps, General ....................................................................................... Pneumatic Equipment System ................................................................. Anchor Windlass-Capstan System ........................................................... Heating System ........................................................................................ Ventilating System ................................................................................... Water Supply System .............................................................................. Food Preparation System ......................................................................... Main Electrical System ............................................................................. Steering System........................................................................................ Navigation Equipment .............................................................................. Searchlight Equipment .............................................................................. Fire Fighting Equipment ............................................................................ Radio Telephone System .......................................................................... Whistle/Horn System ............................................................................... Life Boat Davit ......................................................................................... 5-1 5-32 5-55 5-60 5-69 5-71 5-76 5-78 5-80 5-95 5-101 5-103 5-105 5-107 5-109 5-111 5-1 5-89 6-132 5-141 5-151 5-155 5-162 5-164 5-168 5-173 5-187 5-188 5-192 5-195 5-195 5-197 Appendix A. B. Chapter Section C. 3-3 3-5 4-1 4-3 REFERENCES ......................................................................................... OPERATOR/BOAT SET LIST COMPONENT OF END ITEM.BASIC ISSUE ITEMS. ADDITIONAL AUTHORIZATION AND EXPENDABLE SUPPLIES AND MATERIEL LISTINGS MAINTENANCE ALLOCATION CHART .................................................... INDEX *This manual supersedes TM 55-1925-204-12, 7 December 1964, including changes Change 2 i A-1 B-1 C-1 I-1 LIST OF ILLUSTRATIONS Figure 1-1 1-2 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-26 2-27 2-28 2-29 2-30 2-31 2-32 2-33 2-34 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-17 3-18 3-19 3-20 3-21 3-22 3-23 3-24 3-25 3-26 3-27 3-28 3-29 3-30 3-31 3-32 Legend Page Tug, harbor, diesel, 1,200 hp, steel, 100 foot, design 3006, starboard side ............................................................................................ 1-1 Tug, harbor, diesel, 1,200 hp, steel, 100 foot design 3006, port side ...................................................................................................... 1-2 Pilothouse navigational controls ............................................................................................................................................................... 2-2 After steering station ................................................................................................................................................................................ 2-4 Main engine controls ................................................................................................................................................................................ 2-5 Auxiliary set engine controls and instruments .......................................................................................................................................... 2-7 Main electrical control panel (switchboard) .............................................................................................................................................. 2-9 Heating boiler controls ............................................................................................................................................................................ 2-11 Air compressor controls.......................................................................................................................................................................... 2-14 Water pressure set controls ................................................................................................................................................................... 2-20 Fuel oil system piping diagram ............................................................................................................................................................... 2-24 Fuel oil capacity sounding charts ........................................................................................................................................................... 2-26 Lubricating oil system piping diagram . ................................................................................................................................................... 2-29 Lubricating oil purifier flow diagram ........................................................................................................................................................ 2-32 Marine steering system arrangement ..................................................................................................................................................... 2-34 Compressed air system piping diagram ................................................................................................................................................. 2-36 Ships service power control panel wiring diagram ................................................................................................................................. 2-39 Engineroom lighting control panel wiring diagram................................................................................................................................... 2-40 General lighting control panel wiring diagram ......................................................................................................................................... 2-40 Pilothouse lighting control panel wiring diagram .....................................................................................................................................2.41 Ventilating power control panel wiring diagram ...................................................................................................................................... 2-41 Battery charging control panel ................................................................................................................................................................ 2-42 Navigational light control panel ............................................................................................................................................................... 2-42 Main electrical control panel wiring diagram, rear view............................................................................................................................ 2-44 Engine cooling system diagram ............................................................................................................................................................. 2-47 Bilge and ballast piping diagram ............................................................................................................................................................ 2-49 Chain locker bilge piping diagram .......................................................................................................................................................... 2-50 Fore peak tank capacity and soundings ................................................................................................................................................. 2-52 Aft peak tank capacity and soundings .................................................................................................................................................... 2-53 Fire and salvage system piping diagram ................................................................................................................................................ 2-54 Heating system piping diagram............................................................................................................................................................... 2-56 Markey model VEV-16 anchor windlass ................................................................................................................................................. 2-59 Galley range burner unit ......................................................................................................................................................................... 2-60 Water dispenser (cooler) ....................................................................................................................................................................... 2-62 Gyro compass control cabinet . .............................................................................................................................................................. 2-63 Gyro compass master unit ..................................................................................................................................................................... 2-64 Cylinder head removal and installation.................................................................................................................................................... 3-21 Cylinder compression relief valve............................................................................................................................................................ 3-22 Cylinder head valves .............................................................................................................................................................................. 3-23 Cylinder compression relief valve............................................................................................................................................................ 3-24 Sequence for applying torque to holddown nuts .................................................................................................................................... 3-25 Piston, connecting rod, and rings .......................................................................................................................................................... 3-26 Connecting rod bearing........................................................................................................................................................................... 3-28 Cylinder, sleeve, and rings ..................................................................................................................................................................... 3-30 Fuel oil filters, lines, and transfer (supply) pump . .................................................................................................................................. 3-33 Fuel transfer (supply) pump, cross section ............................................................................................................................................ 3-35 Fuel injection pump, cross section ......................................................................................................................................................... 3-37 Fuel injector (nozzle), cross section ....................................................................................................................................................... 3-38 Fuel injection pump ................................................................................................................................................................................ 3-39 Fuel injector, removal and installation . ................................................................................................................................................... 3-41 Governor (mechanical)............................................................................................................................................................................ 3-43 Half of twin fuel oil filter, cross section ................................................................................................................................................... 3-45 Filter element assembly ......................................................................................................................................................................... 3-46 Propulsion engine, port side view ........................................................................................................................................................... 3-47 Scavenging pump, cross section ........................................................................................................................................................... 3-49 Oil and water pump drive ....................................................................................................................................................................... 3-52 Crankcase breather, cross section ........................................................................................................................................................ 3-54 Engine fresh and raw water pump .......................................................................................................................................................... 3-56 Fresh or raw water pump, cross section ................................................................................................................................................ 3-56 Water inlet header and valve .................................................................................................................................................................. 3-58 Lubrication oil pump ............................................................................................................................................................................... 3-60 Crankshaft main bearings ...................................................................................................................................................................... 3-62 Thrust bearing (Kingsbury) .................................................................................................................................................................... 3-65 Engine order telegraph transmitter ......................................................................................................................................................... 3-67 Engine order telegraph indicator ............................................................................................................................................................ 3-68 Windshield wiper ................................................................................................................................................................................... 3-70 Intercommunicating telephone station (typical) . ..................................................................................................................................... 3-72 Fire and salvage system manifold .......................................................................................................................................................... 3-73 ii LIST OF ILLUSTRATIONS Figure 3-33 3-34 3-35 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25 5-26 5-27 5-28 5-29 5-30 5-31 5-32 5-33 5-34 5-35 5-36 5-37 5-38 5-39 5-40 5-41 5-42 5-43 5-44 Legend Page Educator (jet suction) ............................................................................................................................................................................. 3-74 Sea valve and sea chest (typical) ........................................................................................................................................................... 3-76 Strainer location (typical) ........................................................................................................................................................................ 3-77 Fixed fire extinguisher piping arrangement .............................................................................................................................................. 4-2 Replacing typical component for suppressing radio interference.............................................................................................................. 4-7 Exhaust manifold section removal ............................................................................................................................................................ 4-9 Air receiver (box) removal ....................................................................................................................................................................... 4-10 The air distributor.................................................................................................................................................................................... 4-12 Air start distributor and reverse control .................................................................................................................................................. 4-14 Air start header ...................................................................................................................................................................................... 4-15 Exhaust manifold and outlet pipe ........................................................................................................................................................... 4-17 Silencer (Muffler) ................................................................................................................................................................................... 4-18 The force feed lubricator ........................................................................................................................................................................ 4-20 Lubricator drive ...................................................................................................................................................................................... 4-21 Force feed lubricator, sectional view ...................................................................................................................................................... 4-22 Scavenging oil transfer pump (15130) ................................................................................................................................................... 4-25 Motorcontrols ......................................................................................................................................................................................... 4-26 Camshaft and bearings .......................................................................................................................................................................... 4-27 Instrument panel .................................................................................................................................................................................... 4-29 Flywheel jacking device .......................................................................................................................................................................... 4-30 Shutoff valve, storage tank, and pressure gage ..................................................................................................................................... 4-31 Engine air brake cylinder ........................................................................................................................................................................ 4-32 Brake shoe and linkage .......................................................................................................................................................................... 4-33 Brake air cylinder .................................................................................................................................................................................... 4-34 Cam operated pilot air valve ................................................................................................................................................................... 4-35 Pressure regulating valve ....................................................................................................................................................................... 4-36 Auxiliary set, three quarter right front view ............................................................................................................................................... 5-1 Auxiliary set, three quarter left rear view ................................................................................................................................................... 5-2 Air cleaner, starter and fuel filter .............................................................................................................................................................. 5-3 Raw water pump, lines, and rocker arm cover ......................................................................................................................................... 5-5 Fresh water, pump, lines, and governor.................................................................................................................................................... 5-6 Blower, and inlet air housing ..................................................................................................................................................................... 5-8 Belt guard, oil cooler, and engine mounting bolts.................................................................................................................................... 5-10 Engine generator and voltage regulator .................................................................................................................................................. 6-11 Exhaust pipe and elbow ......................................................................................................................................................................... 5-12 Water cooled exhaust manifold .............................................................................................................................................................. 5-13 Removing injector control shaft and fuel lines ........................................................................................................................................ 5-15 Rocker arms and push rods ................................................................................................................................................................... 5-16 Exhaust valves on two valve, four cylinder head ..................................................................................................................................... 5-17 Removal of valve seat ............................................................................................................................................................................. 5-17 Sequence of tightening cylinder head nuts ............................................................................................................................................ 5-18 Piston, connecting rod, cylinder liner, and rings ..................................................................................................................................... 5-20 Measuring piston clearance .................................................................................................................................................................... 5-21 Measuring piston ring end gap................................................................................................................................................................ 5-22 Checking piston ring side clearance . ..................................................................................................................................................... 5-23 Compressing the piston rings ................................................................................................................................................................. 5-24 Cylinder liner holddown clamp ................................................................................................................................................................ 5-24 Cylinder liner measurement diagram ...................................................................................................................................................... 5-25 Cylinder liner removal.............................................................................................................................................................................. 5-26 Cylinder liner mounted in block ............................................................................................................................................................... 5-27 Installing valve seat ................................................................................................................................................................................. 5-30 Balance weight cover removal and capscrew tightening sequence ........................................................................................................ 5-31 Typical camshaft and balance shaft details ........................................................................................................................................... 5-31 Idler gear details and location of parts .................................................................................................................................................... 5-32 Gear train and timing marks, L.H. rotation ............................................................................................................................................. 5-34 Adjusting the valve clearance ................................................................................................................................................................. 5-36 Crankshaft, main, and thrust bearings ................................................................................................................................................... 5-38 Removing main bearing upper half (with crankshaft in place) ................................................................................................................ 5-39 Removing rear main bearing upper half (with crankshaft in place) ......................................................................................................... 5-39 Typical vibration damper details.............................................................................................................................................................. 5-41 Crankshaft front cover details ................................................................................................................................................................ 5-41 Crankshaft front cover attaching hardware tightening sequence ........................................................................................................... 5-42 Checking crankshaft end play................................................................................................................................................................. 5-44 Typical cylinder block prepared for pressure test ................................................................................................................................... 5-45 Engine lubricating oil pump..................................................................................................................................................................... 5-47 Lubricating oil filter.................................................................................................................................................................................. 5-48 Fuel injector mounting ............................................................................................................................................................................ 5-50 Fuel injector ............................................................................................................................................................................................5.51 Injector tester ......................................................................................................................................................................................... 5-53 Timing fuel injectors................................................................................................................................................................................ 5-55 III LIST OF ILLUSTRATIONS Figure 5-45 5-46 5-47 5-48 5-49 5-50 5-51 5-52 5-53 5-54 5 55 5-56 5-57 5-58 5-59 5-60 5-61 5-62 5-63 5-64 5-65 5-66 5-67 5-68 5-69 5-70 5-71 5-72 5-73 5-74 5-75 5-76 5-77 5-78 5-79 5-80 5-81 5-82 5-83 5-84 5-85 5-86 5-87 5-88 5-89 5-90 5-91 5-92 5-93 5-94 5-95 5-96 5-97 5-98 5-99 5-100 5-101 5-102 5-103 5-104 5-105 5-106 5-107 5-108 5-109 5-110 5-111 5.112 5-113 5-114 Legend Page Fuel transfer pump.................................................................................................................................................................................. 5-56 Typical fuel strainer (filter} ...................................................................................................................................................................... 5-58 Adjusting fuel rod ................................................................................................................................................................................... 5-60 Adjusting for maximum fuel .................................................................................................................................................................... 5-61 Positioning injector control rack . ............................................................................................................................................................ 5-62 Adjusting speed droop ............................................................................................................................................................................ 5-63 Setting maximum speed adjusting screw................................................................................................................................................ 5-64 Hydraulic governor mountings ................................................................................................................................................................ 5-65 Typical air shutdown (inlet) housing........................................................................................................................................................ 5-67 Heat exchanger....................................................................................................................................................................................... 5-68 Lubrication oil cooler and fresh water line .............................................................................................................................................. 5-70 Typical water manifold mounting............................................................................................................................................................. 5-71 Fresh water pump................................................................................................................................................................................... 5-73 Raw water pump ..................................................................................................................................................................................... 5-74 Starting motor ......................................................................................................................................................................................... 5-78 Engine instrument panel ......................................................................................................................................................................... 5-80 Generator removal and installation ......................................................................................................................................................... 5-82 Delco 40kw, 120 vdc generator 5............................................................................................................................................................ 5-83 Stud alignment........................................................................................................................................................................................ 5-84 Brushholder alignment ........................................................................................................................................................................... 5-85 Clutch and pump removal ....................................................................................................................................................................... 5-86 Clutch arrangement (model CL208)........................................................................................................................................................ 5-87 Fire and salvage pump ........................................................................................................................................................................... 5-88 Bilge and ballast pump removal . ............................................................................................................................................................ 5-90 Bilge and ballast pump............................................................................................................................................................................ 5-91 Priming pump ......................................................................................................................................................................................... 5-93 Bilge and ballast pump motor ................................................................................................................................................................. 5-94 Bilge and ballast pump accelerating contactor ....................................................................................................................................... 5-96 Overload relay ........................................................................................................................................................................................ 5-97 Fire pump removal .................................................................................................................................................................................. 5-99 Fire pump.............................................................................................................................................................................................. 5-100 Fresh and saltwater standby pumps, removal ...................................................................................................................................... 5-102 Fresh and saltwater standby pumps .................................................................................................................................................... 5-103 Fuel pump, cutaway.............................................................................................................................................................................. 5-105 Checking coupling alignment ............................................................................................................................................................... 5-107 Controller, fuel oil transfer pump motor, schematic diagram................................................................................................................. 5-108 Overload relay....................................................................................................................................................................................... 5-109 Accelerating contactor .......................................................................................................................................................................... 5-110 Lead dimensions................................................................................................................................................................................... 5-111 Auxiliary contacts .................................................................................................................................................................................. 5-112 Lubricating oil standby pump ................................................................................................................................................................ 5-114 Lubricating oil standby pump, section .................................................................................................................................................. 5-115 Motor, lubricating oil standby pump drive ............................................................................................................................................. 5-117 Controller contactor............................................................................................................................................................................... 5-118 Lubricating oil purifier ........................................................................................................................................................................... 5-119 Oil purifier assembly ............................................................................................................................................................................ 5-120 Sectional view of bowl .......................................................................................................................................................................... 5-121 Pumps and clutches, sectional view .................................................................................................................................................... 5-123 Fresh water pump and motor ............................................................................................................................................................... 5-127 Water pump.......................................................................................................................................................................................... 5-128 Lubricating oil rotary hand pump........................................................................................................................................................... 5-131 Rotary hand pump (typical) .................................................................................................................................................................. 6-132 Air compressor ..................................................................................................................................................................................... 6-133 Air compressor, low-pressure control valves ........................................................................................................................................ 5-134 Air compressor, high-pressure control valve ........................................................................................................................................ 5-135 High pressure diaphragm unloader....................................................................................................................................................... 5-136 Air compressor .................................................................................................................................................................................... 5-138 Motor removal and belt adjustment ....................................................................................................................................................... 5-140 Anchor windlass brake arrangement .................................................................................................................................................... 5-142 Anchor windlass motor and gear box .................................................................................................................................................... 5-143 Anchor windlass, type VEV-16 ............................................................................................................................................................. 5-144 Anchor windlass and master switch ..................................................................................................................................................... 5-146 Capstan. ............................................................................................................................................................................................... 5-147 Motor brake, capstan ............................................................................................................................................................................ 5-148 Master switch control assembly ........................................................................................................................................................... 5-150 Heating boiler burner unit and mounting ............................................................................................................................................... 5-152 Oil burner assembly.............................................................................................................................................................................. 5-153 Typical centrifugal blower assembly .................................................................................................................................................... 5-156 Axial blower assembly (looking up) for engineroom exhaust ................................................................................................................ 5-159 Axial blower assembly, sectional view................................................................................................................................................... 5-160 iv LIST OF ILLUSTRATIONS Figure 5-115 5-116 5-117 5-118 5-119 5-120 5-121 5-122 5-123 5-124 5-125 5-126 5-127 5-128 5-129 5-130 5-131 5-132 5-133 5-134 5-135 5-136 Legend Page Typical washroom fixture placement .................................................................................................................................................... 5-163 The refrigerator compressor unit........................................................................................................................................................... 5-166 Freezer, for cold storage of food .......................................................................................................................................................... 5-167 Battery charging panel ......................................................................................................................................................................... 5-170 Engineroom general alarm bell ............................................................................................................................................................. 5-172 Motor and brake.................................................................................................................................................................................... 5-174 Rudder travel stop adjustment screws.................................................................................................................................................. 5-175 Hydraulic ram assembly ....................................................................................................................................................................... 5-176 Hydraulic pump..................................................................................................................................................................................... 5-178 Valves and fittings ................................................................................................................................................................................ 5-180 Steering console .................................................................................................................................................................................. 5-181 Pump, hand, hydraulic ......................................................................................................................................................................... 5-182 Gears, universal joints, and couplings ................................................................................................................................................. 5-183 Milter gear box, I.h. ............................................................................................................................................................................... 5-184 Milter gear box, r.h ............................................................................................................................................................................... 5-185 Milter gear box, differential .................................................................................................................................................................... 5-186 Searchlight atop pilothouse................................................................................................................................................................... 5-189 Searchlight, cross section .................................................................................................................................................................... 5-191 Typical portable extinguisher position ................................................................................................................................................... 5-193 Pull box (activation) .............................................................................................................................................................................. 5-194 Remote control lever release................................................................................................................................................................. 5-195 Air whistle and electric horn .................................................................................................................................................................. 5-196 V LIST OF TABLES Table 1-1 1-2 1-3 1-4 1-5 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 3-1 3-2 3-3 4-1 4-2 4-3 4-4 Legend Page Torque Limits (Engine Model 37F16) ....................................................................................................................................................... 1-8 Gear Backlash (Engine Model 37F16) ..................................................................................................................................................... 1-8 Wear Limit Tolerance (Engine Model 37F16) ........................................................................................................................................... 1-8 Operating Pressure (Engine Model 37F16) .............................................................................................................................................. 1-9 Operating Temperatures (Engine Model 37F16) ..................................................................................................................................... 1-9 Heating System Control Valves .............................................................................................................................................................. 2-12 Compressed Air System Control Valves ................................................................................................................................................ 2-15 Raw and Fresh Water Engine Cooling System Control Valves .............................................................................................................. 2-16 Fuel Oil System Control Valves ............................................................................................................................................................. 2-17 Fire and Salvage System Control Valves ................................................................................................................................................ 2-18 Lubricating Oil System Control Valves ................................................................................................................................................... 2-19 Bilge and Ballast System Control Valves ................................................................................................................................................ 2-21 Machinery Status Prior to Getting Underway .......................................................................................................................................... 2-22 Fuel Oil System Control Valve Positioning ............................................................................................................................................. 2-27 Lubricating Oil System Control Valve Positioning .................................................................................................................................. 2-29 Compressed Air System Control Valve Positioning ............................................................................................................................... 2-36 Primary Electrical Circuits ...................................................................................................................................................................... 2-39 Engine Cooling System Control Valve Positioning ................................................................................................................................. 2-47 Bilge and Ballast System Control Valve Positioning................................................................................................................................ 2-50 Fire and Salvage System Control Valve Positioning ............................................................................................................................... 2-54 Heating System Control Valve Positioning .............................................................................................................................................. 2-56 Gyrocompass Front Panel Operating Control Functions ....................................................................................................................... 2-64 Operator/Crew Preventive Maintenance Checks and Services ................................................................................................................ 3-2 Operator/Crew Preventive Maintenance Checks and Services ................................................................................................................. 3-7 Troubleshooting ..................................................................................................................................................................................... 3-10 Special Tools, Test and Support Equipment............................................................................................................................................. 4-4 Organizational Preventive Maintenance Checks and Services ................................................................................................................. 4-5 Troubleshooting ........................................................................................................................................................................................ 4-6 Force Feed Lubricator Drop Count ......................................................................................................................................................... 4-24 vi TM 55-1925-204-12 CHAPTER 1 INTRODUCTION Section I. GENERAL NOTE 1-1. Scope This manual is for your use in operating and maintaining the tug, harbor, diesel, steel, 100 foot, design 3006, (fig.1-1 and 1-2), with hull numbers LT-1936 through LT1977 and LT-2202. It provides the necessary information on operation and organizational maintenance of the equipment, with description and function of main units in relationship to other components. DUE TO THE MISSION AND CREW CAPABILITIES OF THE VESSEL, MAIN. TENANCE NORMALLY ASSIGNED TO ORGANIZATIONAL LEVEL OR HIGHER MAY BE ASSIGNED TO OPERATOR/CREW. Figure 1-1. Tug, harbor, diesel, 1,200 hp, steel, I00 foot, design 3006, starboard side. 1-1 TM 55-1925-204-12 Figure 1-2. Tug. harbor, diesel, 1,200 hp, steel. 100 foot. design 3006. port side. 1-4. Equipment Serviceability Criteria (ESC) This equipment is not covered by an ESC. 1-2. Maintenance Forms and Records Maintenance forms and records that your are required to use are explained in TM 38-750, the Army Maintenance Management System (TAMMS). 1-3. Reporting of Errors and Recommending Improvements You can improve this manual by mailing your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to: Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd. , St. Louis, Mo. 63120-1798. 1-5. Destruction of Army Material to Prevent Enemy Use Destroy Army materiel to prevent enemy use as described in TM 750-244-3 1-6. Storage Refer to TB740-93-4 for methods of preservation of vessels for storage. 1-7. Calibration All required calibrations are made by a team of specialists from depots, at prescribed intervals. or upon special request. Section II. DESCRIPTION AND DATA operation. Berthing and messing facilities on board provide for a crew of sixteen. 1-8. Description a. The tug, harbor, diesel, 1,200 hp, 100 foot design 3006, has a hull of welded steel. It has an overall length of 107 feet, and a molded beam width of 26 feet 6 inches. Depth of the molded hull is 14 feet 10 inches. This tug is propelled by a six cylinder diesel engine which develops 1,200 hp at 300 rpm. The engine is directly coupled to the propeller shaft that turns a 7.667 foot, 3 bladed propeller. The propeller has a pitch of 5.16 feet, and moves the vessel at 12.75 knots (light load) with a range of 3,700 nautical miles, while with a loaded tow, it is capable of 294 hours of sustained b. The principal functions of the tug are berthing of large vessels and heavy towing within harbor areas. It can perform offshore towing between terminals, or proceed overseas without assistance from other vessels. c. Three fire monitors are on board the tug. One is on top of the pilot house, and one each on port and starboard sides of the boat deck. These monitors enable the tug to assist in extinguishing fires on board other vessels, or at dock facilities d. The two salvage pumps on board, with a 1-2 Change 7 rated capacity of 500 gpm each at 100 psi, allow tug to assist in salvage operations. b. Tug, Harbor, Diesel, 1,200 hp, Steel, 100 foot Design 3006. e. The maintenance paragraphs of this manual contain detailed description of components. (1) Hull numbers: LT1936 through LT1977 and LT2202 Length, overall............................ 107 ft (feet) Beam, molded............................ 26 ft 6 in (inches) Depth, molded ........................... 14 ft 10 in Displacement: Light ....................................... 295 Ton Loaded ................................... 390 Ton Draft: Light (forward) ....................... 6 ft 1 1/2 in Light (mean) .......................... 8 ft 9 3/4 in Light (aft) ................................ 11 ft 6 in Loaded (forward)..................... 9 ft 5 in Loaded (mean) . ..................... 10 ft 91/4 in Loaded (aft) ........................... 12 ft 1/2 in Freeboard: Mean (light)............................. 6 ft 1/4 in Mean (loaded) ........................ 4 ft (2) Speed: Light ....................................... 12.75 knots Loaded with tow...................... Variable (3) Cruising range: Light ....................................... 3,700 nautical miles Loaded with tow...................... 294 hr (hours) Fuel consumption ................... 68 gph (gallon per hour) (4) Tank capacities: Fuel oil tanks (7) ....................... 21,146 gal (gallons) Fuel oil day tank ........................ 300 gal Lubricating oil tank ..................... 450 gal Dirty lubricating oil tank.................................... 395 gal Lubricating oil sludge tank ............................. 50 gal Potable water tank...................... 2,756 gal Potable water pressure tank . ........................ 42 gal Fresh water expansion tank ................................. 50 gal Sea water ballast tanksFore peak ............................... 2,903 gal (11.1 Tor,' After peak ............................... 5,493 gal (21 Ton) (5) Electrical system. 120 vdc Ivolt direct current) (6) Crew accommodations. 16 men (7) Mess facilities. Complete galley (8) Lifeboat. One 16 man, oar propelled c. Propulsion Data. (1) Engine, diesel. Manufacturer.............................. Fairbanks Niorse Model......................................... 37-F-16 Type........................................... 2 cycle diesel (direct reversible) Number of cylinders ................... 6 Displacement 24.120 Cu In (cubic inches) Bore ........................................... 16 in Stroke ........................................ 20 in Rated horsepower ...................... 1,200 at 300 rpm (revolutions per minute) Firing order ................................ 1-6-2-4-3-5 Lubrication system ..................... Forced Cooling system .......................... 2 pass FM heat exchanger Silencer...................................... Maxim model 32SC 1-9. Difference in Models Hull numbers LT-1936 through LT-1977 and LT2202 were originally identical in construction. A modification program may have changed some items of equipment. These differences will be shown in the tabulated data below as either original or modified equipment. 1-10. Tabulated Data a. Identification and Instruction Plates. The location and informational content of the ten major identification and instruction plates follow: (1) The manufacturers identification and tug name plate, with hull number, specification, and contract number, is located at top of the ladder at engineroom entrance. (2) The propulsion engine identification plate with serial number, hp rating, rpm, and model number is located on the cam shifter housing just below the throttle handwheel. (3) The propulsion engine instruction (warning) plate, to avoid operating between 165 and 200 rpm, is located on left side of engine below the instrument panel. (4) The air compressor identification plate, with manufacturer, model number, bore of 1st and 2nd stages, and stroke length, is located on left side of the compressor. (5) The auxiliary set diesel engine identification plate, with manufacturer, model number, hp rating, rpm, and maximum no load rpm, is located on right side of engine cylinder head just below the rocker arm cover. The generator identification plate, with manufacturer, model number, kw rating, and rpm, is located on right side of generator housing. The pump identification plate, with manufacturer, gpm and psi rating is located on base of pump housing. (6) The battery charging panel identification plate with manufacturer and number, is located on front of the battery charging panel. (7) The oil burning galley range identification plate with manufacturer and model number, is located on front of range above oil burner. (8) The searchlight identification plate, with manufacturer," serial number, type, watts, and voltage, is located on side of searchlight lamp housing. (9) The instruction (warning) plate for fire fighting in the engine room is located on the front of the main electrical control panel. The instruction limits the lighting to a maximum of 1000 watts with steering gear or air compressor in operation, while fire fighting pump is functioning. 1-3 Reflectors: Primary .................................. Silvered glass Secondary .............................. Alzak aluminum Rotation .................................... 3600 pilot house lever control (8) Mechanical telegraph. Manufacturer ............................. Joseph Harper and Son Transmitters............................... Three 12 in. single engine, double face Indicator .................................... One 16 in. (9) Windshield wiper. Quantity ..................................... 3 Manufacturer ............................. Kearfott Co., Inc. Type .......................................... Pendulum electric Motor ........................................ 115 vdc (10) Whistle. Manufacturer ............................. Leslie Co. Type........................................... Typhon Model ........................................ A-1256 Voltage ...................................... 115 vdc Quantity ..................................... 1 (11) Horn. Manufacturer.............................. Cunningham Co. Type........................................... Deck mounting Model......................................... Doran No. lB (12) Radar set. Manufacturer.............................. Radio Marine Corp. of America Model......................................... AN/SPN-18 Transmitter: Model...................................... RT290-SPH-18 Type ....................................... 725A Receiver: Model ..................................... RT290-SPH-18 Type ....................................... Superheterodyne (13) Marine radio telephone (modification). Manufacturer.............................. Raytheon Model......................................... 75A3C Type emission ............................ AM voice Transmitter: Model...................................... AN/SRC-32 Type ....................................... 6A3 Receiver: Model......................................... AN/SRC-32 Type ....................................... Crystal (14) Radio set (original equipment). Manufacturer ............................. Munston Mfg. Co. Model......................................... AN/SCR-8 Receiver: Model...................................... RT306A/SRC-8 Current ................................... AC (alternating current) Frequency............................... 2.0 to 3.5 mc (15) Radio direction finder (original equipment ). Manufacturer.............................. Bludworth Model......................................... DF 1024 Range ........................................ 150 miles Frequency . ................................ 280 to 520 kc's (2) Thrust bearing. Manufacturer ............................. Kingsbury Type........................................... Water cooled (3) Engine control system. Manufacturer ............................. Fairbanks Morse Control location ......................... Port side of engine (4) Propeller shaft and stern tube. Shaft material............................. Forged steel with bronze sleeve bearings Stern tube material ..................... Steel (5) Propeller. Quantity ..................................... 1 Manufacturer ............................. Ferguson Propeller Co. Material ..................................... Manganese bronze Type .......................................... 3 blade Diameter ................................... 7.667 ft Pitch........................................... 5.16 ft Weight ....................................... 2,060 lbs (pounds) d. Navigation Equipment. (1) Compass, gyro (added by modification ). Manufacturer ............................. Sperry Rand Corp. Model . ....................................... Mark 27 system Mod-O or Mod-1 (2) Compass, magnetic. Manufacturer .............................. Wilfrid O. White Model ......................................... Constellation type catalogue no. 6313 (3) Steering system. Manufacturer .............................. American Engineering Company Model ........................................ 5.25 in. ram Power unit .................................. Hele Shaw pump Steering console ........................ Hand pump, reserve oil tank,........................................... relief valves, replenishing valves, installed within steering console (4) Rudder. Material ...................................... Steel Dimension .................................. 11 ft 3 in. h, 6 ft 6 in. w (5) Navigational light panel. Manufacturer .............................. Henschel Corp. Model ......................................... Catalogue No. 40-036 Circuits....................................... 8 Switches..................................... 2 amp (ampere) 115 vdc (6) General alarm. Manufacturer .............................. Henschel Corp. Model ......................................... Contact maker 60-17, type C, 24 vdc Bell: 8 in. vibrating .......................... 3 10 in. vibrating ........................ 1 Power source ............................. Batteries (7) Searchlight. Manufacturer .............................. Carlisle Finch Co. Model ......................................... 12 in. lamp........................................... 500 watts. C13 filament. 115 vdc. mogul base. screw 1-4 Type........................................... 2 stage. back-to-back. centrifugal Drive type................................... Clutch (friction) and vee belt Clutch Mfr .................................. Twin Disc Co. (4) Priming pump. Manufacturer.............................. Kraissi Co. Model......................................... 25-9RS Type........................................... Rotary (vacuum) Drive .......................................... Vee belt and clutch Clutch: Manufacturer........................... Twin Disc Co. Model...................................... H-1035 g. Anchor Windlass (Capstan ) (by Modification ). Manufacturer.............................. Markey Machine Co. Model......................................... VEV-16 Chain capacity ........................... I in. stud link Chain hoist speed ..................... 35 fpm Brake capacity............................ 4,000 fpm Capstan diameter ....................... 18 in Reduction gear........................... Worm and wheel Motor ......................................... Star-Kimble, reversible Horsepower................................ 10 Voltage ...................................... 115 vdc Brake type.................................. Magnetic disc Controller: Mfgr ........................................... New England Trawler Equipment Co. Model......................................... R6460 Capacity..................................... 10 hp Voltage....................................... 115 vdc h. Capstan. Manufacturer .............................. New England Trawler Equipment Co. Model . ....................................... R-6293 Diameter ................................... 21 in. Reduction gear........................... Worm and wheel Capacity..................................... 6,670 lbs at 30 fpm Motor ......................................... Star-Kirpble, reversible Horsepower................................ 10 Voltage....................................... 115 vdc RPM........................................... 1,750 Brake type.................................. Magnetic, single disc, dry Controller: Mfgr ....................................... New England Trawler Equipment Co. Model...................................... D6460 Capacity ................................. 10 hp Voltage ................................... 115 vdc i. Pumps, General. (1) Fuel oil transfer pump. Manufacturer ............................. DeLaval Steam Turbine Company Model......................................... A313A143 Capacity..................................... 15 gpm at 25 psi Motor: Mfgr. ....................................... Electro Dynamics Co. Model...................................... 203 type R HP .......................................... 1 Voltage ................................... 115 vdc RPM ....................................... 1,750 Controller: Mfgr. .......................................... Ward-Leonard Electric Company (16) Radio direction finder (by modification ) Manufacturer .............................. Raytheon Co. Model ......................................... AN/SRD-8 (17) Fathometer (added equipment ). Manufacturer .............................. Raytheon Co, Model ......................................... DE-116 Range ........................................ 120 fathoms Control ....................................... Knob switch e. Compressed Air System. (1) Compressors (engine starting ). Quantity ..................................... 2 Manufacturer .............................. Quincy Compressor Co. Model ......................................... D340 air cooled Rating ........................................ 34.4 cu fpm (feet per minute) at 200 psi Cylinders .................................... 2 Bore: 1st stage................................. 5.25 2nd stage................................ 3 in. Stroke ........................................ 3 in. Motor Mfgr.................................. Fairbanks Morse Co. Model ......................................... DZM drip proof marine Type........................................... 7.50 hp, 115 vdc, 1750 rpm, 40°rise Drive .......................................... Vee belt Controller Mfgr. .......................... Square D Mfg. Col Switch type................................. UL-2, 7.50 hp Pressure switch .......................... Class 7904, type UL-2 (2) Air tanks. Quantity ..................................... 2 Capacity..................................... 50 cu ft Pressure..................................... 250 lbs (3) Whistle air tank. Quantity ..................................... 1 Capacity..................................... 5 cu ft Pressure..................................... 110 Ibs f. Auxiliary Set (Generator and Pump ). (1) Engine, diesel (by modification ). Model ......................................... 4061A Unit ............................................ 4-71 Manufacturer .............................. Detroit Diesel Engine Div. GM Corp. Type........................................... 4 cylinder, 2 cycle Bore ........................................... 4.25 in. Stroke ........................................ 5 in. Displacement ............................. 284 cu in Rotation ..................................... CCW (counter clock wise, viewed from flywheel end) Cooling system........................... Heat exchanger Exhaust system . ....................... Maxim type SC Starting system .......................... 24 vdc electric Lubricating system ..................... Forced feed (2) Generator. Manufacturer .............................. Delco Products Div. of GM Corp. Model ......................................... 1-3644 Rating ........................................ 40 kw, 120 vdc at 1,200 rpm (3) Fire and salvage pump (formerly Dean Hill ). Manufacturer .............................. Patterson Pump Co. Model ......................................... 4LSBB 1-5 Model...................................... 4801, Size 1 Capacity ................................. 1 hp Voltage ................................... 115 vdc (2) Fuel oil/lubricating oil hand pumps. Manufacturer .............................. Blackmer Pump Co. Quantity ..................................... 2 Model ......................................... WH404 Capacity..................................... 10 gpm (3) Purifier, oil lubricating. Manufacturer .............................. DeLaval Seperator Co. Model ......................................... 45-28 Motor: Manufacturer........................... General Electric Model...................................... 5BC74AB1801A HP .......................................... 1/2 Voltage ................................... 115 vdc RPM ....................................... 1.725 Controller ................................... General Electric (4) Lubricating oil standby pump. Manufacturer .............................. DeLaval Steam Turbine Co. Model ......................................... A322AX250 Capacity..................................... 175 gpm at 80 ft head and 35 psi Motor: Manufacturer........................... Electro Dynamics Model...................................... 21D1800 Frame ..................................... D324 Speed ..................................... 1,750 rpm Horsepower ............................ 10 Voltage ................................... 115 vdc Coupling type . ........................... Flexible Manufacturer . ............................ Falk Corp. Controller: Mfgr. ....................................... Ward-Leonard Electric Co. Model...................................... 18965-12 Type ....................................... Marine, w/overload protection, and low voltage release Amperage .............................. 75 Voltage .................................. 115 vdc Horsepower ............................ 10 (5) Fresh water/sanitary pressure sets (pump ). Quantity .................................... 2 Manufacturer .............................. Demming Div., Crane Co. Model ........................................ Figure 1892 Capacity..................................... 580 gpm Motor: Mfgr ....................................... Fairbanks Morse Co. Horsepower ............................ 1/3 Voltage ................................... 115 vdc Speed .................................... 1,750 rpm Pressure switch . ........................ Square D, type ALW-1-2 (6) Circulating and salt water standby pumps. Quantity .................................... 2 Manufacturer .............................. Fairbanks Morse Model ........................................ Figure 5532 Capacity .................................... 400 gpm at 40 ft head Motor Mfgr.................................. Fairbanks Morse Horsepower................................ 7.5 Voltage ...................................... 115 vdc Drive type................................... Flexible coupling Speed......................................... 1,750 rpm Controller ................................... GE type 7904UL2 (7) Fire pump. Manufacturer.............................. Fairbanks Morse Model......................................... Figure 5874 Capacity..................................... 300 gpm at 100 psi Motor ......................................... Fairbanks Morse, type DZM, frame RX364 Horsepower................................ 25 RPM........................................... 3,450 Drive type................................... Flexible coupling Controller ................................... General Electric type WL2 (8) Bilge and ballast pump. Manufacturer.............................. Fairbanks Morse Model......................................... Fig. 5531 Drive type................................... Flexible coupling Motor ......................................... Fairbanks Morse, type DZM, frame RX225 Horsepower................................ 3 Voltage....................................... 115 vdc Speed ........................................ 1,750 rpm Priming pump Mfgr..................... Nash Engineering Co. Model......................................... AL-2 Priming pump drive .................... Vee belt, from bilge pump drive motor Square D, type SL-2 (9) Scavenging oil transfer (heater ) pump. Manufacturer . ............................ Fairbanks-Morse Model ........................................ Fig. 5130 Motor: Manufacturer........................... Marathon Electric Mfg. Horsepower ............................ 1/3 Voltage ................................... 115 vdc Contactor: Manufacturer........................... Marathon Electric Mfg. Voltage ................................... 115 vdc w/overload relay and pneumatic timer j. Heating Unit. (1) Boiler. Manufacturer.............................. Crane Co. Boiler type.................................. Sectional, cast iron, steam Model . ....................................... SO-30-9 Rating . ...................................... 487,000 btu (British thermal units} (2) Burner. Manufacturer ............................. Crane Co. Model ........................................ 2A12C Type........................................... Pressure atomizing k. Ventilation Systems. (1) System number 1 (supply to crew quarters ). Manufacturer . ............................ ILG Industries, Inc. Model ........................................ BC35 Type........................................... Marine, centrifugal Rating ........................................ 3,000 cfm (cubic feet per minute) at 1 in. static pressure Motor Mfgr. ................................ ILG Industries, Inc. Rating ........................................ 1 hp at 1,300 rpm Controller Mfgr. .......................... Monitor Controller Co. Type........................................... 1 hp, 115 vdc, variable speed, two pole line contractor, STOP-START push button 1-6 Ammeter ................................... 0-25-30 amp Supply switch ............................ 2 pole Voltmeter switch......................... Double throw n. Fixed Fire Extinguisher System (C02 ). Manufacturer.............................. Walter Kidde and Co. Inc. Pull (control) box . ...................... One Cylinders (qty)............................ Twelve, with syphon tube Nozzles (qty) .............................. Twelve Net weight of CO2 ...................... 600lbs (50 lbs per cylinder) o. Galley Equipment. (1) Oil burning range. Manufacturer ............................. Stamford Foundry Co. Model......................................... 1300 S Burner........................................ Thermoshipment dc motor driven blower, 115 vdc, 18 amp. 21 watt, 1,900 rpm Day fuel tank capacity .................................. 30 gal (2) Refrigerator. Manufacturer.............................. McCall Refrigerator Corp. Model......................................... 17 SCIM Capacity..................................... 17 cu ft Voltage....................................... 115 vdc (3) Immersion heater. Manufacturer . ............................ Edwin Weigand Model......................................... TM-11O1B Rating ........................................ 1,000 watt, 115 vdc (4) Coffee urn. Manufacturer.............................. Leonard Haimes Co., Inc. Voltage....................................... 115 vdc (5) Deep freeze. Manufacturer.............................. McCall Refrigerator Corp. Model......................................... Reach in type Voltage....................................... 115 vdc (6) Dispenser, drinking water. Manufacturer.............................. Variable Size............................................ 10 Voltage....................................... 115 vdc p. Lifeboat Davit. Manufacturer.............................. Wilen Hand winch ................................ Model H-20 Working load.............................. 1.750 lbs Turning out gear working torque ........................ 61,200 in lbs (2) System number 2 (exhaust from crew quarters ). Manufacturer .............................. ILG Industries, Inc. Model....................................................................F18 Type .....................................................................Marine, centrifugal Rating ..................................................................1050 cfm Motor Mfgr ..........................................................ILG Industries, Inc. Rating...................................................................1/2 hp, 115 vdc, direct drive Controller Mfgr....................................................Monitor Controller Co. Type .....................................................................1/2 hp, 115 vdc, contractor two pole START-STOP button, and emergency STOP button (3) System number 3 (galley exhaust ). Manufacturer .....................................................ILG Industries, Inc. Model ...................................................................SSH-1P Type .....................................................................Marine, centrifugal Rating ..................................................................1,350 cfm Motor Mfgr.................................. ILG Industries, Inc. Rating ....................................... 1/2 hp, 115 vdc, direct drive Controller Mfgr. .......................... Monitor Controller Co. Type........................................... 1/2 hp, 115 vdc, Contactor 2 pole START-STOP button, and emergency STOP (4) System number 4 (supply to engine room ). Manufacturer......................................................ILG Industries, Inc. Model....................................................................BC40 Type......................................................................Marine, centrifugal Motor Mfgr...........................................................ILG Industries, Inc. Rating...................................................................3.5 hp, 115 vdc, direct drive Controller Mfgr....................................................Monitor Controller Co. Type......................................................................3.5 hp, 115 vdc, STARTSTOP button and emergency STOP button (5) System number 5 (exhaust from engineroom ). Manufacturer......................................................ILG Industries, Inc. Model....................................................................AF80 Type......................................................................Marine, axial flow Rating ........................................ 9,000 cfm at 1.5 in. static pressure Motor Mfgr.................................. ILG Industries, Inc. Rating ........................................ 4 hp, 115 vdc, direct drive Controller Mfgr. .......................... Monitor Controller Co. Type........................................... 4 hp, 115 vdc, STOPSTART button and emergency STOP button l. Main Electrical Control Panel. Manufacturer .............................. Pelham Electric Mfg. Corp. Type......................................................................Dead-front switchboard Main circuit breaker...........................................Roller-Smith type RD 375 amp trip Meters ..................................................................Roller-Smith type RD Ground detection lamps..............................................................Dial Light Co. Generator disconnect.......................................DPST 400 amp Transfer, generatorto-shore power ........................ DPDT 600 amp m. Battery Charging Control Panel. Manufacturer .............................. Pelham Electric Mfg. Corp. Type........................................... Dead-front inclosed Transfer switch........................... 4PDT, reverse current relay Voltmeter ................................... 0-50 q. Torque Limits (Engine Model 37F16 ). Refer to table 1-1 for torque application and limitation. r. Gear Backlash (Engine Model 37F16 ). Refer to table 1-2 for minimum and maximum allowable gear backlash. s. Wear LimitTolerance (Engine Model 37F16 ). Refer to table 1-3 for tolerances on wear limit. t. Operating Pressures (Engine Model 37F16). Refer to table 1-4 for normal operating pressures. u. Operating Temperatures (Engine Model 37F16 ). Refer to table 1-5 for normal operating temperatures . 1-7 Table 1-1. Torque Limits (Engine, Model 37F16) Part nomenclature Upper base to cylinder stud Cylinder head stud Connecting rod bolt Main bearing stud Piston pin cap stud Exhaust manifold stud Fuel injector stud Air start check valve stud Ft lbs allowable torque Min 1,500 800 1,020 1,130 425 130 100 75 (nut end) (nut end) (nut end) (nut end) (nut end) (nut end) (nut end) (nut end) Max 1,550 840 1,060 1,160 440 135 120 85 Table 1-2. Gear Backlash Table (Engine Model 37F16) Backlash Min Timing gear train 0.010 Lubrication oil pump drive gears 0.008 Lubrication oil pump impellers 0.003 Water pump drive gear 0.008 Governor drive gear 0.004 Part nomenclature Table 1-3. Wear Limit Tolerance (Engine Model 37F16) Part nomenclature New dimension Min Main bearings: Sleeve to shaft clearance Sleeve thickness Kingsbury bearing Crankshaft: Crankpin journal Crankpin-out of round Crankpin-taper Main bearing journal Connecting rod: Sleeve to shaft Pin sleeve-inner dia Pin sleeve-outer dia Pin diameter Pin to sleeve clearance Side clearance Piston and cylinder: Piston diameter Cylinder bore Cylinder-out of round Piston to cylinder clearance Piston pin bore dia Ibracket) Piston rings (45°angle cut) Compression ring-gap Compression ring side clearance: Top ring Others Scavenge pump Pump piston dia Pump cylinder bore Pump piston sleeve dia: Upper Lower Pump cylinder sleeve bore Piston sleeve scraper ring-gap Piston sleeve seal ring-side clearance 1-8 Max 0.014 0.010 0.005 0.010 0.006 Max Condemnable deimension 0.004 1.9965 0.050 0.006 1.9985 0.070 0.050 min 9.998 0.004 0.004 9.999 10.002 0.003 5.500 6.253 5.493 0.006 0.018 0 005 5.502 6.254 5.494 0.009 0.032 15.983 15.999 0.008 0.014 4.999 15.985 16.001 0.018 5 000 0.040 Bolted 0 060 0.085 0.3125 0.012 0.009 0.016 0.013 0.025 0.022 37.448 37.498 37.452 37.502 4.983 10.479 10.502 0.125 0.004 4.985 10.481 10.504 0.1875 0.015 10.001 5.510 Press fit 5.488 0.020 0.0625 4.975 10.465 10.510 0.015 0.025 Part nomenclalure New dimension Scavenge pump connecting rod: Sleeve to shaft clearance Piston pin sleeve: Inner dia Outer dia Piston pin dia Side clearance-Total Lubrication oil pump drive: Drive shaft to bearing clearance CamshaftSleeve to shaft Thrust bearing end clearance Sleeve-inside diaScavenging pump end Center and drive end Min Max 0.003 0 005 3.4900 4.127 3.4965 0.018 3.5005 4 128 3.4970 0.032 0.005 0.0075 0.001 0.008 0.0065 0.012 2.752 3 503 2.754 3.505 Condemnable dimension 3.505 Press fit 3.493 0.094 Table 1-4. Operating Pressures (Engine Model 37F16) Normal operation of: Lubrication oil header Fuel oil header Soft water inlet Air receiver Starting air-maximum Firing pressure-maximum Hot engine compression: max min Maximum variation between cylinders Exhaust back pressure-inches of water-(measured at cylinder most remote from exhaust outlet) maximum Operating pressure (psi) 15 psi 2 to 6 psi 10 to 15 psi 1.5 to 2.5 psi 250 psi 860 psi 490 psi 420 psi 25 psi 12 in. Table 1-5. Operating Temperatures (Engine Model 37F16) Normal Operation of: Operating temperature in degrees F Min Exhaust: Recommended Individual at cylinder-maximum Soft Water outlet: Recommended Differential: Inlet to outlet Lubrication oil outlet: Recommended Differential: Inlet to outlet-max 400°F Max 580°F 600°F 1350F 10°F 160°F 25°F 1-9 CHAPTER 2 OPERATING INSTRUCTIONS WARNING If this equipment fails to operate, refer to troubleshooting procedures in chapter 3. Section I. OPERATING PROCEDURES 2-2. Controls and Instruments 2-1. General The following paragraphs will describe, locate, illustrate, a. Pilothouse Navigational Controls. and furnish the operator/crew sufficient information (1) Horn lever (1, fig. 2-1). The horn lever is pertaining to the various controls and instruments to located on the overhead of the pilothouse to port of provide for proper operation of the tug, its components, center. Pulling lever down activates the horn 2-1 assemblies, and associated accessories. 2-1 1. 2. 3. 4. 5. Horn lever 6. Whistle cord Search light control switch 7. Magnetic compass Searchlight control handle 8. Engine order telegraph (2) Clinometer 9. Steering wheel Engine rpm indicator 10. Rudder angle indicator Figure 2-1. Pilothouse nauigational controls. (2) Searchlight control switch (2 ). This switch is located on the overhead of the pilothouse to port of center. Turning control switch ON activates the searchlight. above and ahead of the steering wheel. Pulling the cord activates the whistle. (5) Magnetic compass (7 ). This compass is located just ahead of the steering wheel and indicates the magnetic direction. (3) Searchlight control handle (3 ). The handle is located on overhead of pilothouse at center, above the steering wheel. The searchlight is moved (horizontal and vertical) by a similar movement transmitted through the control handle. (6) Steering wheel (9 ). The steering wheel is mounted on the steering console (stand) in the center of the pilothouse. Movement of wheel is paralled by the rudder, and rudder position is shown by (7) below. (4) Whistle cord (6 ). The cord is located 2-2 2-2 rheostat type switches are located inside the pilothouse opposite the windshield wiper it controls. Turning switches regulate the speed of the wipers. (7) Rudder angle indicator (10 ). This indicator is located ahead of steering wheel on center (top) of steering console, and shows plane of rudder in relationship to center line of the tug. (2) Clinometer (4 ). The clinoineter is located on center line of tug at the overhead, ahead of the steering wheel. It indicates the roll of the tug in degrees. b. Pilothouse Engine Controls. (1) Engine rpm indicator (5). The engine rpm indicator is located on forward bulkhead of pilothouse near the overhead. It indicates rpm of engine, and direction of rotation in which it is running. (3) Binnacle light switch. The binnacle light switch is located on the steering console. It controls the binnacle light for ON, OFF, or intensity. d. After Steering Station Controls. (2) Engine order telegraph (8 ). The two engine order telegraph are located to port and starboard of steering wheel. The handle on the telegraph moves a pointer to a desired position on the dial. These telegraphs are connected to a similar instrument in engine room, and at the after steering station. Movement of one handle is paralleled on all of the instruments (also, see d (1) below). (1) Engine order telegraph (1, fig. 2-2 ). The after steering station engine order telegraph is located on the after starboard side of the boat deck. The handle on this telegraph controls a pointer on the dial. Connected to similar instruments in engineroom and pilothouse, a movement of handle is paralleled on all instruments (b (2)). c. Other Pilothouse Controls. (1) Windshield wiper control switches. The 2-3 1. Engine order telegraph 2. After steering control 3. Sound power telephone Figure 2-2. After steering station. (2) After steering control (2 ). The after steering control is a lever type device which moves the rudder. Moving lever to starboard moves rudder to the right. Moving lever to port moves rudder to the left. e. Propulsion Engineroom Controls. (1) Engine order telegraph (1, fig. 2-3 ). The engine order telegraph is located on port side of the engine. This telegraph is connected to similar instruments in pilothouse (para b (2) above) and after steering station (para d (1) above). Movement of pointers are paralleled on all instruments. 2-4 1. 2. 3. 4. 5. 6. Engine order telegraph 7. Airbrake pressure gage Steering gear switch 8. Cylinder relief lever Voice tube (to aft steering station) 9. Thermometers Governor hand control 10. Fuel shutoff reset lever Throttle handwheel 11. Emergency fuel shutoff Astern and ahead handwheel 12. Fuel filter selection lever Figure 2-3. Main engine controls. engine near governor hand control, this is a source of communication between engine operator and the vessel operator at the aft steering station. (2) Steering gear switch (2 ). This switch operates motor that drives hydraulic pump of the steering gear system. It is located on port side of engine, near the engine order telegraph dial. Depressing RUN button starts motor and places steering gear in operation. Depressing STOP button stops motor and secures the steering system. (3) (4) Governor hand control (4 ). This control is located on port side of engine, just above the throttle handwheel. It is used during maneuvering when quick change of engine speed is necessary. Voice tube (3 ). Located on port side or (5) Throttle handwheel (5 ). Located on port side of engine just ahead of the astern/ahead 2-5 2-5 handwheel, turning this control counterclockwise increases engine speed. Turning it clockwise decreases engine speed. end of lever, then moving lever from 11 o'clock to 1 o'clock opens the cylinder relief valves on all cylinders and releases compression from cylinders. (6) Astern/ahead handwheel (6 ). This handwheel starts, stops, and changes the direction of rotation of the engine. It is located on port side of the engine aft of the throttle control handwheel. With handwheel at STOP, moving it clockwise past ASTERN to START position starts the engine turning in that direction. After engine is turning over, move handwheel back to ASTERN and it continues to move in the run position (ASTERN). Moving the handwheel counterclockwise from ASTERN to STOP position stops the engine. NOTE The flywheel airbrake assists in bringing engine to a quick stop. Moving handwheel counterclockwise past AHEAD To START position starts the engine turning in that direction. When the engine is turning over, move handwheel clockwise to AHEAD position and the engine will continue to move in the run position (AHEAD). (9) Thermometers (9 ). The thermometers are located on port side of engine alongside each bearing access plate, and indicates temperature of oil returning from that piston. (10) Fuel shutoff reset lever (10 ). This lever is on port side of engine just ahead of the throttle handwheel. Its purpose is to reset the emergency fuel shutoff after it has been manually tripped. (11) Emergency fuel shutoff (11 ). This control is located on engines port side, on the front of the overspeed governor. Pressing the button cuts off all fuel to the engine in any emergency. (12) Fuel filter selection lever (12 ). This control is part of the fuel filter manifold and cover assembly, and is located on port side of engine, forward of the governor. Positioning lever horizontally in front of the desired filter opens valve in fuel line from the selected filter. It closes valve in line from remaining filter, allowing service to be performed on the filter not in use. f. Auxiliary Set Engine Controls and Instruments. (1) Panel light switch (5, fig. 2-4 ). Located on the engine instrument panel, this switch turns panel light ON or OFF. (7) Airbrake pressure gage (7 ). This gage is located above astern/ahead handwheel and indicates the air pressure available to the flywheel airbrake. (8) Cylinder relief lever (8 ). This lever is located on port side of engine aft of the astern/ ahead handwheel. Depressing the plunger on the 2-6 TM 55-1925-204-12 1. Starter push switch 2. Water temperature gage 3. Oil pressure gage 4. Throttle 5. Panel light switch 6. Ammeter Figure 2-4. Auxiliary set engine controls and instruments. (2) Starter push switch (1). This switch operates the starter motor of diesel engine on auxiliary set. It is located at top left of engine control panel. Push to start. (3) Water temperature gage (2). This gage is located on engine control panel. It indicates the temperature of the water circulating through the engine block. The normal reading of this gage is 165°F. Temperature readings in excess of 1800F. ,or less than 155°F. should be investigated. (4) Oil pressure gage (3). Located on engine control panel, this gage indicates the pressure at which oil is being delivered to all engine lubrication points. Normal reading of this gage when engine is warm is between 30 and 40 psi. (5) Throttle (4). Located on lower right corner of the engine control panel, the throttle controls engine speed and provides a means of stopping the engine. Turning throttle clockwise from STOP to RUN opens metering plungers and engine is ready to start. Turning throttle counterclockwise from RUN to STOP shuts off fuel flow and stops the engine. (6) Ammeter (6). Located at center of engine control panel, the ammeter indicates current flow rate from generator to storage batteries. It should always read on the charging side when the engine is running. g. Fire and Salvage Pump Clutch. This pump is driven with a friction clutch from end of auxiliary set generator rotor shaft. The clutch control lever is located on left side of the auxiliary set. When auxiliary set is in operation, moving clutch control lever forward engages clutch, and moving lever aft disengages clutch to stop the fire and salvage pump. h. Fire and Salvage Pump Priming Pump Clutch. This priming pump is operated by a friction clutch driven with a V-belt arrangement from fire and salvage pump clutch. The clutch control handle is located above the fire and salvage pump, and pulling clutch handle aft engages the clutch. Pushing clutch handle forward disengages the clutch and stops the priming pump. NOTE The priming pump must run until the fire and salvage pump begins discharging water. 2-7 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. i. Fire Pump. The fire pump is directly coupled to its prime mover, a 25 hp electric motor. NOTE Lighting aboard ship is limited to 1000 watts when fire fighting equipment is in action. To start the fire pump depress the START button. To stop the pump depress STOP button. j. Main Electrical Control Panel (Switchboard ). The main electrical control panel is located in the forward section of the engine room (fig. 2-5). Its circuit breakers, meters, rheostat controls, etc. , are listed and described as follows: Key to fig. 2-5: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Circuit breaker, generator no. 2 Power available light, generator no. 2 Calibrating voltmeter Ground lights Clinometer Steering motor amperage Shore power indicator lights Ground switch Generator voltmeter Voltmeter selector switch Power available light, generator No. I Circuit breaker, generator No. 1 Ground detector button Ammeter, generator No. I 2-8 Rheostat, generator No. 1 Disconnect, generator No. 1 Power selector switch Lighting panel switch Fuel oil transfer pump switch Bilge and ballast pump switch Lighting panel switch Fire pump switch Power panel switch General lighting panel switch Navigation light panel switch Fresh water standby pump switch Air compressor switch Radar switch Anchor windlass switch Lubricating oil standby pump switch Steering motor switch Ventilating power panel switch Salt water circulator switch Lubricating oil purifier switch Capstan switch Air compressor switch Shore supply switch Disconnect, generator No. 2 Generator equalizer switch Rheostat, generator No. 2 Ammeter, generator No. 2 Selector switch Figure 2-5. Main electrical control panel ( switchboard (1) Circuit breaker, generator No. 2 (1, Fig. 25). This circuit breaker is used to open or close the electrical circuit between generator No. 2 and the control panel. In the event circuit becomes overloaded the circuit breaker acts as a protective device and opens the circuit automatically. (2) Power available light, generator No. 2 (2). This signal light-, when lighted, indicates that power is available for use from generator No. 2. (3) Calibrating voltmeter (3 ). Indicates total voltage available from generator selected on selector switch (10). (4) Ground lights (4 ). Indicates the location of grounded electrical circuitry by a change in brilliance. (5) Clinometer (5 ). Indicates the angle of roll of the tug (in degrees). (6) Steering motor amperage (6). Indicates the amperage being used by the steering motor. (7) Shore power indicator light (7). When lighted, these lights indicate that power is available to the control panel from the shore cable. (8) Generator voltmeter (9). Indicates available voltage on the unit designated by selector switch (10). (9) Voltmeter selector switch (10). Selects the generator on which a voltage reading is to be taken. (10) Power available light, generator No. 1 2-9 (11). This signal, when lighted, indicates that power is available from generator No. 1. (11) Circuit breaker, generator No. 1 (12). Opens or closes the electrical circuit between generator no. 1 and the electrical control panel. When an overload occurs it opens the circuit automatically. (12) Ground detector button (13). Depressing this button isolates the ungrounded wire and illuminates one of signal lights (4), thereby indicating in which leg of the circuit the ground is located. (13) Ammeter, generator No. 1 (14). This indicates amperage load on generator no. 1. (14) Rheostat, generator No. 1 (15). The field rheostat is used to adjust voltage output of generator no. 1. (15) Disconnect, generator No. 1 (16). This is the line switch between generator no. 1 and the main control panel. (16) Power selector switch (17). This switch is used to transfer load from control panel to shore, or from shore to the control panel. (17) Lighting panel switch (18). This switch controls power to the engine room lighting panel. (18) Fuel oil transfer pump switch (19). This switch controls power to controller of fuel oil transfer pump. (19) Bilge and ballast pump switch (20). This switch controls power to controller of the bilge and ballast pump. (20) Lighting panel switch (21 ). This switch controls power to the pilothouse lighting panel. (21) Fire pump switch (22). This switch controls power to controller of the fire pump. (22) Power panel switch (23). This switch controls power to the engine room power panel. (23) General lighting panel switch (24). This switch controls power to the crews quarters lighting panel. (24) Navigation lighting panel switch (25). This switch controls power to pilothouse navigation light panel. (25) Fresh water standby pump switch (26). This switch controls power to controller of fresh water standby pump. 26) Air compressor switch (27). This switch controls power to controller of the air compressor. (27) Radar switch (28). This switch controls power to the radar control panel in pilothouse. (28) Anchor windlass switch (29 ). This switch controls power to controller of the anchor windlass. (29) Lubricating oil standby pump switch (30 ). This switch controls power to the lubricating oil standby pump. (30) Steering motor switch (31). This switch controls power to controller of the steering motor. (31) Ventilation power panel switch (32). This switch controls power to the ventilation system power panel. (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) Salt water circulator switch (33). This switch controls power to the controller of the salt water circulation standby pump. Lubricating oil purifier switch (34). This switch controls power to the controller of the lubricating oil purifier. Capstan switch (35). This switch controls power to controller of the capstan. Air compressor switch (36). This switch controls power to controller of the air compressor. Shore supply switch (37). This switch controls power to the power panel on main deck that can be used to supply power to another unit from this tug. Disconnect, generator No. 2 (38). This is the line switch between generator No. 2 and main control panel. Generator equalizer switch (39). The equalizer switch is used to balance load between the two generators and prevents one generator from taking load away from the other. Rheostat, generator No. 2 (40). This rheostat is used to adjust voltage output of generator No. 2. Ammeter, generator No. 2 (41). This ammeter indicates amperage load of generator No. 2. Selector switch (42). The calibrating voltmeter selector switch is used to select the generator on which voltage reading is desired. It may be used for either the. incoming generator, or it may be used to check the accuracy of voltmeter (9) by positioning on the same generator or selector switch (10). k. Heating System Controls. (1) Convector stop valves. A stop valve is installed in the steam pipe on inlet side of each convector. This will allow control of amount of steam going to each convector. NOTE The convector in crew's quarters and the heating coil installed in the supply ventilators are either thermostatically controlled, or controlled by siphon tubes. installed in the ventilation system. (2) Thermostat. A thermostat to control the crew's quarters unit heater is located on the bulkhead, for maintaining even temperature in the area. (3) Stack Switch. The stack switch is located on the stack next to the boiler. This switch acts as an automatic safety feature on the heating unit. In case of power failure or momentary interruption during operation, the control will shut the burner off and automatically restart it after the stack gases have cooled, and the starting contacts of the stack switch have closed. In case of flame failure 2-10 during operation the stack temperature and helix will cool, thereby closing the cold or starting contacts, and the burner will lock out after the preset time of 90 seconds. (4) Pressure and vacuum gage (1, fig. 2-6). The pressure and vacuum gage is located on front of the boiler. The normal pressure reading on this gage should be 5 psi, and should never exceed 10 psi. 1 Pressure and gage 2 skater gage 3. Pressuretrol 4 Burner unit 5 Sight glass Figure 2-6 Heating boiler controls (5) Water gage (2). The water gage is located on side of heating unit at top right front. The gage indicates actual level of water in the boiler. Unit should be secured immediately if water level disappears from the gage. The normal water level is at midpoint in the glass. (6) Pressuretrol (3). The pressuretrol is located at the top outboard end of the boiler. The function of this control is to secure the boiler heating unit should pressure exceed 10 psi. (7) Safety valve. The safety valve is located at top of the boiler. Its function is to release the boiler pressure when pressure exceeds 10 psi. (8) Air inlet shutter. The air inlet shutter is located on side of the burner blower housing. Its purpose is to adjust the amount of air being admitted to unit burner. (9) Oil burner cutout switch. The oil burner cutout switch is located adjacent to the oil burner. This switch gives independent control of electric power to the burner unit. (10) Low water cutoff. The low water cutoff is located on forward side of boiler. Its purpose is to secure the boiler heating unit if water level drops below the safe operating level. (11) Heating system control valves. The location and identification of heating system control valves are shown in table 2-1 below: 2-11 Table 2-1 Heating System Control Valves. Valve No. Service 1 2 Supply water to heating boiler. Drain valve from heating boiler. 3 Condensate return. 4 5 19 Main steam supply. Temperature regulator station for fan room. Temperature regulator bypass in fan room. Inlet to temperature regulator bypass in fan room. Steam from temperature regulator station in fan room. Condensate return from fan room heating coil. Temperature regulator station below pilothouse. Temperature regulator bypass below pilothouse. Inlet to temperature regulator station below pilothouse. Steam from temperature regulator station below pilothouse. Condensate return from heating coil below pilothouse. Convector inlet in aft section of crew's washroom. Convector supply in forward section of crew's washroom. Convector return in aft section of crew's washroom. Convector return in forward section of crew's washroom. Convector supply in galley. 20 Convector return in galley. 21 Convector supply in messhall, aft. 22 Convector return in messhall, aft. 23 Convector supply in messhall, forward. 24 Convector return in messhall, forward. 25 27 Convector supply in chief engineer's stateroom. Convector return in chief engineer's stateroom. Convector supply in passageway. 28 Convector return in passageway. 29 Convector supply in middle of pilothouse. port side Convector return in middle of pilothouse, portside. Convector supply in pilothouse, starboard side, rear. Convector return in pilothouse, starboard side, rear. Convector supply, in pilothouse, portside, rear. 6 7 8 9 10 11 12 13 14 15 16 17 18 26 30 31 32 33 Location Portside, below main deck, frame 40. Portside, above engine room floor, frame 40. Portside, above engine room floor, frame 38. Portside, below main deck, frame 39. Starboard side, above boat deck, frame 22. Starboard side, above boat deck, frame 23. Starboard side, above boat deck, frame 22. Starboard side, above boat deck, frame 23. Starboard side, above boat deck, frame 23. Portside, above boat deck, frame 21. Label inscription DRAIN COND. RETURN STEAM SHUT-OFF H.W. TEMP. REG. TEMP. REG. BY-PASS STEAM TO TEMP. REG. STEAM FROM TEMP. REG. CONDENSATE RETURN H.W. TEMP. REG. Portside, above boat deck. frame 21. TEMP. REG. BY-PASS Portside, above boat deck, frame 21. STEAM TO TEMP. REG. Portside, above boat deck, frame 21. STEAM FROM TEMP. REG. Starboard side, above boat deck, frame 21. Portside, above main deck, frame 35. CONDENSATE RETURN Portside, above main deck, frame 30. STEAM INLET Portside, above main deck, frame 35. CONDENSATE RETURN Portside, above main deck, frame 31. CONDENSATE RETURN Starboard side, above main deck, frame 32. Starboard side, above main deck, frame 29. Starboard side, above main deck, frame 26. Starboard side, above main deck, frame 26. Starboard side, above main deck, frame 22. Starboard side, above main deck, frame 22. Starboard side, above main deck, frame 15. Starboard side, above main deck, frame 17. Starboard side, above main deck, frame 21. At centerline, above main deck, frame 21. Portside, above boat deck, frame 21. STEAM INLET Portside, above boat deck, frame 17. CONDENSATE RETURN Starboard side, above boat deck, frame 22. Starboard side, above boat deck, frame 22. Portside, above boat deck, frame 21. STEAM INLET 2-12 STEAM INLET CONDENSATE RETURN STEAM INLET CONDENSATE RETURN STEAM INLET CONDENSATE RETURN STEAM INLET CONDENSATE RETURN STEAM INLET CONDENSATE RETURN STEAM INLET CONDENSATE RETURN STEAM INLET Table 2-1 Heating System Control Valves. Valve No. 34 Service 45 Convector return in pilothouse. portside. rear. Convector supply in middle of pilothouse. starboard side. Convector return in middle of pilothouse. starboard side. Convector supply in pilothouse. starboard side. front. Convector return in pilothouse. starboard side. front. Convector supply in pilothouse. portside. front. Convector return in pilothouse. starboard side. front. Convector supply in captain's Portside. stateroom. Convector return in captain's stateroom. Convector supply in officer's washroom. Convector return in officer's washroom. Engineroom unit heater. aft. 46 Engineroom unit heater. forward. 47 Crew's quarters unit heater. 35 36 37 38 39 40 41 42 43 44 Location Label inscription Portside. above boat deck, frame 22. CONDENSATE RETURN Starboard side, above boat deck, frame 17. Starboard side. above boat deck, frame 19. Starboard side, above boat deck, frame 16. Starboard side, above boat deck, frame 15. Portside. above boat deck. frame 16. STEAM INLET Portside. above boat deck. frame 15. CONDENSATE RETURN above main deck. frame 17. STEAM INLET Portside, above main deck, frame 15. CONDENSATE RETURN Portside. above main deck. frame 23. STEAM INLET Portside. above main deck. frame 24. CONDENSATE RETURN Starboard side, below main deck, frame 40. At centerline, below main deck, frame 25. At centerline, below main deck, frame 18. STEAM INLET CONDENSATE RETURN STEAM INLET CONDENSATE RETURN STEAM INLET STEAM INLET STEAM INLET each of the storage tanks. Normal indication should read above 240 psi. When the reading drops below 240 psi, both compressors will start. l. Air Compressor Controls. (1) Air pressure gages (1, fig. 27). These gages indicate the amount of compressed air in 2-13 1. Air pressure gage 2. Air compressor switch 3. Selector switch 4. Reset button Figure 2-7. Air compressor controls. compressor operation is automatic. Moving selector to OFF secures the units. (4) Reset button (4). The reset button is used to reset the controller if tripped by an overload. Always determine cause of breaker tripping before resetting the switch. (5) Compressed air system control valves. The location and identification of air control valves are in table 2-2 below: (2) Air compressor switch (2). This switch is located on the controller. Moving switch to ON will start both compressors. NOTE Procedures for adjustment of pressure regulating switches are contained in the maintenance paragraph 5-56. (3) Selector switch (3). The selector switch provides choice of mode of operation. With switch at AUTO, 2-14 Table 2-2. Compressed Air System Control Valves. Valve No. 1 2 3 Service No. 1 compressor relief valve, set at 265 psi. No. 1 compressor discharge valve. 4 No. 2 compressor relief valve, set at 265 psi. No. 2 compressor discharge valve. 5 6 7 No. 2 air tank inlet valve. No. 1 air tank inlet valve. No. 2 air tank drains (2). 8 9 10 No. 2 air tank outlet. No. 2 air tank to pressure gage. No. 1 air tank drains (2). 11 12 13 14 No.1 air tank outlet. No. 1 air tank to pressure gage. Moisture separator drain valve. Air line to gage board. 15 Air to engine. 16 Sea chest blowout branch. 17 Sea chest blowout branch. 18 Sea chest blowout branch. 19 Sea chest blowout branch. 20 Ship's service air hose. 21 Ship's service 50 psi air supply. 22 Outlet from 250-50 psi reducing station. Reducing valve for 250-50 psi reducing station. Strainer drain in 250-50 psi reducing station. Inlet to 250-50 psi reducing station. 23 24 25 26 27 28 Bypass for 250-50 psi reducing station. Inlet to 250-100 psi reducing station. 32 Strainer drain in 250-100 psi reducing station. Reducing valve for 250-100 psi reducing station. Outlet from 250-100 psi reducing station. Bypass for 250-100 psi reducing station. Inlet to whistle air tank. 33 Whistle air tank drain. 34 Engineroom air tools. 35 36 37 Main deck air tools. Whistle tank relief valve set at 110 lb. Air to whistle. 38 Sea chest blowout branch 29 30 31 Location Stbd. side, above engineroom floor, frame 20. Stbd. side, above engineroom floor, frame 21. Near centerline, above engineroom floor, frame 20. Near centerline, above engineroom floor, frame 21. Stbd. side, below main deck, frame 21. Stbd. side, below main deck, frame 22. Port and stbd. sides below air tank, frame 21. Portside, below main deck, frame 21. Portside, below main deck. frame 21. Port and stbd. sides below air tank, frame 23. Portside, below main deck, frame 22. Portside, below main deck, frame 23. Portside, below main deck, frame 26. Near centerline, below main deck. frame 26. Near centerline, below air tank. frame 26. Portside, below engineroom floor, frame 22. Stbd. side. below engineroom floor, frame 27. Portside, below engineroom floor, frame 31 Portside, below engineroom floor, frame 25 Stbd. side, above engineroom floor, frame 41. Portside, at bulkhead, at engineroom floor, frame 26. Portside, above engineroom floor, frame 26. Portside, above engineroom floor, frame 26. Portside, above engineroom floor, frame 26. Portside. Above engineroom floor, frame 26. Portside, above engineroom floor, frame 26. Near centerline. below whistle air tank, frame 30. Near centerline. below whistle air tank, frame 31. Near centerline. below whistle air tank, frame 31. Near centerline, below whistle air tank, frame 31. Near centerline, below whistle air tank, frame 30. Near centerline, at whistle air tank, frame 32. Near centerline, below whistle air tank, frame 31. Portside. At bulkhead, above engineroom floor, frame 32. Portside. above main deck. frame 32. Near centerline. at whistle tank. frame 30 Near centerline, below main deck, frame 29 Portside, near bulkhead. At engineroom floor, frame 32 2-15 Label inscription COMP. OUTLET COMP. OUTLET AIR TO TANK AIR TO TANK BLOW OUT AIR FROM TANK GAGE BD. BLOW OUT AIR FROM TANK GAGE BD. MOIST. DRAIN GAGE BD. AIR TO ENG S. C. BLOW S. C. BLOW S. C. BLOW AIR TO SEA CHESTS AIR HOSE 50# AIR SUPPLY 50 # AIR SHUTOFF 250# TO 50# AIR 250#-50# BY-PASS 250# TO 100# AIR 100# AIR SHUTOFF BY-PASS 250#-100# AIR TO WHISTLE TANK DRAIN AIRTOOLS AIR TOOLS AIR TO WHlISTLE S C. BLOW m. Ventilation System Controls. The control switches for the ventilation system blowers are located in the access area to the engine room. (3) Ventilation blower line switches. These switches are located on the ventilation power panel which is on the inboard bulkhead of the engineroom passage. Place the line switch at ON before starting blower. Each switch is clearly marked on the side as to which blower it controls. (2) Blower start-stop switches. These switches are adjacent to the line switches. Pressing the ON button starts blower. Pressing the OFF button stops the blower. Blower emergency stop switches. Emergency stop switches are located in engineroom and pilothouse. Operation of either switch stops all ventilation blowers. (1) n. Raw and Fresh Water Engine Cooling System Controls. (1) Thermometers. Temperature indicating thermometers are installed at the intake and outlet points of the fresh water heat exchangers, lubricating oil coolers, and engine manifold, (2) Valves. The location and identification of each control valve in the system is shown in table 2-3 below: Table 2-3. Raw and Fresh Water Engine Cooling System Control Valves. Valve No. 1 2 3 4 5 Service Fill expansion tank with potable water. Attached fresh water pump suction. 6 Heat exchanger bypass. Heat exchanger inlet. Heat exchanger outlet to fresh water pump. Fresh water pumps drain 7 Fresh water standby pump suction. 8 Low sea chest raw water suction. 9 Attached raw water pump suction. 10 Cutout to gage board. 11 Raw water overboard discharge. 12 Raw water standby pump suction. 13 Raw water standby pump drain. 14 Raw water suction to sanitary pressure set. High sea chest raw water suction. 15 16 18 Compressed air blowout, low sea chest. Compressed air blowout, high sea chest. Raw water to thrust bearing. 19 Raw water to stern tube bearing. 20 Sea chest to port generator. 21 Port generator overboard discharge. 22 23 Compressed air blowout, port generator sea chest. Sea chest to stbd. generator. 24 Stbd. generator overboard. 25 Compressed air blowout, stbd. generator sea chest. 17 Location Near centerline, above main deck, frame 27. At centerline, at engineroom floor, frame 25. Stbd. side, below main deck, frame 37. Stbd. side, below main deck, frame 36. Stbd. side, below main deck, frame 32. Stbd. side, below engineroom floor, frame 26. Stbd. side, above engineroom floor, frame 33. Portside, below engineroom floor, frame 32. At centerline, at engineroom floor, frame 25. Stbd. side, at bulkhead, above engineroom floor, frame 29. Stbd. side, near bulkhead below main deck, frame 38. Portside, above engineroom floor, frame 34. Stbd. side, near centerline, below engineroom floor, frame 35. Portside, near bulkhead, at engineroom floor, frame 32. Portside, at bulkhead, at engineroom floor, frame 32. Portside, near bulkhead, below engineroom floor, frame 32. Portside, near bulkhead, at engineroom floor, frame 32. Stbd. side, below engineroom floor, frame 39. Stbd. side, below engineroom floor, frame 39. Portside, above engineroom floor, frame 22. Portside, above engineroom floor, frame 26. Portside, above engineroom floor, frame 26. Stbd. side, above engineroom floor, frame 26. Stbd. side, above engineroom floor, frame 22. Stbd. side, above engineroom floor, frame 22. 2-16 Label inscription ATT. F. W. PUMP SUCT. F. W. BYPASS F. W. TO HT. EXCH 'R F. W. FROM HT. EXCH'R DRAIN F. W. STDBY PUMP SUCTION LOW S. W. TO HT. EXCH'R ATT. S. W. PUMP SUCT. GAUGEBD. S. W. FROM HT. EXCH'R S. W. STDBY. PUMP SUCT. DRAIN S. W. SUCT. S. W. TO HT. EXCH'R S. C. BLOW S. C. BLOW S. W. TO THRUST BEARING S. W. TO SHAFT BR'G P. GEN. S. W. SUCT. P. GEN. S. W. DISCH. S. C. BLOW S. GEN. S. W. SUCT. S. GEN. S. W. DISCH. S. C. BLOW Valve No. 26 Service Raw water standby pump discharge to lubricating oil cooler. Fresh water standby pump discharge to engine. Attached raw water pump to lubricating oil cooler. Attached fresh water pump to engine 27 28 29 Location Portside. above engineroom floor. frame 35. Stbd. side. above engineroom floor. frame 33. Portside. above engineroom floor, frame 26. Stbd. side. above engineroom floor. frame 26. Label inscription S. W. STDBY. PUMP DISCH. F. W. STDBY. PUMP DISCH. TO ENG. ATT. S. W. PUMP DISCH. ATT. F. W. PUMP DISCH. o. Fuel Oil System Control Values. The fuel oil system control valves are located and identified in table 24 below: Table 2-4 Fuel Oil System Control Values. Valve No. Service 1 Fuel oil overboard discharge. 2 3 4 Fuel oil deck discharge. Deck fill. Fill line shutoff valve. 5 Discharge, No. 1 F. O. Tank. 6 Fill line shutoff, No. 1 F. O. Tank. 7 Discharge, No. 2 port F. O. Tank. 8 Fill line shutoff No. 2 F. O. Tank. 9 Discharge, No. 2 stbd. F. O. Tank. 10 Fill line shutoff, No. 2 stbd. F. O. Tank. Discharge, No. 3 port F. O. Tank. 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Fill line shutoff, No. 3 port F. O. Tank. Discharge, No. 3 stbd. F. O. Tank. Fill line shutoff No. 3 stbd. F. O. Tank. Discharge, No. 4 port F. O. Tank. Fill line shutoff No. 4 port F. O. Tank. Discharge, No. 4 stbd. F. O. Tank. Fill line shutoff, No.4 stbd. F. O. Tank. Transfer pump suction. Crossover from F. O. transfer pump to fuel fill manifold. (For shifting fuel between tanks.) Fuel oil transfer pump discharge. Fuel oil transfer and hand pump discharge to day tank. Fuel oil transfer and hand pump discharge crossover. Hand fuel oil pump manifold suction. Hand pump discharge to galley range tank. Location Label inscription Engineroom. stbd. side. Frame #38 at hull plating. Main deck, stbd. side. near capstan. Main deck. Stbd side. near capstan. Engineroom. Stbd side. above valve manifold. Engineroom. stbd. side. Fuel oil valve manifold. Engineroom. stbd. side. Fuel oil valve manifold. Engineroom. stbd. side. Fuel oil valve manifold. Engineroom, stbd. side. Fuel oil valve manifold. Engineroom. stbd. side. Fuel oil valve manifold. Engineroom, stbd. side Fuel oil valve manifold. Engineroom, stbd. side. Fuel oil valve manifold. Engineroom, stbd. side. Fuel oil valve manifold. Engineroom, stbd. side. Fuel oil valve manifold. Engineroom, stbd. side. Fuel oil valve manifold. Engineroom, stbd. side. Fuel oil valve manifold. Engineroom, stbd. side. Fuel oil valve manifold. Engineroom, stbd. side. Fuel oil valve manifold. Engineroom, stbd. side. Fuel oil valve manifold. Engineroom, stbd. side, above F.O. transfer pump. Engineroom, stbd. side, below valve manifold. OVBD DISCH. Engineroom, stbd. side, above valve manifold. Engineroom, stbd. side, on overhead above F.O. transfer pump. Engineroom, stbd. side, above hand pump. Engineroom, stbd. side below hand pump. Fidley, below galley range tank. F. O. PUMP DISCH 2-17 DECK DISCH. DECK FILL F. O. SUCT 1 F. O. FILL 1 F. O. SUCT. 2P F. O. FILL 2P F. O. SUCT 2S F. O. FILL 2S F. O. SUCT 3P F O. FILL 3P F. O. SUCT 3S F. O. FILL 3S F. O. SUCT 4P F. O. FILL 4P F. O. SUCT 4S F. O. FILL 4S F. O. PUMP SUCT F. O. PUMP TO FILL MAN-IF. F. O. TO DAY TANK F. O. PUMPS DISCH CROSSOVER F. O. TO PUMP F. O. TO GALLEY TK Valve No. 26 Service Location Pump discharge to deck and overboard discharge valves. Day tank residue drain to F. O. hand pump. Day tank residue drain to F. O. hand pump. Emergency fuel oil shutoff. 27 28 29 30 Fuel oil shutoff to both port and stbd. generator sets. Fuel oil shutoff to generator No. 1. Fuel oil shutoff to generator No. 2. Fuel oil shutoff to heating boiler. Fuel oil shutoff to main engine. Galley range tank outlet to galley range. 31 32 33 34 35 36 Suction and discharge shutoff for No. 2 port F. O. Tank. Used for trimming ship during refueling. Suction and discharge shutoff for No. 2 stbd. F. O. Tank. Used for trimming ship during refueling. 37 p. Label inscription Engineroom, stbd. side, above hand pump. Engineroom, stbd. side, below hand pump. Fidley, below F.O. day tank. F. O. TO DECK DISCH Fidley, below F.O. day tank. Control from handwheel outside aft end of deckhouse. Engineroom overhead forward of operating side of main engine. On generator No. 1. On generator No. 2. On boiler burner. On operating side of engine. Fidley, below galley range tank. Control from handwheel at fidley top. Valve on tank No. 2 port. Control from handwheel in passageway outside officer's staterooms. Valve on tank No. 2 port. Control from handwheel in passageway outside officer's staterooms. F. O. EMERG. SHUTOFF F. O. DAY TANK DRAIN F. O. DAY TANK HAND PUMP GEN'R F. O. SUPPLY F. F. F. F. F. O. O. O. O. O. SUPPLY SUPPLY SUPPLY TO ENGINE TO GALLEY RANGE F. O. TO TANK #2P F. O. TO TANK #2S the fire and salvage system is shown on table 2-5 below: Fire and Salvage System Control Values. The location and identification of control valves of Table 2-5. Fire and Salvage System Control Valves. Valve No. Service 1 2 3 4 5 Deck wash, port side. Suction for fire water shore supply. Fire station, port deck. Fire station, port engineroom. Overboard discharge shutoff. 6 Sea chest shutoff, port side. 7 14 Sea suction shutoff for port fire and salvage pump. Salvage line suction portside. Port fire and salvage pump discharge. Forward fire monitor shutoff. Stbd. fire and salvage pump discharge. Salvage line suction stbd. side. Sea suction shutoff for stbd. fire and salvage pump. Sea chest shutoff stbd. side. 15 Salvage system crossover. 16 Aft fire monitor shutoff. 17 18 Fire main crossover to fire and salvage pumps. Fire pump discharge. 19 Fire pump suction. 20 Engineroom fire station, stbd. side. 8 9 10 11 12 13 Location Main deck, portside at frame 30. Main deck, portside at frame 30. Main deck, portside at frame 30. Engineroom, portside at frame 32. Engineroom, stbd. side at frame 22 near overhead. Engineroom, portside at frame 22. Engineroom. portside at frame 23. Engineroom. portside at frame 25. Engineroom. portside at frame 25. Top of pilothouse. aft end. Engineroom. stbd. side at frame 24. Engineroom. stbd. side at frame 25. Engineroom. stbd. side at frame 25. Engineroom. stbd. side at frame 27. Engineroom, at frame 25, to port of centerline near overhead. Engineroom. stbd. side at frame 23. Located below deck plating. Engineroom. portside at frame 25. near overhead. Engineroom. portside at frame 29 above fire pump. Engineroom, portside at frame 31 above sea chest. Engineroom. stbd. side at frame 35. 2-18 Label inscription DECK WASH, P FIRE WTR FROM SHORE FIRE STATION FIRE STATION SALV. SYS. O.B. DISCH. P. FIRE & SALVAGE PUMP SUCT. P. SEA SUCT. P. SALVAGE LINE SHUTOFF P. FIRE AND SALV. PUMP DISCH. FIRE MONITOR S. FIRE AND SALV. PUMP DISCH. S. SALVAGE LINE SHUTOFF S. SEA SUCT. S. FIRE AND SALVAGE PUMP SUCT. SALVAGE CROSSOVER FIRE MAIN TO FIRE STATIONS TO FIRE MAIN FIRE PUMP SUCT. AFIRE STATION Valve No. 21 22 Service Fire station, stbd. deck. Suction for fire water from shore supply. Deck wash, stbd. side. Stbd. aft fire monitor shutoff. Port aft fire monitor shutoff. Fire monitor drain. 23 24 25 26 Location Label inscription Main deck, stbd. side at frame 30. Main deck, stbd. side at frame 30 FIRE STATION FIRE WTR FROM SHORE Main deck, stbd. side at frame 30. Boat deck, stbd. side aft. Boat deck. portside aft. Engineroom, stbd side at frame 37. DECK WASH FIRE MONITOR FIRE MONITOR DRAIN q. Lubricating Oil System Control Valves. The location and identification of lubricating oil system control valves are shown in table 2-6 below: Table 2-6. Lubricating Oil System Control Valves. Valve No. Service 1 L. O,. discharge to deck connection. 2 3 L. O. standby pump discharge to deck. L. O. standby pump discharge. 4 L. O. cooler bypass. 5 Engine L. O. pump discharge. 6 8 Auxiliary L. O. pump from engine crankcase. L. O. filter dirty oil drain to L. O. hand pump. L. O. filter outlet to crankcase. 9 Purl-filter discharge to crankcase. 10 Purl-filter suction from crankcase. 11 Puri-filter discharge to dirty L. O. tank and standby pump suction. Puri-filter discharge. 7 12 13 14 15 16 17 L. O. standby pump discharge to dirty L. O tank Dirty L. O. tank inlet. L. 0. standby pump discharge to dirty L. 0. tank. L. O. standby pump suction. 18 L. O. standby pump suction from L. O. storage tank Hand service tank fill 19 L. O. storage tank drain. 20 L. 0. storage tank outlet. 21 22 Overboard discharge from purifilter. Engine discharge to L. 0. cooler. 23 L. O. cooler outlet to engine. Location Portside, forward above main deck, frame 20. Portside, forward below main deck, frame 20 Portside, at engineroom floor, frame 23. Starboard side, above engineroom floor, frame 36. At centerline. forward of main engine. frame 26 Portside, below engineroom floor. frame 21. Portside. above engineroom floor, frame 27. Portside, above engineroom floor, frame 27 Portside. below engineroom floor, frame 28 At centerline, below engineroom floor, frame 21. Portside, below engineroom floor, frame 28. At centerline, above engineroom floor. frame 21 Portside. below engineroom floor, frame 25. Portside, below engineroom floor, frame 29 Portside. at engineroom floor, frame 23 Portside. above engineroom floor. frame 24. Portside, below engineroom floor, frame 23. Portside, above engineroom floor, frame 41 Portside. above engineroom floor. frame 21. Portside. above engineroom floor, frame 25. Portside. above engineroom floor. frame 21 Starboard side. above engineroom floor, frame 36 Starboard side, above engineroom floor. frame 30. 2-19 Label inscription L O. DK DISCH L O. TO DK DISCH L O. DISCH TO COOLER L O. COOLER BY-PASS ATT L. O PUMP DISCH AUX L. O PUMP SUCT DRAIN L O. FILTER OUTLET L. O PURIF. TO CRANKCASE PURIF. SUCT L. O. PURIF. TO STRG. TK I.B TK. PURIF. DISCH DIRTY L. O. TO PURIF L O. I B. TK TO PUMP SUCT. L. O. DISCH. TO I. B. TANK L O SUCT. FROM ENGINE L O. FROM STRG & I. B.. TANK HAND TK. FILL. DRAIN L O TANK OUTLET L O. WASTE FROM PURIF.TO OB L O. COOLER INLET L.O. COOLER OUTLET and OFF to maintain the preset pressure ((2) below) of the system. Pressure can be increased by turning the knob on front of switch in a clockwise direction. r. Fresh Water System Controls. (1) Automatic switch (1I fig. 2-8 ). The automatic switch turns the water pressure set ON 1. Automatic switch 3. Air volume control 2. Pressure gage 4. Relief valve Figure 2-8. Water pressure set controls. system should the automatic switch become inoperative. This prevents damage to other system components. (2) Pressure gage (2). This gage indicates the pressure on the system. Pressure reading of 20 psi starts the reciprocating pump. A reading of 40 psi stops the pump through the automatic switch (1). (3) Air volume control (3). This control maintains a predetermined amount of air on water in the volume tank at all times. (4) Relief value (4). This is a protective device that releases excess pressure from the s. Sanitary System. (1) Water pressure set. The controls of this set are identical with those described in subparagraph r. above. (2) Valves. Each valve in the sanitary system must be open when the system is in operation. 2-20 t. Bilge and Ballast System Control Valves. The location and identification of all control valves in this system are shown in table 2-7 below: Table 2-7. Bilge and Ballast System Control Valves. Valve No. Service 1 Sea chest shutoff. 2 3 Independent bilge suction. Engineroom bilge suction manifold shutoff. Emergency bilge suction to fire pump. Bilge and ballast pump suction. Bilge and ballast pump discharge. 4 5 6 7 11 Engineroom bilge suction, stbd. side. Engineroom bilge suction, portside. Void space bilge suction. Emergency bilge suction to fire pump. Aft peak ballast tank discharge. 12 Aft peak ballast tank suction. 13 Fore peak ballast tank discharge. 14 Fore peak ballast tank suction. 15 Fuel oil tank No. 1 ballast discharge. 16 Fuel oil tank No. 1 ballast suction. 17 Engineroom bulkhead shutoff valve for line from fore peak tank. 18 Fore peak tank emergency shutoff. 19 Engineroom bulkhead shutoff valve for ballast line from fuel oil tank No. 1. 20 Main overboard discharge. 21 Crew's quarters bilge suction portside. 22 Crew's quarters bilge suction, stbd. side. 23 Bilge suction from aft storage spaces. Bilge suction from aft storage spaces. Suction, chain locker bilge. Overboard discharge and priming, chain locker bilge. 8 9 10 24 25 26 Location Label inscription Engineroom. stbd. side between frame 26 and 27. Engineroom. stbd. side. at frame 26. Engineroom. stbd. side at frame 29. S. W. TO BILGE & BALL PUMP Engineroom. stbd. side at frame 29. BILGE SUCT. TO FIRE PUMP Engineroom. stbd. side at frame 30. Engineroom. stbd. side between frame 30 and 31. Engineroom. stbd. side at frame 29. BILGE & BALL PUMP SUCT. BILGE & BALL PUMP DISCH. Engineroom. stbd. side at frame 29. Engineroom. stbd. side at frame 29. Engineroom, portside. frame 29, at fire and salvage pump. Engineroom. stbd. side. frame 29, ballast manifold. Engineroom. stbd. side, frame 29, ballast manifold. Engineroom, stbd. side, frame 29, ballast manifold. Engineroom, stbd. side. frame 29, ballast manifold. Engineroom, stbd. side, frame 29. ballast manifold. Engineroom, stbd. side, frame 29. ballast manifold. Engineroom forward bulkhead stbd. side, below deck plate. Control from handwheel at bulkhead. At fore peak tank. Control from handwheel located above chain locker on main deck forward. Engineroom forward bulkhead stbd. side, below deck plate. Control from handwheel in passageway outside officers staterooms. Engineroom stbd. side frame 30, near overhead. Engineroom, stbd. side forward, below deck plate at frame 23. Control from handwheel at engineroom floor. Engineroom, stbd. side forward, below deck plate at frame 23. Control from handwheel at engineroom floor. Aft engineroom at bulkhead, portside. Aft engineroom at bulkhead, stbd. side. Bottom of chain locker. Main deck, forward, at chain locker hand pump, frame 7. ENG. RM. BILGE SUCT. P. AFT VOID-BILGE SUCT. BILGE SUCT. TO FIRE PUMP DIRECT BILGE SUCT. SUCT. FROM BILGE MANIFOLD ENG. RM. BIIGE SUCT. S. AFT PEAK BALL DISCH AFT PEAK BALL SUCT. FORE PEAK BALL DISCH FORE PEAK BALL SUCT. F. O. TANK NO. 1 BALL DISCH F. O. TANK NO. 1 BALL SUCT. FORE PEAK TANK FORE PEAK TANK BHD. STOP F. O. TANK NO. 1 BILGE & BALL OVB'D DISCH CREW'S QTRS-BILGE SUCT. CREW'S QTRS-BILGE SUCT. STORES SPACE-BILGE SUCT. STORES SPACE-BILGE SUCT. HAND PUMP PRIMING 2-3. Operating procedures a. operation of this equipment. It is essential that operator/crew know how to perform every operation of which the General. The instructions contained in these paragraphs are published for the information and guidance of personnel responsible for 2-21 Tug is capable, and. For coordinating the basic motions to perform the specific tasks for which the equipment was designed. Since nearly every job presents a different problem, the operator may have to vary given procedures to fit the. Individual job. b. Preliminary Preparation for Movement. (1) Perform preventive maintenance checks and services (tables 3-1 and 3-2). (2) Prior to actually starting the equipment, the following auxiliary equipment must be either operating, set for automatic operation, or in a standby condition as shown in table 2-8. NOTE Before operating the harbor tug, all personnel must be thoroughly familiar with TM 55-501. Table 2-8. Machinery Status Prior to Getting Underway. Equipment Operating Auto Standby Generator set No. 1............................................................................. X Generator set No. 2.............................................................................. .......................... ......................... X Fire and salvage pump ......................................................................... .......................... ......................... X Bilge and ballast pump ......................................................................... .......................... ......................... X Fire pump ............................................................................................ .......................... ......................... X Fresh and salt water standby pump ..................................................... .......................... ......................... X Steering motor .................................................................................... X Fuel oil transfer pump .......................................................................... .......................... ......................... X Lubricating oil transfer pump ................................................................ .......................... ......................... X Lubricating oil standby pump............................................................... X Ventilating fans .................................................................................... ......................... X Air compressor No. 1 ........................................................................... ......................... X Air compressor No. 2 ........................................................................... ......................... X Water pressure set............................................................................... .......................... ......................... X Searchlight.......................................................................................... X Engine order telegraph transmitter....................................................... X Anchor windlass ................................................................................... .......................... ......................... X Heating unit boiler (see note 1)............................................................ X 1 Operating to furnish domestic hot water. or both heat and hot water, depending on the climatic conditions. 2-4. Starting-Ahead from Stop (Propulsion Engine) speed desired. The governor hand control (4) is used in conjunction with the throttle handwheel to obtain a fine speed adjustment when required. a. At the Pilot house. Place the engine order telegraph (8, fig. 2-1) at the desired AHEAD speed position. b. In the Engine room. 2-5. Starting-Astern from Stop (1) Acknowledge message on engine order telegraph (1, fig. 2-3). (2) With throttle handwheel (5) pointer at the extreme clockwise position, turn the governor hand control (4) to the extreme counterclockwise RUN position. (3) Quickly turn the astern-ahead handwheel (6) counterclockwise from stop past the AHEAD position to START. As soon as the engine starts move the astern-ahead handwheel clockwise to AHEAD position. (4) The engine should now be turning over at slow speed and firing on all cylinders. a. At the Pilothouse. Place the engine order telegraph (8, fig. 2-1) at the desired ASTERN speed position. b. In the Engineroom. (1) Acknowledge engine order telegraph (1, fig. 2-3). (2) With the throttle handwheel (5) pointer at the extreme clockwise position, turn the governor hand control (4) to the extreme counterclockwise RUN position. (3) Quickly move the astern-ahead handwheel (6) full clockwise past astern to START. As soon as the engine starts, move the astern-ahead handwheel counterclockwise to ASTERN. (4) The engine should now be turning over at slow speed and firing on all cylinders. (5) Move the throttle handwheel (5) counterclockwise until the engineroom rpm indicator shows the correct number of turns for the desired speed. Use the governor hand control (4) in CAUTION Do not run engine continuously between 165 and 200 rpm. Do not run engine in excess of 200 rpm until engine heat exchanger water outlet temperature has reached 1300F. (5) Move the throttle handwheel (5) counterclockwise until engineroom revolution (rpm) counter indicates the correct number of turns per minute for the 2-22 conjunction with the throttle handwheel to obtain a fine speed adjustment when required. ASTERN. The engine is now reversed and the engine will run astern. Adjust throttle handwheel for the required number of rpm's. 2-6. Stopping the Engine 2-8. Ahead Start To stop the engine, move the astern-ahead handwheel (6, fig. 2-3) clockwise (or counterclockwise) to the center STOP position. a. At the Pilothouse. Place the engine order telegraph (8, fig. 2-1) at the desired speed AHEAD. 2-7. Reversing-Astern from Ahead b. In the Engineroom. a. At the Pilothouse. Place the engine order telegraph (8, fig. 2-1) in the desired ASTERN position. (1) Acknowledge the engine order telegraph (1, fig. 2-3). (2) Move the astern-ahead handwheel counterclockwise to center STOP position. CAUTION Do not move the astern-ahead handwheel past the STOP until the engine has stopped. (3) Then quickly move the astern-ahead handwheel counterclockwise to the AHEADSTART position. As soon as the engine starts, move the astern-ahead handwheel clockwise to AHEAD. The engine is reversed and will now run ahead. (4) Adjust the throttle handwheel or governor hand control as necessary for the required rpms. 2-9. Post Operations Secure equipment as instructed, then perform preventive maintenance checks and services (tables 3-1 and 3-2). b. In the Engineroom. (1) Acknowledge the engine order telegraph (1, fig. 2-3). (2) Move the astern-ahead handwheel clockwise to center STOP position. CAUTION Do not move the astern-ahead handwheel past the STOP until the engine has stopped. (3) Quickly move astern-ahead handwheel clockwise past astern to START. As soon as the engine starts, move the asternahead handwheel counterclockwise to Section II. OPERATION OF AUXILIARY EQUIPMENT 2-10. General (3) Check fresh water level in expansion tank. (4) Check alignment of raw water to the heat exchanger (para 2-18). (5) Check alignment of fuel oil system (para 212 below). Vent the engine fuel system. (6) Check crankcase oil level. (7) Set throttle (4, fig. 2-4) at three-quarters open position. (8) Check the starter motor and assure that all electric terminals are tight. (9) Use fuel priming pump to assure fuel filter, lines, manifold, and injectors are full of fuel. (10) Assure that fire and salvage pump clutches are disengaged. This section will provide information on the operation of equipment auxiliary to, but necessary for overall successful operation of the tug. Reference will be made to figures, tables, and maintenance paragraphs as required to give a thorough coverage of procedures for placing the equipment in operation for every mode intended; to place the equipment in standby condition, or place it in shutdown status. 2-11. Operation of Auxiliary Set (Generator and Pump) a. General. The auxiliary set consists of a 40 kw dc generator; fire and salvage pump; clutch; priming pump with V-belt drive, and clutch for disengagement. The prime mover of this set is a General Motors model 4061A diesel engine, unit No. 4-71. Two of these sets provide the ships electric service. CAUTION Do not operate starter motor more than 30 seconds at one time without resting it for one minute. b. Diesel Engine Starting. (1) Inspect exterior of engine and area around it for loose gear, tools, and waste material that could become entangled with moving parts. Perform preventive maintenance checks and services (tables 3-1 and 3-2). (2) Position disconnect (16, or 38, fig. 2-5) on main electrical panel in OFF position. (11) Push starter switch (1) and release when engine starts, or at 30th second of operation. See caution above. Repeat if necessary until engine starts. 12) Run engine at half speed until the water temperature reaches 1500F. You may then set throttle at full speed. (13) The generator is now ready to place on the line (para 2-17, g. , (7), (d ) ). 2-23 (4) Close the throttle (4) and stop the engine. (5) Secure the fuel oil system (para 2-12). (6) Secure the raw water system (para 2-18). c. Fire and Salvage Pump. (1) Start the engine (b). (2) Check that inlet and discharge valves are in line, and that pump packings are damp. (3) Engage clutches to both pumps. (4) Disengage priming pump clutch when fire and salvage pump begins discharge of water. (5) Disengage clutch to fire and salvage pump when no longer required. 2-12. Fuel Oil System Operation a. General. The fuel oil system consists of seven inner bottom fuel oil tanks (fig. 2-9); one 300 gallon day tank; one 30 gallon galley range day tank; one electric drive fuel oil transfer pump; one hand operated rotary pump, and interconnected piping, vents, sounding tubes, and filling and discharging deck fittings. The fuel oil piping connects directly to the propulsion engine, the two auxiliary set engines, the heating system burner, and the galley range burner. d. Stopping the Auxiliary Set Engine. (1) Remove load from generator para 2-17, g, (7), (f). (2) Gradually slow the engine speed to idle speed (650 rpm) by turning throttle (4, fig. 2-4). (3) Run at idle speed for at least 5 minutes to allow engine to cool. Figure 2-9. Fuel oil system piping diagram. engine and supplies fuel oil to the propulsion engine, the diesel auxiliary sets, and the heating system oil burner by gravity flow. The galley range day tank is filled by using the rotary hand pump, which takes fuel oil from the storage tanks and discharges oil into the 30 gallon galley range day tank. If overflow occurs, the overflow line connects into the 300 gallon day tank. If the fuel oil is to be moved off the tug, you may pump b. Operation. The fuel oil is pumped into the tug at the starboard side deck hose connection, and using proper valve positioning fuel oil can be directed into any of the seven storage tanks. The 300 gallon day tank is filled from the storage tanks by means of the electric fuel oil transfer pump. If that pump is inoperative, you can use the rotary hand pump to fill the day tank. The fuel oil day tank is located in the upper engine room, aft of the propulsion 2-24 the description on valve label. T able 2-9 lists the various operations to be performed in the fuel system, with valve positions and procedures necessary to accomplish them. Table 2-9 is also keyed to figure 2-9. Figure 2-10 gives sounding charts for equalizing fuel load to keep tug on an even keel. it through the overboard discharge hose connection by either the electric fuel oil transfer pump or the rotary hand pump. c. Valve Positioning. Figure 2-9 is a diagram of the tugs fuel oil system. Table 2-4 is keyed to figure 29; identifies each valve in the fuel oil system: and gives its location, function. and 2-25 Figure 2-10. Fuel oil capacity sounding charts. 2-26 NOTE All fuel oil valve labels attached to valve handles are marked in red. The only other valves marked in red are the sea chest valves. Table 2-9. Fuel Oil System Control Valve Positioning. Operation Open valve Close valve Take on fuel WARNING Observe all fire and safety precautions. Have hand fire extinguishers on deck. Have hose static grounds attached. Observe the no smoking rule. (4) (8) (10) (12) (14) (16) (18) (36) (37) (20) (5) (6) (7) (9) (11) (13) (15) (17) Transfer fuel from one storage tank to another. Transfer fuel from storage tanks to off ship using fuel oil transfer pump. Fill day tank using fuel oil transfer pump. Fill galley range day tank using fuel oil transfer pump. Procedure Fill port and starboard No. 2, 3 and 4 tanks at the same time to maintain tug on-even keel. Close valves 36 and 37 as required to prevent list. Take soundings according to figure 2-10 When each tank is filled to proper capacity. close appropriate valve. When all tanks are filled, open valve (6) and fill tank No. 1. Secure all valves and refasten deck fill cover. WARNING Observe all fire and safety precautions. Have hand fire extinguishers on deck. Have hose static grounds attached. Observe the no smoking rule. (19) (20) (4) (24) (21) (5) (7) (9) (11) (13) (15) (17) (361 (37) (19) (21) (23) (26) (2) (19) (21) (22) (6) (8) (10) (12) (14) (16) (18) (24) (22) (25) (1) (19) 121) (23) (25) (24) (22) (26) (24) (23) (28) Open suction valve on tank to be emptied and fill valve on tank to be filled at manifold. Start transfer pump and take soundings until proper amount of fuel is transferred. Secure pump. Secure all valves. Secure off ship discharge line to deck discharge connection. Start fuel oil transfer pump and continue pumping until required amount is transferred. Secure pump. Secure all valves. Open suction valve of inner bottom tank to be used at manifold. Start pump and continue pumping until day tank is filled. Secure pump. Secure valves. Open suction valve of inner bottom tank to be used at manifold. Start pump and continue pumping until galley range tank is filled Secure pump. Secure valves NOTE Galley range tank into day tank. 2-27 Operation Open valve Close valve Use fuel oil hand pump to fill day tank. (24) (23) (22) (19) (21) Use fuel oil hand pump instead of fuel oil transfer pump to fill galley range. Supply engine with fuel oil from day tank. (24) (19) (21) (23) Supply generator sets with fuel oil (29) (30) (31) (32) (29) (33) Supply heating boiler with fuel oil. Drain fuel oil day tank using fuel oil rotary hand pump. Procedure Open suction valve of inner bottom tank to be used at manifold. Crank hand pump until day tank is filled. Secure valves. Position valves as shown and proceed as with fuel oil transfer pump. (29) (34) NOTE Valve (29) is an emergency shutoff and should be left open at all times. Valve (311 controls generator No. 1. Valve (32) controls generator No. 2. Valve (30) is common to both. (28) (27) (26) (1) Valve (29) is an emergency cut off and should be left open. Open valve (33) as required. To remove sediment from tank, turn hand crank until a few gallons have been removed. To drain completely, turn crank until tank is dry. To drain, close valve (1) and open valve (2). and catch fuel oil from deck discharge in a suitable container. (24) (23) (25) (2) d. Fuel Oil Pump Operation. does not permit stopping pump at the controller, press the emergency STOP button mounted outside the engine room door. (1) Transfer pump. The fuel oil transfer pump is a rotary type, electric motor driven, and is located on starboard side of engine room. A controller with a START-STOP push switch, overload, and low voltage protection is mounted next to the pump. (2) Fuel oil hand pump. (a) The fuel oil hand pump is of the rotary type and is located on bulkhead at starboard side of the engine room, aft of the propulsion engine. (b) Align fuel oil system as described in table 2-9 to accomplish the desired function. (c) Pump by turning hand crank clockwise. (d) To secure the system, stop pumping and secure valves (table 2-9). (a) Align fuel oil system as shown on (table 2-9), to accomplish desired function. (b) Move the fuel oil transfer switch (19, fig. 2-5) to ON position. (c) Push the START button on controller to start the pump. (d) To secure the pump, press STOP button on controller, then move fuel oil transfer switch (19, fig. 2-5) to the OFF position. Then secure valves (table 2-9). 2-13. Lubricating Oil System Operation a. CAUTION If the pump trips from an overload, do not reset and operate the pump until cause of overload has been determined, and the fault corrected. (e) To reset controller panel after an overload has tripped, press the RESET button on the controller panel. (f) Should an emergency occur which 2-28 General. The lubricating oil system stores and supplies lubricating oil to the propulsion engine lubricating system by pumps. The engines of the auxiliary sets are not connected to the lubricating oil system, therefore you must fill them manually from the LO hand service tank (fig. 211). This system contains a 450 gallon storage tank a lubricating oil hand service tank, a 395 gallon dirty lubricating oil tank, a 50 gallon sludge tank, an electric motor driven lubricating oil standby pump, auxiliary pump, hand pump, filter and purifier. The piping and control valves complete the system. Figure 2-11. Lubricating oil system piping diagram. b. formed in the system, and the valve position necessary to accomplish the function. Table 2-10 is also keyed to figure 2-11. Operation of Lubricating Oil System. Table 2-6 shows the service, location, label description of each valve in the system, and is keyed to figure 211. Table 2-10 lists all operations to be per- Table 2-10. Lubricating Oil System Control Value Positioning. Operation Open valve Close valve To fill 460-gal. storage tank. To fill hand service lubricating oil Tank To pump lubricating oil from a storage tank to a container using standby pump. (19) (18) (20) (19) (20) 18) (20) (17) (2) (1) (16) (15) (3) (11) (14) 2-29 Procedure Fill storage tank through deck fill F21. fig. 2-111 on side of main deck. To fill tank. remove filling cap and connect filling hose to deck fill. Oil level is indicated by a sight glass on the tank. When tank is full. remove hose and replace cap. Remove tank cap and open valve. When tank is full. close valve and replace tank cap. NOTE The hand service lubricating oil tank is vented through the tank cap. Remove cap discharge connection and connect discharge hose. Press starter button on lube oil standby pump. When sight glass indicates that storage tank is empty, stop standby pump and close all valves. Disconnect discharge hose and replace cap. NOTE Do not pump lubricating oil overboard. Operation Open valve To pump 395-gal. dirty L. O. tank into containers using standby pump. Close valve (14) (17) (2) (1) (13) (11) (20) (16) (3) To pump 50-gal. sludge tank into containers using hand pump. Remove cap from discharge connection and connect discharge hose. Press starter button on lubrication oil standby pump. When tank is empty, stop pump and close all valves. Disconnect discharge hose and replace cap. NOTE Do not pump lubricating oil overboard. Turn pump handle in clockwise direction. Take soundings of the sludge tank. When the tank is empty, stop pumping. NOTE Do not pump lubricating oil overboard. Normal operation, engine running. (5) (22) (23) (9) (11) (14) Lubricating oil standby pump operation, engine running. To operate puri-filter. (16) (3) (12) (10) (9) (11) (14) (17) (13) (15) To drain purl-filter filter into container. Procedure (18) (19) (20) (1) (2) (16) (17) (4) (3) (15) (12) (21) (6) (7) (8) (17) (2) (21) (2) (3) (20) When engine is secured, keep valves in same position as when engine is running. Start lubrication oil standby pump. Secure when finished. Start standby pump lubrication oil through Secure pump and valves when finished NOTE Puri-filter is only used from 8 to 12 hours as required each day. For operation, refer to paragraph 2-13c. (5) (a). (21) (12) c. Lubricating Oil System Pump Operation. When finished with purl-filter. drain residue into container. (2) Hand rotary pump. (1) Lubricating oil transfer pump. (a) The hand rotary oil pump is of 10gpm capacity, located on port side of engine room on the forward bulkhead and may be used to pump oil into a container, or to the deck connection. (b) Align lubricating oil system as described in table 2-10 to accomplish desired function. (c) Start pumping by turning handle in a clockwise direction. (d) Secure by stopping handle, then return valves moved in step (b) above to their original position. (a) This transfer pump has a capacity of 3½ gpm; is an electric motor driven rotary type, and is located on port side of engine room at the forward bulkhead. Purpose of this pump is to move oil from the propulsion engine dirty oil tank, through the purifier. NOTE This pump may be referred to as the scraper ring oil Pump. (3) Lubricating oil standby pump. Align lubricating oil system as described in table 2-10 to accomplish desired function. (c) Press START button on controller. (d) Secure the pump by pressing STOP button on controller, then close valves opened in step (b) above. (b) (a) This pump is located on port side of engineroom and may be used to supply oil with pressure to the propulsion engine, while engine oil 2-30 to puri-filte pressure pump is down for repairs, or for the transfer of lubricating oil on or off the tug. described in table 2-10 to accomplish the required function. (c) This pump will start when the propulsion engine begins running. (b) Align the system as described in table2-10 to accomplish the desired function. NOTE (c) To start the pump, press the START button on controller. The engine lubricating oil pressure pump has a reversible impeller and delivers oil under pressure to engine while it is turning either ahead or astern. CAUTION If pump controller trips from an overload, you must not reset or operate the pump, until cause of overload has been determined and the defect corrected. (5) Lubricating oil purifier system. (a) This system consists of a centrifugal disc type oil purifier with flange mounted pumps and motor, a thermostatically controlled low watt density type electric heater; filters, and an automatic air vent. It is located on port side of the engine room of forward bulkhead. The controller is mounted on bulkhead and includes a magnetic switch for motor and heater, start-stop push switch, and protection for overload, or low voltage. (d) To secure the pump, press STOP button on the controller, then return valves moved in step (b) above to their original position. (4) Engine oil pressure pump. (a) This pump is driven by the propulsion engine pump drive (accessory drive) and is located at forward end of the engine. It supplies engine with lubricating oil under pressure. (b) Close valve (5, fig. 2-12) and open valve (2). (b) Align the lubricating oil system as 2-31 1. 2. 3. 4. Relief valve Air vent valve Three-way two port valve Rotosight 5. Control valve 6. Three-way two port valve 7. Sampling cocks Figure 2-12. Lubricating oil purifier flow diagram. (c) Press the START button on controller of the purifier. (d) Prime the bowl through the priming valve on top of the bowl by opening valve two turns, then pour in water. After bowl is filled to overflowing, it can be seen through the observation port in the water discharge chamber. Close priming valve. (e) Move the heater selector switch on controller to AUTOMATIC. You have then turned the heater ON so that it will maintain oil temperature at 1800F. (f) Position valve (3, fig. 2-12) so that purified oil will flow back to the reservoir through the filter bypass line. NOTE The top of plugs in three-way two port valves have port positions marked with white paint. (g) Position valve (6) to draw oil from the reservoir. You have now bypassed the filters. NOTE It is always best to bypass the filters while purifier and heater are warming up. (h) 2-32 Open control valve (5) slowly. Operate purifier with valve (5) only partially open for several minutes. Check the observation cup that is (i) (j) (b) Remove bolts holding covers on filters, then remove covers. (c) Lift compression springs out of filters. (d) Grip handle on top filter element pressure plate and lift top element out of each filter. located in the top of the frame cover. If an overflow of unpurified liquid is observed, the bowl is clogged and must be cleaned (para. 5-48). When it is evident that unpurified liquid is not flowing out of the observation cup, and that bowl and heater are operating satisfactorily, open control valve (5) fully open. With heater and bowl now warmed up, position valve (3) so that oil is directed through the filters. The unit is now delivering clean filtered lubricating oil to the reservoir. NOTE A special lifter hook is placed in each filter to assist in removal of lower element. (e) Use special lifters and remove each lower element. (f) Replace special lifters in each filter. (g) Insert two new filter elements in each filter with element pressure plate uppermost. (h) Install new gasket in each filter cover. (i) Position compression spring in each filter. (j) Install covers and tighten bolts. (k) Purifier is now ready for operation. (6) Bypassing the purifier filters. To bypass the filters, position valve (3) so that oil is directed into bypass line, leaving all other valves unchanged. (7) Draining the purifier filters. (a) Bypass the purifier filter (step (6) above). (b) Position valve (6) to draw oil from filters through filter drain line. When the pressure gage on the inlet side of the purifier shows no pressure, the filters are empty. (9) Securing the lubricating oil purifier. (a) Drain filters (step (7) above). (b) Close control valve (5). (c) Press STOP button on purifier controller, then apply brake by pressing gradually oil the brake plunger. NOTE While the filters are draining, the automatic air vent permits air to be drawn into filters, thereby eliminating their collapse by the vacuum created by purifier pump. 2-14. Steering System Operation a. Steering System Pilothouse Control. (1) Starting. (c) When filters are empty position valve (6) to draw oil from the reservoir. (a) (8) Changing filter elements. (a) Drain filters (step (7) above). 2-33 Align system by closing the two valves at base of steering console (1, fig. 2-13) and the bypass valve at steering unit. 1. Steering console 2. Steering wheel 3. Control cable 4. Ram 5. Motor starter 6. Motor Figure 2-13. Marine steering system arrangement. (b) Place steering wheel (2) in the FORWARD position. (d) e) NOTE You should always bring the rudder to amidships (0 degrees) prior to securing the steering gear. The next step will permit motor (6) to be started prior to having a load placed on it by the hydraulic pump. (f) (c) Assure that rudder angle indicator located on top of steering console (1) indicates 0 degrees. 2-34 Start the electro-hydraulic steering unit by pressing the START push switch. You can now move the rudder by turning the steering wheel (2). Check hydraulic ram (4) while moving rudder fully to starboard, then to port. If ram (4) chatters or is noisy, the steering system must be vented. To vent the system, open air vents alternately on pressure side of hydraulic system while ram (4) is moving out. (1) Starting, or shifting to hand steering control. (2) Stopping the steering system. (a) Stop steering system by pressing STOP push switch on controller. (b) Align steering system by opening the two valves at base of steering console (1). (c) Place steering wheel in AFT position. (d) The tug can now be steered by using the hand pump in steering console (1). (a) Move rudder to amidships (0 degrees on angle indicator). (b) Stop steering motor (6) by pressing STOP push switch on controller. b. Steering System Trick Wheel Operation. (1) Starting, or taking control on trick wheel. (a) Check the two valves at base of steering console (1) and the bypass valve at steering unit to assure they are closed. (b) Ascertain that rudder angle indicator on the steering console (1) indicates 0 degrees. (c) Place steering wheel (2) in AFT position. (d) Disengage the shaft clutch. (This is done primarily to reduce the effort required to turn the trick wheel). NOTE The rudder angle indicator will not function while operating by hand steering controls. (2) (a) Move rudder to amidships position. (b) Place steering wheel (2) in the FORWARD position. (c) Close the two valves at base of steering console (1). (d) Start the steering unit by pressing START push switch on controller. NOTE When running, and control is being shifted to trick wheel, the next step is unnecessary because motor (6) will be running. (e) (f) Stopping, or shifting to electro-hydraulic control. d. Aft Steering Station Operation. Start the electro-hydraulic steering unit by pressing the START push switch on controller. The tug can now be steered from engine room by using the trick wheel. (1) Steering at aft steering station. (a) Engage aft steering station by pushing the steering gear switch (2, fig. 2-3) START push switch. (b) The tug can now be steered from the aft steering station by using a lever movement of steering control handle. (2) Stopping, or returning control to steering wheel. (a) Move rudder to amidships position. (b) Place steering wheel (2) in the FORWARD position. 2-15. Compressed Air System Operation a. General. The system consists of the piping, storage tanks, and control valves used to store and deliver air from compressors to the using equipment. Pressure is delivered from system as follows: CAUTION It is absolutely necessary that rudder and steering wheel (2) be at amidships position prior to the engaging of shaft clutch. (1) 250 psi available for starting, stopping, and reversing the propulsion engine. (2) 100 psi for' operation of the whistle and pneumatic tools. (3) 50 psi for ships service air and sea chest blowdowns. (c) Engage shaft clutch. NOTE b. Operation. Table 2-2 is keyed to figure 2-14, the compressed air system piping diagram, and gives function, location, and label description for each valve in the system. Table 2-11 lists the various operations to be performed and the valve positions and procedures necessary to accomplish them. This table is also keyed to figure 2-14. If control is being returned to the steering wheel (2) do not stop the steering unit. (d) Stop steering unit by pressing the STOP push switch on controller. c. Hand Steering, Pilothouse Control. 2-35 Figure 2-14. Compressed air system piping diagram. Table 2-11. Compressed Air System Control Valve Positioning. Operation To turn on air supply from compressors to engine manifold. To turn off air supply to engine. To operate whistle tank and whistle. Open valve Close valve (2) (4) (5) (6) (8) (9) (11) (12) (14) (15) Procedure Start air compressors (para 2-15, C). (15) (28) (31) (33) (2) (4) (5) (6) (8) 2-36 If reducing station fails to supply air to whistle section, open valve (31) slightly, so relief valve does not pop off. Close valve (27). TM 55-1925-204-12 Operation Open valve To operate whistle tank and whistle --continued (9) (11) (12) (27) (29) (30) (32) (37) To turn off whistle. To operate air tools. (37) (2) (4) (5) (6) (8) (9) (11) (12) (27) (29) (30) (34) (35) To turn off air tool supply. (34) To operate sea chest blowout lines. (2) (4) (5) (6) (8) (9) (11) (12) (25) (23) (22) (19) (16) (17) (18) (38) Close valve (31) (32) (35) (26) (24) To turn off blowout supply lines. To operate ship's service air line. Procedure If reducing station fails to supply air to air tools, open valve (31) slightly, so relief valve does not pop off. Close valve (27). 1. Before turning on sea chest blowout valves .close the sea chest suction valves. Operate blowout valves until bubbles appear beside ship. This is an indication that the sea chest is free of restrictions. 2. If reducing station fails to supply air to blowout valves, open valve (26) slightly so relief valve does not pop off. Close valve (25). (19) (2) (4) (5) (6) (8) (9) (11) (12) (22) (23) (25) (21) (20) (24) (26) To turn off ship's service supply lines. To prevent loss of air during overnight docking. If reducing station fails to supply air to ship's service air lines, open valve (26) slightly so relief valve does not pop off. Close valve (25). (21) (5) (6) (8) (11) Open these valves when ready to start. c. Air Compressor Operation. The two identical electric motor driven air compressors are located on starboard side of the engine room forward of the main electrical control panel. They are two stage, aircooled type, each with a capacity of 22 cfm at 250 psi. The compressors are controlled from individual controllers, each wired for manual or automatic operation. The automatic feature includes individual pressure switches; the no. 1 switch starts its compressor at 230 psi and secures 2-37 it at 250 psi. The no, 2 switch starts its compressor at 240 psi and secures it at 250 psi. Compressors can be set to operate in either of the following methods: Both automatic; one automatic one manual, or both manual. (1) Both compressors on automatic operation. (a) Inspect area around compressors for loose gear, tools, and waste material that could become entangled in moving parts. (b) Check crankcase oil level. (c) Align compressed air system valves as described in table 2-11 to accomplish required function. (d) Place switches (27 and 36, fig. 2-5) at main electrical control panel in ON position. (e) Move both controller selector switch levers to AUTOMATIC position. (f) Press START push switch on each controller. Compressors are now operative. NOTE If storage tanks are full with both gages reading 250 psi, neither compressor will start. If there is less than 250 psi, but not less than 230 psi pressure, only No. 2 compressor will start. (2) One compressor on automatic operation. (a) Perform steps (1), (a), (b), and (c) above. (b) Place switch of selected compressor on main electrical control panel at ON (either 27, or 36, fig. 2-5). Leave remaining switch at OFF. (c) Move selector switch lever on controller of selected compressor to AUTOMATIC. (d) Press the START push switch on controller for selected compressor. If the no. 1 compressor was selected, and there is less than 230 psi on gage, the compressor will start, then stop when pressure gage reads 250 psi. (3) Both compressors on manual operation. (a) Perform steps (1), (a), (b), (c), and (d) above. (b) Move selector switch lever on both controllers to HAND position. (c) Press START push switch on both controllers. Compressors will start. (d) Secure both compressors when the pressure gages read 250 psi by pressing STOP push switch. 2-16. Ventilation System Operation a. General. There are two supply and three exhaust systems installed on the tug. The crew's quarters supply blower is rated at 3,000 cfm and is driven by a 1-hp motor at 1,300 rpm. The crew's quarters exhaust blower is rated at 1050 cfm and is driven by a 1/2-hp motor at 1,750 rpm. The engine room exhaust blower is rated at 9,000 cfm and is driven by a 4 hp motor at 1,750 rpm. The engine room supply blower is driven by a 31/2 hp motor. The galley exhaust blower is driven by a 1/2-hp motor at 1,350 rpm. Ducting connects the tugs ventilation compartments for air delivery. b. Starting Crew's Quarters Supply Blower. (1) Inspect area and vents to assure they are free of tools, waste, or material that could become entangled with moving parts. (2) Move switch (32, fig. 2-5) to ON position and energize the ventilation system power control panel. (3) Move line switch for crew's quarters supply blower, located on ventilation system power control panel to the ON position. (4) Press the START push switch which is located in crew's quarters to start the blower. (5) Secure the blower by pressing the STOP push switch. c. Starting Crew's Quarters Exhaust Blower. (1) Move line switch for crew's quarters exhaust blower, located on ventilation system electrical power control panel, to the ON position. (2) Press the START push switch, located in crew's quarters, to start the blower. (3) Secure blower by pressing STOP push switch. d. Starting Galley Exhaust Blower. (1) Move line switch for galley exhaust blower, located on ventilating system electrical power control panel, to the ON position. (2) Press the START push switch located in galley to start blower. (3) Secure the blower by pressing STOP push switch. e. Starting Engine room Supply Blower. (1) Move the line switch for engine room supply blower, located on the ventilation system electrical control panel, to the ON position. (2) Press the START push switch, located in engine room, to start blower. (3) Secure the blower by pressing STOP push switch. f. Starting Engine room Exhaust Blower. (1) Move the line switch for engine room exhaust blower, located on the ventilation system electrical control panel, to the ON position. (2) Press the START push switch, located in engine room, to start the blower. (3) Secure the blower by pressing the STOP push switch. g. Emergency Stopping of Blowers. In case of emergency, ventilating blowers can be secured by pressing one or more of the EMERGENCY STOP push switches located in the passageway at the head of engine room access ladder. If this station is not accessible, all ventilation blowers may be secured by pressing the EMERGENCY STOP push switch located in the pilot house. 2-17. Electrical System Operation a. General. The tugs service electrical system is 2-38 a two-wire, 120 vdc system, powered by two 40 kw diesel driven auxiliary sets. The system may be supplied by shore power through the shore power receptacle located on the port side of the after deck house. Power is supplied by the generators, or shore power, through the main electrical control panel (fig. 2-5), to the various power and lighting circuits throughout the tug. Individual switching with overload protection is provided at the main electrical control panel for the primary circuit. CAUTION Use only 120 vdc power from source of shore supply. b. Ships Service Power Operation. (1) Primary circuits, circuit designation, and main electrical control panel overload settings are listed in table 212 below. Table 2-12 Primary Electrical Circuits. Equipment No 1 Air compressor No. 2 Air compressor Salt water circulating (standby) pump. Fire pump Fresh water circulating (standby) pump. Lubricating oil (standby pump) Bilge pump Fuel oil transfer pump Lubricating oil purifier Power panel Steering motor Windlass Capstan Vent power panel Circuit No. P1 P2 P3 Overload se 90A 90 90A P4 P5 275A 90A P6 P7 P8 P9 P10 P11 P12 P13 P14 90A 35A 25A 70A 100A 200A 100A 100A 100A (2) Circuit P10 feeds the electrical power panel located in the passageway at head of the engine room access ladder. Identical switches and fuses for circuits supplied are located on the power control panel (fig. 2-15). Figure 2-15. Ships service power control panel wiring diagram c. Ships Service Lighting Operation. (1) The engine room lighting control panel, located at head of the engine room access ladder on port side, is supplied from main electrical control panel by circuit L1. This panel contains individual switches and fuses for the engine room lighting circuits (fig. 2-16). 2-39 Figure 2-16. Engine room lighting control panel wiring diagram. from main electrical control panel by circuit L2. Individual switches and fuses are provided in this power panel for the circuits used (fig. 2-17). (2) General lighting control panel operation. The general lighting control panel, located in athwart ship passageway, main deck frame 21 center of ship, is supplied Figure 2.17. General lighting control panel wiring diagram. fuses are provided in the panel for circuits supplied (fig. 218). (3) The pilothouse lighting control panel, located in pilothouse on the after bulkhead, is supplied from main electrical control panel by circuit L2A. Individual switches and 2-40 Figure 2-18. Pilothouse lighting control panel wiring diagram. by circuit P14. Individual switches and fuses are provided in the panel for circuits supplied (fig. 2-19). (4) The ventilating power control panel, located in the engine room, is supplied from main electrical control panel Figure 2-19. Ventilating power control panel wiring diagram. means of charging the general alarm batteries without disconnecting batteries from the alarm circuit. d. Battery Charging Control Panel Operation. (1) The purpose of the battery charging control panel (fig. 2-20), located in the upper engine room, is to provide a 2-41 (2) To charge the general alarm batteries proceed as follows(a) Move switch P10-1 (fig. 2-15) to ON position. 1. 2. 3. 4. Voltmeter Ammeter Battery selector switch Trickle charge switch 5. 6. 7. 8. (b) Rotate rheostat control (6, fig. 2-201 clockwise as far as it will go. (c) Move main control switch (5) to ON position. (d) Move trickle charge switch (4) to OPEN position. (e) Move battery selector switch (3) to BATTERY No. 1 on BUS. (f) Move battery volt switch (7) to ON position. (g) Turn rheostat control (6) counterclockwise until desired rate of charge (TM 9-6140-200-15) is indicated on ammeter I2). (h) To charge battery no. 2, move battery selector switch (3) to BATTERY NO. 2 on BUS. (i) To charge general alarm batteries by a trickle, move trickle charge switch (4) to CLOSED position. (j) To secure the battery charging control panel, reverse the procedures in steps (a) through (i) above. e. Navigational Light Control Panel Operation. (1) This control panel (fig. 2-21) is supplied from the main electrical control panel circuit RL (25, fig. 2-5) and is located in pilothouse. This panel provides individual switching and fuses for the running lights, towing lights, anchor light, and blinker light circuit. Main control switch Rheostat control Battery volt switch Panel access door Figure 2-20. Battery charging control panel. Figure 2-21. Navigational light control panel. 2-42 (d. above). This system is fuse protected, and consists of the following: (1) A general alarm switch located in the pilothouse. (2) A ten-inch bell and lamp with a red lens located in engine room at port side. (3) An eight-inch bell located in crew quarters. (4) An eight-inch bell located in main deck passageway at center of ship. (5) An eight-inch bell located on bulkhead in the galley. (6) Operate the general alarm by moving switch in pilot house to ON. (7) Secure the general alarm by moving switch to OFF. g. Main Electrical Control Panel Operation. This panel is located in the engine room and is the primary control station for the tug electrical system. It is of the dead-front type, with all connections made on back of the panel (fig. 2-22) and the purposes that follow: (2) The running lights are provided with double filament lamps, and a fused circuit to each filament. An alarm system employing a common warning buzzer (and individual indicator lamps) function to indicate filament or fuse failure. When buzzer sounds, test the fuse (Replace a defective fuse). If fuse is serviceable, and buzzer still sounds, move applicable switch (fig. 2-21) to the reserve filament circuit. Replace a defective lamp at earliest opportunity. (3) The towing lights (upper and lower) and anchor light are supplied and controlled from the navigational light control panel. These lamps are single filament. (4) The blinker light circuit consists of two lights mounted on the yardarms, and two blinker key stations. One station is located on top of, the other inside the pilothouse. This circuit is supplied by, and controlled from, the navigational light control panel. f. General Alarm System Operation. The general alarm system is powered by batteries, kept at full charge through the battery charging control panel 2-43 Figure 2-22. Main electrical control panel wiring diagram, rear view. (5) Provides individual circuit overload protection for all auxiliary equipment by means of circuit breakers. (6) Provides a ground detector to test the generator and all power and lighting circuits for the presence of accidental grounds. (7) Operation of the various components listed and described in paragraph 2-2 j, (1) through (41) above, and in figure 2-5, is described below: (a) Open or close circuit breaker for generator no. 1 (12, fig. 2-5) or circuit breaker for (1) Provides the controls and instruments necessary for operation of the two generators. (2) Provides switching arrangements to go from ships generators to s? )re power, and from direct power to the various electrical loads throughout the tug. (3) Provides necessary switching to parallel the service generators. (4) Provides overload and reverse current protection to service generators by means of the generator circuit breakers. 2-44 generator no. 2 (1) by turning handle left to CLOSED position. Turn handle to the right to TRIP position for an open circuit. connecting the generator to the control panel. 7. Close generator equalizer switch (39). (f) To secure one generator form parallel operation, proceed as follows: 1. Check ammeters (14 and 41) to see that loads of both generators are equal. Adjust with rheostat to obtain an equal load if necessary. 2. Open generator equalizer switch (39). 3. Remove load from the generator to be secured by turning rheostat clockwise slowly until generator being left on line indicates that it is carrying 75 percent of the load. Turn circuit breaker handle to TRIP position. 4. Adjust voltage to 115 volts. 5. Open generator disconnect switch (16 or 38) of the generator to be secured. 6. Secure auxiliary set (para. 2-lid). (g) To shift the electrical load to shore power, proceed as follows: 1. Check that the shore power supply switch (37) is in the OFF position. 2. Connect the shore power supply cable to a source of 120 volt dc, then plug cable into the receptacle on after deckhouse. Energize the source. 3. Check that shore power indicator light (7) is illuminated. 4. Place voltmeter selector switch (10) in SHORE POWER position. 5. Close shore supply switch (37) and check voltmeter (10). Meter should read 120 volts. If meter needle is deflected to left (below zero), polarity is reversed. Correct by reversing cable connection at power source. 6. When meter reading in step 5 above, is correct, reduce the electrical load on generator as much as possible by deenergizing all unnecessary electrical equipment. This is to reduce the amperage load. 7. Quickly move power selector switch (17) from GENERATOR BUS position to SHORE POWER position. 8. Trip the generator circuit breaker, open the disconnect switch, and secure the auxiliary set (para 211d). (h) To shift from shore power to generator power, proceed as follows: 1. Start an auxiliary set (para. 2-llb). 2. Select the generator started on voltmeter selector switch (10). 3. Adjust generator voltage to 120 volts. 4. Close generator disconnect switch (16 or 38). 5. Close generator circuit breaker (1 or 12). 6. Reduce electrical load as much as possible. 7. Quickly move power selector switch (17) from SHORE POWER position to GENERATOR BUS position. NOTE The disconnect switches below are large knife type blades and operate stiffly. Be sure you use enough pressure to completely operate switches. (b) Open or close the generator disconnect switches (16 and 38) by pulling handle away from panel for OFF, or push toward panel for ON. (c) The electrical distribution switches (18 through 37) close the circuit when moved right to ON, and open the circuit when moved left to OFF. CAUTION Do not close a switch that has been tripped by an overload until the cause of the overload has been determined and the defect corrected. (d) Connect a generator to the control panel as follows: 1. Start an auxiliary set (para 2-llb). 2. Assure that generator disconnect switches (16 and 38) and generator circuit breakers (1 and 12) are in the OPEN position. Place voltmeter selection switch (10) in position to read voltage of the generator to be started. 3. Adjust voltage to 115 volts with generator rheostat. 4. Close generator disconnect switch (16 or 38). 5. Close generator circuit breaker (1 or 12). 6. Check voltage. Adjust to 115 volts. (e) To parallel the generators, with one generator in operation supplying the electrical system, proceed as follows: 1. Start the remaining auxiliary set (para 2l1b). 2. Select the incoming generator with voltmeter selector switch (10) and the operating generator with selector switch (42). 3. Adjust voltage of incoming generator to a value of 2 volts higher than the operating generator; i.e. if operating generator voltage is 120 volts, adjust voltage of incoming generator to 122 volts. 4. Close generator disconnect switch (16 or 38) for the incoming generator. 5. Close generator circuit breaker (1 or 12) for the incoming generator. 6. Using rheostats (15 and 40), equalize ammeter readings between the generators, and adjust voltage to 115 volts. NOTE Be sure that the power selector switch (17) is in the GENERATOR BUS position when 2-45 (13) and observe the ground lights (4). If an accidental ground is present, one of the lights will increase its brilliance and the other will darken. If the (-) light is brightest, the ground exists on the negative leg of the system. If the (+) is light is brightest, the ground exists on the positive leg of the system. To isolate a ground indicated on ground lights (4), proceed as follows} 1. Operate the distribution switches (18 through 37) one at a time to OFF and ON. If the ground lights return to normal brilliance when a switch is in the OFF position, yet indicates an accidental ground when that switch is at the ON position, the ground is in the system supplied by that switch. The ground may be isolated further' by placing switch of the grounded circuit in ON position, then opening switches on branch circuits, pulling fuses, or opening line switches. 2. If the ground is not located by operation of the distribution switches in 1 above, shift power source from one generator to the other and repeat the test. If ground indication disappears, the defect lies in circuit of generator initially in use. 3. If power is being supplied from shore when ground is detected, shift the load to one of the tug generators and disconnect shore power. Repeat the test. If the ground indication disappears after the shore power cable has been disconnected, the ground is not in the tugs electrical system. 2-18. Engine Cooling System Operation a. General. The cooling system for the propulsion and auxiliary set engines is divided into two subsystems; fresh water, and raw water. The fresh water system circulates through each engine block, and transfers heat from the engine to its heat exchanger. The raw water system circulates through all heat exchangers and removes the heat from the fresh water. See figure 2-23. 8. Adjust generator voltage to 120 volts. 9. Move shore power supply switch (37) to OFF. 10. Deenergize shore power source and disconnect shore power cable. NOTE After shifting to or from shore power, check that all electrical equipment has restarted. Restart equipment as necessary. (i) To secure one generator from parallel operation. 1. Check ammeters (14 and 41) to see that load indications are the same on both generators. Adjust the rheostat to obtain this condition if necessary. 2. Open the generator equalizer switch (39). 3. Remove the load from the generator to be secured by turning rheostat clockwise slowly until the ammeter of the generator being left on line indicates it is carrying 75 percent of load. Turn the circuit handle to TRIP position to open the circuit breaker of the generator to be secured. 4. Adjust the voltage to 115 volts. 5. Open the generator disconnect switch (16 or 38) for the generator to be secured. 6. Secure the generator set (para. 2-11). (j) The ground detector system consists of two clear lens lights connected in series across the main distribution bus bars of the control panel. The ground detector button (13, fig. 2-5) connected in series between the ground lights (4) on one end, and connected to ground on the control panel frame, is a part of the ground detector system. The ground detector lights (4) burn at half brilliance at all times the tugs electrical system is energized. Test for accidental ground of system by pressing in on ground detector button 2-46 Figure 2-23. Engine cooling system diagram. valve position for each and the procedure necessary to b. Operation. Table 2-3 is keyed to figure 2-23 and accomplish them. identifies each valve in the cooling system, gives its location, function, and label description. Table 2-13, also keyed to figure 2-23, lists the various operations to be performed, the Table 2-13. Engine Cooling System Control Value Positioning. Operation Open valve Close valve To cool port generator engine. (20) (21) (22) To cool stbd. generator engine. (23) (24) (25) To cool main engine normally. (4) (5) (11) (2) (9) (8) (15) (10) (11) (18) (19) (7) (27) (29) (4) (1) (7) (6) (12) (13) (16) (17) To cool main engine, using standby pumps. (1) (2) (6) (16) 2-47 Procedure NOTE Clean sea strainers daily, or more often, if conditions demand continuous cooling operation. NOTE Clean sea strainers daily, or more often, if conditions demand continuous cooling operation. These valves should remain in the positions indicated whenever the main engine is running. Start standby pumps. Operation Open valve To cool main engine, using standby pumps-- continued To fill expansion tank. Close valve (5) (11) (8) (15) (28) (10) (12) (26) (18) (19) (1) Procedure (17) (9) (13) (4) (2) (6) (7) Observe sight glass and close valve (1) when tank is full. NOTE Always keep expansion tank at least two-thirds full. flaming area. Move the horn slowly from side-to-side, and follow the receding flames upward. 2-19. CO2 Fire Extinguishing Equipment Operation a. Installed Equipment. The installed (fixed) CO equipment (para. 4-2) release (pull box) is located on bulkhead outside the engineroom door, port side. Operate as follows: NOTE The valve can be opened and closed repeatedly without loss from leakage. (g) When continuous operation is desired, the dip yoke ring to the carrying handle is slipped over the operating release lever, when the lever is depressed. (2) To operate the disc-type valve CO, extinguishers, proceed as follows: (a) Repeat steps (a) through (c) in (1) above. (b) Open valve by turning wheel to left, and start discharge of CO, on the fire. (c) Repeat steps (d) through (f) of (1) above. WARNING All crew members must be out, and clear of the engineroom before the release handle is pulled. If time permits, close and secure all compartment doors, hatches, and vents. (1) In the event of a fire in the engineroom, break glass and pull the release handle. This action releases the COI from twelve 50-pound cylinders through the eight nozzles located in engineroom, and sounds the siren alarm. When the release is pulled all ventilation blowers in the engine room will be automatically secured. NOTE The discharge of CO2 may be temporarily halted by turning valve wheel to right. (d) Close the valve as soon as conditions permit, and continue to open and close the valves as necessary. (e) Do not stop the discharge too soon. When the flame has been extinguished, coat the entire surface around the fire area with CO, "snow". This coating will retard or prevent reflash. 2-20. Bilge and Ballast, and the Fire and Salvage System Operation a. General. The bilge and ballast, and the fire and salvage system is an interconnected piping system with two diesel engine driven fire and salvage pumps, one motor driven fire pump, and a motor driven bilge and ballast pump. b. Bilge and Ballast System. This system's motor driven pump is located on starboard side of the engineroom. A hand operated rotary pump is used to pump bilge from chain locker, and is located on bulkhead aft of the chain locker. There are eight bilge suction points that can be pumped. Two are located in engineroom on port and starboard side. Two are located in crew quarters on port and starboard side. Two are located in aft NOTE Open all vents, doors, and hatches as soon as the fire is out. (2) To reset the CO, release, push the release handle to the SET position. b. Hand Extinguishers. There are eight 15- pound and four 4-pound extinguishers installed throughout the tug. (1) To operate the sequence grip C02 extinguisher, proceed as follows: (a) Carry the extinguisher in an upright position and approach the fire as closely as possible. (b) Remove the locking pin from the valve. (c) Grip the horn handle. (d) Squeeze the release lever, and at the same time direct the flow of CO, toward the base of the fire. (e) Fight the fire from windward side, so that the wind will blow the heat away from the operator, and at the same time carry the C02 over the fire. (f) When fighting fire in electrical equipment, or on a bulkhead, direct the discharge at the bottom of the 2-48 gives location, function, and label description. Table 2-14 lists the various operations to be performed, the valve positions, and procedures necessary to accomplish them. It is also keyed to figure 2-24 and 2-25. storage spaces, port and starboard. One located in the Void space, and one located in the chain locker. (1) Valve positioning. Figure 2-24 is a diagram of the bilge and ballast piping system of the tug. Figure 2-25 is a diagram of the chain locker system. Table 2-7 is keyed to figures 2-24 and 2-25. It identifies each valve in the--system, Figure 2-24. Bilge and ballast piping diagram. 2-49 Figure 2-25. Chain locker bilge piping diagram. Table 2-14. Bilge and Ballast System Control Value Positioning. Operation Pump engine room and void space bilges. Pump crew's quarters and storage dry. compartment bilges. Pump chain locker bilge. bilge Use independent bilge suction connection. Fill fore peak ballast tank. Open valve Procedure (3) (5) (6) (20) (5) Open valve (7) and start bilge pump. Pump until bilge is dry. Close valve (7). Repeat procedure for valve (8) and (9) Secure pump. Secure all valves. (6) (20) (26) Close valve (21). Repeat procedure for valves (22), (23) and (24). Secure pump. Secure all valves. Prime pump if necessary. Crank handle on chain locker Open valve (21) and start bilge pump. Pump until bilge is hand pump until bilge is dry. Secure valve (26). Connect hose to independent bilge suction connection and drop other end into area to be pumped. Start bilge pump and pump until dry. Remove hose. secure pump.. Secure all valves. Start bilge pump. Take soundings of fore peak tank (fig. 2-26). When filled to required level. secure pump. Secure all valves. (2) (5) (6) (20) (1) (5) (6) (13) (17) (18) 2-50 Operation Open valve Procedure Fill aft peak ballast tank. (1) (5) (6) (11) Start bilge pump. Take soundings of aft peak tank (fig. 2-27). When filled to required level, secure pump. Secure all valves. Fill fuel oil tank No. 1 with ballast. (1) (5) (6) (15) (19) Before filling fuel oil tank No. 1 with ballast, transfer any fuel oil to the other tanks (para. 2-12). Start bilge pump and fill tank as required. When the bow rides properly, the tank can be cut off from valve (19). Secure pump. Secure all valves. CAUTION Keep fuel oil tank No. 1 valves (15 and 16) wired closed when not in use to prevent contamination of fuel oil . Empty fore peak tank. (18) (17) (14) (5) (6) (20) Start bilge pump. Take soundings of fore peak tank (fig. 2-26). When emptied to required level, secure pump. Secure all valves. Empty aft peak tank. (12) (5) (6) (20) Start bilge pump. Take soundings of aft peak tank (fig. 2-27). When emptied to required level, secure pump. Secure all valves. Empty ballast from fuel oil tank No. 1. (19) (16) (5) (6) (20) Start bilge pump and empty tank as required. Use valve (19) to cut off flow when bow rides properly if desired. If emptying tank completely, be sure that tank is dry before filling with fuel oil lpara. 2-12). Secure pump. Secure all valves CAUTION Keep fuel oil tank No. 1 valves (15 and 16) wired closed when not in use to prevent contamination of fuel oil. Transfer ballast from fore peak tank to aft peak tank. (18) (17) (14) (5) (6) (11) Start bilge pump and take soundings of both fore and aft peak tanks. (figs. 2-26 and 2-27). When required transfer is complete. stop pump and secure all valves. Transfer ballast from aft peak tank to fore peak tank. (12) (5) (6) (13) (17) (18) Start bilge pump and take soundings of both fore peak and aft peak tanks. When required transfer is complete, secure pump. Secure all valves. Emergency bilge suction using fire pump. (4) (10) Use fire pump in conjunction with normal bilge pumping operations. Start fire pump and open valves between fire pump and fire nozzles. 2-51 Figure 2-26. Fore peak tank capacity and soundings. 2-52 Figure 2-27. Aft peak tank capacity and soundings. (c) The engine room fire stations are fitted with an outlet gate hose valve and 1 /2 in x 50-foot length of fire hose. (d) The fire system can be operated by using the diesel engine fire pump. (e) Another method of operating the fire station is to use the shore side deck connection. (f) The fire system can be operated in the following modes: through the port and starboard shore supply deck connections into the fire main; through the diesel driven fire and salvage pumps at 500 gpm at 100 psi pressure; through the electric motor driven fire pump at 300 gpm at 100 psi pressure. (2) Operation. Normal operation is to keep all valves closed when not pumping. Open only those valves necessary to perform the required operation as indicated in table 2-14. Keep all other valves closed. When the bilges are to be pumped, open only one suction valve and pump one bilge suction point dry at a time, close that valve and proceed to the next suction point. If more than one valve is open, and one strainer is not covered with water, the pump will become airbound and not pump. c. Fire and Salvage System Operation. (1) Fire system. The fire system consists of two diesel engine driven fire and salvage pumps (auxiliary set) rated 500 gpm at 100 psi, and a motor driven fire pump rated 300 gpm at 100 psi. The fire and salvage pumps discharge into fire stations, three fire monitors and two deck wash stations. (a) One fire monitor is located on top of pilothouse, and two are located on boat deck, port and starboard side aft. All three are supplied by the 6-inch fire main line. Each fire monitor nozzle has a capacity of 1,100 gpm. (b) The port and starboard fire stations are located on the main deck. Both are fitted with three outlet gate hose valves and a 21/2 in x 50-foot length of fire hose. WARNING When shore side supply is connected into the fire main, the diesel driven fire and salvage pumps and the electric motor driven fire pumps must not be cut into the fire main. (2) Salvage system. The salvage system consists of the two diesel engine driven fire and salvage pumps (the auxiliary sets) interconnected 2-53 to the salvage connections. This system is used to pump out any vessel, or barge, that is flooded or sinking, by placing the suction hose into the 'flooded area and pumping. (3) Operation. Figure 2-28 is a diagram of the fire and salvage system. Table 2-5 is keyed to figure 2-28 and identifies each valve in the fire and salvage system, giving its function, location, and label description. Table 2-15 lists the various operations to be performed, valve positions, and procedures necessary to accomplish them. It is also keyed to figure 2-28. WARNING Do not attempt to pump oil, or any explosive fluid with the fire and salvage pumps. Figure 2-28. Fire and salvage system piping diagram. Table 2-15. Fire and Salvage System Control Valve Positioning. Operation Supply fire water to engineroom using electric fire pump. Supply fire water to deck using electric fire pump. Supply fire water to engineroom using fire and salvage pump (s). Open valve Procedure (19) (18) (4) (20) (19) (18) (3) (21) Connect hose to engineroom fire stations. Start electric fire pump. Secure pump and valves when finished. (6)* (7)* (9)* (14)** (13)** (11)** (17) (4) (20) Connect hose to engineroom fire stations. Start port and/or starboard pump as required. When finished, secure pump (s). Secure all valves. *Open only if port pump is used. **Open only if starboard pump is used. Connect hose to deck fire fire stations. Start electric fire pump. Secure pump and valves when finished. 2-54 Operation Open valve Procedure Supply fire water to deck using fire starboard and salvage pump (s). (6)* Connect hose to deck fire station. Start port and/or (7)* (9)* (14)** (13)** (11)** (17) fire and salvage pump as required. When finished secure pump(s). Secure all valves. *Open only if port pump is used. **Open only if starboard pump is used. Supply fire water to fire main from shore. or (21) as necessary. (2) (22) Connect shore supply to valve (2) or (22) as required. Close valve not being used. To fight fire, open valve (3), (4), (20) CAUTION Do not connect shore supply to valve (3) or (21). Check to be sure that valve (17) is closed. Do not operate fire pump when connected to shore supply to prevent contamination of shore supply water system. Supply fire water to forward fire monitor. (6) (7) (9) (14) (13) (11) (10) Start both fire and salvage pumps. Open valves on monitor and position monitor to obtain desired water trajectory. Secure valve on monitor when finished. Secure both pumps. Secure all valves. Use starboard fire and salvage pump in salvage operation from starboard side. (12) (11) (5) Salvage operation using both fire and salvage pumps. (15) (12) (11) (8) (9) (5) Connect hose to starboard salvage connection and drop strainer end into area to be pumped. Start starboard fire and salvage pump. When finished, stop pump and secure all valves. Connect hose to port or starboard salvage connection. Start both fire and salvage pumps. When finished, secure both pumps. Secure all valves. Wash decks Secure (19) Start electric fire pump. Secure pump when finished. (18) (1) (23) all valves. Supply fire water to aft fire monitors. (6) (7) (9) (14) (13) (11) (16) (24) (25) Start both fire and salvage pumps. Open valves on monitor and position monitors to obtain desired water trajectory. Secure both pumps. Secure all valves. Use port side fire and salvage pump in salvage operation from port side. (8) (9) (5) Connect hose to port salvage connection and drop strainer end into area to be pumped. Start port fire and salvage pump. When finished, stop pump and secure all valves. and an oil burner driven by a fractional l/4 hp electric motor. Heat is distributed throughout by means of convecting piping, unit heaters, convectors, and heating coils. Two unit heaters are located in the engineroom, and one in crews quarters. Two convectors are located in crews washroom; six in the pilothouse; one in the captain's stateroom; one in the chief engineer's stateroom; one in the passage way; two in the crews mess hall; one in the officer's (4) Bilge and ballast pump operation. (a) Move bilge and ballast pump switch (20, fig. 2-5) to the ON position. (b) Position valves to task required (table 2-14), then press START push switch at pump. (c) To secure the pump, close bilge or ballast valves, then press STOP push switch at pump and move bilge pump switch (20, fig. 2-5) to OFF, 2-21. Heating System Operation a. General. The heating system consists of a sectional cast iron steam boiler, a 3-1/2 gpm tankless hot water heater, 2-55 valve in the system, gives its location, function, and label description. Table 2- 16, also keyed to figure 2-29, lists the various operations to be performed, valve positions, and procedures necessary to accomplish them. washroom, and one in the galley. Two heating coils are located in the ventilator fan room, and one in the void space below the pilothouse. b. Operation. Figure 2-29 is a diagram of the heating system. Table 2-1 is keyed to figure 2-29 and Identifies each Figure 2-29. Heating system piping diagram. Table 2-16. Heating System Control Valve Positioning. Operation Open valve Close valve To fill boiler. (1) (2) For normal operation of heating system. (3) (4) (1) (2) To heat the galley. (3) (4) (19) (20) (3) (4) (15) (16) (17) (18) (3) (4) (29) (30) (1) (2) To heat the crew's washroom. To heat the pilothouse. (1) (2) (1) (2) 2-56 Procedure Fill boiler with fresh water until sight glass is 1/2 full. Close valve (1). Energize boiler unit electrical circuit by closing switch in engine room passageway. Open fuel oil supply valve to heating boiler and close oil burner switch adjacent to heater. Operation To heat the pilothouse-continued To heat the captain's stateroom. To heat the chief engineer's stateroom. To heat the passageway. To heat the crew's mess hall. To heat the crew's mess hall. To heat the officer's washroom. To heat the crew's quarters. To heat the engine room. To drain the heating boiler. To operate heating coils and temperature regulating station in blower room. To bypass temperature regulating station in blower room. To operate heating coils and temperature regulating station under pilot house. Open valve Close valve (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) 13) (4) (41) (42) (3) (4) (26) (25) (3) (4) (27) (28) (3) (4) (27) (28) (3) (4) (21) (22) (23) (24) (3) (4) (43) (44) (3) (4) (47) (3) (4) (45) (46) (2) (4) (3) Procedure (1) (2) (1) (2) (1) (2) (1) (2) (1) (2) (1) (2) (1) (2) Set the thermostat in crew's quarters for the desired room temperature. (1) (2) (1) (3) (4) (5) (7) (8) (9) (3) (4) (6) (9) (8) (3) (4) (10) (12) (13) (14) (1) (2) (6) (1) (2) (5) (7) (1) (2) (11) 2-57 Open the electrical circuit to the heating boiler. Allow the boiler to cool and the water temperature to drop to 0°. When sight glass indicates empty, close valve (2). Operation To bypass temperature regulating station under pilot house. Open valve Close valve (3) (4) (11) (14) (13) Procedure (1) (2) (10) (12) b. Operation, Power Hoisting the Chain and Anchor. (1) Move switch (29, fig. 2-5) to ON position. (2) Place the emergency stop switch lever of controller at ON position. (3) Insert bar in slot provided in capstan barrel cover and move capstan barrel cover to engage the two axial keys. This will put wildcat in motion when controller is operated. (4) Release the chain stopper. (5) Anchor can now be raised or lowered by moving the controller handle to HOIST position. (6) To stop windlass, move controller handle to NEUTRAL position. (7) Replace the chain stopper. (8) To secure, disengage the axial keys, and turn switch (29) to OFF, then remove bar from slot in capstan barrel cover. c. Burner Operation. (1) Energize boiler unit by closing switch on power panel in engineroom passageway. (2) Open fuel oil supply valve to heating boiler burner and close oil burner switch adjacent to the boiler. (3) Secure the boiler by reversing steps (1) and (2) above. 2-22. Anchor Windlass Operation a. General. The anchor windlass, located on main deck forward of the pilothouse, is used for lowering or hoisting the anchor. It can also be used for warping, and snubbing of manila lines. The Markey type VEV-16 anchor windlass has a .single vertical capstan barrel, with the wildcat located directly below. The capstan barrel is keyed to the main shaft, and is in continuous motion while the motor is running. The wildcat is driven off the capstan by two axial keys which may be engaged, or disengaged, by turning the capstan barrel cover (clutch). An inner drum, to which the capstan barrel cover is bolted, provides two axial cams which engage the two keys, and moves them up or down as the barrel cover is turned. Indicator plates show key engagement, and spring ball locks are provided to hold the shifter mechanism in either position. A hand operated brake engages the smooth turned drum (Formed by the lower flange) of the wildcat. The windlass is driven by a 10 hp electric motor with electric brake. The controller is mounted on the main deck, starboard side, aft of the windlass and provides 5 points of acceleration for lowering or hoisting. NOTE It is considered good practice to place the emergency stop handle on the controller at OFF position, when the windlass is to be left unattended. c. Operation, Lowering the Anchor and Chain by Hand. (1) Assure that brake is on by turning the brake handwheel fully counterclockwise (fig. 2-30). 2-58 Figure 2-30. Markey model VEV-16 anchor windlass. (2) Turn capstan barrel cover and assure that the axial keys are disengaged. (3) Remove chain stopper. (4) Lower anchor by turning the brake handwheel clockwise to release the brake. come to a sudden stop, and results in unnecessary wear on brake (3) To bring a line in, move controller handle to HOIST position. (4) To stop warping, move controller handle to NEUTRAL position. (5) To let out, move controller handle to LOWER position. (6) To secure, move controller handle to NEUTRAL, move emergency stop switch to OFF, and move switch (35) to OFF. 2-24. Potable Water System Operation a. General. The potable water system consists of a tank with a capacity of 2,756 gallons, a maximum sounding depth of 6 feet 11 inches, and with a fitting and sounding connection located between frames 44 and 49. The system supplies fresh water to the propulsion engine cooling system expansion tank, the heating boiler, water dispenser (drinking fountain), galley sink, coffee urn, shower baths, and lavatories. The tank is filled through a fresh water hose connection located on the port side of main deck, aft, from the shore or supply connection. The operating pressure for the system is furnished by an electric motor driven reciprocating pump located in the engineroom. This pump, with an automatic pressure switch (fig. 2-8). keeps pressure between 20 and 40 psi automatically. It has a pumping capacity of 625 gph. b. Taking on Fresh Water. (1) Remove cap from fresh water hose con- NOTE The anchor and chain will fall freely when the brake is released. Brake must be used to control the speed. Do not allow chain to run out too slowly, as the brake when slipping continuously will develop excessive heat. However, chain must not run so fast that it jumps out of the wildcat. (5) To stop lowering, turn brake handwheel counterclockwise to apply the brake. (6) To secure, replace the chain stopper. 2-23. Capstan Operation a. General. The capstan is mounted vertically and driven by a 10 hp, 1,750 rpm, 115 vdc motor. It is installed on aft main deck, starboard side. A pedestal mounted controller, that provides 5 speeds in either direction, is located nearby. The capstan is used for handling manila lines in warping and towing operations. b. Operation. (1) Move switch (35, fig. 2-5) to ON position. (2) Move the emergency stop switch lever to ON position. NOTE The emergency stop switch should be used only in an emergency, never for normal stopping. since it causes motor to 2-59 NOTE nection on main deck, port side aft, and connect hose between tug and supply. (2) Remove sounding tube cap and take sounding. (3) Open fresh water shore supply valve. (4) When sounding indicates the tank is full, close the supply valve. Disconnect the fresh water hose, and replace the sounding tube and hose connection caps. c. Water Pressure Pump Operation. (1) Open fresh water supply valve to the pump. (2) Move pressure pump switch on engine room electric power panel to ON and pump will start automatically when pressure in system drops to 20 psi. 1. 2. 3. 4. 5. 6. Blower motor Airshutter control Oil receptacle Burner unit Fuel connection Font plate If the water pressure pump overload relay trips, do not reset the relay until the trouble has been found and corrected. (3) To reset the overload relay, press the RESET push button. 2-25. Galley Range Operation a. General. The galley range is an oil burning type, supplied from a 30 gallon day tank of the tugs fuel oil system (para 2-12). The oil burner unit is shown in figure 2-31. 7. Oil metering valve 8. Shutoff valve 9. Control Valve 10. Strainer nut 11. Blower mounting screws 12. Cap screws Figure 2-31. Galley range burner unit. (3) Place a crumpled piece of paper in receptacle (3) and start it burning with a match. Allow it to burn for a few minutes with blower not running. b. Starting. (1) Open shutoff valve (8, fig. 2-31) by lifting and turning counterclockwise. (2) Turn pointer of oil metering valve (7) full counterclockwise. 2-60 (4) When frost is dissipated, wipe inside of cabinet with a solution of baking soda in cold water to remove food odors, then move switch toward COLDER until desired temperature is attained. 2-27. Deep Freeze Unit Operation a. General. The deep freeze unit, located in the lazarette, has an 18 cubic foot capacity. It is a cabinet type with a top opening door, and designed to maintain an average compartment temperature of -5°F to -20F without food load, when the ambient temperature is 120°F. The compressor uses Freon 12 as a refrigerant, and is complete with a fan cooled condenser. The controls include an automatic cycling device to maintain a near constant (--3) temperature, a warning signal to indicate undue temperature rise, a temperature selector, and a thermal overload cut-out with automatic reset for the motor. The compressor, alarm signal, motor, and controller are installed on a bracket foundation in the engine room and secured to the after port side bulkhead. b. Operation. (1) Connect the electric power cable to the tugs electrical system. (2) Move controller to ON. (3) Move selector switch past NORMAL toward COLDER until chest compartment reaches the desired temperature, then place switch at NORMAL. It will maintain this temperature to within 3°F. 2-28. Water Dispenser (Cooler) Operation a. General. This is a vertical type dispenser, and is located in the crews messhall. The unit has a hermetically sealed compressor unit, and a fan cooled condensor that uses freon 12 refrigerant. The cooling coils and storage tank are located in the upper portion of the cabinet. It has a thermostat control, with a temperature adjusting screw, a relay, and an overload protector. It is heavily insulated with cork. b. Operation. (1) Assure that dispenser is connected to the fresh water supply, and that drain is also attached. (2) See that electric cable (12, fig. 2-32) is connected to tugs electrical system. (4) Place air shutter control (2) in closed position (pushed against front plate (6)). (5) Move motor switch to ON. Allow motor to run for a few minutes, then adjust oil metering valve (7) and air shutter control (2) to a desired flame without smoking. NOTE Too much air or oil may extinguish the fire. When this occurs. turn off oil metering valve and blower motor. and allow fire to burn out. After fire is dead. relight by following procedure shown in steps (1) through (5) above. c. Securing. Close oil metering valve (7), shutoff valve (8), and allow blower motor to run about 15 or 20 minutes with air shutter control (2) fully open. This will allow oil and carbon to be fully consumed. NOTE If excess carbon accumulates on the receptacle. loosen with a scraper to expedite its consumption. 2-26. Refrigerator Operation a. General. The refrigerator, located in the galley, is used to store perishable food. It is equipped with a temperature and defrost control switch. The compressor and motor are located in a compartment at bottom of the refrigerator cabinet. b. Operation. (1) Move switch on power control panel to ON. (2) Move temperature regulating switch in cabinet to the desired temperature for refrigeration, (this is generally accepted to be near 40 degrees F.) then close door. NOTE When an inspection of the interior shows an excessive accumulation of frost, proceed to step (3) below. (3) To defrost interior, move switch inside cabinet to DEFROST. This cuts power for a warming of the interior. The defrost process can be expedited by placing containers of hot water on the shelves, and using a plastic scraper to remove heavily caked frost. 2-61 1. 2. 3. 4. 5. 6. 7. Bypass valve Drain Water projector Push button Dryer Refrigerant line Self-closing stop 8. Storage tank 9. Insulation 10. Temperature adjusting screw 11. Thermostat control 11. Thermostat control 12. Electric cable 14. Relay Figure 2-32. Water dispenser (cooler). (3) Move switch on controller to ON, to start cooling unit in operation. Adjust temperature adjusting screw (10) as required. 2-29. Coffee Urn and Immersion Heater Operation a. General. The coffee urn is of stainless steel, with an immersion heater of 4,000 watts, and a three position switch 15. 16. 17. 18. 19. 20. Overload protector Compressor Fan and Motor Suction line Liquid line Precooler and waste line for selecting the desired heat. The immersion heating element is replaceable. b. Operation. (1) Fill urn with water and the correct amount of coffee. 2-62 c. Speed Regulation. Speed of wipers stroke is increased by turning rheostat knob clockwise away from OFF. Decreased by turning counterclockwise toward OFF. d. Stop. Secure the windshield wipers by turning rheostat knob counterclockwise until it snaps into OFF position. 2-32. Gyrocompass Operation a. General. These instructions will enable operator to start and settle the compass in azimuth in a minimum of time under all sea conditions. Although operation does not require continuous attention to the controls and adjustments, operating personnel should be fully knowledgeable of the meaning and purpose of the various in- dicating lamps, meters, switches, and alarms described in table 2-17 below and figures 2-33 and 2-34. (2) Place electric plug in a receptacle. (3) Turn switch to the desired heat. 2-30. Searchlight Operation a. General. The searchlight control (3, fig. 2-1) permits elevation or depression of the beam 45° from the horizon, and rotation through 360°. b. Operation. (1) Move switch (2) to the ON position. (2) Release the star wheel horizontal lock. (3) Turn knurled handle on control (3) counterclockwise one-half turn to release the vertical lock. You may now position the light as desired. 2-31. Windshield Wiper Operation a. General. There are three windshield wipers. One on each of the front windows of pilot house. b. Start. These wipers are started by turning rheostat control knob clockwise from the OFF position. Figure 2-33. Gyro compass control cabinet. 2-63 Figure 2-34. Gyro compass master unit. Table 2-17. Gyrocompass Front Panel Operating Control Functions. Control Function RPTR switch................................ ......... This switch controls the internally generated power for operating external repeater equipment. N-S switch ................................ ............ This switch is used in conjunction with the latitude corrector to select for north or south latitude correction. CAGED indicator ................................ .. This indicator will be illuminated anytime the gyro is caged and the equipment is on. It will go out after uncaging and will stay out during normal operation of the compass. LEVEL meter ................................ ........ This meter provides an indication of the tilt of the gyro spin axis. It is used primarily during starting of the compass to assure the gyro is started level. Its sensitivity is approximately 2 minutes per division. 2-64 Control FOLLOW-UP-ALARM indicator............ POWER indicator ................................ . DIMMER control ................................ ... TILT/AZIMUTH switch ........................... LATITUDE corrector control .................. MODE SELECTOR switch .................... RPTR. 1 AMP, fuze.............................. A-C 1 AMP fuze................................ .... D-C 8 AMP fuze................................ .... Function This indicator will illuminate if there is any failure in the follow-up system or in the power to the servo amplifier. This indicator will illuminate when external power is turned on and the internal power supply is supplying power to the compass and control circuits This rheostat controls the brightness of the compass card illumination This switch provides two functions. When slewing the compass, it controls the direction of rotation of the compass element. It also provides a signal to level or to increase the tilt of the gyro spin axis. This corrector provides a latitude correction signal This switch selects the various circuits used to control operation of the compass. In SLEW position. all compass circuits are energized except the gyro wheel and repeater excitation. The compass is slewed to ship's heading prior to starting the gyro using the TILT/AZIMUTH switch. In START position. all circuits are energized and the gyro wheel is brought up to speed. Repeater circuits will remain deenergized until an internal relay switches after the gyro comes up to speed. In RUN position. the TILT/AZIMUTH switch is disconnected so the gyro cannot be accidentally tilted during normal operation In MANUAL position. tilting or leveling of the gyro is done using the TlLT/AZIMUTH switch. In AUTO LEVEL position. the gyro will automatically be brought to an almost level position and held there. This mode is only used if the gyro has dumped or when the level meter indicates full scale. Protects the Internal power supply when used with external repeaters. Protects the basic 120-v-olt a-c internally generated power Protects the internal power supply of the Electronic Control Assembly b. Operation. (1) Starting the compass. NOTE When practical, starting procedures should begin at least two hours before the gyro-compass is required for service. (a) Normal sea starting. For use where roll and pitch are less than 10 degrees, and the compass has been stopped for at least 1 hour. Proceed as follows: 1. Insure that the RPTR switch and the MODE SELECTOR switch are in the OFF position. 2. Place MODE SELECTOR switch to SLEW. NOTE Compass will slew rapidly if gyro is uncaged. 3. CAGED lamp should be lighted. If lamp is off, push the cager button on top of the binnacle to cage the gyro and wait 5 minutes to allow ballistic fluid to stabilize. 4. Use the TILT/AZIMUTH switch to slew the compass as close as possible to the ship's heading. Pushing the switch in the (+) direction will make the compass card rotate counterclockwise; pushing in the (-) direction will make the card rotate clockwise. Wait 5 to 10 seconds between reversals of the switch to allow the follow-up servo amplifier to stabilize. 5. Turn MODE SELECTOR switch to START. Wait 10 minutes for gyro to come up to speed. Then, firmly push the cager button on top of the binnacle to uncage the gyro. Caged lamp must go out or gyro has not been uncaged. 6. Move MODE SELECTOR switch to MANUAL LEVEL immediately after uncaging the gyro. 7. Operate the TILT/AZIMUTH switch to bring the gyro to a level position as indicated by the LEVEL meter. Push the switch in the direction of desired pointer movement and hold it until the meter pointer has reached its center position. If it overshoots, reverse direction as needed until the pointer has been centered. 8. Place MODE SELECTOR at RUN. 9. Set N-S switch for north or south latitude . 10. Set LATITUDE corrector control to the ship's latitude. NOTE When step repeaters are used they should be synchronized to the compass card reading prior to turning RPTR switch ON. 11. To operate repeater, move RPTR switch to ON. 12. Adjust DIMMER control for satisfactory brightness. (b) Routine Operation. Because operation of the compass is almost completely automatic, the only routine operating procedures that need to be performed are the checks for each watch that follows: 1. Check setting of LATITUDE corrector control and reset to local latitude, if required. 2. Check setting of N-S switch and reset to proper hemisphere, if required. 3. Make normal azimuth checks on compass to determine accuracy of heading indication. 2-65 1. Moue MODE SELECTOR to MANUAL 4. Record the LEVEL meter reading when the compass is settled for reference. (c) Stopping the compass. Stop the compass as follows: 1. Move RPTR switch to OFF. NOTE When seas are rough, turn MODE SELECTOR to OFF. Wait 30 minutes then cage the gyro. 2. Move MODE SELECTOR to SLEW. 3. Push cager button (on top of binnacle) to cage the gyro. CAGED lamp should light. 4. Move MODE SELECTOR to OFF. (d) Operation, should compass become dumped. If the compass should become dumped after the wheel has come up to speed, as indicated by a full scale LEVEL meter reading and a rapidly slewing compass, move the MODE SELECTOR to AUTO LEVEL. This will stop the slew and level the gyro, but will leave compass at some heading other than that desired. To restore compass heading, proceed as follows: LEVEL. 2. Push cager button (on top of binnacle) to cage the tyro. The CAGED lamp should light. 3. Push the TILT/AZIMUTH switch in the same direction as that in which the card should rotate to return to the desired heading. Release the switch when the LEVEL METER indicates the maximum. 4. Compass card will slowly rotate toward the desired heading. 5. Allow compass to rotate past desired heading by 2 or 3 degrees and immediately uncage the gyro by pushing the cager button on the binnacle. CAGED lamp should go out. 6. Move MODE SELECTOR to AUTO LEVEL. This will approximately level the gyro. 7. Move MODE SELECTOR to MANUAL LEVEL and operate TILT/AZIMUTH switch to center the pointer of the LEVEL meter. 8. Move MODE SELECTOR TO RUN. Section III. OPERATION UNDER, UNUSUAL CONDITIONS and remove them from circuit as soon as the engine is running. b. Electric Motors and Generators. Check lubrication orders for correct winter weight lubricants (para 3-2). c. Steering System. Test the steering system by moving rudder, slowly, full left then right, to- dislodge any ice that formed at water line. d. Hull and Hull Fittings. (1) Keep covers installed on all filler connections, except when filling tanks, to prevent contamination. Be sure and remove all accumulations of ice, or dirt, before removing covers. (2) Drain all water from firm main risers, until level of standing water is below boat deck. (3) Adjust closure of vent aft of pilot house. This closure can be adjusted to direct some of heated exhaust back into supply system of crew mess and quarters for added comfort. e. Running Lights, Searchlight, and Horn. Remove all ice formations carefully, and frequently, during icing conditions to keep them always operable. f. Windshield Wipers. There are two types of blades available. For extreme cold, use the felt blade soaked in a solution of alcohol and glycerin, half of each. Fill blade reservoir with a similar solution. 2-33. General Operation of the tug in extreme cold creates a special problem with lubricants, above deck icing, and some fuel or starting problems with the diesel engines. Other problems occur during operations in extreme heat. These will be described in the following paragraphs. 2-34. Operation in Extreme Cold a. Diesel Engine Starting. (1) Assure that lubrication meets requirements of the lubrication orders (para 3-2). (2) Keep the engine room as warm as possible without shutting off ventilation completely. (3) Use decompression valves on engines so equipped. WARNING Never use a blowtorch, or other open flame method of heating the fuel or oil lines. (4) Fuel lines have a tendency to become airlocked when fuel is cold. Vent fuel system before trying a start. NOTE Never run engine above a fast idle until engine oil has warmed, and pressures have dropped back to normal. (5) When starting by air is hard, and air pressure becomes low, use the cartridge starting aid. (6) On electric starting diesels, check batteries for full charge and tight terminal connections. It may be necessary to add a booster set. If boosters are used, be sure NOTE In nonfreezing weather, fill reservoirs with fresh water to keep salt off windows. 2-66 2-35. Operation in Extreme Heat a. Diesel Engines. (1) Change lubricants as directed in the lubrication orders (para 3-2). (2) All diesel engine cooling systems will be carefully watched, and lubricating oil and cooling water temperatures maintained within operating limits. Oil temperature should not exceed 185 °F. Water temperature should not rise above 170°F. b. Electric Motors and Generators. The electric motors and generators will have a tendency to run hot. Take care that motor or generator is not overloaded as this may cause the winding to burn out. It is best, if at all possible, to run these intermittently, shutting them off'15 to 20 minutes every time the housings become so hot that it is impossible to touch them comfortably. c. Batteries. Inspect water level in batteries more frequently in extremely hot weather. Keep level at lea st 3/8 inch above plates (TM 9-6140200-15). WARNING Volatility of fuel and oil fumes is a hazard of extreme heat. Keep fuel and oil lines free of leaks. Wipe up all spills. Pump bilges regularly. 2-67 TM 55-1925-204-12 CHAPTER 3 OPERATOR/CREW MAINTENANCE INSTRUCTIONS Section I. LUBRICATIONS INSTRUCTIONS 3-2. Lubrication Instructions 3-1. General Refer to the lubrication orders listed below for lubricants to be Lubrication of the tug components, assemblies, and auxiliary used on components named: systems are covered by lubrication orders. The performance, interval, and type of lubricants are mandatory. C91001L LO 55-1925-204-12-1 LO 55-1925-204-12-2 LO 55-1925-204-12-3 LO 55-1925-204-12-4 LO 55-1925-204-12-5 LO 55-1925-204-12-7 LO 55-1925-204-12-8 Fuels, Lubricants, Oils and Waxes Tug, harbor, diesel, 1,200 hp, steel, 100 foot, Design 3006, (Flight One) Engine, diesel, marine (Fairbanks-Morse 37-F-16) Steering Device, electric Motor driven (American Engineering Model 51/4" Ram). .Air Compressor (2), motor driven, (Quincy Model D340) Capstan, motor driven (New England Trawler Equipment Co. Model R6293) Auxiliary Set (Generator and Fire and Salvage Pump) (GM Engine 4061A, Delco Generator -3644, Patterson Pump 4LSBB, and Kraissal priming pump 25-9RS) Lubricating Oil Purifier, motor driven, (DeLaval Steam Turbine Co. Model 45-28). Windlass, motor driven, marine (Markey Marine Co. Model VEV-16) Motor and Pumps, Models A313A143 and A322AX250 Section II. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES 3-2.1. General Preventive maintenance is the systematic care, servicing and inspection of equipment. The purpose of P.M. is to keep the equipment in serviceable condition, and to prevent, find and repair conditions that could render the equipment unserviceable. The vessel crew is responsible for operator/organizational maintenance. The engineering/deck personnel engaged in preventive maintenance checks and services should correct any deficiencies noted at the time of the check/inspection. Deficiencies noted that are above the crew level or maintenance will be reported to DA/GS level utilizing DA Form 2407 (Maintenance Request) in accordance with TM 38750. 3-2.2. Procedures for Preventive Maintenance Checks and Services. The personnel performing the PMCS will utilize DA Form 2404 (Equipment Inspection and Maintenance Work Sheet). The form will be annotated in accordance with para 3-4. Figures, and 3-5 TM 38-750. The DA Form 2404, used for recording the PMCS, will be furnished to the appropriate supervisor for action. When all corrected faults have been recorded on DA Form 55-40 (Deck Department LOG), DA Form 55-44 (Engine Depart LOC) and all uncorrected faults have been transcribed on to DA Form 2407 (Maintenance Request), the DA Form 2404 can be discarded unless its required for historical data. 3-2.3. PMCS Schedule PMCS will be accomplished as outlined in the enclosed table. To ensure that the vessel is serviced and ready fob operation at all times, it will be serviced in accordance with the intervals out lines in the PMCS Table. 1. Before Operation: The required preventive maintenance services will be preformed before operating. Any deficiencies noted will be corrected prior to operating the equipment. Change 1 3-1 TM 55-1925-204-12 2. During Operation: The during operation services is a check on the vessels performance. evidenced that will result in damage to the equipment, operation of said equipment will be halted. If any deficiencies are 3. After Operation: After operation services are the basic daily preventive maintenance services. These services will be performed at intervals based on the normal operation of the equipment. When abnormal conditions exist, the services will be performed at intervals to allow for them. 4. operation. Monthly Operation: The required monthly services will be performed to ensure vessels stay ready for continued 5. Quarterly and Biannually Operation: The services are accomplished on a scheduled basis, and definite tasks are accomplished i.e., draining and filling, equipment with oil, changing or cleaning the oil strainers and filters, fuel filters and air filters. Accomplishing minor and some major adjustments. Motor brush checks etc. To ensure continued operation of vessel equipment. 3-2 Change 1 TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: 1 External hull above waterline Crew inspect for structural damage above waterline Watertight integrity or operational capability is impaired. 2 External hull(below the waterline). Rudder, zinc anodes, digital depth sounder transporter, sea chest strainers Crew inspect accessible hull for flooding. *If crew inspection reveals hull leakage/flooding, divers inspect underwater hull for damage. Underwater hull is damaged/deteriorated to extent that watertight integrity is impaired. 3 Propeller and propeller shafts Check for misaligned/bent propeller shaft and worn shaft bearing. Stand on stern of vessel while running free. Should the vibration be above normal, propeller shaft shall be inspected by divers. Propeller/propeller shaft and/or shaft (cutlass) bearing are damaged/excessively worn. 4 Anchor windlass Inspect for proper operation in speeds ahead and astern. Check oil reservoir to level plug. Lubricate IAW L055-3950-20512 and 55-3950-209-12. Vessel has to use anchors. 5 Stern capstan Inspect for proper operation in all speeds ahead and astern. Check oil level monthly. Maintain level to filler plug (10 gal capacity). Lubricate IAW L055-3950-20412. 6 Steering system and rams Inspect steering rams through inspection cover for excessive leak off from ram packing glands. Check packing glands for proper torque and adequate seal. Check steering motor for arcing and overheating by visual and touch inspection. Check reservoir for proper level of steering fluid OE10O/HDO (' full sight glass). Check directional check valves for leakage and torque on pipe unions. Ensure mechanical stops are set properly 350 port and stbd. Change 1 3-3 Rudder does not respond to wheel house control. No fluid in sight glass. Mechanical stops improperly set. Steering motor draws excessive amps and overheats. Emergency steering fails to function during routine test. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: 7 H Bitt, bitts and chocks. Inspect for damage, cracked welds, structural damage and deterioration. 8 Shore power connection box Inspect for damage/deterioration, loose connections, burned insulation. and melted/burned socket/receptacle. 9 Lazy boys (stern) Inspect lazy boys for proper securement, deterioration, and oil leakage from steering ram cover. 10 Baffle covers and air ports Lubricate dogs and hinges on baffle covers and air ports. Ensure air port glass is intact (not cracked). Check seals for leakage and W.T. fit. Replace all defective seals. 11 Watertight doors, scuttles, hatches, and manholes Inspect for worn hinge pins, defective locking dogs and warping of door/hatch. Check combing for deterioration and proper fit (chalkbest). Check rubber door seal for deterioration. Ensure knife edge is free of paint, rust and other foreign matter. Damaged/deteriorated deck hatches/door combing. 12 Fire stations Inspect for damaged or missing hoses, nozzles, applicators, valve handle and spanner wrenches, inoperative valves and strainers. Ensure stations are marked with station number. Check fire axe for oxidation and cutting edge for honing. Ensure hoses are stenciled with last test date (a yearly requirement). Bottles will be inspected monthly. Nonportable will be inspected at cycle drydock period. Fire fighting capability is impaired so as to effect the vessel ability to effectively fight fire. 13 Damaged control equipment Ensure shoring, plugs, gasket material, OBA, flame safety lamp axe and life line are aboard and in acceptable condition (no dry rot, deterioration, etc.) Damage control equip ment is not on board. 3-4 Change 1 H Bitt, bitts and chocks are damaged. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: 14 Tank vents Ensure vents pipes are free from corrosion/deterioration. Check flame arrestor screen for rust and paint. Ensure ball check valves operate correctly - ball free. 15 Vertical ladders, scupper drains, bulwark, freeing ports. Inspect preventer bars for fractures, check drain pipes for internal corrosion. Check ladder securements and hand rail for deterioration/corrosion. Ensure non-skid is applied to ladder steps. 16 Life raft, life rings, light marker, rail and mounting brackets. Inspect for damage to life raft and hydrostatic release. Ensure life ring marker lights are operative. Ensure hull number/name of vessel is marked on life ring. Check brackets for damage, deterioration and ease of removal. Check life ring buoy for sufficient life line. Life raft is damaged/ nonoperational. 17 Life jackets and life jacket stowage locker. Inspect life jackets for hull number, bears missing straps, oil paint soaks and deterioration. Check life jacket locker for marking and deterioration. Ensure locker cover floats free upon submerging locker. Life jackets are missing, damaged/deteriorated. Life jacket lock will not float free/cannot be removed upon submerging. 18 Cargo lights Ensure cargo lights are operational, check for damaged plug and frayed wiring. Ensure lenses are intact and lights can be elevated for work on fan tail/lazy boy area. Cargo lights are inoperative. 19 Stack house Check the exhaust uptakes for condition and mounting. Check for carbon streaks and other indications of exhaust leaks. Tighten the mounting bolts and connections. Ensure manifolds and gaskets are in good condition, secure and not leaking. Check insulation (main engine and both Uptakes are leaking exhaust fumes creating a carbon monoxide safety hazard to crew, and operating personnel.. l Change 1 3-5 Vent tube is ruptured/sheared allowing S.W. into fuel tank endangering vessel and crew. Rubber ball is missing from check valve. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: generators) for deterioration and cracks. Empty the carbon collector on the exhaust silencer. Check flapper valve for free movement and closing post operation. 20 Main mast and spar, stays, shrouds, signal and navigation lights, whistle, radar antenna and wave guide. Inspect for structural damage. Ensure all mast lights are intact and functional. Ensure signal halyard is installed and functional. Ensure radar guide wave is properly secured to mast and is watertight. Check mast for rust and deterioration. Visually inspect ship's whistle and air supply lines for damage. Mast and spar is damaged to extent that radar and lights are adversely affected. 21 Navigation lights Check navigation lights for satisfactory operation. Check running light lenses for cracks and proper insulation. Ensure running, mast head and range light are bright lights. Check navigational light control panel test circuit for loose connections and ground. Navigation lights are inoperative. 22 Radion, ADF and IFF antenna Inspect for damage and deterioration. Ensure insulators and securements are properly secured, free of rust and corrosion. Damage impairs radio operation, no vessel communication./contact with navigation aids. 23 Search light Check search light for proper operation and ensure stuffing tube does not leak from flying bridge to pilot-house. 24 Windshield wipers and motors Ensure blades are free of rust and check rubber for dry-rot. Check motors for overheating and proper operation. Check for crack, broken or missing glass. Check for inoperable opening or closing mechanism, and obstructed casement drains. I 3-6 Change 1 TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: 25 Magnetic compass Check compass for bubbles and loss of fluid. Ensure compass will swing freely (pointer moves smoothly). Check heading on two known courses. Check deviation whenever electronic/metal structure changes are made. Ensure deviation card is up to date, and annual deviation has been posted. 26 Gyrocompass Check gyrocompass for proper operation/error. Put compass on line in accordance with data plate instructions. Ensure gyrocompass has time to warmup/settle prior to getting underway. While underway/sailing determine gyro error daily by celestial azimuth or terrestural bearing and record in DA Form 55-40 (Deck Log Book). Gyrocompass indicates malfunction error. Use back up magnetic cornpass evidence error/malfunction the vessel will be reported not ready. 27 Radar Conduct functional check of the radar to insure satisfactory operation. Radar is inoperative. 28 Communication/electronics equipment: AN/URC-92 AN/VRC-46 AN/SRC-6A AN/URC-80(v)1 AN/PRC-94 LS 518/519/S1C OK-295/URC-80 AN/SPS-59(v)1 AN/SQN-15 AN/SRN-18 AN/SSN (MK-27) ID Type B repeater PP-7078/U PP-2953/U AS-3095/URC PP-7334/U Other CN&E equipment installed as mission required. See applicable TM's outlined in TB 43-0117, Feb 76. (Marine Electronics Configuration Directory). Conduct an operational test of communication equipment to ensure satisfactory operation of equipment. Communication between vessels on navigation and safety channels and between vessel and Port Authority is impaired. Radar does not perform properly. 29 Clinometer Check to ensure vessel is on even keel. No port or stbd list. Transfer fuel if list is evident. Vessel is listing to port or stbd 50 or more. l Change 3 3-7 TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: 30 Fire monitors 31 Plumbing, deck drains, and sounding tubes 32 Sewage discharge and vents Inspect to ensure vent is open, discharge valve is functional and cap is available for discharge line. 33 First aid kit Check first aid kit for condition and supply of necessary items. Check items against replenishment list and replace short/damaged items from local dispensary/hospital. 34 Tools and repair parts Ensure running (repair parts) spares are onboard and in a ser viceable condition IAW TM 551925-204-12 and TM 55-1925-20512. Ensure tools are clean, serviceable and properly mounted or stowed. Ensure tools are marked IAW para 18J AR735-5. There are no tools or run. ning spares on board vessel. 35 Batteries Ensure batteries are secure and clean, check electrolythe level, and add water to split ring. Check specific gravity (1220) for condition/rate of charge. Replace vent caps upon completion of check. Check cables for torque and casing for cracks. Batteries will not start ship service generators. 36 Ship service generators, engines port and stbd, caution Prior to starting engine, ensure circuit breaker is open on shipservice switch board. a. Engine lubricating oil Use SAE 30 HD oil. Ensure oil is level with top mark of dip stick. b. Oil capacity Model 306/A 15 qts. Model 406/A 17 qts. Ensure fire monitors stop valve does not leak. Check elevation and swing (3601). Ensure worn gear is lubricated and functional. Check to ensure drains are not obstructed and sounding tubes are clear. 3-8 Change 1 Vessel is employed in a fire fighting situation with defective monitors. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: c. Change intervals Oil should be changed as a minimum every 200 hrs. However, TB43-0210 may justify additional hrs by oil test results. d. Lubricating oil filters Lub-oil filters are changed when lubricating oil is renewed. e. Temperature and pressure Oil pressure gauge installed. Operating pressure at 1450 RPM 30-40 PSI. Pressure below 25 PSI. f. F.W. expansion tank Fill with coolant to within one inch of radiator cap. Coolant below heat exchanger core. g. Zinc anode Inspect and service monthly renew if deteriorated 50% or more. h. F.W. circulating pump Check pump for leakage, check temperature for normal operation. Check expansion tank for loss of coolant and proper circulation. Engine reflects high coolant temperature (exceeds 185°F). i. Coolant temperature At 1450 RPM: 160-1800F. Check cooling water level and quality of antifreeze. Refill or replace as necessary. In winter months when antifreeze is used make hydrometer test, and add antifreeze as required. Use ethylene glycol base antifreeze. Protect to -32°F or as local conditions dictate. Temperature exceeds 1850F. j. S.W. circulating pump Check for excessive leak off temperature of engine. Check impeller by observing overboard discharge. Engine reflects excessive high operating temperatures (exceeds 185°F). k. S.W. suction and discharge valves. SW line strainer Remove strainer top with suction and discharge valves closed. If leakage is apparent suction/discharge valve leaks. Check strainer for foreign objects and deterioration of strainer basket. Clean SW strainer and replace if defective. Sea chest is clogged impairing proper engine cooling. Change 1 3-8.1 An oil change directed by the AOAP is not completed, or a change is required due to dilution or emulsion. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. 37 B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: l. Fuel strainers Change filter at lubricating oil change intervals. Drain water and sediment and wipe casing with clean wiping rag. m. Air filters/cleaners Service filter IAW local environment. Check to see that the oil in the filters is at the proper level, and is not excessively dirty. Clean the element and refill with clean oil. Filters should be serviced at every lubricating oil change or sooner, should local conditions dictate. n. Ammeter Check ammeter to see that it indicates properly. Heavy charge after starting engine (10-15 amps) slowly returning to zero as charge is replenished. o. Oil pressure gauge Inspect oil pressure gauge to see that it functions properly. If the instrument does not indicate, stop engine immediately and investigate cause. Oil pressure gauge does not indicate oil pressure is below 25 psi. p. Temperature gauge Engine temperature should increase gradually during warmup period. Should a high temperature be indicated, caused by a defect in the cooling system, faulty gauge or improper lubricating, engine must be stopped immediately and the trouble investigated. Coolant temperature exceeds 185°F. q. Tachometer See that the tachometer is operating properly and indicates engine revolutions. Hand-tach crankshaft to check accuracy of tachometer. Ship service generators (40k) With generator in operation check for arcing at brushes. Check commentator for cleanliness and condition (groving & rough spots). Remove rough spots with fine sandpaper. Blow dust off with 3-8.2 Change 1 Field is reversed. Brushes evidence excessive wear and high arc at commentator. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: low pressure dry air. Renew brushes if they are worn to onehalf of original length. Inspect connections and wiring for insecure mounting, damaged or frayed insulation. 38 Drip pans Ensure drip pans are in place under generator engines. Check fore and aft crankshaft seals for leaks. Check airbox drain for oil leaks. Ensure valve and hand hole inspection covers do not leak. Check oil connections to lubricating oil pressure gauge for oil leaks. 39 Ship service switch board: (power distribution) Inspect for broken glass, bent pointers, dirty or corroded terminals and for accuracy. a. Circuit breakers Inspect for proper operation and overload trip. b. Power available light Ensure the signal light indicates by illuminating when power is available from generators. c. Voltmeter Ensure the selector switch is in proper position, indicates meter on line. Ensure the prescribed voltage level (120 VDC) is registered. d. Calibrating voltmeter The calibrating voltmeter selector switch, should be utilized to check online voltage of operating generator, and check accuracy periodically of functioning voltmeters. e. Ammeter Ensure the ammeter functions correctly, and operator does not redline generator (exceed 333 amps). Change 1 3-8.3 Circuit breakers are defective. Voltmeter is defective and does not indicate on line voltage. Ammeter is inoperative. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure f. Ammeter steering gear Inspect ammeter for overload of steering pump. See rated amperage on pump name plate data. Check motor for heat by touch if excessive amps are registered. g. Ground Light Inspect for proper operation, indicated by change in brilliance when ground is present. Find ground by isolating individual circuits. h. Field rheostat Ensure rheostat is functioning properly by exercising field voltage prior to closing circuit breaker. i. Disconnect switch Ensure disconnect switch is functional by exercising closed and opened positions. Check with circuit breaker closed. j. Equalizer switch Check with switch closed. Equalize load between generators in loop. When load diminishes and one generator can handle the demand, transfer load to desired generator and open equalizer and circuit breaker switches, on generator coming off line. k. Share power light Ensure the light indicates when shore power has been energized, and is available at the switchboard. Air Compressor Check dry type air cleaner, and back blow with low pressure air, if required (dirty). Compressor oil should be changed every 500 hrs or every 90 days, whichever occurs first. Use OE/HDO 30 six Qts. Check drive belts for wear and replace as a set if required. Ensure air compressor discharge valve is open, and oil is up to I 40 3-8.4 Change 1 Equipment Will Be Reported Not ready/Available If: Rheostat malfunctions. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: prescribed level (level with full cap). Start air compressor and jam air to 250 psi. Automatic regulator will stop air compressor; bleed air by hand to ensure regulator cuts in the compressor within the specified limits. Check low pressure alarm for proper operation. 41 Sea chests and S.W. strainers Check S.W. strainer for foreign bodies, and sea growth. Ensure strainer baskets are intact. Place zinc in baskets affixed by machine screw to prevent deterioration. Back blow sea chests to remove marine growth. Sea chests openings are 40% or more restricted. 42 Main propulsion engine Ensure that the engine idles and responds to the controls satisfactory by accelerating and decelerating through full operating range, ahead and astern. Analyze the engine performance: listen for unusual noise, lack of power, flat spots, unusual exhaust smoke and temperature. Be alert for improper lubricating oil pressure, and temperature. Engine fails to start and/or reverse. Engine fails to come up to rated RPM running free. Engine reflects no lubricating oil pressure. Engine operating with excessive high temperatures. 43 Starting main propulsion engine Ensure engine is prelubricated and blown down prior to starting engine. Ensure lubricating oil is up to prescribed level on dipstick. Ensure FW and SW suction and discharge valves are open. Ensure FW pump is properly vented. Close blow down valve, set fuel rack and start engine. Check level of coolant in expansion tank. Ensure engine registers lubricating oil pressure. If no lubricating oil pressure is evidenced/indicated, stop engine immediately. Check F.O. pressure on rollover for positive reading. No lubricating oil pressure indicated on oil pressure gauge. No F.O. pressure evidenced on F.O. pressure gauge. Change 1 3-8.5 TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure a. Air starting system Check system for leaks and loose connections. Ensure the system operates properly to deliver adequate cranking air. Drain sediment and water from air flasks hourly. Check starting air control valve, air .check valve, and air blow down valves for leakage and satisfactory operation. Ensure the air flasks are paralleled by checking flask stop valves. Check air pressure gauge for satisfactory operation. Drain air line accumulator hourly, to ensure dry clean air to engine start controls. b. Fuel filters Change filters when fuel oil pressure drops below normal range usually 15-20 psi at 300 RPM. Fuel filters should be changed at a minimum of 400 operating hours. On Flight II fluctuating F.O. gauge indicates a clogged fuel filter. c. Lubricating oil, filters and strainers Use OE/HDO 30/40 weight lubricating oil. If engine has been running, wait twenty minutes before checking oil level (a ten hour check), add make up oil, if necessary. Check oil in accordance with TB 43-0210 or onboard test kit; change oil if dilution or emulsion exist or sooner if indicated by test above. Drain, clean and refill the lube system every 2400 hrs or every year whichever occurs first. Every four hours turn lube oil strainer handle. Every 600 hrs clean strainer, and every 200-400 hrs replace filters. d. Air filter Check intake screen for dirt or other foreign materials. The filter silencer is equipped with removable screens. Remove screens and take filter screen topside; back blow all dirt, and foreign matter from screen with 3-8.6 Change 1 Equipment Will Be Reported Not ready/Available If: Low or no starting air available to turn engine over for blowdown and starting. Oil level is below bottom mark on dipstick/oil is diluted. Oil does not meet test standards. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: compressed air. Clean with hot water and blow dry. Dip in OE/HDO 30/40 oil and reinstall. e. Expansion tank Check coolant in engine, and heat exchanger expansion tank 1/2 high in sight glass column. During winter months when antifreeze is used, make hydrometer test, and add anti-freeze as local conditions dictate. Normal operating temperature is 135°F. On Flight II vessel 1650F. No coolant evidenced in engine/operating at excessive high temperatures. Temperature exceeds 140°F. Flight II vessels 1700F. f. Attached pumps Inspect FW and SW. Pumps for proper operation and leakoff. Normal leakage is 10-15 drops per minute. Ensure pumps are properly vented. SW/FW pump is/are inoperative. g. Lubricating oil, fresh water and salt water standby pumps Check all standby pumps for leaks and proper operation. Start all pumps and observe for vibration, loose pump connections, and faulty drive couplings. Lube oil: 175 GPM 35 psi Salt water: 300 GPM 25 psi Fresh water: 580 GPM 15-20 psi All should stay lined up (all pertinent valves open in system). Exception S.W. standy pump sea chest suction should be closed when pump is not in use. Salt water and fresh water pressure exceeds 30 psi. h. Zinc anode Check zinc pencils and discs on engine salt water side; wire brush zincs and check deterioration. Should the zincs be more than 50% deteriorated, replace with new zinc pencil or disc. i. S.W. induction thermometer The S.W. induction thermometer indicates the temperature of the S.W. entering the heat exchanger. When the thermometer indicates 50°F or below, check the F.W. temperature at the engine as it Change 1 3-8.7 TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: may require throttling down the S.W. overboard discharge to maintain the engine coolant at normal operating temperature (130-1350F at heads). On Flight II vessels 160-165°F. j. Startingair pressure gauge The starting air pressure gauge indicates the pressure of the starting air available in the storage flasks. Air pressure readings in excess of 265 psi, and less than 125 psi, should be investigated. Low air pressure engine fails to turn over/start. k. Lubricating oil pressure gauge Ensure the gauge indicates properly. If the gauge does not indicate, stop the engine immediately, investigate the cause and correct deficiency. Normal operating pressure of engine is 15 psi. Oil pressure is at or below 10 psi. l. Fuel oil pressure Indicates the pressure of the fuel Extremely low/no fuel oil gauge oil being delivered to the injection pressure indicated. Flight pumps. Normal operating II vessel 3500 psi. pressure is 2-6 psi. Readings below normal pressure indicate a restriction/dirty fuel oil filters. On Flight II vessels minimum 4000 psi maximum 7000 psi. m. F.W. &S.W. pressure gauge The F.W. pressure gauge indicates the water pressure at the pump discharge. Engine temperature should increase gradually during warm-up period. In case of extremely high indication, caused by defect in the cooling system, engine should be slowed or stopped immediately, and cause investigated. Normal operating pressure is 10-15 psi. S.W. pressure fluctuates with engine RPM. A drop in pressure indicates a restriction in the S.W. side. Check S.W. strainer for debris or foreign bodies. On Flight II vessels 6-7 psi. Should the strainer evidence no restriction, back blow sea chest with 3-8.8 Change 1 No pressure indicated at pressure gauge. Defective FW/SW pump. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: compressed air to clear chest of sea growth and other foreign materials. n. Pyrometer The pyrometer is used to measure engine load by temperature of engine exhaust. Minimum 4000F. Flight II 3500F. Recommended 580°F. Flight II 8000F. Maximum 600°F. Flight II 9000F. Temperature at or above 600°F, must be investigated, and the engine RPM must be lowered until cause is determined/rectified. Flight II vessels temperature at or exceeding 900°F. o. Tachometer Ensure the tachometer indicates properly, and reflects engine revolutions. Check tachometer with wheel house indicator for accuracy, and equal readings. p. Automatic alarm system Check that the panel box, delay and alarm relay, terminal block, electric horn and horn silencing switches are properly mounted and functioning correctly. Ensure the lights function correctly by exercising test switch. If lights are out check circuit, bulbs and fuses. 44 Shaft thrust bearing (Kingsbury) Ensure bearing oil level is at prescribed level. Half the length of the sight glass with shaft in motion. Check every two hours with vessel underway. No oil evidenced in bearing by sight glass check. On Flight II vessels engine oil pressure gauge. 45 Heat exchangers, lubrication oil and fresh water Ensure the piping is secured, correctly assembled, securely mounted and not leaking. Inspect heat exchangers for leaks at end plates, and connections. Pull end plates, check core and zinc plates for dirt, clogging and corrosion. Replace zinc plates if 50% or more deterioration evidenced. Use water lance to clean heat exchanger core, if necessary. Heat exchangers are restricted impeding proper engine cooling. Change 1 3-8.9 Tachometers are defective/nonoperational. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: 46 Stern tube shaft packing gland Check shaft packing gland during operation for excessive leak off and heat. Leakage should be-1015 drops per minute to lubricate shaft bearing and packing. Should it become necessary to tighten gland, ensure bolts torque is staggered to afford even movement on packing gland. Use lock nuts to stop torque nuts from vibrating loose. Vessel is flooding through shaft packing gland. 47 Fuel system Check quantity of fuel in tanks, noting any indication of leaks. Add fuel to top-off as necessary. Tank capacities: Fuel oil tanks (7) 21 214 gals Day tank 300 gals Galley range tank 30 gals Lubricating oil 450 gals Dirty lube oil 395 gals Sludge tank 50 gals Check service tanks with sounding tape. Inspect fuel oil transfer pump for leaks and proper operation (15 GPM at 25 psi). Ensure relief valve lifts when pump discharge valve is closed. Check tank vents co insure flame arrestor is installed, and free of rust and corrosion. Ensure ball check valve operates correctly - ball free. Transfer pump is inoperative. Excess water is evidenced in fuel system. 48 Warning Day tank overflows into number four service tank port side. Ensure inner bottom fuel oil storage tank (4 port) is at a level to accept overflow. Keep tank at 70% capacity or below, to prevent oil spillage from day tank overflow. 49 Fire and salvage pump Ensure pump, line and strainers are in good repair and properly mounted. Check piping for leaks, and ensure suction and discharge valves are in good repair and operational. Ensure pump is lined up prior to starting. Open suction 3-8.10 Change 1 Fire and salvage pumps are inoperable in fire and salvage situation. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: valve, and throttle down on discharge valve until pump is fully primed. Check packing glands for excessive leak off around pump shaft. Pump operating pressure is 100 psi. 50 Bilge and ballast pump and emergency fire pump Check bilge pump for leaks. Line up pump through manifold to bilge rose box. Do not open pump discharge valve until positive head is indicated on pump discharge gauge. Open discharge valve slowly; this will prevent losing pump suction. Ensure pump suction strainers are cleaned periodically for trouble free suction. Cross connect fire pump in emergency situation. Upon securing pumps, ensure all suction and discharge valves are secured, and bilge manifold valves are all in the closed position to prevent flooding of vessel. Check pump packing glands for excessive leak off around pump shaft. Lubricate IAW L055-1925205-12-1. Bilge and emergency fire pump are inoperative. 51 Sanitary water system Check the water pump, storage and air volume tanks and outlets for leaks. Ensure flushometers function correctly. Check sanitary pump for proper operation and excessive leak off. Sanitary system is inoperative. 52 Fresh water system Check pump and storage tank IAW item 51. Ensure F.W. system is topped off prior to mission. Probable water: 2756 gals Ensure fresh water is available at galley and crews WC. Service IAW L055-1925-205-12-1. Fresh water system is inoperative. 53 Ships service boiler and oil burner unit Inspect system for fuel and water leaks. Ensure stack switch is operational. Ensure water is visible in feed water sight glass- 1/3 2/3 level. Check boiler thermometer for proper temperature Change 1 3-8.11 TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: and altitude gauge for pressure in vessel heating system. Maintain burner unit IAW. L055-1925-20512-1. Boiler electrodes should be pulled periodically, cleaned, gapped and reinstalled. Check Navy manual for gap setting. 54 Ventilation system Check all fans, blowers, filters, screens, dampers, ducts and mechanical exhausts to ensure that they are in good condition, secure and in satisfactory working order. Lubricate motors IAW L055-1925-205-12-1. Check line start and stop switches for proper operation. Ensure ventilation outlets in mess-deck, galley, living spaces, and engine spaces are functioning correctly; with adequate discharge and no restrictions. Ventilation is impaired endangering safety of crew. 55 Fire extinguishers Inspect for corroded nozzles/damaged hoses. Ensure seal is intact. Check weight of portable cylinders monthly. Replace cylinders under prescribed weight. Nonportable should be visually inspected for proper hook-up and intact seals. At cyclic drydock period the nonportable C02 cylinders will be tested IAW ships repair specifications. Required fire extinguishers are not on board vessel. 56 Ships, electrical system Check power panel, ships service lighting, general lighting, blackout light circuit, and primary circuits for proper installation and operation. Ensure fuses are applicable to end item application. Inspect all electrical wiring to ensure that it is securely connected, clean and undamaged. Check insulation for cracks and chafing. Ensure kick pipes, conduits, and shielding are secure and in good repair. No power available at switchboard. 3-8.12 Change 1 TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - After B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure 57 Lazaretted freezers and galley chill box Start freezer units and observe bullseye for short charge. Check drive belts for wear, and replace as one unit. If bubbles are present in unit bullseye, test unit with halide torch for leaks. Repair leaks, and recharge unit. Check operating pressures with charging manifold for proper operation. Ensure TXV is feeding properly. Check seal on boxes for wear and deterioration. Ensure box temperatures are lowering with unit running-hourly check. Ensure thermometers are in freezers, and chill box to indicate operating temperature. Chill box: +36- + 420F. Freezer: 0 to -100F. 58 Drinking water fountain Check water temperature Freon12 charge and compressor operation. 59 Galley range Check galley fuel oil day tank for adequate oil supply. Open stop valve, and set oil throttle valve to fire box. Check fire box for oil presence. Start fire in fire box with paper. Cut in blower motor and monitor combustion. Regulate fire at desired temperature. Check range, occasionally for proper operation and overfeeding of oil supply. 60 Sanitizing sink heater Check for proper operatiori and correct temperature (180-190°F). Ensure sink is filled with water prior to energizing the heating element. 61 Battle lantern Ensure battle lanterns are in good repair and functional. Check lantern by dropping electrical load, and observe lantern for emergency light. Change 1 3-8.13 Equipment Will Be Reported Not ready/Available If: No refrigeration available for onboard foods. Sink heater, galley range and the ships boiler are inoperative. TM 55-1925-204-12 Table &1. Operator/Crew Preventive Maintenance Checks and Services Tug Diesel Large Design 3006 B - Before D - During A - Aft er B/A - Biannually M - Monthly Q - Quarterly Intervals Item No. B D A M Q B/A Item To Be Inspected Procedure Equipment Will Be Reported Not ready/Available If: 62 Oil/water separator system Check outlet against inlet pressure. Check pump sets for satisfactory operation. Check oil discharge to sludge tank for evidence of water. Check overboard discharge for evidence of oil. Oil/water separator not operational. 63 Sewage handling system Check operating pressures in accordance with commercial manual. System is out of commission. Table 3-2. Deleted. 3-8.14 Change 1 TM 55-1925-204-12 Section III. TROUBLESHOOTING (d) Ventilate the compartments thoroughly 3-3. General for at least ten minutes to remove a. When performing maintenance (troubleshooting) fumes before starting the engines. observe carefully for the following safety precautions: (e) Cold weather operation requires special (1) When working around electrical equipment precaution, due to tendency of observe for the following: personnel to restrict ventilation for (a) Faulty electrical equipment constitutes personnel comfort. Be sure ventilation a hazard to the associated equipment blowers are operating and that air is and personnel. freely circulating when hot water boiler (b) Do not attempt electrical repairs while oil burner is in operations. circuits are energized. (3) During fueling or defueling operations, the (c) Danger tag the electrical controls or following safety precautions will be observed: switches while performing repairs to (a) Inspect the fuel tank vents and make associated equipment; if possible, sure the flame arrestor screens are in remove fuses. place and free of corrosion. (b) Do not (d) Do not attempt adjustments to the permit smoking on the tug and within running generators. 50 feet of fueling connection, or greater (e) Do not energize the electrical circuits if distance if required by the local harbor heavy water condensation is present. regulations. (f) Do not overload the circuits with (c) Ground fueling nozzle to filling unauthorized appliances or electrical connection with the grounding wire tools. provided. (g) Do not add to or supplement the (d) Have a member of the crew standing by circuits. with a 15 pound CO, extinguisher (h) Do not work on electrical apparatus during the operation. when hands or clothing are wet. (e) Close all ports in the vicinity of fueling (i) When working within four feet of connections. electrical equipment, do not wear any (f) Keep a close watch at all times so as clothing with exposed zippers, buttons not to overflow tanks while fueling. or metal fasteners. (4) Around batteries, observe for the following: (j) Personnel shall not wear loose or (a) Keep flame and sparks away from the flapping clothing in the vicinity of vicinity of batteries. rotating equipment. (b) When using tools around batteries, (k) Do not wear flammable articles such as exercise care not to short circuit battery. celluloid cap visors. (c) Never open batteries unless the area is (l) Personnel will remove rings, wrist ventilated. watches, bracelets or other metal items (d) Keep the battery compartment before performing work on or within four temperature below 95°F., if possible. feet of electrical equipment with (e) Do not make repairs to battery circuits exposed current-carrying parts. when the circuit is energized. (m) Sparking electrical equipment is an (f) Battery acid must be poured carefully. 3xplosion and fire hazard. Stop the Never pour water into acid. The acid equipment, letermine the cause and must be poured slowly and carefully take corrective action. into water. Guard eyes and skin from (2) Around gaseous conditions observe for the splashing acid. following: (5) Around compressed air, observe for the (a) Volatile gases being heavier than air following: tend to collect to the bottom of the hull. (a) Do not attempt repairs on air lines or Accumulations of oil fumes present an associated equipment unless the air explosion hazard and must be lines are turned off and the air pressure prevented by ventilation. is released. (b) Battery gases (hydrogen) are explosive. (b) Do not "dust off" clothing with air hose. (c) Carbon monoxide is a deadly Flying particles can lodge in eyes. poisonous gas, which is colorless and (c) Do not under any circumstances use odorless. It is a by-product of the propulsion engine air lines for any combustion in internal combustion other purpose than what they were engines. To safeguard against designed for. personnel casualties from carbon (d) Air tools must be connected properly monoxide, adequate ventilation must be and inspected before using. provided in the spaces where engines b. This section contains troubleshooting information for are running; exhaust silencers and locating and correcting most of the operating troubles associated piping must be free from which may develop in the tug leaks. Change 1 3-9 TM 55-1925-204-12 and its components. Each malfunction for an individual component, unit, or system is followed by a list of test or inspections which will help you to determine probable causes and corrective actions to take. You should perform the tests/inspections and corrective actions in the order listed. c. This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by the listed corrective actions, notify your supervisor. 3-4. Troubleshooting Probable malfunctions, with tests and inspections, and corrective actions are listed in table 3-3 below. Table 3-3. Troubleshooting. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION NOTE Before you use this table, be sure you have performed all applicable operating checks. 01 GROUP-PROPULSION ENGINE 1. ENGINE STOPS SUDDENLY OR STALLS FREQUENTLY. Step 1. Check for sufficient fuel. See that there is fuel in day tank and that shutoff valves are open. Step 2. Check that fuel system is primed. Unscrew vent at injector, revolve engine on air and see if fuel is flowing. If noL, prime the fuel system (para 310). Step 3. Check for dirty fuel. Clean the fuel filters and the entire fuel oil system. Step 4 Check for water in fuel. Drain and clean the entire fuel oil system, (including the day tank) fill with clean fuel, then proceed with regular priming and starting procedure. Step 5. Check for plugged fuel line. Check fuel supply lines for any obstructions. Step 6. Check for dirty or choked fuel oil filters. Service the filters (para 3-14). Step 7. Check that fuel injection pumps are primed. Prime the injection pumps (para 3-10). Step 8. Check that governor is not stuck. Remove all binds from governor and fuel injection pumps linkage mechanism. Step 9. Check that fuel oil lines are not loose at the injectors. Tighten all fuel lines. 2. LOSS OF POWER Step 1. Check for broken or worn compression rings. Replace rings (para 3-7). Step 2. Check for low scavenging air pressure. Clean scavenging air pump intake, and check piping system (para 3-16). Step 3. Check for low lubricating oil pressure. Examine the lubricating oil pump and repair or replace (para 3-22). Step 4. Check fuel injector tips for carbon. Clean tips (para 3-12). 3-10 Change 1 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 3. 4. 5. 6. 7. Step 5. Check cylinder head gaskets Replace defective gaskets (para 3-61. Step 6. Check for carbon on air inlet ports Clean ports (para 4-15 b. Ill (ill Step 7. Check for faulty injector. Replace injector (para 3-12). Step 8. Check for dirty fuel oil Drain and clean entire fuel system. Step 9. Check if fuel system is completely primed. Determine weak or missing cylinder by taking exhaust temperatures with the pyrometer. Weak cylinders will be indicated by low exhaust temperatures. Prime fuel system of weak cylinders. Step 10. Check for cylinders incorrectly balanced. Inspect the position of the injection pump control racks. Step 11. Check air intake for clogged entry. Clean intake. Step 12. Excessive exhaust back pressure. Clean exhaust ports (para 4-151. Step 13. Engine exhaust port carboned. Clean exhaust ports (para 4-15). Step 14. Poor cylinder wall lubrication Check force feed lubrication (para 4-16). BLACK OR GRAY EXHAUST. Step 1. Check scavenging air for low pressure. Check scavenging air pump (para 3-16). Step 2. Check cylinders for incorrect balance. causing overload. Inspect the position of the injection pump control racks. Step 3. Check for defective injector. Replace injector (para 3-12). Step 4. Check for obstruction in air intake. Remove obstructions. Step 5. Check for late fuel pump timing. Check fuel pumps for proper timing (para 3-11). Step 6. Check for low engine temperature. Check engine heat exchanger (para 3-21). BLUE SMOKE. Step 1. Check that lubricating oil may be entering combustion chamber. Piston cracked, replace piston (para 3-7). Step 2. Check for excessive cylinder wall lubrication. Check force feed lubrication (para 4-16). WHITE SMOKE. Step 1. Check for water leaking into combustion chamber. Isolate fuel injection system of each cylinder, one at a time to determine which cylinder has water leaks, determine leak source, repair. ENGINE DETONATES. Step 1. If there is a hard knock indicating detonation in one or more cylinders. STOP the engine immediately to prevent serious damage due to the excess of pressure accompanying detonation. Detonation is caused by the presence of fuel or lubricating oil in the cylinder during the compression stroke. This may be caused by leaky injectors, improper timing of the fuel injection pump and sometimes by the lubricating oil working up from the crankcase into the combustion chamber. Knocks other than fuel are either loose bearings, flywheels, pistons, improperly adjusted valves, or blow-by caused by broken or stuck piston rings. Trouble from knocking, other than fuel knocks, can usually be found by the nature of the sound, under different load conditions and by cutting out one cylinder at a time. Where the loose or incorrectly adjusted part is found, the remedy is usually obvious and references to articles under part effected will be found helpful in making needed correction. OVERHEATING. Step 1. Check for excessive back pressure in exhaust system. Inspect exhaust silencer and clean exhaust manifold (para 4-15). Step 2. Check for low rpm under full load. Adjust governor linkage (para. 3-13). Step 3. Check for late fuel injection. Retime fuel injection pumps (para 3-11). Step 4. Check for insufficient supply of fresh water. Check fresh water expansion tank, and piping for leaks. Tank should be at least half full at all times. Step 5. Check for defective fresh water pump. Replace pump (pars 3-18). Step 6. Check for clogged heat exchanger. Clean heat exchanger (para 3-211. 3-11 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 7. Check if the raw water line is clogged at sea chest. Blow out sea chest with compressed air. 8. LACK OF OIL PRESSURE. Step 1. Check for worn lubricating oil pump. Replace pump (para 3-22). Step 2. Check lubricating oil lines for thick, or slow flow. See lubrication order for correct oil (LO 55-1925-204-12/2). Step 3. Check for worn bearings. Adjust bearing clearance (paras 3-7 and 3-24). Step 4. Check for faulty lubrication oil pressure relief valve. Replace valve (para 3-22). 9. ENGINE FAILS TO START AT TEMPERATURE ABOVE 32°F. Step 1 Check for closed fuel shutoff valve. Open valve (fig. 2-9). Step 2. Check if fuel oil day tank is empty. Fill day tank and prime system. Step 3. Check for low engine starting air pressure. Pump up starting air to 250 psi. Step 4. Check for fuel oil system airbound. Prime system. Step 5. Check for tripped overspeed governor. Reset overspeed trip (para. 3-8). 10. UNEVEN RUNNING AND EXCESSIVE VIBRATION. Step 1. Check for incorrectly balanced fuel supply to cylinders. Inspect the position of injection pump control racks. Step 2. Check for governor surge. Replace broken or weak springs. (paras. 3-13). Step 3 Check for air in fuel lines. Prime fuel system. 02 GROUP-PROPELLER, SHAFT AND STUFFING BOX. 1. VIBRATION IN STERN AREA WHEN TUG IS OPERATING. Step 1 Check for fouled or damaged propeller. Remove items fouling propeller. Report damage to Gen. Sup. Maint. Step 2. Check for bent shaft. Report damage to general support maintenance. 2. LEAK AROUND SHAFT Step I. Check for loose or worn packing. Adjust packing (para 3-26). 03 GROUP-WINDOW WIPER 1. VWIPER BLADE STREAKS GLASS WHEN WIPING. Step 1. Check if blade is dirty or oily Clean blade. Step 2. Check if blade is hard or glazed. Sandpaper clean edge with fine sandpaper, or replace with new blade (para 3-28). 2. ICE FORMS ON 'WINDOW. Step 1 Check freezing temperature. Saturate felt blade with a mixture of Glycol and fill reservoir. 3 SAI,T DEPOSITS ON WUINDOMW. Step 1. Check salt spray. In nonfreezing weather. fill reservoir of felt blade with fresh water. in freezing weather use solution of water and glycol. 4. IMOTOR DOES NOT OPERATE See troubleshooting motors in group 04. 04 GROUP-AUXILIARY SET AND RELATED SYSTEMS (DIESEL ENGINE. DC GENERATORS. DC MOTORS. BATTERIES. ETC} 1. ENGINE STOPS SUDDENLY OR STALLS FREQUENTLY. Step 1. Check fuel system for prime. Loosen high-pressure line fitting. if no fuel is flowing, prime fuel system. Step 2. Check for insufficient fuel. See that there is fuel in the day tank and shutoff valve is open (fig. 2-9). Step 3. Check for restriction in fuel flow. Check lines for obstruction or breaks. Step 4. Check for faulty transfer pump. Replace transfer pump (para 5-14). 3-12 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 5. Check for water in the fuel. Drain and clean entire fuel system; prime fuel system. Step 6. Check for internal binding. B3ar engine over manually; if unable to turn engine, check for foreign objects in gears, on top of piston, and for piston seizure. Step 7. Check for improper valve clearance. Adjust valves (para 5-7). Step 8. Check for clogged or dirty filters. Clean primary filter, replace secondary filter if clogged (para 5-15). Step 9. Check for leaky cylinder head gasket. Clean head and block surfaces; replace gasket (para 5-3). Step 10. Check for burned or sticking valves. Clean and grind valves, replace as required (para 5-7). Step 11. Check for faulty injection nozzle. Clean and grind valves, replace as required (para 5-13). Step 12. Check for low cooling water temperature. Remove, clean, and check thermostat; replace as required (para 5-20). 2. LOSS OF POWER. Step i. Check for air in fuel lines. Check connection; bleed fuel system. Step 2. Check for clogged air cleaner. Clean and service air cleaner (para 5-17). Step 3. Check if piston rings are worn or broken. Check and replace rings not up to specifications (para 5-4). Step 4. Check for leaky cylinder head gasket. Clean head and block surfaces; replace gasket (para 5-3). Step 5. Check for valves holding open, no tappet clearance. Adjust valve tappet clearance (para 5-7). Step 6. Check if cylinder liner inlet ports are clogged. Remove cylinder liners and clean (para 5-5). Step 7. Check for carbon on injection nozzle tips. Clean tips (para 5-13). 3. BLACK OR GRAY SMOKE. Step 1. Check if engine is overloaded. Reduce load. Step 2. Check for high exhaust back pressure. Check for obstruction in exhaust. Step 3. Check for low engine cooling water temperature. Check thermostats, raise temperature (para 5-20). Step 4. Check if air cleaner is clogged. Clean and service air cleaner (para 5-17). Step 5. Check if cylinder liner ports are clogged. Remove cylinder liner and clean (para 5-5). 4. BI,UE SMOKE. Step 1. Check for pull over of lubricating oil from air cleaner. Check oil level in cleaner (para 5-17). Step 2. Check for too much oil in crankcase. Check crankcase lube oil level on dip stick, drain to FULL mark if necessary. Step 3. Check for worn or stuck rings. Replace rings (para 5-4). 5. WHITE SMOKE. Step 1. Check for faulty injector nozzle. Clean and test faulty nozzles for pressure leakage and spray pattern (para 5-13). Step 2. Check if water leaking into combustion chamber. Isolate fuel injection system of each cylinder, one at a time, to determine which cylinder has water leak. Remove cylinder head, determine leak source (para 5-3). 6 ENGINE DETONATES. Step 1. If there is a hard knock indicating detonation in one or more cylinders, STOP engine immediately to prevent serious damage due to excess of pressure. Detonation is caused by the presence of fuel or lubricating oil in the cylinder during the compression stroke. This may be caused by leaky injectors or by improper timing of fuel injection pump and sometimes by lubricating oil working up from the crankcase into the combustion chamber. Knocks other than fuel are either from loose bearings, pistons, flywheels, improperly adjusted valves, or blowby caused by broken or stuck piston rings. Trouble from knocking, other than fuel knocks, can usually be found by the nature of the sound, under different load conditions and by cutting out one cylinder at a time. When the loose or incorrectly adjusted part is found, the remedy is usually obvious and references to articles under part effected will be found helpful in making needed correction. 3-13 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 7. OVERHEATING. Step 1. Check for scale or deposits in fresh water cooling system. Clean cooling system (para 5-20). Step 2. Check for scale or deposits in raw water side of heat exchanger. Clean heat exchanger (para 5-20). Step 3. Check if sea water (raw water) inlet is clogged at sea chest. Blow out sea chest with compressed air. Step 4. Check for insufficient supply of fresh water. Fill expansion tank: check for water leaks. Step 5. Check if raw water pump is worn. Replace pump (para 5-22). Step 6. Check if fuel injection is too late. Retime fuel injection (paras 5-13 and 5-16). Step 7. Check for back pressure in exhaust line. Clean exhaust system. Step 8. Check if overloading the engine. Reduce load. 8. LACK OF LUBRICATING OIL PRESSURE. Step 1. Check for dirt in lubricating oil relief valve, or broken spring. Clean valve, replace spring if broken (para 5-10). Step 2. Check if oil supply is low in crankcase. Check dip stick, add oil to FULL mark. Step 3. Check if suction screen plugged. Remove screen and clean in solvent (para 5-10). Step 4. Check for worn bearings. Replace worn bearings (paras. 5-4 or 5-8). Step 5. Check for worn oil pump. Repair or replace (para 5-10). Step 6. Check for use of improper lubrication. See lubrication order for correct oil (LO 55-1925-204-12-5). Step 7. Check if oil filter is clogged. Remove and clean (para 5-11). 9. ENGINE FAILS TO START AT TEMPERATURE ABOVE 320 F. Step 1. Check for governor stop control in STOP position. Put control in operating position. Step 2. Check if fuel shutoff valve is closed. Open valve. Step 3. Check for water in fuel. Drain fuel system; refill and prime. Step 4. Check for battery not sufficiently charged to turn engine over fast enough. Replace with fully charged battery. Step 5. Check for insufficient fuel. Fill fuel oil day tank. Step 6. Check for low compression. Adjust tappet clearance (para 5-7). Inspect compression rings; replace worn or stuck rings (para 5-4). 05 GROUP-DIRECT CURRENT MOTOR AND AUXILIARY SET GENERATORS. 1. MOTOR WILL NOT START. Step 1. Check for open circuit in control. Check control for open starting register, open switch, or burned fuse. Close switch. Replace a fuse. Step 2. Check for low terminal voltage. Check generator output. Adjust voltage to 115 volts (para. 2-17 g. (7) (d) 3). Step 3. Check for frozen bearing. Replace bearing. Step 4. Check for an overload. Reduce load. Step 5. Check for excessive friction. Check lubrication in bearings to make sure that oil has been replaced after installation of motor. Disconnect motor from driven machine and turn motor by hand to see if trouble is in motor. Strip and reassemble motor; then check part by part for proper location and fit. 2. MOTOR STOPS AFTER RUNNING SHORT TIME. Step 1. Check if motor is getting power. Check voltage at the motor terminals also check fuses, clips, and overload relay. 3. MOTOR ATTEMPTS TO START BUT OVERLOAD RELAYS OPERATE. Step 1. Check if motor is started with weak or no field. If adjustable speed motor, check condition of rheostat. Check field coil for open windings. Check wiring for loose or broken connection. 3-14 TM 55-1925-204-12 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 4. MOTOR RUNS TOO SLOW UNDER LOAD. Step 1. Check if line voltage is too low. Check and remove any excess resistors in supply line, connections or control. Step 2. Check if brushes are ahead of neutral. Set brushes on neutral Step 3. Check for overload. Reduce load. 5. MOTOR RUNS TOO FAST UNDER LOAD. Step 1. Check for weak field. Check for resistance in shunt field circuits. Check for grounds. Step 2. Check if line voltage is too high. Adjust voltage to 115 volts (para. 2-17 g. (7) (d) 3.). Step 3. Check if brushes are ahead of neutral. Set brushes on neutral. 6. SPARKING AT BRUSHES. Step 1. Check if commutator is in bad condition. Clean commutator and reseat brushes. Step 2. Check for broken or sluggish acting brush holder spring. Replace spring. and adjust pressure. Step 3. Check if brushes too short. Replace brushes. Step 4. Check if machine is overloaded. Reduce load. Step 5. Check for short circuit in armature. Check commutator and remove any metallic particles between segments. Check for short between adjacent commutator risers. Test for internal shorts in armature. Replace defective armature. 7. BRUSH CHATTER OR HISSING NOISE. Step 1. Check for excessive clearance of brush holders. Adjust holders. Step 2. Check for incorrect angle of brushes. Adjust to correct angle. 8. SELECTIVE COMMUTATOR (ONE BRUSH TAKES MORE LOAD THAN IT SHOULD). Step 1. Check for insufficient brush spring pressure. Adjust to correct pressure making sure brushes ride free in holders. 9. EXCESSIVE SPARKING. Step 1. Check for poor brush fit on commutator. Seat in brushes and polish commutator surface. Step 2. Check if brushes binding in the brush holders. Remove and clean holders. Step 3. Check if brushes are off neutral. Set brushes on neutral. 10. SPARKING AT LIGHT LOADS. Step 1. Check for paint spray, chemical, oil or grease, or other foreign material on commutator. Clean commutator and provide protection against foreign matter. 11. COMMUTATOR OVERHEATS. Step 1. Check if brushes are off neutral. Adjust brushes. Step 2. Check for excess spring pressure on brushes. Decrease brush spring pressure but not to the point where sparking is introduced. 12. GROOVING OF COMMUTATOR. Step 1. Check if brushes are properly spaced. Space brushes. 13. BRUSHES WEAR RAPIDLY. Step 1. Check for rough commutator. Resurface commutator and undercut mica. 14. FIELD COILS OVERHEAT. Step 1. Check for short circuit between turns or layers. Replace defective coil 15. ARMATURE OVERHEATS. Step 1. Check if motor is installed in location where ventilation is restricted. Arrange for free circulation of air around motor. Step 2. Check if armature winding is shorted. Replace armature. Step 3. Check for motor overload. Reduce load to correspond to allowable load. 3-15 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 06 GROUP STORAGE BATTERY. (Refer to TM 9-6140-200-14). 1. GRAVITY LESS THAN 1.215. Step 1. Check for discharged battery. Charge battery, and tighten all connections. Step 2. Check for broken connections between generator and battery. Repair all connections. Step 3. Check if voltage regulator is operating properly. Replace a defective regulator (para. 5-25). Step 4. Check if generator is operating properly. Check and make necessary repairs. 2. VERY LOW SPECIFIC GRAVITY OR NO READING OBTAINABLE ON HYDROMETER. Step 1. Check if plates badly sulphated. Cycle battery (TM 9-6140-200-14). Step 2. Check if battery polarity is reversed. Generator not charging properly. Check connection and correct. Check and repair generator or regulator. 3. LOW ELECTROLYTE LEVEL IN CELL. Step 1. Check for open charging circuit. Trace circuit and make corrections. Refill as required. 4. BATTERY DISCHARGES OVERNIGHT. Step 1. Check for short circuits in wiring. Test all circuits connected to battery and repair, or replace. 07 GROUP-PUMPS GENERAL 1. PACKING GLAND LEAKS. Step 1. Check if packing is loose. Adjust packing gland. 2. PUMP DOES NOT DELIVER RATED CAPACITY. Step 1. Check if impeller is worn. Replace impeller. Step 2. Check for leaks in suction line allowing pump to pull air. Inspect piping, repair leak. Step 3. Check if pump rpm low. Check rpm, bring up to rating. Step 4. Check clutch adjustment. Adjust clutch. Step 5. Check if suction line closed. Open valve 3. NOISY OPERATION Step 1. Check if pump out of alignment Realign. Step 2. Check for excess heat in bearings. Recheck alignment. 08 GROUP-FUEL TRANSFER PUMP. 1. PUMP LEAKS AROUND SHAFT. Step 1. Check for leaking packing gland or worn packing. Tighten or replace packing. 2. PUMP DOES NOT DISCHARGE AFTER RUNNING 1 MINUTE. Step 1. Check valves in system for proper alignment. Align valves (para. 2-12). 3. PUMP MOTOR See troubleshooting on dc motors in group 04. POTABLE PUMP. (sanitary water pump same) 1. PUMP WILL NOT PRIME. Step 1. Check if cup leather thoroughly soaked. Soak leathers in water. Step 2. Check for leaky valve plate gasket. Replace gasket: tighten bonnet capscrews. Step 3. Check for valves not seating properly or valves sticking to seat. Clean dirt from valves and seats. See that there are no burrs at valve seat openings. Step 4. Check for leaky suction line. Inspect all lines, tighten joints. 2. PUMP LOOSES PRIME AFTER BEING IN OPERATION. Step 1. Check if bleeder holes in valve plate are plugged. Open bleeder holes. Step 2. Check for dirt under valves. Clean valve seats. 3-16 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 3. Check if valves are worn out after long service. Replace with new valves. Step 4. Check for slow leak in suction line. Tighten suction line at joints. 3. PUMP NOISY IN OPERATION. Step 1. Check if strainer is clogged. Clean strainer. Step 2. Check if suction line is closed. Open suction line. Step 3. Check if pipes vibrate. Support or cushion pipes. 4. PUMP STARTS AND STOPS TOO FREQUENTLY. Step 1. Check for pressure switch operating properly. Adjust switch. 5. PUMP MOTOR DEFECTIVE. See troubleshooting on dc motors in group 05. LUBRICATING OIL STANDBY PUMP. 1. PUMP LEAKS AROUND SHAFT. Step 1. Check for leaking packing gland or worn packing. Tighten or replace packing. 2. PUMP DOES NOT DISCHARGE AFTER RUNNING 1 MINUTE. Step 1. Check if pump is airbound, Prime pump. Step 2. Check for leak in suction pipe. Inspect lube oil system; repair leaks. Step 3. Check if valves in system are properly aligned. Align valves (para. 2-13). 3. PUMP MOTOR See troubleshooting on dc motors in group 05. FRESH AND SALT WATER STANDBY PUMPS 1. PUMP DOES NOT DISCHARGE AFTER RUNNING 1 MINUTE. Step 1. Check for insufficient supply of fresh, or salt water. Check fresh water expansion tank, and piping. tank should be at least half full at all times. Check inlet on sea chest for salt water supply. Step 2. Check for leaks in suction pipe. Inspect water systems: repair leaks. Step 3. Check that valves in system are properly aligned. Align valves (para. 2-24). Step 4. Check if pump is airbound. Prime pump. 2. PUMP MOTOR. See troubleshooting on dc motors in group 05. 3. EXCESSIVE VIBRATION. Step 1. Check if pump out of alignment. Realign pump. Step 2. Check for worn bearing. Mounting foundation is loose. Replace bearings. Secure mounting. 09 GROUP-PNEUMATIC EQUIPMENT. AIR COMPRESSOR 1. AIR PRESSURE BELOW 230 PSI. MOTOR RUNNING. Step 1. Check that compressor #1 Is operating. Reduce load. or start compressor #2. Step 2. Check that pressure switch is serviceable. Test switch against opposite compressor gage. Step 3. Check for leak in lines. Test joints A with a soapy solution and watch for bubbles. Tighten loose connections. Step 4. Check for loose drive belt. Adjust drive belt. 2. MOTOR HAS TROUBLE TURNING COMIPRESSOR. Step 1. Check that centrifugal unloader is operating. Repair or replace unloader (para. 5-56). Step 2. Check for stuck piston. or restriction in lines to tanks. Replace piston (para. 5-56). Remove restriction from lines (para. 5-57). Step 3. Check for weak motor. See dc motor troubleshooting in group 05. 3-17 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 10 GROUP-ANCHOR WINDLASS, CAPSTAN 1. WINDLASS FAILS TO STOP AT SAME RATE OF SPEED AS STARTING. Step 1. Check if magnetic brake out of adjustment. Adjust magnetic brake (para. 5-66). Step 2. Check for oil on brake band. Remove. using cleaning solvent Fed. Spec P. D. 680. Step 3. Check if brake band worn. Replace band. 2. HANDBRAKE SLIPS. Step 1. Check for brake out of adjustment. Adjust brake. Step 2. Check for brake band wear. Replace band. 3. WINDLASS MOTOR. See troubleshooting on dc motors in group 05. CAPSTAN. 1. CAPSTAN FAILS TO STOP AT SAME RATE OF SPEED AS STARTING. Step 1. Check for brake not properly adjusted. Adjust brake (para. 5-66). Step 2. Check if friction linings worn out. Replace linings (para. 5-66). Step 3. Check for proper airgap in magnetic brake. Adjust airgap (para. 5-66). 2. CAPSTAN MOTOR. See troubleshooting on dc motors in group 05. 11 GROUP-HEATING SYSTEM 1. BOILER SMOKING. Step 1. Check for partially clogged nozzle. Clean nozzle (para. 5-70). 2. INSUFFICIENT DRAFT OVER FIRE. Step 1. Check for restriction in stack. Inspect stack: remove restriction. 3. IMPROPER ATOMIZATION. Step 1. Check for dirty screen in nozzle. Clean screen. Step 2. Check for nozzle orifice clogged or film or carbon over face of nozzle. Clean nozzle. 4. ACCUMULATION UNEXPANDED GASES. Step 1. Check if nozzle too large. Use smaller nozzle. 5. ALTERNATELY DELAYED IGNITION. Step 1. Check the setting of electrodes. Adjust electrodes. 6. BOILER BURNER MOTOR. Step 1. See troubleshooting on dc motors in group 05. 7. CONVECTORS NOT HOT ENOUGH. Step 1. Check for low steam pressure. Increase pressure. Step 2. Check if thermostat setting too low. Raise thermostat setting. Step 3. Check if steam supply valve closed. Align valves (para. 2-21). 12 GROUP-VENTILATING SYSTEM 1. COMPARTMENT NOT PROPERLY VENTILATED. Step 1. Check if outlet closed or restricted. Open outlet cover, remove restriction. Step 2. Check if blower impeller dirty. Clean impeller. Step 3. Check dampers in ventilation lines. Adjust to supply ample air. 2. BLOWER MOTOR Step 1. See troubleshooting on dc motors in group 04. 3-18 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 13 GROUP-FOOD PREPARATION SYSTEM (FREEZER-REFRIG ERATOR) 1. TEMPERATURE RISES. Step 1. Check for V-belt slippage. Tighten a loose belt Step 2. Check for leakage of freon. Tighten all connections. Add freon. 2 MOTOR NOISY. Step 1. Check mountings Turn motor by hand to discover bearing trouble. Tighten all mounting hardware. Replace a defective motor (para. 5-79). GALLEY RANGE 1. BURNER FAILS TO IGNITE. Step 1. Check for no fuel Fill day tank. check that supply and control valves are open. 2. FLAME GOES OUT. Step 1. Check for too much air. Adjust air supply. Step 2. Check for dirty fuel strainer. Clean strainer. 3. BURNER SMOKES Step 1. Check if blower stopped. Check motor. fuses, and supply switch. Step 2. Check for insufficient air. Adjust air supply. 4. OIL OVERFLOWS IN FIRE BOX. Step 1. Check for faulty control valve or improper setting. Adjust control valve setting. Replace valve if oil continues to overflow (para. 5791. 5. BURNER MOTOR. Step 1. See troubleshooting on dc motors in group 05. IMMERSION HEATERS (COFFEE URN) 1. FAILS TO HEAT. Step 1. Check for power. Turn switch ON; check fuses. 2. ELEMENT FAILS. Step 1. Check for burned out element. Replace heater element (para. 5-79 b.). 14 GROUP-STEERING. 1. RUDDER DOES NOT MOVE WHEN STEERING WHEEL IS MOVED. Step 1. Check if steering motor operating. Turn steering motor ON. Step 2. Check if contactor dirty or not making contact. Clean contactors. Step 3. Check if hydraulic oil tank is empty. Fill tank, check for leaks. Step 4. Check for loss of electrical power. Check electrical circuit from panel to equipment. Step 5. Check if rudder or cable jammed. Free rudder and cable. Step 6. Check for incorrect brake adjustment. Adjust brake. 2. RUDDER MOVES WHEN STEERING WHEEL IS HELD STEADY. Step 1. Check for slack in cable. Adjust cable by tightening turnbuckle on quadrant. Step 2. Check if brake is slipping. Adjust brake. 3. MOTOR. Step 1. See troubleshooting on dc motors in group 04. 15 GROUP-SEARCHLIGHT 1. LIGHT WILL NOT LIGHT. Step 1. Check for burned out bulb. Replace bulb. Step 2. Check if circuit is deenergized. Trace out circuit. Turn switch ON. 3-19 MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 2. SEARCHLIGHT WILL NOT ROTATE OR ELEVATE. Step 1. Check If linkage is bent. Straighten. Step 2. Check if stuffing box is dry. Lubricate in accordance with LO 55-1925-204-12-1. 16 GROUP-FIXED CO2 SYSTEM 1. CO2 SYSTEM INTERLOCK DOES NOT TRIP VENTILATING MOTORS ON TEST. Step 1. Check for faulty interlock Replace. 2. CABLE DOES NOT TRIP LEVER ON TEST Step 1. Check if cable is broken. Replace cable 17 GROUP-WHISTLE/HORN 1. WHISTLE DOES NOT SOUND WHEN LANYARD IS PULLED. Step 1. Check for no air. Move air supply valve to Open Check lanyard operated pilot valve. Replace defective valves. 2. WEAK SOUND Step 1. Check for low air pressure. Check the compressed air system from the 250-100 P & I Reducing Station (fig. 2-14). Step 2. Check for a cracked diaphragm. Replace the diaphragm 3. HORN DOES NOT OPERATE. Step 1. Check for loose electrical connections. Tighten all loose connections. Step 2 Check for no power. Trace out circuit. Repair if necessary. 4. BUTTON DOES NOT OPERATE. Step 1. Check for loose connection under horn button. Tighten all electrical connections. Section IV. MAINTENANCE PROCEDURES b. Removal. To remove the cylinder head proceed as follows: (1) Drain engine cooling system and expansion tank by opening drain valve located below exhaust manifold on right side of engine. 3-5. General This section will cover those maintenance functions assigned crew by the MAC. These functions do not appear elsewhere in this manual. Crew functions within MAC groups, where organizational maintenance is involved, are described in chapters 4 and 5 below. NOTE Due to the mission of this vessel (operation in remote area) functions normally involving organizational maintenance may be performed at operator/crew level. NOTE It is good practice to remove valves from cylinder head before pulling head. (2) Back off capscrews and lift bracket holding fuel line to cylinder head off the head. CAUTION Wrap ends of all fuel oil lines with a clean cloth to prevent dirt from entering, as damage may result. 3-6. Cylinder Head Assembly a. General. The cylinder heads are made of cast iron and are water cooled. Each is an individual unit and houses the fuel injector valve, air starting valve, safety valve, and compression relief valve. The cylinder head is held to the cylinder block by eight studs and nuts. A strong back (plate, connecting cylinder head to the adjoining head), connects one cylinder head to the other and is held in place by two studs and nuts. The cylinder head serves as the upper half of the combustion chamber. A gasket placed between the cylinder head and block provides the compression seal. (3) Disconnect fuel pressure line (fig. 3-1) between fuel injector valve and fuel injection pump. Remove the fuel pressure line. NOTE Fuel pressure line may be removed as one piece or two depending on storage space available. Tag fuel line in order to replace it in its proper reassembly location . 3-20 Figure 3-1. Cylinder head removal and installation. (4) Disconnect fuel return line between fuel injector valve and fuel return manifold. Remove line. (6) Disconnect air start line (fig. 3-1) between air start valve and starting air distributor. Back off the three stud nuts holding starting air valve to cylinder head. Lift air starting valve from the cylinder head. CAUTION When all fuel injector valves are to be removed for overhaul, dip the spray tip in clean fuel oil. Do not allow spray tips to dry as damage may result if they are stored for any length of time. NOTE It may be necessary to use a pry bar to break the air starting valve loose from the cylinder head. Place the air starting valve in a wooden rack. (5) Back of both nuts holding fuel injector valve (fig. 3-1) to the cylinder head. Place two jackscrews in the tapped holes provided in the injector valve body. Turn jackscrews clockwise, keeping an even pressure, and jack the fuel injector free of the cylinder head. Place the injector valve in a rack and wrap the spray tip with a clean lint free cloth. Wet cloth with clean fuel oil. (7) Remove the safety relief valve by turning the valve cage and nipple counterclockwise. Lift valve from cylinder head. Store in a safe place where it will not be damaged. (8) Disconnect the air line below the compression relief valve (fig. 3-2). Do not remove the compression relief valve at this time. 3-21 Figure 3-2. Cylinder compression relief valve (9) Back off the cap bolts holding the water manifold to the cylinder head and the cylinder block. Lift off the water manifold and store in a safe place. (12) Place two eye bolts in the threaded holes provided for this purpose -in the cylinder head. Position a chain hoist over the cylinder head to be removed. Using a wire sling, make fast to the chain hoist hook and the eye bolts. Hoist the cylinder head clear of the cylinder block studs. Move the cylinder head to a working area. Set the cylinder head on wooden blocks or a plank. NOTE Before removing head stud nuts, mark position of the stud nuts by making a small punch mark on the cylinder head and a punch mark on the head stud nut. When the cylinder head is installed, draw down on the stud nuts until the punch marks line up to insure proper seating. Punch mark each head stud nut and stud starting from one to eight. It is important that the head stud nuts be returned to the same stud from which it was removed. (10) Back off head stud nuts and tag them with the number of the cylinder from which removed (13) The compression relief valve can now be removed. Back off the cap bolts holding compression relief valve cage to the cylinder head, and lift compression relief valve from the cylinder head. Store in a safe place. (14) Remove the cylinder head gasket. NOTE Use new gaskets when installing the cylinder head. c. Cleaning, Inspection, and Repair. (11) Back off the two head stud nuts on the adjoining cylinder head to remove the connecting plate (plate connecting cylinder head to the adjoining cylinder head). Lift off the connecting plate and store in a safe place. Return the head stud nuts to the corresponding studs on the adjoining cylinder and tighten. NOTE When al cylinder heads are to be removed for overhaul, it will not be necessary to replace the head stud nuts on the adjoining cylinder after the connecting plate has been removed. (1) Clean carbon deposits from the cylinder head. Use a wire brush on stubborn deposits, then blow clean with ships service air. (2) Inspect the combustion chamber portion of the cylinder head for minute cracks. When defects are found report them to general support maintenance, or replace the head with a new one. (3) Inspect the water coolant passages in the cylinder head for clogging scale. Scrape it clean then blow out with ships service air. 3-22 (4) Clean all valve ports, and be sure that all gasket surfaces are free of particles, ready for installation. (1) Disassemble by backing off nut (36, fig. 33) and plug (34). Life valve (32), shim (35), and spring (31) out of cage (30). Remove gasket (33). d. Safety Relief Valve. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Holder Cartridge Gasket Post Gasket Valve assembly Gasket Piston Nut Gasket Gasket Valve 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Stud Spring Cover Nut Ring Packing Packing nut Nut, w/cotter pin Piston Stud Gasket Spring 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Valve Gasket Gasket Valve Valve Relief Cage Spring Valve Gasket Plug Shim Nut Figure 3-3. Cylinder head valves. (2) weak spring. Inspect the spring (31). Replace a broken or (4) Assemble the spring loaded safety relief valve in reverse order of disassembly given in steps (1) through (3) above. Place in a rack for safe keeping until the cylinder head from which it was removed, is ready for installation. (3) Clean valve (32) in clean fuel oil and wipe dry with a clean cloth. Inspect face of valve for burn, or bend. Replace a defective valve. NOTE e. Air Starting Check Valve. (1) Disassemble by removing bushing cotter pin and nut (20, fig. 3-3) and lift out piston (21). Remove spring (24), then pull check valve (25) from the cage. The spring loaded safety relief valve may have one or more shims. When assembling the valve be sure you can use the correct number of shims. (2) Clean the air starting check valve in fuel oil. Wipe dry with a clean lint free cloth. Inspect 3-23 the valve face for burn or crack. Replace a defective valve. Inspect and clean parts as follows: safekeeping until cylinder head from which it was removed is reinstalled. (a) Inspect the cage for warp or pits. Replace a defective cage. f. Cylinder Compression Relief Value. Minimal maintenance required on this valve. Check for moisture, wipe dry, and coat with a film of lubricating oil. (b) Clean the spring (24) in fuel oil and wipe dry. Inspect for break or weakness. Replace a defective spring. NOTE (1) Disassemble by removing four nuts (8, fig. 34), cover (1), and gasket (2). Remove cotter pin and nut (7), lift piston (6), rings (5) and spring (4) out of cage (3). Remove gasket (10) from cylinder head, and valve (9) from the cage. Use new gaskets at reassembly of valve. (3) Assemble the air starting check valve in reverse order of disassembly. Place valve in a rack for 1. 2. 3. 4. 5. Cover Gasket Cage Spring Ring 6. Piston 7. Nut 8. Nut 9. Valve 10. Gasket Figure 3-4. Cylinder compression relief valve. (a) Inspect all parts for moisture or corrosion, then wash all parts in clean fuel oil and wipe dry with a lint free cloth. (b) Inspect gaskets and spring deterioration. Replace defective spring or gaskets. g. Cylinder Head Installation. Installation of the cylinder head(s) is accomplished by reversing the procedures used in steps (1) through (12) of b. above, and applying torque to holddown nuts as they are tightened in the order shown on figure 35. for (c) Cover all parts with a light coat of oil before reassembly. (2) Assemble the cylinder compression relief valve in reverse order of disassembly, (1) above. 3-24 NOTE Use new gaskets at all positions on assembly, and remove tags from nuts as they are installed on same studs from which removed. (1) Install head stud nuts hand tight, then torque to 100 ft. lbs. Inspect nuts for an even drawdown. If drawdown has been satisfactory, retorque (in same sequence) to 800-940 ft. lbs. (2) Retighten stud nuts at end of 100 hours of operation. NOTE See paragraph 3-12 for fuel injector repair, removal, and installation instructions. 3-7. Piston, Connecting Rod, Bearings, Rings, and Cylinder Sleeve a. General. The piston is of the trunk type, oil cooled, and fitted with five piston rings. The connecting rod is of forged steel and is fitted to the piston by a pin and sleeve bearing. It is fitted to the crankshaft by a box type bearing assembly. The bearings are babbitt type inserts. The cap and box (bearing shells) are not interchangeable. When one requires replacement, replace both. Figure 3-5. Sequence of applying torque to holddone nuts.. (3) Use the flywheel ratcheting device to turn engine over until the desired piston is at top dead center. (4) Disconnect the cylinder oil baffle by unscrewing the capscrew securing the cooling oil stationary pipe flange to the outlet pocket, and the nuts at the opposite side of the baffle. The foot of the rod will now go through the baffle opening. Remove the baffle by spreading it at the split section until it will clear the rod. b. Piston, Connecting Rod, and Rings. NOTE When a cylinder head is being removed for access to the piston group, do not remove fuel injector or valves from the cylinder head. Disconnect and cover line ends and ports only, to prevent contamination. (1) (5) Install the two 3/4 in. eyebolts in tapped holes provided in piston. Connect sling to eyebolts and a hoisting device, then take up slack. (6) Remove two cotterpins and two nuts (9, fig. 3-6), and tap the two bolts (8) out of the bearing box. Remove the cylinder head (para. 3-6). (2) Remove the crankcase inspection plates from both sides of the upper base, for the appropriate cylinder. NOTE After the cylinder head is removed, inspect the counterbore at top of cylinder for a ridge of carbon deposit. Remove any ridge with fine emery cloth to prevent ring damage when piston is lifted from cylinder bore. 3-25 Figure 3-6. Piston, connecting rod, and rings. 3-26 piston to block the connecting rod so that it will not damage piston while it is being moved to a clear working area. KEY to fig. 3-6: 1. 2. 3. 4. 5. 6. 7. 8. Rings Bracket Pin. dowel Bearing Pin Bracket Pipe, telescopic Bolt (7) Tag the identification. 9. Nut 10. Shims 11. Rod 12. Stud dowel 13. Nut 14. Cap 15. Pin, dowel NOTE The connecting rod bearing box can be left on the crankshaft journal. If this is a complete disassembly, remove bearing box as described in c. below. nuts and bolts for reinstallation (16) Move piston and connecting rod to a clear working area and place it in a wood cradle. Position it so that weight of connecting rod will not overbalance the piston. (8) Make a punchmark on foot of connecting rod and the gearing box to assure placement at installation. (17) Remove piston pin brackets and caps (6 and 14) on both sides of piston. Tag the caps (14) for reinstallation identification. CAUTION The foot of the connecting rod will score the wall of the cylinder unless guides are used. (18) Remove the telescopic pipe (7). Remove nuts (13) from studs (12), then remove piston pin (5). Wrap pin in a clean cloth to prevent damage then lay it in a protected area. (9) Clamp the connecting rod guides (table 41) to foot of the connecting rod. NOTE Before removing the connecting rod from piston, place an identifying punchmark on rod and piston to assure reassembly is same relative position. Do not reverse the rods position in the piston. (10) Hoist piston until foot is clear of the bearing box, then remove shims (10). Tag the shims for proper installation identification. (11) Hoist the piston until the five ring grooves are above the cylinder head studs, then check all rings for freedom of movement. Stuck rings may be loosened by tapping lightly with a lead or plastic hammer. If rings are too solid for this method of loosening, they must be removed after the piston has been placed in a cradle. (19) Withdraw the rod (11) from the piston and store in a protected area. c. Connecting Rod Bearings. NOTE These bearings can be replaced without removing cylinder head and piston. Proceed as follows: (1) Remove the appropriate crankcase inspection plate from both sides of the engine. (2) Use the flywheel ratcheting device to turn engine over until the desired piston is at top dead center. (12) Remove piston rings (1) by using three thin strips of steel (old hacksaw blades will serve) placed at equal distance around the piston and under the rings. Do not spread the rings any more than is necessary to remove them. Removing rings at this time makes piston less difficult to handle. (13) Tag all rings to indicate the groove and piston from which removed for replacement identification. After inspection some rings may be re-used. (3) Install the two piston clamps (table 4-1) on lower end of cylinder wall with capscrews provided. Be sure the other end of clamps project upward into the cylinder bore. (14) Hoist the piston and rod clear of the cylinder, then remove the connecting rod guides. (15) (4) Remove cotterpins and nuts (3, fig. 3-7) from the two bolts (2), then remove the two bolts (2). Position two tapered wooden blocks inside 3-27 NOTE The connecting rod cap is issued as a complete assembly, including box, dowel, shims, bolt, nut, and cotterpin. When new bearings are installed it is necessary that cap and box be scraped and lapped to give proper clearance and face-to-face fit. (c) Coat the connecting rod journal of crankshaft with Prussian blue. (d) Place the connecting rod bearing halves on journal, and with a firm pressure on bearing halves, rotate bearing on crankshaft one-quarter turn. (e) Remove bearing halves from crankshaft and inspect the blue left on bearing. If the marks do not give indication of approximately 67 percent face-to-face fit, scrape and lap as follows: 1. Use a scraper and remove the blue marks from babbitt, a little at a time. 2. Replace bearing on crankshaft and rotate as in (d) above. 3. Remove bearing and repeat step 1. above. Repeat this process until a good face-to-face contact is shown. 4. When both bearing halves show a good face-to-face contact, wash crankshaft to remove the Prussian blue. Plug the lubrication hole in crankshaft with a small wooden plug, cut flush with crankshaft. 1. 2. 3. 4. 5. Connecting rod Bolt Nut Shims Bearing box 6. 7. 8. 9. 10. 5. Apply a thin coat of medium grinding compound on crankshaft. Install connecting rod bearing on crankshaft. Rotate the bearing back and forth one-half turn on the crankshaft. 6. Remove the connecting rod bearing and wash bearing and crankshaft with fuel oil, to remove the Prussian blue. CAUTION Nut Shims Bolt Bearing cap Dowel Figure 3-7. Connecting rod bearing. (5) Remove cotter pins and nuts (6) from bolt (8). Remove bearing cap (9). Be sure and remove wood plug from crankshaft oil hole, to prevent damage. (6) Remove shims (7) and tag for proper installation identification. 7. Position four pieces of soft lead wire (0.010 in. dia) on bearing cap. Secure them in place with a dab of grease. 8. Install the bearing box and cap to the correct journal and tighten nuts to a torque of 150 ft lbs. (7) Turn engine over until piston is resting on the clamps. Continue to turn engine over slowly until foot of connecting rod leaves bearing box (5) then remove shims (4). (8) Tag shims (4) to insure proper installation (9) Remove bearing box (5). thickness. (10) 9. Remove the bearing box and cap and measure the thickness of lead wires. Where the thickness is between 0.003 and 0.005 in. the clearance is correct. If clearance is less than 0.003 in., add shims. If clearance is more than 0.005 in., remove shims. Clean, inspect, and repair the bearings as follows: (a) Wash the bearings in clean fuel oil and wipe dry. Wash off the crankshaft journal and wipe dry. (11) Installation of the connecting rod bearing after scraping and lapping has been accomplished, is described in steps (12) through (15) below. (b) Inspect all bearing surfaces for scoring, scratches, or discoloration signs of overheating. Replace defective bearings. (12) Position bearing box (5) and bearing cap (9) on the correct journal, with shims (7) in place, then install bolt (8) and nut (6). Tighten nut finger tight. 3-28 NOTE (13) Position foot of connecting rod over the box by backing up the ratcheting device slow and easy, then install shims (4). Secure with bolts (2) and nuts (3). Turn nuts (3) finger tight. Cylinder and cylinder sleeve are a matched unit and are not interchangeable. When a cylinder sleeve needs replacing, the cylinder and sleeve must be replaced as a unit. Replacing sleeve alone is no longer authorized. (14) Be sure that shims (7) and (4) are in place with tags removed, then tighten nuts (6) to a torque of 150 ft. lbs. and install the cotter pin. (15) Tighten connecting rod bolt nuts (3) to a torque of 350 ft. lbs. and install the cotter pins, then remove the piston clamps from the cylinder wall. NOTE (1) the cylinder. Remove the oil outlet pipe from the bottom of (2) Remove piston and connecting rod (b. above). (3) Remove six nuts (1, fig. 3-8) from studs (2), mark for position at reassembly, and withdraw sleeve (24) and rings (22) from the cylinder. End play of connecting rod bearing must be checked before inspection plates are installed. See f. (9) below. CAUTION d. Cylinder Sleeve and Scraper Rings. To the lower part of each cylinder a sleeve is bolted. This sleeve holds three oil scraper rings. The function of these rings is to collect surplus cylinder cooling and lubricating oil in order to prevent an over supply of oil accumulating in the lower base. It is not necessary to remove the cylinder in order to replace scraper rings. Replace as follows: Cylinder sleeve must be replaced in same position as removed. The scribe mark on both cylinder and cylinder sleeve must be aligned when sleeve is reinstalled on the cylinder. 3-29 1. 2. 3. 4. 5. 6. 7. 8. 9. Nut Stud Flange Gasket Nut Capscrew Nut Pin Pin 10. 11. 12. 13. 14. 15. 16. 17. 18. Nut Lockwasher Washer Stud Stud Nut Stud Capscrew Gasket 19. 20. 21. 22. 23. 24. 25. 26. 27. Capscrew Post, zinc Stud Ring Gasket Sleeve Gasket Connection Tube Figure 3-8. Cylinder, sleeve, and rings. CAUTION NOTE Scraper rings may be replaced individually or in sets. If a new ring is used it must be installed in the top scraper ring space, and the old ones moved down. Assure that the scraper rings are installed with the knife edge and slots toward the bottom, and the flat side up. 3-30 Press the sleeve bearing into the connecting rod. check to assure that both holes are lined up. (4) Lift the scraper rings off their spaces on sleeve marking them for installation in same space in the event they are re-used. (d) Coat the piston pin (5) with prussian blue. Insert piston pin into sleeve bearing, then rotate the pin back and forth through one-quarter turn. Remove the pin. (5) Clean rings and sleeve with clean fuel oil, then remove all accumulated carbon. Inspect the rings and sleeve for abnormal wear, breaks, or cracks. Replace defective cylinder and sleeve assembly. or rings. (e) Inspect the bottom surface of the sleeve bearing for blue marks. When a minimum of 67 percent of bottom bearing surface shows blue, the piston pin is properly fitted. If less than 67 percent shows blue, it must be scraped and fitted. (6) Install the rings on sleeve (see notes and cautions above), align scribe marks, then position sleeve in cylinder. (7) Make a NOTE In addition to scraping for fit, when fit is attained, it must be aligned with the foot of the connecting rod. This may require scraping of the bearing to assure pin and foot are horizontal with each other. Secure flange to cylinder with six nuts (1). (8) Install piston and connecting rod, then install oil outlet pipe to bottom of cylinder. NOTE Be sure that oil baffle is in place on bottom of cylinder. (f) Use a machinists scraper, and scrape away the blue from bearing surface, a little at a time. Repeat the marking and scraping process until bearing is fitted. e. Cleaning, Inspection, and Repair of Piston and Rod. (1) Use a soft metal bar, the same width as the piston rings, to pry out frozen rings. (g) Place fitted pin in sleeve bearing of connecting rod. then stand connecting rod on its foot. or use a straight edge across the foot, and measure the distance from foot to each end of the piston pin Unless both sides measure exactly the same. the high side must be scraped off of bearing surface until the distances match. (2) Use a soft metal scraper (or a piece of broken ring with edge ground blunt) to remove hard carbon from ring grooves in piston. (3) Wash piston inside and out with clean fuel oil. Wipe dry with a lint free cloth and blow clean with ships service air. (10) After the sleeve bearing has been fitted, use the dowel pin hole in rod eye as a guide, drill holes in bearing for new dowel pins, and insert the pins. Blows away all drill chips with compressed air. (11) Wash piston rings in clean fuel oil and remove all carbon. (4) Use a wire brush to remove carbon from crown of piston. Wash in clean fuel oil and wipe dry with a lint free cloth. (5) Inspect top (crown) of piston for cracks. Replace a defective piston. NOTE Piston rings that were stuck in groove are worn thin on one side. and must be replaced. (6) Wash the connecting rod in clean fuel oil and wipe dry. Use a rod or wire to remove any obstructions from lubricating oil passages in the rod, then blow passages clean with compressed air. Start air through passage from the foot of the rod, up to the piston pin sleeve bearing. (12) Use a micrometer and measure thickness. Replace a damaged or worn ring. (7) Wash the piston pin in clean fuel oil and wipe dry with a lint free cloth. ring (13) Place the five rings for a cylinder in the cylinder one at a time, and measure the end gap. Proper gap should be between 0.085 and 0.090 inch. If ring gap is less than 0.085 inch, file the ends a little at a time, until proper gap is attained. Replace a ring with more than 0.090 inch end gap. (8) Insert piston pin in piston pin sleeve bearing. Use a feeler gage to measure clearance from top of pin to bearing. This clearance should be between 0.004 and 0.006 in. When clearance is more than 0.008 in., check the piston pin diameter at ends and center for a measurement of between 5.493 and 5.494 inch., If piston pin is worn, or out of round; or the diameter is less than 5.488 inch, replace the piston pin. If piston pin meets requirements, replace the sleeve bearing. (14) (13) above. When new rings are to be used. check as in f. Installation. (1) Install the connecting rod and piston pin to the piston in reverse order of their removal. (9) To replace a piston pin sleeve bearing, proceed as follows: (2) Using a ring expander, expand rings only enough to get them over the piston. Install rings in groove from which removed, then remove tags. Stagger the end gaps 900 to prevent blow-by. (a) Drill out the two pins (3, fig. 3-6) that hold sleeve bearing in position. (b) Drive or press the old bearing (4) out of the connecting rod (11). (3) Hoist piston over the cylinder from which it was removed. Check that the connecting rod foot is in position relative to bearing box. (c) Scribe a mark on the new sleeve bearing through the center of the lubricating oil hole. Align this scribe mark with the oil hole in the connecting rod. (4) 3-31 Place the connecting rod guides (table 4-1) on foot of rod, then lower piston so the rod foot enters the cylinder bore. (a) Place a short bar at side of bearing and move it to the other side of journal, then place indicator point at side of bearing. Pry bearing to the opposite side of journal. (5) Compress the piston rings with the guide piston ring (table 4-1) as they enter the cylinder. Stop lowering the piston as soon as rings are in the cylinder, and remove the piston ring guide. (b) Check the indicator reading. A side clearance of between 0.018 and 0.032 inch is acceptable. (6) Level the connecting rod bearing box with the crankshaft journal at top dead center. Remove the connecting rod guides from foot. Install shims (10, fig. 3-6) then lower piston and guide the rod foot over bearing box. Install bolts (8) through shims (10) and foot of rod (11). Install nuts (9) on bolts (8) and tighten to a torque of 350 ft lbs. (11) Install the cylinder head (para. 3-6) and fill the engine cooling system. (10) Replace crankcase inspection plates. 3-8. Emergency Fuel Shutoff Reset Lever a. General. The emergency fuel shutoff reset lever (10, fig. 2-3) is connected to the emergency fuel shutoff manual trip (11) through linkage and is located on port side of engine at the control station (10, fig. 2-3). The purpose of this lever is to return the engine to operating condition after the emergency fuel shutoff manual trip (11) has been operated. (7) Turn engine over with ratcheting device slowly for one revolution. When piston moves freely in cylinder, install new cotterpins through nuts (9) on bolts (8). NOTE b. Maintenance and Adjustment. Before going further with installation, there are two clearances that should be checked. (1) To reset the emergency fuel shutoff reset lever (10) after it has been tripped, pull it down and hold it until the emergency fuel shutoff manual trip (11) is pulled out, then release the lever. (8) Check bearing to journal clearance as follows: (a) With bearing well lubricated, position a dial indicator at the rod foot; a bar under the bearing, and pry for upward movement. The indicator should show between 0.003 and 0.005 inch clearance. If it shows more clearance, remove 1 or 2 shims from between box and cap on both sides then recheck. (b) If bearing checked without changing shims, proceed to (9) below. If shims were removed or added, be sure that bearing cap and bearing box nuts were torqued as shown in c. (15) above.. (9) Check the connecting rod bearing side clearance as follows: (2) 3-32 Check the operation of the cam by pushing Figure 3-9. Fuel oil filters, lines and transfer (supply) pump. 3-33 c. b. Removal. (1) Shut off fuel oil supply to fuel oil transfer (supply) pump (34, table 2-4). (2) Disassembly. (1) Remove capscrew (11, fig. 3-10) and remove pump drive arm and key from pump rotor shaft (15). Disconnect fuel oil suction and supply lines (fig. 3-1). (3) Remove capscrews and lockwashers (fig. 39) and remove fuel pump from camshaft housing. 3-34 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Bearing, sleeve Packing Packing gland Bearing, ball Plug Gasket Valve, discharge Valve, suction Cover plate Drive ion camshaft) Capscrew Seal, oil 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Gasket Capscrew Shaft, rotor Capscrew Gasket Gasket Rotor Seal, oil Pin Bushing Head, pump Housing, pump Figure 3-10. Fuel transfer (supply) pump, cross section. 3-35 (2) Remove bearing (4) and seal (12). (4) Turn engine over with starting air until pump is primed. It may be necessary to open pump discharge line slightly, to aid in priming the pump. When primed, tighten discharge line. (3) Remove the 5 capscrews from cover plate (9) and remove head (23) and gasket (18). Tag gasket for installation identification. (4) bushing (22). (5) g. Adjustment. Remove pin (21), seal (20), rotor (19), and (1) Check the packing gland. If leaking, draw it up tight, then back it off one-quarter turn. Loosen packing gland (3). (2) Start the engine and run AHFAD, then check packing gland. Tighten if leaking. (6) Remove shaft (15), then remove packing (2) and packing gland (3). (7) (3) Reverse the engine to ASTERN. Check for leaks. Tighten if necessary. NOTE There is a pressure relief valve near the pump discharge (set for 15 psi) that will by-pass the fuel oil back to the day tank if the pressure becomes too high. Remove two plugs (5) and gaskets (6). (8) Remove valves (7 and 8). installation identification. Tag valves for d. Inspection, Cleaning, and Repair. (1) Clean all parts 'n clean fuel oil and wipe dry with a lint free cloth. CAUTION Tighten packing gland just tight enough to allow an occasional drip. Excessive tightening of gland nut will score the shaft. (2) Check the clearance between rotor (19) and bushing (22). If the clearance exceeds 0.005 in., replace rotor (19), oil seal (20), and bushing (22). (3) Use a straight edge along rotor shaft (15). If bent, replace shaft. (4) Use a wire brush to remove clinging gasket material then wash in clean fuel oil, and wipe dry with a lint free cloth. NOTE Use new gaskets at assembly and installation. 3-10. Fuel Priming Pump a. General. The fuel injection pumps are used as a priming pump for fuel line and fuel injector (nozzle) of each cylinder. To remove all air from line and injector, proceed as follows: (5) Remove all packing (2) then use a wire brush to clean threads of the packing gland (3). (3) Turn the ASTERN/AHEAD handwheel (6, fig. 2-3) counterclockwise to the limit of its travel, then move clockwise back to START. (6) Check the discharge and suction valves (7 and 8) for wear or corrosion. Replace a defective valve. Shut off the starting air valve to engine. (2) Open the fuel oil supply valve to the engine. (4) Remove the cover (15, fig. 3-11) from the injection pump housing, then loosen vent plug (2, fig. 3-12) on the fuel injector. KEY to fig. 3-11 1. Delivery stop 2. Holder 3. Spring 4. Nut 5. Stud 6. Valve 7. Gasket 8. Gasket 9. Plunger 10. Pinion 11. Washer 12. Control rack 13. Guide (upper) 14. Control lever 15. Cover. housing 16. Adjusting screw 17. Adjusting nut 18. Adjusting nut 19. Adjusting shim 20. Plug 21. Push rod 22. Socket 23. Guide (lower) 24. Tappet 25. Spring 26. Barrel 27. Setscrew 28. Valve seat (7) Inspect oil seals (12 and 20) for wear or deterioration. Replace a defective oil seal. e. Assembly. NOTE Measure the thickness of the head gasket (18) tagged at disassembly. The new head gasket must be exactly the same thickness. (1) Assemble fuel transfer pump in reverse order of disassembly. (2) Place key on shaft (15), slide drive arm over key, then tighten capscrew (11). (3) Install packing in packing gland. Use new packing cut into individual rings with a small end gap. Position the gaps 90 degrees apart to assist in preventing leaks. Tighten packing gland finger tight. f. Installation. (1) Position pump into camshaft housing, so that arm on pump shaft engages drive (10) on camshaft, then secure with lockwashers and capscrews (fig. 3-9). (2) Reconnect fuel lines to pump. Open fuel oil supply valve to transfer pump (34, table 2-4). (3) (1) Bar the engine over to assure pump has free rotation. 3-36 Figure 3-11. Fuel injection pump, cross section 3-37 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Retainer Plug, vent Ball Body Sleeve Filter Gasket Gasket Housing Gasket Stop 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Body Needle Sleeve Gasket Tip Gasket Retainer Push rod Seat Spring Shim Figure 3-12. Fuel injector (nozzle), cross section. (5) Use priming lever (table 4-1) under the shoulder of the pushrod (21,.fig. 3-11), and work the shoulder up and down until fuel oil flows out of the vent plug (2, fig. 312). When this oil is free of air bubbles, tighten the vent plug. cover (15, fig. 3-11). Replace cover on other half of housing in a like manner. (6) Prime each fuel injection pump in turn, as described in steps (3) through (5) above, then replace housing b. Start Engine. Start the engine (para. 2-4, or 2-5). If any of the injectors are not receiving fuel, stop the engine (para. 2-6) and prime that fuel injection pump. (7) 3-38 Open the starting air valve to the engine. measured amount of fuel, under pressure, to the fuel injectors (nozzles). 3-11. Fuel Injection Pump a. General. There are six fuel injection pumps, one for each cylinder. They are located on the control (port) side of the engine. in the fuel and air valve housing above the camshaft. The pumps are of the plunger type. and are actuated by the camshaft. Their purpose is to deliver a timed. b. Removal. (1) Remove 8 nuts and lockwashers (fig. 3-13) and the housing cover from the fuel and air valve housing. Figure 3-13. Fuel injection pump. c. (2) Disconnect the fuel supply line from the fuel injection pump and the fuel injector at the cylinder. Cover ends of line to prevent contamination of the fuel system. Disassembly. (1) Remove nut (4, fig. 3-11,.holder (2), stop (1), and spring (3). (3) Disconnect the injection pump control rack (12, fig. 3-11) from the control lever (14) and remove rack from the pump. (2) Lift out valve (6), valve seat (2w9, and gasket (7). NOTE (4) Remove the four mounting screws (fig. 313) and remove the injection pump as a unit, from the fuel and air valve housing. Tag valve and valve seat for reinstallation identification. (3) Remove plunger (9), loosen setscrew (27), then remove barrel (26) and gasket (8). 3-39 NOTE (3) Tag barrel and plunger for reinstallation identification. Use new gaskets at reassembly. NOTE Teeth of pinion (10) and rack (12) are designed so they cannot be meshed incorrectly. (4) Lift out upper guide (13), spring (25), and lower guide (23). (5) g. Adjustment. Assure that all cylinders are s supplied the same amount of fuel. To do this, proceed as follows: (1) Inspect for position of control racks. The pointer on pump body should indicate the same graduation on each pump rack. The pumps are all calibrated to deliver a set amount for each graduation mark. Remove pinion (10) and washer (11). d. Cleaning, Inspection, and Repair. (1) Wash all parts in clean fuel oil and wipe dry with a lint free cloth. (2) If more than one rack was removed, be sure that injection pump was installed in correct cylinder. Inspect all racks for same setting. If one is incorrect, disconnect it from pinion and mesh teeth so it has the same reading as the other five. (2) Inspect springs (3 and 25) for damage. Replace a defective spring. (3) Insert plunger (9) into barrel (26). The fit should be snug. Replace plunger and barrel, if worn. (4) Inspect valve (6) and valve seat (28) for scratches. If badly scratched, replace valve and seat. Small scratches are caused by dirty fuel oil, and may be removed by grinding the valve to the seat. Use a fine grade of pumice or jewelers rouge for the grinding. Place the valve in the seat, then rotate the valve. Wash away all grinding compound in clean fuel oil. Inspect valve and valve seat. When all scratches have been removed, the valve and seat can be reused. (3) Install cover (fig. 3-13), then connect fuel line to fuel injector and fuel injection pump. NOTE The fuel injection pump body and the injection pump pointer are stamped with the cylinder number corresponding to the fuel injection pump. When more than one fuel injection pump is removed, install them on the engine in the position from which removed. (5) Inspect rack (12) for burrs or other damage. Replace a damaged rack. (6) Inspect pinion (10) for bend, or other damage, Replace a damaged pinion. 3-12. Fuel Injector (Nozzle) a. General. The fuel injector (nozzle) is of the spring loaded differential type. Its purpose is to atomize, then spray the fuel delivered by the fuel injection pump into the cylinder. The fuel is metered by the pump; forced under pressure to the injector; where it is released as a spray into the cylinder, when the pressure reaches 2,500 psi. (7) Inspect upper guide (13) and lower guide (23). If worn, or scratched, replace both guides. e. Reassembly. Reassemble the fuel injection pump in reverse order of disassembly. Assure that no dirt gets into the assembly while putting it together: b. Removal. f. Installation (1) Insert the fuel injection pump in its housing on engine, in its marked location. Install nuts (4) on studs S15) and tighten. (2) ,pinion. (10). Connect rack (12) to the control lever (14). injector. Install rack (12) and adjust it to mesh with 3-40 (1) Shutoff fuel to engine (34, table 2-4). (2) Refer to figure 3-14 and remove the fuel Figure 3-14. Fuel injector removal and installation. (3) needle can then be tapped loose from the sleeve. Place the fuel injector on a clean work bench. c. Disassembly. (5) Place body (12) on workbench in an inverted position. Use a wood block over tip (16). Strike the block with a hammer and remove tip (16), then remove gasket (15). (1) Clamp the body (12, fig. 3-12) in a vise and remove retainer (1), housing (9), gasket (10), spring (21), shim (22), and pushrod (19). Tag the shim for proper reinstallation identification. (2) NOTE When more than one fuel injector is removed use individual oil pans. Do not mix injector parts. Remove retainer (18), vent plug (2), and ball (3). (3) Remove body from vise. Place a clean cloth on workbench. Invert the body and the stop (11) will drop out. (6) clean fuel oil. (4) Replace the body in the vise. Insert a needle lapping tool, or a piece of soft wood slotted at the end, and tap it gently to wedge it to the top of the needle (13). Withdraw the tool used, with needle (13) attached. Place fuel injector parts in a pan filled with (7) Replace body (12) in vise to remove body (4) and gasket (8). (8) Remove gasket (7), then push sleeve (5) and filter (6) from body (4), NOTE If the needle is stuck and will not come out with the tool used. strike the tip (16) with a block of wood. This will loosen the sleeve (14), so that sleeve and needle (13) can be removed by inverting the body. The d. Cleaning, Inspection, and Repair. (1) Soak the tip (16) in fuel oil to loosen the carbon. Use compressed air at tip to blow loose carbon from spray orifice. 3-41 NOTE The cleaning of spray orifices is a delicate operation requiring good light and a magnifying glass. The cleaning tool must be inserted into the orifices gently with a rotating motion. No attempt should be made to push tool into orifices if they are filled with hard carbon or other dirt. Discard tip, and needle, when either show signs of discoloration at tip. (2) Using a magnifying glass, examine the spray orifices in the tip. Compare them with those in a new tip. If the edges appear ragged or distorted, discard the tip. (6) Screw housing (9) firmly into body (12). (7) Install ball (3) and tighten plug (2). Install a new gasket (8) before installing the filter (6). Place filter (6) into body (4), then screw body (4) into body (12). f. Testing. (1) Place fuel injector in tester. Prime the tester by using very quick strokes until some fuel is ejected from injector in a fine spray. Then pump with slow even strokes. When the injector is working properly, a continuous uniform "popping" will occur. (2) When opening pressure has been reached, the needle will lift from its seat and quick pressure drop will be indicated on gage. The highest pressure reached before this drop, as indicated on the gage, will be the opening pressure. (3) Clean the tip thoroughly. If the tip cannot be properly cleaned, discard it and replace it with a new tip. (3) Check the spray pattern of the injector. All fuel injector sprays in the engine should be of the same density and provide an even spray in all directions. The needle should return to its seat sharply when pumping ceases. (4) Clean the tip seat in body. Dip the needle (13) in clean fuel oil and place it in the sleeve (14). Remove needle from sleeve. Wipe needle clean with a lint free cloth. Inspect needle seat, if scratched or pitted, replace the needle and sleeve. NOTE Needle and sleeve are lapped together when new, and must be replaced together at the same time. (5) When the needle seat has been inspected, and found in good condition, wipe needle dry. Place it in the sleeve. If it will fall into place by its own weight, it is considered to be free and will not bind in the sleeve. (6) Inspect ball (3). If out of round, replace. (7) Inspect filter (6). (4) Check the fuel injector opening pressure ((2) above). The fuel injector should open at 2,500 psi. If the injector opens before 2,500 psi, remove shims (22) from under the retainer (1). If injector opens after 2,500 psi, add shims under retainer (1). NOTE Shims (22) are available in 0.004 in., 0.0149 in., and 0.0299 in. sizes. These shims will change pressure by approximately 100 psi, 400 psi, and 1,000 psi respectively. If broken or damaged, replace it. (8) Prior to reassembly, clean all parts again in clean fuel oil. Assure that threaded items, and all parts are carbon free. Wash again in clean fuel oil and blow dry with compressed air. NOTE The spring push rod (19) causes very little injector trouble and should not have to be replaced. If for any reason the push rod must be replaced, it and the stop (11) must be lightly lapped in place. e. Reassembly. NOTE Prior to installing fuel injectors in the cylinder head, install a new gasket (17) in the cylinder head fuel injector port. g. Installation. Install in reverse order of the removal (fig. 3-14). Turn on fuel to engine (34, table 2-4). 3-13. Governor (Mechanical) a. General. The governor is a flyball (weighted) type, having a vertical spindle driven from the camshaft by a flexible driver gear. As the engine speed increases or decreases, because of load variations, the weights swing in and out and force the governor yoke up, or down. The governor yoke is connected through linkage to the fuel control shaft, which turns slightly on its axis as the yoke moves. The governor spring is designed to give a specific resistance to the centrifugal force on the weights, and it allows the yoke to move the desired amount for certain speed changes. The governor is lubricated by the engine lubrication system. (1) Place a new gasket (15) on tip (16) and insert tip and gasket in body (12). (2) Use a square end soft metal rod to tap the tip into its seat in the body. (3) Place the needle (13) and stop (11) in sleeve (14). Insert this subassembly into body (12) on top of tip (16). (4) Install retainer (18) with tapered end up. Install a new gasket (10). (5) To assemble the housing (9), first insert the push rod (19) in housing with the large rounded end at the top, then install seat (20), spring (21), shim (22), and retainer (1). CAUTION Do not use undue force in screwing down the housing (9) or retainer (11), or the parts may be distorted and cause needle to bind in sleeve. b. Removal and Disassembly. (1) Disconnect the oil line from spray tip (3, fig. 3-15), and governor linkage. 3-42 1. 2. 3. 4. 6. 6. 7. 8. 9. Cover Washer, yoke Oil spray tip Setscrews Bearing Pin, weight Adjusting screw Block Bushing, pin 10. 11. 12. 13. 14. 15. 16. 17. 18. Shaft Spring Stop screw Nut Gear, drive Bearing Bracket Nut Shims Figure 3-15. Governor, (mechanical). 3-43 19. 20. 21. 22. 23. 24. 25. 26. 27. Bearing Nut Bearing Spindle Roller Seal, oil Gasket Governor shaft Spring NOTE Be sure the adjusting setscrews (4) are adjusted evenly, then install safety wire through holes in head that are lined up. Also, check that rollers (23) of the weights, and the weights, move freely. (2) Remove the capscrews from housing cover (1), lift off housing cover, and gasket (25). (3) Back off the adjusting screw' (7) and remove block (8); this will relieve tension on spring (11). Tag the block (8) for proper reinstallation identification. (4) Remove the pipe plug located in the upper governor housing to the left side of the governor hand control (4, fig. 2-3). (5) Pull the shaft (10, fig. 3-15) from the speed control lever and remove the lever. (6) Back off nuts (17) and remove the upper governor housing and gasket. (7) Remove nuts (20) and lift the governor assembly from the lower governor housing. (8) Position the governor assembly in a vise. Use soft jaws to avoid damage. (9) Back off adjusting setscrews (4) and remove the oil seal (24) and bearing (5). (10) Lift off the spindle (22) and weight assemblies. (11) Remove bearing (21), bearing (19), and shims (18). Tag the shims for proper installation identification. (12) Remove cotter pin from governor shaft and nut (13), then remove nut (13). Pull drive gear (14) from governor shaft (26). Remove drive gear key and tag for proper reinstallation identification. (13) Remove bearing (15), then pull out governor shaft (26) and spring (27). c. Cleaning, Inspection, and Repair. (1) Wash the governor parts in clean fuel oil and wipe dry. (2) Use a wire brush and clean all gasket surfaces. Use new gasket when assembling and installing the governor. (3) Inspect all bearings for cracked race, worn or scored balls, or rough operation. Replace defective bearings. (4) installation. Oil each bearing with clean engine oil prior to (5) Check oil seal (24) for excessive wear, or other damage. Replace a defective oil seal. (6) Inspect drive gear (14) for worn teeth, or other defect. Replace a damaged drive gear. d. Reassembly and Installation. (1) Install the drive gear (14), tighten nut (13), and install a new cotter pin. (2) Install bearing (15). Install spring (27), governor shaft (26), and spindle (22) in bracket (16). NOTE Be sure that all shims are reinstalled in same position from which they were removed. (3) Install shims (18) and bearing (19). (4) Position the governor assembly in the lower governor housing and tighten nuts (20) evenly. 3-44 (5) Position weights on spindle (22), install oil seal (24), and bearing (5), then install the adjusting setscrews (4). (6) Position new gasket on lower housing, and install the upper housing. Install nuts (17) and tighten. (7) Position the speed control lever and insert shaft (10). (8) Install and tighten the pipe plug located in the upper housing, on left side of the governor hand control (4, fig. 2-3). (9) Install block (8, fig. adjusting screw (7). 3-15) and tighten the (10) Position a new gasket (25) on upper housing, install cover, then tighten nuts securing cover evenly. (11) Connect oil line to oil spray tip (3) and reconnect the governor linkage. e. Test and Adjustment. (1) Start engine and check the governor for speed control as follows: (a) Use throttle hand wheel (5, fig. 2-3) to set varying rpm levels. (b) Use governor hand control (4) to refine the desired level. (c) If the governor fails to respond, remove nuts securing cover (1, fig. 3-15), remove cover (leave gasket on upper housing) then reach in with a screw driver and turn the adjusting screw (7) until speed levels off at throttle setting. (2) Stop the engine, and reinstall the cover (1) and tighten the cover nuts evenly. 3-14. Fuel Filter and Relief Valve a. General. The fuel oil filter is a duplex pressure filter with woolen-bag filter elements. By positioning the control valve handle (fig. 3-9), one filter may be in service while the other is being cleaned without stopping the engine. With the control handle in a vertical position, fuel oil will flow through both filters. One filter at a time can be shutoff and cleaned when the filters become dirty. b. Inspection, Service, and Repair. Turn handle (fig. 39) from the vertical to the horizontal with pointer at filter being left in service. Then service as follows: (1) Position a pan under filter to catch drainage. (2) Remove drain plug from near bottom of filter not in service (the L. H. filter shown on figure 3-9). Inspect the draining fuel oil to determine degree of contamination. TM 55-1925-204-12 (3) Loosen capscrews in filter head, holding filter body to keep it from dropping after screws are fully disengaged. (4) Place the body in the pan, remove the filter element from body and open as follows: (a) Unscrew the two nuts (4, fig. 3-16) until they touch the pin (5). Turn the pin (5) one-quarter turn to release the bag (10). Remove bag (10) and spacer (8) from spool (6). (b) Remove gasket (13) from filter head (14). NOTE On some hulls, it may be necessary to drain the fuel oil day tank before removing the relief valve. (c) To remove the relief valve, isolate the fuel oil discharge line to the fuel oil day tank. Break the two unions (one above, one below the relief valve). Place the relief valve and piping in a vise. (d) Use a pipe wrench and turn the nipples out of the inlet side of the relief valve. (5) Wash the body (3) in clean fuel oil and wipe dry with a lint free cloth. (6) Wash spacer (8) in clean fuel oil and blow dry with compressed air. (7) Use a wire brush and clean gasket surface of filter head (14), to remove any traces of the old gasket. Wash in clean fuel oil and wipe dry with a lint free cloth. (8) Inspect nipples removed from the relief valve. Clean threads with a wire brush, if necessary. (9) Place a new relief valve in vise, tighten carefully. Do not pinch the valve. Use a pipe wrench and install nipple in inlet port. Reposition valve in vise and install nipple in outlet port. Tighten nipples. (10) Use a new bag and assemble as shown on figure 3-17. 1. 2. 3. 4. 5. Capscrew Screen Body Nut Pin 6. 7. 8. 9. Spool Spring Spacer Spring 10. 11. 12. 13. 14. Bag Clamp Ring Gasket Filter head Figure 3-16. Half of twin fuel oil filter, cross section. 3-45 Figure 3-17. Filter element assembly. (11) Install a new gasket (13, fig. 3-16) in filter head (14). (13) Reverse the position of selection handle to (12) Position body (3) in filter head (14). Hold body flush with head and tighten capscrews evenly. 3-46 take the remaining fuel oil filter out of service, and then repeat the above procedure. 3-15. Engine Starting Aids a. General. To aid in starting the engine under extremely cold and adverse weather conditions, starting cartridges are provided. b. Use of Starting Aid. First. remove two or three of the spring loaded safety relief valves from the cylinder heads, then proceed as follows: (1) Insert the starting cartridge holders in those cylinders from which the relief valve was removed. 1. 2. 3. 4. 5. 6. Scavenging pump Cylinder head Lubricator Handwheel Injection pump Governor control (2) Ignite and insert starting cartridges in the holders. Then repeat starting procedures (para 2-4 or 2-5). (3) When engine is started and warmed up, stop the engine (para 2-6,) remove cartridge holders, then reinstall the spring loaded safety relief valves. 3-16. Scavenging Pump (Air) a. General. The scavenging pump (1, fig. 3-18) is located at forward end of engine, and is driven by the crankshaft. It supplies scavenging air to the air receiver (box) at a pressure of between one and one half. and two and one half psi. The pump receives its air from the air intake, and from the crankcase breather (para 3-17). 7. Fuel oil filter 8. Fuel oil pump 9. Raw water pump 10. Fresh water pump 11. Lube oil pump 12. Breather, crankcase Figure 3-18. Propulsion engine, port side view. b. Disassembly. (1) Drain the engine cooling system and expansion tank. The drain valves are located below the exhaust manifold. This prevents water from spilling into the . 3-47 scavenging pump should the water inlet pipe be damaged during disassembly. (2) Remove the inspection plate from troth sides of scavenging pump. (3) Bar the engine until the scavenging pump connecting rod is at top dead center. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. (4) Remove the capscrews securing housing (1, fig. 319) and lift off the housing and gasket (30). KEY to fig. 3-19: 1. Housing 2. Spring 3. Guide 4. Seat (outer) 5. Rod (upper) 6. Rod (lower) 7. Bearing, sleeve 8. Piston pin 9. Gasket 10. Ring 11. Ring 12. Spring 3-46 Seat, (inner) Ring Ring Shims Volt Bolt Cap Nut Gasket Ring Ring Stud Piston Gasket Nut Cover Cylinder head Gasket Figure 3-19. Scavenging pump, cross section. or journal. (8) Inspect the rods (5 and 6). Replace rods that are bent, or have damaged threads. (5) Remove all nuts (27) and lift off cover (28). (6) Remove cylinder head (29) and gasket (26). (7) Remove guide (3) and spring (2). (8) Remove nut from rod (5) and lift out seats (4). Remove rods (5 and 6) and air valve seat assembly. (9) Remove 2 nuts (20) and bolts (18). Tag nuts and bolts for installation identification. Remove nuts from the two bolts (17), then remove cap (19) and shims (16). Tag shims for installation identification. (10) Remove piston (25) and rings, connecting rod and connecting rod bearing. (11) Remove rings (10 and 11), spring (12), seat (13), and rings (14 and 15) from the air valve pump assembly. Expand the rings only as far as necessary to remove them. c. Cleaning, Inspection, and Repair. (1) Use a wire brush and remove carbon from cylinder head (29). (2) Wash all parts in clean fuel oil and wipe dry with a lint free cloth. (3) Inspect the piston (25). Replace a piston that is cracked, or out-of-round. (4) Inspect the rings. Use a micrometer and measure thickness of an old ring, then measure a new ring. If the difference in thickness is 0.002 in. or more, replace the rings. (5) Remove pin (8) and key from the connecting rod sleeve bearing (7). Wash and wipe dry then insert pin in bearing for measurement. If a feeler gage shows more than 0.003 in. clearance between pin and bearing, replace the bearing (7). (6) Inspect the pin (8). Replace a pin that is pitted or scratched. (7) Inspect the connecting rod bearings and cap (19). If bearings are pitted or cracked they must be. replaced. To fit a new connecting rod bearing proceed as follows: (a) Wash the crankshaft journal surface with clean fuel oil and wipe dry. Cover journal with a light coat of prussian blue. Place bearing (top half) on crankshaft. Install shims (16) and cap (19). Install bolts (17) and nuts, and tighten them evenly. Rotate bearing one half turn back and forth. Remove bearing and cap. Examine the bearing surfaces. When bearing surfaces are 80 percent covered with blue, it indicated good (adequate) face-to-face contact with the journal. (b) Wash journal and bearing surfaces to remove blue and wipe dry. (c) Use four strips of 0.010 in. soft lead wire under bearing cap (they may be held in place by dabs of grease as cap is installed). Be sure that bolts tighten cap down evenly, then remove cap. Measure thickness of the lead wire. When the bearings are new, wire should have compressed to between 0.003 and 0.005 in. If clearance is less than 0.003 in., add shim. If over 0.005 in. remove a shim. (d) When bearing is fitted to crankshaft with proper clearance, leave it installed for the moment to prevent damage to bearing NOTE Before beginning reassembly of the scavenging pump, service the crankcase breather as described in paragraph 3.17 below. d. Reassembly. (1) Position connecting rod in the piston (25) and install the pin 18). (2) Replace the rings (22 and 23). (3) Position rod and piston assembly in the sleeve and lower the assembly until the rod rests on the rod bearing. Be sure holes in bearing line up with those in the rod, then replace bolts (18) and nuts (20). Tighten the nuts evenly. (4) Replace rings (10 and 11), spring (12), seat (13), and rings (14 and 15). Install the air valves in the scavenging pump cylinder and replace rods (5 and 6). Tighten the nuts. (5) Replace the spring (2) and guide (3). Use a new gasket (26) and replace the cylinder head (29). Tighten nuts securing cylinder head evenly. (6) Replace top cover (28) and tighten nuts (27) securing cover evenly. (7) Use a new gasket, then install housing (1) and tighten nuts evenly. (8) Refill expansion tank and the engine cooling system. (9) Install the inspection plates on both sides of the scavenging pump. (10) Run the engine at half speed for 10 minutes, check the scavenging air pressure, then stop the engine. (11) Remove one inspection plate and check the scavenging pump connecting rod bearing. Feel of the bearing. If the bearing feels hot to the touch, remove the bearing and check the lube oil supply passage for a possible clogged opening. (12) Start the lube oil standby pump and watch for oil to flow out of the passage in journal. If lube oil does not flow out of the passage, use a wire and remove the blockage. When oil is flowing, stop the pump and install the bearing. (13) Replace the inspection plates and start the engine. Recheck the connecting rod bearing as described in steps (11) and (12) above. e. Hand Lubrication Pump. Normal lubrication to the scavenging pump piston sleeves is from the force feed lubricator. To furnish this lubrication before the engine is started, use the hand lubrication pump that is mounted near the scavenging pump, as follows: (1) Fill the pump with oil through the port on top of pump. 3-50 (2) Pull handle of pump out as far as it will go, then push it all the way in, slowly, until increased resistance to movement indicates that the lines are full. f. Oil and Water Pump Drive. The oil and water pump drive is located in the engine base, at forward end, and is driven by the crankshaft. It operates the raw water pump, fresh water pump, and the engine lubrication oil pump, through a gear train. (1) Remove the crankcase inspection plates from both sides of the scavenging pump section (fig. 3-18). (2) Remove capscrews securing the handhole cover (15, fig. 3-20) to the oil and water pump drive housing. Lift off handhole cover and gasket (16). 3-51 1 2. 3. 4. 5. 6. 7. 8. 9. Bracket Capscrew Spacer Spindle Capscrew Cap Gear Nut Shaft 10. 11. 12. 13. 14. 15. 16. 17. Arm Capscrew Sleeve bearing Housing Shim Handhole cover Gasket Fitting Figure 3-20. Oil and water pump drive. 3-52 (c) Compare shaft against a straight edge for straightness. Replace a bent shaft. (d) Inspect teeth of drive gear (7). Replace a defective gear. (e) Examine the bracket (1) and spring for bend or break. Replace a defective bracket or spring. (f) Inspect spindle (4) for straightness. Replace a bent spindle. (g) Inspect cap (6) and spring for wear, or damage. Replace a defective spring or cap. (h) Examine spacer for wear, burr, or out of-round. Replace a defective spacer. (12) Install the oil and water pump drive by reversing the removal procedure, being sure that the drive gear (7) meshes properly, then bar engine over carefully to assure that the drive turns freely. Install cover and inspection plates. 3-17. Crankcase Breather a. General. The crankcase breather (12, fig. 3-18) is located on the front wall of the scavenging pump housing. Access to the screens is from inside pump housing, and they should be cleaned when the scavenging pump is being serviced (para 3-16). The valves may be serviced at any time. b. Removal and Disassembly. (1) Remove bolts and nuts securing flange (3, fig. 3-21). Disconnect clamp (4), then place the assembly on a workbench. (3) Bar engine over until scavenging pump piston is at top dead center. (4) Remove capscrews and bracket (1), then remove spring. (5) Remove capscrews (5), cap (6), and spring. (6) Remove capscrew (11) and arm (10) from shaft (9). (7) Remove capscrews (2) and spacer (3). (8) Remove cotterpin and nut (8). Tap the shaft (9) out of gear (7), and bearing (12). Remove key from shaft (9) and tag for reinstallation identification . (9) Remove oil fitting (17) from housing (13). Remove capscrews, then lift out housing (13). (10) Drive, or press sleeve bearing (12) out of housing (13). (11) Clean, inspect, and repair as follows: (a) Wash all parts in clean fuel oil and wipe dry with a lint free cloth. (b) Check that shaft (9) fits snugly in the sleeve bearing (12). Replace a bearing that is loose. NOTE Be sure the new sleeve bearing is provided with an oil hole. If not, use hole in housing as a guide, and drill an oil hole in bearing. 3-53 1. 2. 3. 4. Pipe Nut Flange Clamp 5. 6. 7. 8. Breatner Screen Guide Spring 9. 10. 11. 12. Gasket Valve (inner) Valve seat Valve (outer) Figure 3-21. Crankcase breather, cross section. (2) Remove the capscrews securing breather (5) to scavenging pump housing (from inside housing). Remove breather (5) and pipe (1), then place this assembly on the workbench. (3) Remove nuts (2) from capscrews and separate guide (7) from valve seat (11). (4) Remove spring (8), valve (inner) (10) and valve (outer) (12). Lift off gasket (9). Use a new gasket at reassembly. (4) Inspect the springs for loss of tension. Replace a weak or broken spring. d. Reassembly and Installation. (1) Install screens (6) in positions from which they were removed. (2) Install breather (5) on housing and tighten the capscrews. Replace clamp (4) and tighten the clamp bolt. (3) Replace springs (8), gasket (9), valve (inner) (10), valve (outer) (12), valve seat (11), and guide (7). Tighten nuts (2) on capscrews. (4) Install flange (3) and tighten nuts evenly. 3-18. Engine Fresh Water Pump a. General. The reversible centrifugal fresh water pump (10, fig. 3-18) is located at forward end of the engine and driven by the oil and water pump drive gear. The fresh water pump circulates fresh water through the engine water jackets, exhaust manifold, and heat exchanger. b. Removal. (1) Close inlet valve (fig. 3-22), then drain the expansion tank and engine cooling system (table 23). NOTE The breather is fitted with three screens; two coarse, one fine. Tag the screens for reinstallation identification. (5) Remove screen (6) from breather (5). c. Cleaning, Inspection, and Repair. (1) Wash screens and all parts in clean fuel oil and blow dry with compressed air. Inspect screens, if damaged, replace them. (2) Inspect the valves. Replace a bent or damaged valve. (3) Inspect valve seats for warp. Replace a damaged valve seat. 3-54 Figure 3-22. Engine fresh and raw water pump. (2) Remove short ell from outlet flange. (3) Remove the inlet valve. (4) Remove the nuts (7, fig. 3-23) holding the volute bracket (21) to the oil and water pump housing, then maneuver pump free of the housing. 3-55 1. 2. 3. 4. 5. 6. 7. 8. 9. Volute Gasket Nut Ring Connector Packing Nut Packing gland Oil seal 10. 11. 12. 13. 14. 15. 16. 17. 18. Bearing Washer Spacer Bearing Capscrew Driven gear Nut Shaft Gasket 19. 20. 21. 22. 23. 24. 25. 26. 27. Nut Clamp Volute bracket Plug Wearing ring Key Locknut Lockwasher Impeller Figure 3-23. Fresh or raw water pump, cross section. c. Disassembly. (1) Remove nuts (3) and remove volute (1), then remove wearing ring (23). (2) Remove locknut (25), lockwasher (26), and the impeller (27) off shaft (17). (5) Remove the safety wire from capscrews (14), remove the capscrews, then remove retainer and bearing (13) off shaft (17). (6) Slide spacer (12) and washer (11) off shaft (17). (7) Remove shaft (17) from support bracket, then remove bearing (10), oil seal (9), and ring (4). (8) Remove the connector (5) from the packing housing in support bracket (21). d. Cleaning, Inspection, and Repair. (1) Wash all pump parts in clean fuel oil and wipe dry with a lint free cloth. Do not blow bearings dry. (2) Inspect bearings for roughness, signs of wear, or overheating (discolored). Replace a NOTE The impeller is keyed to the shaft, therefore a wheel puller may be required to remove it (3) Remove nuts (19), clamp (20), and packing gland (8). (4) Remove the packing (6). Remove cotterpin from nut (16), then remove the nut. Pull the driven gear (15) from shaft (17). 3-56 (1) Use a wrench on the two nuts (19) and tighten packing gland (8) just sufficiently to set the packing. defective bearing. Repack ball bearings and lay them on and cover with a clean cloth while awaiting reassembly. (3) Clean all gasket bearing surfaces. Use new gaskets for (2) and (18) at reassembly. (4) Inspect the impeller (27) and wearing ring (23) for excessive wear. Replace when worn. Replace an impeller that is heavily corroded. (5) Inspect oil seal (9). If deteriorating, or damaged, replace. Replace the connector (5) if threads are defective. e. Reassembly. (1) Install impeller key on shaft (17). Place the impeller (27) on shaft (17), followed by lockwasher (26) and locknut (25). Tighten locknut securely, then bend tabs of lockwasher in place. (2) Position shaft in bore of support bracket (21). Install wearing ring (23) in volute (1). Position volute on support bracket (21) and secure with nuts (3). (3) Install ring (4), packing (6), and packing gland (8). Replace clamp (20) and nut (19). Install connector (5). (4) Install oil seal (9), bearing (10), washer (11), and spacer (12) over shaft (17). (5) Install bearing (13) and retainer, then secure with capscrews (14). Tighten the capscrews and secure with safety wire. (6) Install key in shaft (17) and slip driven gear (15) into place over key. Install nut (16), tighten, then secure with cotterpin. f. Installation. (1) Position fresh water pump into oil and water pump drive housing. Be sure that teeth of driven gear mesh with drive gear, and bracket (21) fits over studs. (2) Install nuts (7) on studs and tighten securely. (3) Install and connect inlet valve (fig. 3-22) and short ell in discharge line. (4) Turn on fresh water, then fill engine and expansion tank (table 2-3). (5) Bar the engine over to assure that fresh water pump turns freely. g. Maintenance of Packing. When packing (6, fig. 3-23) has been replaced, or when leaking around the shaft, adjust the packing as follows: (2) When leak has stopped, back the nuts (19) off one turn, then bring them up to gland just finger tight. CAUTION Keeping packing gland (8) in too tight will cause overheating, and burn out the packing. 3-19. Engine Raw Water Pump a. General. The raw water pump (9, fig. 3-18) is identical to the fresh water pump, except that it furnishes raw (salt) water to the cooling portion of the heat exchanger. b. Maintenance. Perform maintenance on the raw water pump exactly as described in paragraph 3-18 above. 3-20. Water Inlet Header a. General. The engine fresh water cooling system is a closed system, with the same water used over again in cycles. The fresh water pump (para 3-18 above) draws water from the heat exchanger, and circulates the cooled water to the water inlet header. From the header, water is forced through each individual cylinder, upward to the cylinder head. After cooling the fuel injectors, the water then moves to the exhaust manifold for cooling the exhaust. The water then moves to, and through the heat exchanger, through an inlet on top of the exchanger to eliminate the possibility of air locks. After passing around the tubing of the raw water bundle, and being cooled, the water continues its circulation toward the inlet header, where it begins the engine cooling cycle again. b. Inspection. In addition to watching the inlet and outlet thermometers for indication of improper operation, frequent inspections should be made to insure minimal buildup of corrosion, or scale, inside the header. To do this, proceed as follows: (1) When engine is not in operation, shutoff the valve at line into the inlet header. Close the valve next in line after the header, then drain the engine block. (2) Remove one bonnet and regulating valve (8, fig. 324) from the inlet header section. 3-57 1. 2. 3. 4. 5. Gasket Gasket Capscrew Capscrew Gasket 6. 7. 8. 9. 10. Inlet header section Nut Valve, regulating Spacer ring Packing Figure 3-24. Water inlet header and valve. NOTE Watch the water level in the expansion tank. If water rises abnormally, it may be due to a leak in raw water. If the level drops, a leak in the fresh water line is indicated. 3-21. Heat Exchanger (Water Cooling) a. General. The water cooling heat exchanger is mounted in a horizontal position, head high, on the starboard side of the engine room. It is a two pass cooler, with the fresh water connections mounted on top so they do not form air pockets. Raw water enters the side of the heat exchanger, flows through the inside of a cooling tube bundle and discharges to the overboard discharge. Baffles are located in the tube bundle to. insure a flow of fresh water over the outer surface of all tubes. A bypass valve line is fitted to the heat exchanger to provide a path around it should it become clogged, thus assuring a supply of cooling water to the engine. Thermometers are installed at inlet and discharge connections to indicate temperature of fresh water entering, and as it leaves the heat exchanger. Zinc corrosion eliminator plates are installed in the heat exchanger to compensate for the electrolytic action of the raw water. The purpose of the heat exchanger is to remove heat from the fresh water circulating through the engine. The operating temperature should range from 140°F and 160 °F. b. Disassembly for Cleaning and Repair. (1) Shutoff fresh and raw water to the heat exchanger. Drain the heat exchanger. (2) Disconnect all inlet and outlet (fresh and raw) water lines. (3) Remove the fresh water bypass line. (4) Remove the stationary endbell. Loosen the packing gland nuts on the floating endbell, then remove the endbell (3) Examine the valve stem carefully for corrosion, or excessive scale formation. (4) Inspect the inside of header visible through the valve port. Check valve seat carefully. When excessive scale, or corrosion is seen, remove the water inlet header for repair or replacement. c. Removal. (1) Perform step (1) in b. above, then place a lifting sling around the header. Connect the sling to a lifting device. (2) Remove nuts from studs securing the header to the cylinders, steadying the header by tightening up the lifter device. (3) Disconnect flanges of gaskets (1) by removing nuts (7), then remove header sections (6). d. Cleaning and Repair. (1) Use the solvent MIL-C-11796B for cleaning the cooling system and remove the scale. (2) Clean the valves. Scrape scale or corrosion off the valve seats and stems with a stiff brush. Soak to soften scale, if necessary. (3) Replace a defective spacer ring at bonnet. (4) Replace a defective performed packing. (5) Replace a defective inlet header. e. Installation. Install the inlet header sections by reversing the procedure in c. above, then removing the sling and lifting device. f. Thermostats (Thermometers). Replace a broken or defective thermometer. . 3-58 (4) Tighten nuts evenly on the packing gland. (5) Install the stationary endbell, head and shell ring. Tighten the nuts evenly. (6) Install the zinc corrosion plates (anodes) and tighten the nuts. (7) Install the fresh water bypass line. Tighten all nuts and unions. (8) Reconnect all (fresh and raw) water lines. (9) Open fresh and raw water valves to the heat exchanger after closing the drain valve. (10) Start the auxiliary fresh and raw water pumps. (11) Watch fresh and raw water circulation for leaks. If leaks are found, repair by tightening flanges or installing new gaskets. (12) Secure the fresh and raw water pumps. NOTE On some vessels the heat exchanger must be lowered to the deck before removing the endbells and tube bundle. (5) Remove the head and ring at the raw water discharge end of the heat exchanger and break the tube bundle free. Pull the tube bundle out of the heat exchanger housing. (6) Remove nuts securing the zinc corrosion plates and remove the plates. c. Cleaning, Inspection, and Repair. (1) Inspect the zinc corrosion plates (anodes). If the plates are excessively corroded, replace the zinc. Clean the gasket surface and use a new gasket when reinstalling the plates. (2) Remove the packing gland and the packing from the stuffing box. (3) Inspect the tube bundle, both inside and out. If the tubes are coated, or partially clogged, they must be cleaned. Clean the tubes by circulating a mild solution of oakite through the bundle. If the tube bundle remains partially, or totally clogged, report to higher maintenance for possible replacement. (4) Clean the heat exchanger housing inside and out with a cleaning solvent conforming to Fed. Spec. P-D-680, and hose down with clean fresh water. Wipe dry. (5) Use a wire brush to clean the packing gland. Wash in clean fuel oil and wipe dry. Use a wire brush to clean all gasket surfaces. Wash in clean fuel oil and wipe dry. (6) Inspect the fresh water bypass valve packing. If the packing ring is tightened all the way down, remove the ring and packing. Repack the valve, install the packing ring, and tighten. NOTE A When the main engine pumps are put into operation, check the stuffing box and packing gland. Be sure the packing gland nuts are tightened evenly so the tube bundle is free to contract and expand without causing strain. e. Maintenance Adjustments. (1) When packing has been replaced in the stuffing box, inspect for leaks frequently, and tighten nuts on packing gland with an even pressure on each nut. (2) Prevent, or stop leaks, by tightening all flange bolts and nuts. 3-22. Lubrication Oil Pump (Engine) a. General. The lubrication oil pump (11, fig. 318) is a gear type pump fitted with reversing valves to give a positive flow of oil to engine at either direction of rotation. The pump is located at forward end of the engine. This pump is driven by the crankshaft through the oil and water pump drive. It supplies oil to the lubrication system under pressure, and keeps the force feed lubricator constantly filled. b. Removal. (1) Close the shutoff valves on suction and discharge lubrication oil lines. (2) Disconnect the suction and discharge lines at the pump. (3) Remove nuts (6, fig. 3-25) securing housing (21) to bracket (8). NOTE Use new gaskets when assembling the heat exchanger. d. Reassembly. (1) Install the tube bundle in heat exchanger housing. (2) Repack the stuffing box. Do not allow the packing to overlap. (3) Install the stuffing box and floating endbell. Tighten nuts evenly. 3-59 1. Cover 2. Gasket 3. Impeller 4. Vent plug 5. Stud 6. Nut 7. Plate 8. Bracket 9. Nut 10. Locknut 11. Shaft 12. Bearing 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Bearing Bearing Gear, drive Locknut Coupling Coupling Impeller Drain Housing Plate Pin, dowel 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. Plug Bearing Nut Rod Valve Spring Guide Nut Stop Spring Valve Figure 3-25. Lubrication oil pump. (4) Remove housing (21) from bracket (8). Place housing (pump) on workbench. (5) Remove bracket (8) from studs (5). Pull the drive from housing and place it on the workbench. c. Disassembly. (1) Remove locknut (16) and coupling (18). (2) Remove locknut (10) and bearing (12) from shaft (11). (3) Remove nuts (26) and (9). Lift cover (1) off dowel pins (23). (4) Remove locknuts from bearings (25) then remove the bearings. (5) Move plate (22) off pins (23) and remove plate. (6) Remove the impellers (3 and 19). (7) Remove nut (31), stop (32), spring (33), and valve (34). (8) Lift out guide (30), spring (29), valve (28), and rod (27). NOTE During disassembly of housing (21), tag the components for reassembly identification. (9) Remove nut from end of shaft (11) and pull off the gear (15). (10) Remove retainer and bearing (14) from shaft. (11) Remove coupling (17) and shaft (11) out of bearing (13) then remove the bearing. d. Cleaning, Inspection, and Repair. (1) Inspect bearings for roughness or looseness. Replace defective bearings. (2) Inspect impellers (3 and 19) for significant wear. Replace worn impellers. (3) Wash all parts in clean fuel oil and wipe dry. Clean all gasket surfaces. NOTE Use new gaskets at reassembly of the pump. (4) Examine stop (32). Replace a worn or scratched stop. (5) Insert rod (27) in the guide (30). If rod is loose in guide, replace the guide. Inspect the rod (27). Replace a worn or bent rod. (6) Inspect springs (29 and 33). Replace broken or weak springs. 3-60 (7) Inspect valves (28 and 34). Replace a bent or worn valve. b. Maintenance, Removal, Repair and Installation. Maintenance of the oil cooler is identical to that of the water cooling heat exchanger. See paragraph 3-21 for details, except, substitute "oil" for "fresh water". 3-24. Crankshaft, Main Bearings and Crankcase Explosion Valves a. General. The crankshaft is made of forged steel and supported by main bearings of the interchangeable shell, babbitt type. These must be scraped and lapped when installed to give a good bearing surface. The purpose of the crankshaft is to convert the reciprocating movement of the pistons into rotary motion. The crankcase explosion valves are located on the crankcase inspection plates. The purpose of the explosion valves is to relieve pressure in the crankcase should combustion ever take place or excessive pressure build up. b. Removal. (1) Prior to removing main bearings, check bearings for clearance. Slip a feeler gage between the crankshaft and the bearing cap. The proper clearance is from .004 to .006 inch. When the clearance is found to be excessive, remove sufficient shims from each side of the bearing. Example: Where the clearance is found to be .012 inch, remove a .006inch shim from each side of the bearing. Excessive clearance may be indicated by loss of pressure in the lubricating oil system. The thickness of the main bearing shims are as follows: .006, .020 and .064 inch. It is good practice to replace the main bearings when the clearance is found to be in excess of .030 inch. (2) Remove the appropriate crankshaft inspection plates on each side of engine. (3) Remove cotter pins and back off stud nuts (9, fig. 3-22). Lift off main bearing and cap; place on the workbench. Remove and tag shims (10) for proper reinstallation identification. (8) Remove crankcase inspection plates on each side of the engine. Wash out the sump with clean fuel oil and wipe dry. Inspect all lubrication oil lines. Replace a damaged oil line. (9) Remove the lubrication oil strainer. Wash the strainer in clean fuel oil, then reinstall the strainer. (10) Examine the lubrication oil thermometer. Replace a defective thermometer. e. Reassembly. Assemble the lubrication oil pump in reverse order of disassembly, using new gaskets in all places. f. Installation. (1) Slide bracket (8) over studs (5) and mesh the gear (15) with the oil and water pump drive. (2) Install housing (21) by sliding plate (7) over studs (5). Use a new gasket between plate (7) and bracket (8). (3) Align the couplings (17 and 18). (4) Install nuts (6) and tighten. (5) Bar engine over slowly to make sure the lubrication oil pumps works freely. (6) Connect the suction and discharge oil lines to the pump. (7) Open shutoff valves in suction and discharge lines. (8) Reinstall the crankcase inspection plates. 3-23. Lubrication Oil Cooler (Heat Exchanger) a. General. The lubrication oil cooler is a two pass heat exchanger mounted horizontally on starboard side of engine room, just aft of the water cooling heat exchanger. The raw water enters the cooler and flows through the tube bundle and out to the water cooling heat exchanger. The lubrication oil flows through the housing and over the outside surfaces of the tube bundle. The purpose of the cooler is to remove engine heat from the lubrication oil. A bypass valve and line is fitted to the cooler to provide a path for oil, should the housing become clogged. Zinc protector plates (anodes) are located in the cooler to compensate for the electrolytic action of the raw water. 3-61 1. 2. 3. 4. 5. 6. 7. Drive gear Bearing half Crankshaft journal Bearing half Bearing half Cap dowel Shim dowel 8. Cap stud 9. Stud nut 10. Shims 11. Bearing half, lower 12. Crank web 13. Bearing half, lower 14. Bearing half, lower Figure 3-26. Crankshaft and main bearings. (4) Place a small jack under the nearest crank web (12) of the bearing to be removed. Jack the crankshaft up only enough to take the load off the lower main bearing being removed. (5) Push lower half of main bearing (11) out of saddle bore and lift from crankshaft. (6) Tag upper and lower bearing halves and bearing cap for proper reinstallation identification. c. Cleaning, Inspection, and Repair. (1) Before cleaning the bearing, check its surfaces for the presence of "wet liquid oil." This is not an oil smear at the top of the bearing metal, but liquid oil that has collected during engine operation. When oil is present, the bearing is worn and must be replaced. (2) Wash main bearing halves in clean fuel oil and wipe dry. (3) Test the bond between the babbitt bearing (upper) and the steel back of the bearing cap by holding in one hand and striking the steel back (bearing cap) with a hammer. It should give a clear ringing sound. If a dull thud is heard, the bond between the bearing metal and its steel shell (bearing cap) has probably failed and the bearing should be replaced. (4) Inspect the bearing surface to detect fine cracks. Fine cracks can be caused by a poor fit of the bearing shell in its cap or saddle bore, overloading, or overspeeding of the engine. Replace bearings that are cracked, however slight. (5) Examine the bearing surface for pitting. When the bearing is found to be badly pitted, replace the bearing. (6) Inspect the crankshaft bearing surface by feeling for a slight ridge around, and in line with, crankshaft oil hole. If a ridge is found, report to higher maintenance level. d. Replacement of Main Bearing. (1) To replace the main bearings proceed as follows: (a) Remove the old bearing (shell) from the bearing cap, upper half. Wash the bearing cap in clean fuel oil and blow dry with compressed air. (b) Coat the back of the new bearing shell with a thin coat of white lead and press the new bearing shell in the bearing cap. Check to see that the bearing ends are flush with the bearing cap. (c) Coat the back of the new bearing shell (lower) with a thin coat of white lead. Position the bearing on the crankshaft and roll the bearing into the saddle bore. (d) Remove the small jack from under the crank web. (e) Lock the lower shell into position with clamps bored to fit over the bearing studs. The clamps must be wide enough to cover the edges of the bearing metal without touching the crankshaft. Use lengths of pipe to hold the clamps in position and tighten with bearing stud nuts. (f) Coat crankshaft with a thin coat of Prussian blue and revolve crankshaft a few times. (g) Remove clamps holding the lower bearing in position. Place the small jack under the crank web. Jack up the crankshaft just enough to relieve weight from the lower bearing. (h) Roll the lower bearing out and lift from 3-62 the crankshaft. Examine the bearing; any high spots will be clearly indicated by blue marks left from the prussian blue. At least 80 percent of the bearing surface should contact the crankshaft bearing surface, if it does not-the bearing must be scraped to fit. (i) Use a machinist's scraper and scrape the high spots indicated by the Prussian blue: scrape very little at a time. Replace the bearing as described in 1c), (d), (e), and (f) above. (j) Remove bearing as described in (g) and (h) above. Continue the scraping until checks show that at least 80 percent of the bearing area contacts the crankshaft bearing surface. When the bearing has a good face-to-face contact with the crankshaft bearing surface, the blue marks will show on the bottom of the bearing and up the sides, covering about 80 percent of he bearing surface. (r) Use clean fuel oil and wash the Prussian blue from the crankshaft bearing surface. Place a wooden plug in the crankshaft oil hole cut flush with the crankshaft bearing surface. Apply a thin coat of medium grinding compound to the crankshaft bearing surface. Lap the main bearing to the crankshaft. To remove any scratched or small digs left from scraping, proceed as follows: 1. Replace shims, and bearing cap. Tighten the bearing cap stud bolts. 2. Rotate the crankshaft ten complete turns forward and ten complete turns in reverse. 3. Remove bearing cap stud nuts, bearing cap and shims. Tag, the shims for proper reinstallation identification. 4. Examine the bearing surface. If the small scratches have not been removed repeat the lapping process. until the bearing surface is smooth. 5. After completing the main bearing lapping process, wash the bearing cap and bearing in clean fuel oil to remove he grinding compound, wipe dry with a clean, lint free cloth. NOTE After scraping and adjusting the bearing, clean bearing before permanently fitting it to crankshaft. (k) Roll the properly fitted bearing into the bearing saddle bore and remove the jack from under the crank web. 6. Wash the crankshaft bearing surface with clean fuel oil and wipe dry. Rotate the crankshaft during the cleaning process. 7. Remove the lower bearing shell as described in b. (4) and (5) above. 8. Wash the lower bearing in clean fuel oil and wipe dry to remove grinding compound. 9. Recheck the camshaft bearing surface for signs of grinding compound. Wash in clean fuel oil and wipe dry. 10. Remove the wooden plug from the crankshaft lube oil hole. (l) Replace shims on both sides of the main bearing from which they were removed. Check to see that the crankshaft is sufficiently coated with Prussian blue. If not coat the crankshaft again. (m) Position the main bearing cap on the j crankshaft and tighten main bearing stud nuts. Roll crankshaft over two turns. (n) Remove stud nuts and lift the bearing cap from crankshaft. Examine the bearing shell. Any high spots will be clearly indicated by the blue marks left from the Prussian blue. High spots will have to be scraped. CAUTION Be sure to remove the wooden plug from the crankshaft lubricating oil hole, or damage will result. NOTE High spots are the blue marks left on the sides of the bearing shell. These high spots indicate poor bearing fit. 11. Replace the lower main bearing in saddle bore. (o) Use a machinist's scraper and scrape the high spots indicated by the Prussian blue. Scrape very little at a time. (p) Replace bearing cap as described in (m) above. (q) Continue to scrape and fit the bearing to the crankshaft bearing surface, until checks show that at least 80 percent of the bearing area contacts the crankshaft bearing area contacts the crankshaft bearing surface. When the bearing has a good face-to-face contact with the crankshaft bearing surface, the blue marks, left from the Prussian blue, will show on the top of the bearing and down the sides, covering about 80 percent of the bearing surface. 12. Remove the small jack from under the crank web. 13. Replace main bearing shims. NOTE After the main bearing has been scraped and fitted to the crankshaft the bearing must be checked for proper clearance. 14. Take four pieces of .015-inch soft lead wire and place on the crankshaft main bearing surface. The lead wires can be held in place by grease. 15. Replace main bearing cap and bearing shell. Tighten main bearing studs nuts evenly. Check to see that the main bearing cap is drawn down evenly on the shims. 16. Remove the main bearing cap, do not disturb shims. NOTE After scraping and adjusting the bearing cap, clean bearing before fitting it to crankshaft. 3-63 17. Measure the thickness c the soft lead wire. For proper clearance the thickness should be .004 to .006 inch. If the clearance is less than .004 inch add shims to each side of the bearing. Example: When the clearance is found to be .002 inch add a .003-inch shim to each side of the main bearing. When the clearance is found to be .011 of an inch, remove a .006-inch shim from each side of the main bearing. NOTE When adjusting the main bearings for proper clearance by adding or removing shims always recheck the bearing clearance, as outlined above. NOTE The location and number of crankcase explosion valves may vary with different installations. In most cases there are four crankcase explosion valves located on the left side of the engine and three located on the right side of the engine mounted on the crankcase inspection plates. (3) Remove bearing tool. Use a straight edge to assure lower bearing half is properly seated in saddle bore. (4) Lock lower bearing half in position with clamps bored to fit over studs (8, fig. 3-26). Clamps must be wide enough to hold bearing half in saddle bore, yet not touch crankshaft journal. Use lengths of pipe over studs (8) so nuts (9) will be able to tighten down enough to hold clamps in place. (5) Coat crankshaft journal with prussian blue and turn crankshaft through about three revolutions so that high spots in bearing half will pick up some blue. (6) Remove clamps installed in (4) above. Install bearing tool in oil hole in journal, then turn crankshaft to roll bearing half out of saddle bore. Lift bearing half from journal and examine surface. If at least 85 percent of surface has picked up blue it is ready for lapping. If less than 85 percent is blue, the bearing half must be scraped 3-25. Thrust Bearing (Kingsbury) a. General. The kingsbury thrust bearing is a two-shoe propeller thrust bearing. It has two pairs of thrust shoes, (two for ahead, and two for astern) individually adjustable fore and aft by jack screws and a journal bearing, all mounted in one housing with a suitable end closures (fig. 3-27). It is installed just aft of engine (between flywheel and propeller shaft). 18. Install main bearing cap with the shims in their proper position. 19. Replace the main bearing stud nuts and tighten evenly to 350 foot-pound torque. 20. Replace cotter pins. NOTE When all main bearings are to be removed for repair, remove and replace every other bearing. (2) To remove the crankcase explosion valve proceed as follows: (a) Back off capscrews holding the crankcase inspection plates and lift off. (b) Remove explosion plate cover, gasket, and spring. (c) Wash in clean fuel oil and wipe dry. (d) Inspect the spring. If broken, replace spring. (e) Assemble crankcase explosion valve in reverse order of disassembly. Use a new gasket. 3-64 Figure 3-27. Thrust bearing (Kingsbury). 3-65 b. Inspection and Adjustment. To check a watertight door or hatch, proceed as follows: (1) Trace a solid chalk mark around the knife edge of the door or hatch coaming. (2) Close, then dog the fitting. (3) Undog, then open fitting. Inspect the watertight gasket. When chalk mark has been transferred evenly with same general width to gasket, that fitting is watertight. c. Defective Fittings. When knife edge does not meet gasket evenly, adjust the dogs, or build up the knife edge until it does meet gasket evenly. d. Cleaning. Rub gaskets with a piece of wood that is the same width of the gasket, until all foreign matter is removed. e. Defective Gaskets. Replace deteriorating gaskets. b. Cleaning and Inspection (1) Inspect housing for cleanliness. Allow no accumulation of oil and dirt. Wash housing with fuel oil and wipe dry. (2) Place finger under air vent (when operating) and check that air is escaping. If you feel none, remove vent pipe and blow clean with ships service air. Install the vent pipe. (3) Remove drain plug from lower half of housing (aft, portside) and take a sample of oil. Inspect for presence of water or sludge. If any, drain and fill with clean oil. NOTE There is an instruction plate attached alongside the oil gage, showing "HIGH" and "LOW" oil levels. NOTE Be sure that the knife edges are highly polished. Do not use emery cloth or sandpaper to polish. Do not use paint on the knife edges. (4) Check that oil level in gage is between HIGH and LOW; nearer high while in operation, at high when stopped. CAUTION Make sure that added oil is clean. Do not take up hard on stuffing box glands, as this will make shaft run hot and transfer heat to the thrust bearing. f. Ladders. Inspect all ladders for worn or broken treads. Report defects to general support maintenance. g. Machinery Mountings. (1) Inspect all machinery hold down bolts for security. Replace all bolts that cannot be tightened. (2) Report all unusual machinery foundation conditions to general support maintenance. h. Ventilation Fittings. (1) Inspect all moving parts of ventilator housing. Report worn or improperly operating parts to general support maintenance. (2) Lubricate moving parts for freedom of movement (LO 55-1925-204-12-1). i. Anchor and Chain. Inspect and maintain the anchor and chain in accordance with TM 55-501. 3-28. Miscellaneous Hull and Accessory Items a. General. The tug is equipped with. three windshield wipers, intercom devices, engine order telegraph indicator and transmitters, and the eductor system. The motor driven windshield wiper is a swinging arm type with totally enclosed mechanism and a 110-120 volt ac/dc motor. The engine order telegraph system has an indicator in the engine room, two transmitters in the pilothouse and a third at the aft steering station. The handle (1, fig. 3-28) controls pointer (3, fig. 3-29) on indicator. When engine operator acknowledges order by moving handle (4, fig. 3-29) to coincide with pointer (3), it also moves pointer (4, fig. 3-28) to coincide with pointer on handle (1). Voice tubes are run from pilothouse to engine room and aft steering station. The vessels telephone system, a five station hook-up, is for intercommunication between pilothouse, engine room, aft steering station, captain, and chief engineer. An eductor (5) Remove plug in oil fill hole, and add oil, only when stopped, until gage reaches "HIGH" on plate. Install plug. 3-26. Propeller and Shaft a. General. This design 3006 tug is propelled by a three blade, right hand rotation propeller manufactured of manganese bronze. It has an overall diameter of 7.667 feet, and a pitch diameter 5.160 feet. The shaft is a single piece of forged steel, finished to a length of 23 feet and a diameter of 9.500 inches. b. Stuffing Boxes. There are two stuffing boxes fitted around the shaft. One is at the aft engine room bulkhead and is known as the forward stuffing box. The other is in the aft bulkhead of the void space through which the shaft runs. Flax packing rings are used as a seal between shaft and stuffing box. c. Inspection and Adjustment. (1) Inspect for excessive leaking at the packing gland of stuffing box (forward). (2) Adjust to limit leakage by turning the eight nuts securing the packing gland clockwise one-quarter turn. (3) When the packing gland can not be tightened further, and the leak is still more than a drip, notify general support maintenance. 3-27. Hull Assembly Access a. General. The doors, hatches, vents, windows (port lights) and ladders are installed on tug to provide access into, between decks and compartments, or ventilation. Many of these fittings are watertight. 3-66 TM 55-1925-204-12 system, by means of two jet stream suction valves connected in fire and salvage system. enables the 1. Handles 2. Cover vessel to dewater sunken or flooded vessels, or barges. 3. Face 5. Plate, inspection 4. Pointer 6. Rheostat Figure 3-28. Engine order telegraph transmitter 3-67 7. Cover 1. Chain 3. Pointer 2. Face 4. Handle Figure 3-29. Engine order telegraph indicator. 3-68 (3) Remove nuts (19, fig. 3-30) from mounting bolts (20), then lift the wiper assembly from the foundation. b. Windshield Wiper Removal. (1) Turn off electrical power to wipers at the control panel. (2) Tag and disconnect the electrical leads. 3-69 1. 2. 3. 4. 5. Bolt Lever, drive Screw Rod Pin 6. 7. 8. 9. 10. Disc 11. Bushing, sleeve Motor 12. Setscrew Oilcup, shaft 13. Spring Bearing 14. Housing Shaft 15. Arm Figure 3-30. Windshield wiper. 3-70 16. 17. 18. 19. 20. Blade Cover Screw Nut Bolt c. Cleaning, Inspection, and Repair of Windshield Wipers. (1) Remove screws (18) and cover (17). (2) Remove dust or dirt by use of ships service air, (3) Inspect motor for worn brushes. Replace defective brushes. Replace a defective motor. (4) Replace a defective variable resistor. NOTE The wiper arm hinge pins should be oiled semiannually. fig. 3-29) and lift off handle. Remove screws, then remove cover and face (2) NOTE Cable portion of telegraph system seldom requires replacement, but when replacement is required. be sure a line, strong enough to pull cable back into position, is attached to end of cable being withdrawn, and pulled through pulleys as the cable is withdrawn. If cable being replaced is broken. you must connect the broken ends together in order to pull both pieces out of the same end. NOTE There is a felt blade for use during freezing conditions. (5) Replace a defective wiper blade. d. Installation of Windshield Wiper. (1) Position wiper against foundation. Use filler pieces (spacers) to keep housing in position so that swing of blade is parallel to glass at several points in its arc. (2) Install bolts (20) and secure with nuts (19). (3) Remove tags, then reconnect electrical leads. If blade swing is improper, adjust as in e. below. (4) Install cover (17) and secure with screws (18). (5) Turn on power at electrical power panel. e. Adjustment of Windshield Wipers. (1) Remove screws (18) and cover (17) from windshield wiper. (2) Remove pin(5) and rod 14) from disc (6). Position pin (5) and rod (4) into an adjacent hole in disc (6). NOTE The holes in disc are elliptical around the pivot pin. The hole farthest from pin will provide arm with its maximum arc. (3) Install cover (17) on housing and secure with screws (18). (4) Adjust blade speed by turning rheostat clockwise to increase speed, counterclockwise to decrease. f. Cleaning, Inspection, and Repair of Engine Order Telegraph. Partial disassembly of telegraph transmitters and indicator are required to perform crew maintenance. Proceed as follows: (1) Remove screws from clamping portion of handles (1, fig. 3-281 'then remove handles from shaft (7) Remove screws securing the inspection plate (5, fig. 3-28) to column, then lift plate from column. Position handles (1) until the sleeves and cable ends are visible. Disconnect sleeve from chain. When a cable requires replacement, attach a line to cable end, one that is capable of threading a new cable (8) Disconnect chain (1, fig. 3-29) from sleeve, being sure that cable end is that loosened above, then withdraw cable and line from its housing (9) Attach a new cable of correct length to line securely, and pull line out of transmitter column (fig. 328) until new cable is in position. Secure cable in position with out attaching to chain at this time. Remove other cables in a similar manner as required (10) Unhook bell trip spring from its hook, then lift out of indicator housing. Lift chains out of transmitter and indicator housing (11) Clean, inspect, and repair all parts as follows: (a) Use ships service air and blow dust and dirt from the housing (b) Inspect and test the lamp. Replace a defective lamp (c) Clean and inspect the rheostat. Test operation. If rheostat operated improperly before removal, replace it with a new one (d) Wash chains and trip springs in clean fuel oil and blow dry with ships service air. Inspect bell trip springs for breaks, bends, or weakness Replace a defective spring (e) Inspect chains for excessive wear, bends, or binding links. Replace a defective chain with one of exactly the same length (12) Replace all parts by reversing the order of removal in steps (1) through (10) above, adding a thin film of oil on chains and sprockets. Tighten turnbuckles until cables are taught, but not too tight (13) Test the operation of all stations for the sound of bell and position of handle pointer to the same order. Test the engine room acknowledgment pointer for alignment with order pointer at all stations (14) Adjust any pointer deficiencies by backing off locknuts on turnbuckle at ends of affected control cable (s) and shorten or lengthen (2) Remove screws, then remove covers (2 and 7) and face (3) (3) Remove transmitter lamp from socket inside the (4) Tag and disconnect electrical leads from rheostat (6). Remove knob and locknut, then lift rheostat from housing (5) Unhook the bell trip spring and bring it out of the housing (6) Remove clamping screw from handle (4, 3-71 (fig. 3-31) is operated by opening cover, turning station selector switch to desired station, lifting receiver/transmitter off hook, then turning crank for a bell signal at selected station. cable (s) as required until pointers match, then tighten locknuts on turnbuckles g. Intercommunicating Telephone System. station intercommunication telephone The five system Figure 3-31. Intercommunicating telephone station ( typical). until they are required for salvage operations. To place h. Eductor System. The system consists of two one, or both, in operation, proceed as follows: (1) portable aluminum alloy eductors (jet suction) Connect one end of a fire hose of suitable length to reach bottom of sunken, or flooded area to be These are equipped with female hose couplings on dewatered, to one outlet of the fire and salvage manifold pressure inlet and discharge ports. Both eductors are (fig. 3-32). stored in a gear chest on starboard side of the boat deck 3-72 Figure 3-32. Fire and salvage system manifold. 3-73 (2) Connect other end of that hose to the pressure inlet ofeductor (fir. 3-33). Figure 3-33. Eductor ( jet suction ). 3-74 water line on curvature of the hull, one above the other in pairs. They are box link structures inside, with screened openings to the water. The screens are to keep marine life and help from entering the sea valves (fig. 3-34) which control raw water entry for the cooling and the fire fighting systems Anodes may be tacked (spot weldedl to wall, or in rings at valves, to minimize the chemical action of raw water on metal. Strainers (fig. 3-351 are located in lines to further filter matter from the raw water. NOTE Attach suction strainer to eductor before using. (3) Connect a discharge hose of suitable length to discharge overboard from bottom of sunken, or flooded object to the discharge port of eductor (fig. 3-33). Anchor the discharge end of hose above water level and overboard (4) Drop eductor into area to be dewatered (5) Place the remaining eductor in operation in a similar manner 3-29. Sea Valves, Strainers, and Sea Chests a. General. The sea chests are located below the 3-75 Figure 3-34. Sea valve and sea chest ( typical). 3-76 Figure 3-35. Strainer location (typical) b. Sea Valves. (1) Inspect the sea valve for leaks. (2) Tighten nuts (fig. 3-34) evenly to stop leaking. If leak cannot be stopped, notify higher maintenance salt water circulating or standby pump is slow in discharging water c. Sea Chests. The sea chests must be blown out with ships service air frequently, and any time the Note the condition of mesh of screens or baskets, and replace if defective d. Strainers. Inspect and clean all circulating water strainer (fig. 3-35) screens and by-passes 3-77 CHAPTER 4 ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Section I. SERVICE UPON RECEIPT OF EQUIPMENT 4-1. General WARNING NOTE Volatile materials will not be brought Organizational maintenance aboard; electric circuits will not be instructions as outlined below are energized; fuel tanks will not be filled, normally performed at the and engines or motors will not be organizational level. However, due to started unless firefighting devices are the mission of the vessel and available and operative. capabilities of the assigned crew 4-2. Inspecting and Servicing the Equipment members, these tasks are to be a. Fire Fighting System. The firefighting system accomplished by the operator/crew is composed of portable extinguishers strategically with assistance as may be required located throughout the vessel, and a fixed C02 system from the organization. piped around the engine room (fig. 4-1) The Tug may have been delivered new from the builder, or new/used from storage. In either case, a preoperative check must be made to assure that the equipment, and its components, are complete and ready for operation without danger to personnel or equipment 4-1 Figure 4-1. Fixed fire extinguisher piping arrangement. (1) The portable system consists of eight 15pound and four 4-pound hand type CO, extinguishers (c) extinguisher Replace a damaged or defective (2) The fixed system consists of twelve 50pound CO, cylinders, with control heads and an emergency control (pull) box. The cylinders are located at aft bulkhead, port side, of engine room and the emergency control box is located aft of hatch entering engine room from main deck, port side (d) Inspect the fixed system for complete piping, connection of all control heads, and weight of C02 in cylinders. Check that the lead to the emergency control box is intact and connected (e) Repair defective piping and replace a defective control or cylinder (3) Inspect the portable system first, in order that operable devices will be available during further tests of the system, then inspect as follows: (a) Assure that portable cylinders are fully charged by comparing weight. , as indicated on tag, or cylinder (4) After the inspection of electrical and air compressor systems, and ships service air is available, test the C02 pressure operated warning siren as follows: (a) Disconnect the CO, pipe line from siren (b) Test operation extinguishers (para 2-19) (b) Connect an air line from ships service air outlet (34, fig. 2-14) in engineroom to siren. of the portable 4-2 h. Diesel Engines. Check propulsion and auxiliary set diesel engines as follows: (1) Check level of oil in crankcase (2) Check level of cooling water in engine and heat exchanger expansion tank (3) Open valves in fuel oil supply and return lines between engine and day tank (4) Bleed all air from fuel system (5) Assure that circuit breaker on main electrical control panel is disengaged (for auxiliary set engines) (6) Assure that all engines are free of tools, waste, or other foreign matter, and that all accessories are installed (7) For auxiliary set engines, see that starting battery is fully charged; water level in cells is i/4 in. above plates; and terminals are clean and securely fastened (8) For propulsion engine, drain all condensate from air supply lines before starting i. Air Compressors and Tanks. Align compressed air system valves (para 2-21). Start air compressors (para 2-15) j. Fire Pump and Bilge and Ballast Pump Inspect packing in pump packing glands. If packing is dried out, do not run pump until fresh packing has been installed and adjusted (para 531) k. Lubrication. All components requiring lubrication will be lubricated in accordance with the current lubrication order l. Hull Fittings. Inspect all hull fittings as follows: (1) Inspect watertight doors, hatches, manhole covers, and window (portholes) for watertightness Check for freedom and ease of operation (2) Inspect anchor and chain in accordance with TM 55-501 (3) Inspect all towing bitts and mooring fittings for serviceability m. Missing Parts. As inspection and service progresses, all missing or defective parts will be listed, verified, and placed on order. Equipment with missing parts will be prominently tagged, at the starting control, to prevent operation until parts have been received and installed. NOTE Between 40 and 50 psi air pressure is required to operate the siren alarm (c) Open ships service air valve and the siren alarm should sound (d) Repair or replace a defective siren alarm (e) When test is complete, turn off air valve, disconnect air line from siren, and reconnect C02 line to siren alarm b. Electrical Power. Inspect the electrical system by checking all switch operation and fuse or circuit breakers (fig. 2-5). Align shore power to main control panel (para 2-2j), then energize circuits immediately required. Energize additional circuits as required c. Hull. Inspect engine room and interior of the hull for leaks. Check all piping system connections, inspect all sea valves closely for visible signs of leakage. Check lubricating oil system for possible leaks around crankcase, oil tanks, oil filters, oil coolers, or lines. Inspect fuel oil system for leaks with particular attention directed at connecting hose. Trace all leaks to their source, without regard to system, and correct or report them to general support maintenance for replacement Carefully remove all signs of fuel or oil drippings by wiping them clean immediately after corrections have been made. Direct members of crew to begin moving stored equipment interfering with working or berthing areas to its proper location d. Ventilation. Remove all preservatives, covers, or devices from ventilation supply and exhaust blowers. Turn each blower fan by hand to assure free movement. Lubricate duct closure devices, then start all blowers of ventilation systems (para 2-16) e. Storage Tanks. Fill all fuel oil, lubricating oil, water storage and day fuel tanks as described in paragraphs 2-2o, 2-2q, and 2-2r. Trace out all pipe lines and align valves in accordance with tables called out in indicated paragraphs f. Water Systems. Align valves for drainage of showers, sinks, and water closet as described in paragraphs 2-2r, and 2-2s. Start water pressure and sanitary pressure set pumps (para 2-24) g. Heating System (in Applicable Weather ). Fill system with fresh water (para 2-24). Vent and align fuel oil valves (para 2-12) Section II. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT and organizational maintenance on the tug are listed, 4-3. Tools and Equipment and their use is described on table 4-1. The special tools required to perform operator/crew 4-3 Item Table 4-1. Special Tools, Test and Support Equipment FSN or Reference Use Reference No. Fig. No. No. Wrench: piston pin bracket stud nut Guide: connecting rod, with clamp 5120-362-6626 5120-362-6621 3-7 3-7 Plate: sleeve lifting 5120-522-2885 3-7 Guide: piston ring Lever: priming pump 5120-362-6620 2910-362-6270 3-7 3-10 Puller: discharge valve seat 5120-522-2880 3-11 Gage: injection setting 2815-363-2284 3-11 Drill: injector valve tip Tester: diesel fuel injector nozzle Clamp: scavenging pump piston 5120-362-6619 4910-255-8641 2815-363-2282 3-12 3-12 3-16 Wrench: scavenging pump piston and flywheel hub bolt Puller: main bearing half Wrench: main bearing stud nut Wrench: Wrench: upper base to cylinder stud nut Wrench: 5120-363-0960 3-16 5120-362-6624 5120-363-0957 5120-415-2378 5120-362-6627 3-24 3-24 4-14 4-13 5120-363-0956 4-15 Cleaner, valve: guide 5120-766-2141 5-3 Installer, valve guide: Remover: push rod (set of three) Remover: valve guide Remover: valve seat insert Wrench Box: 5120-706-5588 5120-724-8447 5120-473-7392 5120-706-5586 5120-494-1915 5-3 5-3 5-3 5-3 5-3 Reamer Fixture: set 4910-219-8392 5-4 Reamer Set: Remover: cylinder liner Driver, Bearing and Bushing: Driver, Valve Seat Insert: Remover: injector valve spring Test Set, Diesel Engine: 4910-789-2104 (33287) J1918-02 5120-363-7572 5120-423-6723 5120-219-8400 4910-690-8452 Tool Set: fuel pump Wrench, Fuel Pump: 5180-219-8407 5120-591-2685 Wrench, Bowl Coupling: Drift: forged steel point Clamp: bowl top lifting Wrench, Nut: combination Scoop, Bowl Shell: Stand, Bowl: Wrench, Spanner: Wrench: 5120-152-2420 5120-213-0460 4330-163-0159 5120-213-0352 4330-213-0425 4330-774-6438 5120-317-2518 4320-073-2138 5-23 5-4 5-5 5-7 5-7 5-13 5-13 5-14 5-14 5-21 5-48 5-48 5-48 5-48 5-48 5-48 5-49 Gasket 4-4. Special Tools and Equipment The special tools required for organizational maintenance of the tug are listed and illustrated in TM 55-1925-204-20P and in table 4-1 above. 4-5. Maintenance Repair Parts Repair parts and equipment for maintenance of the Piston pin removal and installation Holds connecting rod during removal To remove cylinder sleeve from cylinder To install piston rings To operate push rod while priming the injector To pull valve seat from injection pump Adjusting amount of fuel to each cylinder To clean fuel injector nozzles To test nozzle for proper dispensing To secure scavenging pump piston during replacement Scavenging pump piston or flywheel removal or installation. To remove main bearing half Main bearing removal or installation Air start pipe removal or installation Cylinder removal and installation Repair of the adapter tube packing gland Brush to clean interior of the valve guide Installing the valve guide Replacement of push rods Replacement of valve guides Replacement of valve seat inserts Removal or installation of cylinder head Connecting rod bearing sleeve installation Piston pin bearing sleeve installation Remove liner Installing tool Installing tool Fuel injector repair Adjusting fuel rack; timing injector, and setting valves Fuel pump repair Also used on water pump Bowl repair Pin removal Bowl removal Purifier repair Cleaning bowl shell To hold bowl during repair of purifier Removal of bowl replacement in sanitary pump tug are listed and illustrated in TM 55-1925-20420P. On board spare parts necessary for mission accomplishment are listed in appendix B of this manual. 4-4 Para. TM 55-1925-204-12 Section III. LUBRICATION INSTRUCTIONS Instructions for lubrication of the tug and its components are covered in chapter 3 above. Section IV. PREVENTIVE MAINTENANCE CHECKS AND SERVICES Table 4-2. Organizational Preventive Maintenance Checks and Services. Q- Quarterly Total man-hours required: 8.1 Sequence Number ITEM TO BE INSPECTED PROCEDURE Work time (M H) NOTE The preventive maintenance checks and services appearing on tables 3-1 and 3-2 are to be considered a part of this table. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. FORCE FEED LUBRICATOR. Check the drop feed rate of the force feed lubricator per table 4-4. Adjust when necessary. AIR COMPRESSORS. Inspect compressor operation, for action of valves. See that the compressors are properly mounted and correctly aligned. MOUNTING, VIBRATION DAMPERS. Inspect outside of engine for loose nuts, bolts, and clamps. COMPRESSION. Test cylinder compression, with engine at idle speed, and at operating temperature. EXHAUST PIPING AND MUFFLERS. Check exhaust piping and mufflers for condition and mounting. Check for carbon streaks and other indications of exhaust leaks. Be sure drain holes in mufflers are not clogged. Tighten all mounting bolts and connections. Check that manifold and gaskets are in good condition and secure. AIR STARTING SYSTEM. Check system for leaks, damaged lines or connections. See that system operates properly to deliver adequate cranking air. Drain dirt and water from air tanks. Inspect air valves for leakage and satisfactory operation. REFRIGERATION UNITS. Check for gas shortage. Test the refrigerant. Add if necessary. Check oil in system, and lubricate in accordance with the current LO. BLOWER MOTORS. Check for cleanliness, and for condition of commutator and brushes. Check that all electrical connections are clean and tight. MASTER SWITCHES AND CONTROLLERS Check the general condition, movement, and effectivity of master switches and/or controllers. STEERING GEAR. Check operation of the steering gear motor, hydraulic pump, and rudder movement. Examine the condition of hydraulic valves and piping of console, along with the hand hydraulic pump. 0.5 0.5 0.4 0.8 0.3 1.0 1.0 1.0 2.0 0.6 Section V. TROUBLESHOOTING of test or inspections which will help you to determine probable 4-6. General causes and corrective actions to take. You should perform the a. This section contains troubleshooting information for tests/inspections and corrective actions in the order listed. locating and correcting most of the operating troubles which may develop in the tug and its components. Each malfunction b. This manual does not list all malfunctions for an individual component, unit, or system is followed by a list 4-5 TM 55-1925-204-12 that may occur, nor all tests or inspection and corrective actions. If a malfunction is not listed, or is not corrected by the listed corrective actions, notify Direct Support Maintenance. 4-7. Troubleshooting Probable malfunctions, with tests or inspections and corrective actions are listed in table 4-3 below. Table 4-3. Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION NOTE Use table 3-3 for troubleshooting and expand by using these additional steps. -01 GROUP1. BLUE SMOKE. Step 1. Check for excessive cylinder wall lubrication. Check and adjust force feed lubricator (para 4-16). 2. OVERHEATING. Step 1. Check for excessive back pressure in exhaust system. Check and repair exhaust silencer or pipes (para 4-15). -04 GROUP1. BLACK OR GRAY SMOKE. Step 1. Check for high exhaust back pressure. Check muffler (para 5-23). 2. OVERHEATING. Step 1. Check for back pressure in exhaust. Check muffler (para 5-23). Section VI. RADIO INTERFERENCE SUPPRESSION The ventilating blower motors, pump motors, and electrical generators have been suppressed with capacitors. 4-8. General Methods Used to Attain Proper Suppression Essentially, suppression is attained by providing a low resistance path to ground for stray currents. The methods used include shielding the ignition and high frequency wires; grounding the frame with bonding straps, and the use of capacitors, resistors, and internal-external toothed washers. 4-10. Replacement of Suppression Components a. When interference exists, test components as described in paragraph 4-11. 4-9. Interference Suppression Components b. Replace defective suppressors as described on figure 4-2. 4-6 TM 55-1925-204-12 Figure 4-2. Replacing typical component for suppressing radio interference 4-11. Testing of Radio Interference Suppression Components a. Motor Test. proceed as follows: (3) If step (2) above did not stop interference, switch generator sets (para 2-11). If interference still exists, move to step (4) below. When the radio indicates interference, (1) Secure all ventilating blowers momentarily. If the interference is still heard, the trouble is elsewhere. Turn blowers ON. (4) Secure momentarily each pump motor that is in operation. When interference stops, replace the capacitor on that motor. If interference still exists, see b. below. (2) If both generating sets are generating power, refer to paragraph 2-11 and secure one generator. If this test stops the interference, the defective suppressor may be in the 40 KW power generator or the 24 vdc battery charging generator of the diesel engine. Replace defective capacitor (fig. 4-2). 4-7 b. Component Check. Arcing electrical contacts will also create interference. When tests in a. above have not isolated the interference source, secure each individual electrical circuit on the main electrical control panel (fig. 2-5), one at a time. When a troublesome circuit becomes known, TM 55-1925-204-12 further isolation may be necessary if it is one of the power panel (18, 21, 23, 24, 25, or 32, fig. 2-5). Continue testing of individual circuits until source of interference is detected and corrected. Section VII. MAINTENANCE OF THE PROPULSION ENGINE 4-12. General The propulsion engine is a Fairbanks-Model 37F16, slow speed, two cycle diesel fuel injection engine. It has six vertical individual cylinders, with a bore of 16 inches, and a stroke of 20 inches. It turns with a maximum speed of 300 rpms, and develops 1,200 hp. Intake and exhaust ports are openings on the sides of cylinders, at approximately 650 above bottom dead center. Scavenging air enters cylinders from the air receiver (intake manifold) upon opening of intake ports by the passing of the piston on its downward (power) stroke. This fresh air, at a pressure of from one and one-half to two and one-half psi, assists in removing the exhaust gases from the cylinder, as well as forming the combustible when the piston moves upward on the compression stroke. This engine is directly reversible, and is attached to the propeller and shaft through a thrust bearing at the stern (flywheel) end. 4-13. Cylinder and Sleeve 4-8 a. General. The cylinder is a one piece casting with an integral water jacket. The water jacket is a cored annular space thru which cooling water is circulated. The cylinder wall is lubricated through tubes, with oil supplied by the force feed lubricator. A sleeve is bolted to the lower part of each cylinder, holding three oil scraper rings. These rings collect surplus oil in order to prevent an oversupply of oil in the lower base. b. Removal. (1) Remove the cylinder head and valves (para 3- (2) Remove the piston and connecting rod (para 3- 6). 7). (3) Remove the exhaust manifold section (fig. 4-3), by removing all connection, and side hole covers, then reach through side hole covers and disconnect manifold from exhaust port by removing nuts from the studs. Remove the water header section (para 3-19). TM 55-1925-204-12 Figure 4-3. Exhaust manifold section removal. (4) Refer to figure 4-4 and remove 16 nuts and the air receiver cover. Disconnect the section to be removed from the other; reach inside the air receiver and remove nuts from studs at inlet ports, then remove air receiver section from cylinder. 4-9 TM 55-1925-204-12 Figure 4-4. Air receiver (box) removal Disconnect the cylinder lubricating tubes. If a new cylinder and sleeve is to be installed, be sure upper base mounting (6) Remove 8 nuts and washers (fig. 4-4), then lift surface and the cylinder flange are free of the cylinder off the upper base. burrs. And, install new rings on the piston (para 3-7). (7) Remove the cylinder sleeve and scraper rings (para 3-7d). d. Installation. (5) (8) Remove other cylinders in a similar manner. c. Cleaning, Inspection, and Repair. (1) Clean the exhaust and air inlet ports. Check the exhaust port bridge for a slight growth. Check with a thickness gage and a straight edge. If any growth has occurred, the port bridges must be stoned, or ground even to the original cylinder bore. A slight relief of 0. 001 to 0. 002 inch will do no harm. Round the edges of the ports to a radius of approximately 1/16 inch. (2) Check the water jacket for formation of scale. Scrape and wash with a solvent, then rinse, and blow dry. Check surfaces of cylinder flange where it meets the upper base. Be sure that the flange is clean, and free of burrs. Give cylinder bore, and all machined surfaces a light coat of lubricating oil. Wipe away any surplus oil with a dry cloth. (3) Check the cylinder for wear, against tolerances established and shown in table 1-3. Replace a defective cylinder. (4) Examine the zinc post (20, fig. 3-8) for wear and errosion. Replace a defective zinc post. (5) Examine the water cooling tubes (27) for signs of leaking. Replace defective water cooling tubes. Be sure and use new gaskets (18) under each one. NOTE 4-10 (1) (para 3-7d). Install the cylinder sleeve and scraper rings (2) Install a new cylinder to upper base gasket (4, fig. 3-8). (3) Install the new cylinder. Be sure that the cylinder is in perfect alignment by placing a long straight edge across the machined surfaces of the air receiver and exhaust flanges of the new cylinder and adjacent cylinders. Both air and exhaust sides must be checked, especially if the cylinder being replaced is on the end. (4) Install the 8 washers and nuts (fig. 4-4) and tighten them evenly and securely to the torque given in table 1-1 (1,500 to 1,550 ft lbs). (5) Continue by reversing the procedures in steps (1) through (5) in b. above. (6) Install remaining cylinders in a similar manner. 4-14. Air Starting System a. General. The air start system consists of the piping and engine starting mechanism. Air piping is arranged so compressor air discharges into storage tanks (reservoirs). Moisture is trapped in the tanks and may be released through the air tank drain valve. This lessens the chance of moisture getting into the engine. The engine is TM 55-1925-204-12 started by high pressure. air reacting against the piston and cylinder head dome in the proper firing order. Air is admitted to all cylinders in firing order rotation until the engine begins to fire. The starting mechanism is set into operation by moving the control handwheel quickly past asternor-ahead to START. This turns the air start control cam into position and moves the air start shutoff valve upward to its open position. High pressure air is then admitted to the starting air header and to the closed air start check valve in each cylinder head. Air from the header also passes to the air start distributor. The distributor contains one air valve for each cylinder. Each valve is operated by a cam and is normally held open and away from the cam by a spring. High pressure air closes all but three of the valves. Due to the cam contour, one valve remains open and two are partially open. Air then flows through the open valves to their respective cylinder air start check valves. The valves are held in a closed position, and need this secondary air to open the valve and permit the primary starting air to enter the cylinder chamber. After the engine has started, and the control handwheel is at "Ahead" or "Astern", the air start valves return to their open position away from the cam. 4-11 b. Air, Distributor. The marine air start distributor is designed for "ahead" or "astern" rotation. It is correctly timed when the matchmark on the cam is aligned with the center line of No. 1 valve, and the No. 1 piston is at top dead center. Number one piston is at top dead center when the chisel mark on the ratcheting device gear aligns with the crankshaft position pointer. The usual cause of air distributor failure is from leaking air line bushings or gaskets. Be sure the air reservoirs (tanks) are drained of moisture, frequently. (1) Cleaning, Inspection, and Repair. The air distributor requires little attention other than a periodic inspection of the valves for wear, and the line fittings and gaskets for leakage. Proceed as follows: (a) Close the starting air valve. (b) Remove the bolts and clamps (view A, fig. 4-5), and the 7 air lines, as required. TM 55-1925-204-12 Figure 4-5. Air Distributor. 4-12 TM 55-1925-204-12 (c) Remove the 6 capscrews and cover. (2) Removal. To remove the air starting distributor, for overhaul, or to clear upper base, proceed as follows: (d) Remove the 6 plugs, valve retaining (one (a) Refer to view B of figure 4-5 and remove bolts and clamps. at a time). (e) Remove spring and valve from the valve (b) Tag and remove the oil line. port. (c) Disconnect the reversing shaft. CAUTION If the valves are going to be removed more than one at a time, mark them for reinstallation in the same valve port, with the same guide. The valve and guide are lapped and MUST be reinstalled as a unit. (d) Tag and remove the 7 air lines. (e) Remove the 14 capscrews. (f) Clean parts in clean fuel oil and blow dry with ships service air. Inspect the spring for damage or weakness. Replace a damaged spring. (g) Lubricate the lapped surfaces of guide and valve. Install in valve port. Reach inside housing and push valve and guide back and forth to determine they operate freely, but are not loose from wear. (h) Install spring over valve, place new gasket at port, then install plug. (i) Repeat steps (e) through (g) above for the remaining valves (one at a time). U) If valve and guide are defective in any of the 6 valve ports, replace the air starting housing by removing 6 nuts (view A, fig. 4-5) and air starting housing with valves and guides. Install a new gasket under the new housing. (k) When valves are clean and serviceable, place new cover gasket on housing, install cover, and secure with 6 capscrews. (l) Uncover ends and install air lines removed, then secure lines with bolts and clamps. starting valve. Open (f) Remove the air distributor, then lift gasket off the upper base. (3) Installation. Refer to view B of figure 4-5 and reverse the procedure in steps (a) through (f) of (2) above. c. Reverse Control. Turning the control handwheel past "stop" moves a crank that operates the reversing shaft in the reversing mechanism, which in turn moves the cam shifting shaft. This shaft operates to move the proper cam into position for timing the air distributor valves so that the desired rotation and firing of the cylinders is achieved. For inspection and firing of the cylinders is achieved. For inspection and replacement of defective parts, proceed as follows: (1) Removal. (a) Close starting air valve. (b) Remove the air distributor (b., (2) above) place it on a suitable workbench. (2) Disassembly. (a) Remove 6 capscrews (view A, fig. 4-5), cover, and gasket (20, fig. 4-6). 4-13 TM 55-1925-204-12 1. Capscrew 2. Adapter 3. Shaft 4. Bearing 5. Shim 6. Arm 7. Shim 8. Rod 9. Arm 10. Crank 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Washer Capscrew Shim Gasket Spring Nipple Shaft Cam Sleeve Gasket 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Gasket Housing Gasket Gasket Cover Gear Valve Key Sleeve Bracket 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. Shim Gasket Spool Shaft Capscrew Adapter Gasket Gear Screw Gear 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. Screw Shaft Bearing Pin Lever and setscrew Roller Pin Key Gasket Shim Figure 4-6. Air start distributor and reverse control. 4-14 TM 55-1925-204-12 (b) Remove capscrews (35) and adapter (36), arm (6) and shaft (3). (c) Remove nut from shaft (17), cam (18) and sleeve (19). (a) Remove capscrews securing header connections at cylinders and receiver, then remove header from the receiver, and connector (5, fig. 47) from line by uncoupling flanges. (b) Remove and discard gaskets (3 and 4). (d) Remove capscrews securing cover (25) then remove cover (25) from gear (26). Remove gasket (24). (3) (c) When necessary, remove covers from housing then remove and discard gaskets (1 and 2). Cleaning, Inspection, and Repair. (3) (a) Clean all parts in clean fuel oil and blow dry with ships service air. Cleaning, Inspection, and Repair. (a) Wash all parts in clean fuel oil then wipe (b) Inspect forward cam (18) and the reverse cam attached for wear or rough lobes. Examine movement of shaft (17). If there is end play in shaft, remove capscrews securing sleeve (29) and remove a shim (50) and a shim (31). Replace and secure sleeve (29), then try shaft end play. Removal of shims should have reduced end play by allowing bracket (30) to cause reversing mechanism to meet spool (33) earlier, therefore reduce end play. dry. (b) Be sure that all gasket material is removed from surfaces to be gasketed. (c) Inspect header sections for dirt, or moisture residue. (4) (c) If forward cam (18) or reverse cam attached is defective, separate the cams. Replace the defective cam (s). (4) Reassembly. Assemble the air distributor by reversing the procedure in step (2) (a) through (d) above. (5) Installation. Install by procedures in step (1) (a) and (b) above. reversing Installation. (a) Replace new gaskets (1 and 2), if removed, then install covers. (b) Replace new gaskets (3) under header sections at the receiver and tighten capscrews securing header sections. Install new gaskets (4) at flanges of connector (5), then bolt to header sections at both ends of connector. the d. Air Start Header. The air start header is the piping arrangement of air to cylinders for starting (reversing) the engine. The principal maintenance requirement is to stop leakage of air from header. When an air leak is suspected, test and correct. (1) Testing. If a leak can not be felt by the fingers at joints, make up a solution of soap and water and apply at all gasketed connections of header (fig. 4-7) at cylinders. e. Air Receiver (BOX). The air receiver distributes air from the scavenging pump to cylinders under the proper pressure (from 11/2 to 21/2 psi) for forcing exhaust gases out, and filling cylinder with combustion air. (1) Removal. Refer to paragraph 4-13, b. (4) and remove the air receiver sections. (2) Cleaning, Inspection, and Repair. (a) Wash the receiver parts in clean fuel oil and wipe dry. (b) Clean all gasket surfaces. Be sure that all particles are removed, and the machined surfaces are smooth. (c) Inspect receiver for cracks, or other damage. Replace a defective receiver section, or cover. 1. Gasket, housing cover 4. Gasket, pipe flange 2. Gasket, housing cover 5. Connector, air start header, 3. Gasket, receiver to header flexible, with flanges Figure 4-7. Air start header (2) Removal. 4-15 TM 55-1925-204-12 (d) Discard old gaskets and replace with new ones. the water cooled manifold, flows out through the exhaust outlet fitting into the silencer, then out to the atmosphere. (3) Installation. Refer to figure 4-4 and paragraph 4-13 b. (4) and install the air receiver by reversing the removal procedures. b. Cleaning, Inspection, and Repair. The exhaust system requires periodic inspection and cleaning by removing accumulations of carbon. The procedure follows: (1) 4-15. Exhaust System a. General. The exhaust system conducts the combustion gases from cylinder exhaust ports to the atmosphere. The combustion gases flow out of the cylinders when the pistons uncover the exhaust ports. The gases enter 4-16 Exhaust manifold. (a) Drain the engine cooling system. (b) Remove hand hole covers (fig. 4-8) for access to all exhaust ports. TM 55-1925-204-12 Figure 4-8. Exhaust manifold and outlet pipe. 4-17 TM 55-1925-204-12 (c) Remove and clean the thermocouples of all accumulations of carbon, then lay aside for later installation. (d) Use the ratcheting device to turn the engine over until the piston (of the cylinder which is to be cleaned) is at bottom dead center. (e) Reach in through hand hole in exhaust manifold, and thoroughly clean the exhaust ports of all carbon deposits, as well as the interior of the manifold section. (f) Remove the cylinder compression relief valve (para 3-6 f. ), insert a ships service air hose through the opening, and blow the carbon off the piston so it is perfectly clean. CAUTION (h) Repeat the procedure in steps (b) through (g) above for each cylinder of the engine. NOTE To effectively clean air receivers, first use a cloth -dampened in clean fuel oil, then wipe dry with a clean cloth. (i) Remove the air receiver covers by removing nuts (fig. 4-4) and repeat the procedures in steps (b) through (f) above on all cylinders then reinstall covers. Use a new gasket under each cover. (2) Silencer (muffler) and pipe. The silencer is located in the smoke stack. It can be reached for cleanout from door in stack on the boat deck. Proceed as follows: Turn the engine over one complete revolution, to make sure no carbon has ledged on top of the piston. (a) Remove 8 nuts (fig. 4-9) and clean out cover from silencer. (g) Remove all carbon from the exhaust manifold and piping. When that cylinder is clean, install the thermocouple, install new gasket at handhole cover, install the cover and secure with nuts on the studs. (b) Remove the accumulation of carbon from the bottom of the silencer. When the accumulation is above normal, disconnect the exhaust pipe at top and bottom. Slide it over on outlet section (fig. 4-8) and away from silencer Figure 4-9. Silencer (muffler). 4-18 TM 55-1925-204-12 until the inside can be scraped relatively free of carbon. Blow clean with ships service air. (c) Position the exhaust pipe properly on the outlet section of manifold and at silencer, (fig. 4-9) then secure with bolts, washers, and nuts. The lubricator is equipped with a handcrank for delivering oil to lubrication points prior to starting the engine. 4-16. Forced Feed Lubricator (1) Removal. To clean out the reservoir, or to repair the lubricator, it is necessary to remove the lubricator from the engine. Proceed as follows: a. General. The force feed lubricator supplies positive lubrication to the power cylinders and scavenging pump sleeves. The lubricator is kept constantly filled by the engine lubricating oil pump. The lubricator is of the sight feed type in which the drops of lubricating oil being delivered to each lubrication point can be seen dropping into each sight feed cup. 4-19 b. Force Feed Lubricator. (a) Refer to figure 4-10 and disconnect all oil lines at the lubricator. Plug or cover ends and ports to prevent contamination. Tag for identification at reconnection. TM 55-1925-204-12 Figure 4-10. The force feed lubricator. (b) Remove the cover mounting screws; lift cover off the housing, then carefully remove the gasket. Save for reuse at installation. 1. 2. 3. 4. 5. TM 55-1925-204-12 (c) Disconnect the lubricator drive link (4, fig. 4-11) by removing pin (3). Gasket 6. Crosshead Arm 7. Strap Pin 8. Bolt Link, lubricator drive 9. Key Sleeve Figure 4-11. Lubricator drive. (d) Remove mounting capscrews (fig. 4(b) Use clean fuel oil and wash the 10) at brackets, then lift the force feed lubricator off of the interior of the lubricator, then blow dry with ships service camshaft housing, and move it to a workbench. air. Do not turn hand crank while washing the reservoir. (2) Disassembly. Under normal conditions, (c) Drive the split end taper pin out of the disassembly for repair is infrequent, but when the collar (8, fig. 4-12). Then loosen the shaft bearings at pumping unit (s) cannot be adjusted to the correct each end of reservoir by backing off the locknut at each discharge rate, proceed as follows: bearing. (a) Move container under the drain cock (fig. 4-10) then open drain cock and remove the oil from the reservoir. 4-21 TM 55-1925-204-12 1. 2. 3. 4. 5. 6. 7. Pin Pawl Spring Gland. packing Bearing sleeve Gasket Wheel, ratchet 8. 9. 10 11 12 13 14 Collar, drive 15 Tube. with cup 22. Ring. packing Retainer. Pawl 16. Yoke 23 Packing. performed Spring 17 Eccentric 24. Retainer. packing Gasket 18. Spindle 25 Gasket Arm assembly 19. Pumping unit 26. Bearing. sleeve Packing 20. Strainer 27. 'lube lube, feed 21. Bearing 28. (Gasket Figure 4-12. Force feed lubricator. sectional view. 4-22 TM 55-1925-204-12 (d) You can now move the shaft out as far as required by pulling out on the crank handle. (e) To remove a pumping unit, pull shaft out until end is clear of the unit to be removed; unscrew connector to which the oil line was attached, then remove the capscrew from below the connector (both on rear outside of housing) and lift unit out of housing. CAUTION Remove one pumping unit at a time. If more than one is removed, be sure they are tagged to identify exactly where each one is from. They must be returned to their original position in the housing. (f) Remove locknut at each end of reservoir then remove drive shaft bearings (5 and 26), packing gland(4) and retainer (24). (g) Remove bearing (21) from partition of housing by removing ring (22) then remove packing (23). (h) Remove two roundhead screws from housing, then lift out pawl retainer (9) and spring (10). (3) Cleaning, Inspection and Repair. CAUTION Do not wipe lubricator with lint rags or waste. It should be flushed with clean fuel oil, then blown dry with ships service air. (a) Flush the lubricator housing with clean fuel oil then blow dry with ships service air. Wash the three sight feed glass hoods with clean fuel oil and wipe dry. (b) Wash the pumping units in clean fuel oil and wipe dry. Inspect the by-pass opening in pumping unit (19, fig. 4-12). If plugged, use a wire to clean the opening, then blow out with ships service air. Inspect the pumping unit (19) body for cracks, dents, or other damage. Replace a defective pumping unit. Wash the strainer (20) in clean fuel oil and blow dry. (c) Wash the drive shaft in clean fuel oil and wipe dry. (d) Position bearings on drive shaft. If the fit of bearing to shaft is loose, replace the bearings. (e) Wash the ratchet wheel (7) in clean fuel oil and blow dry. Inspect teeth. Replace a damaged ratchet wheel. (f) Wash the pawl (2) arm assembly in clean fuel oil and blow dry. Inspect the plunger spring (3). Replace defective spring. (g) Inspect the retainer pawl (9) and spring (10). Replace a broken spring. (4) Reassembly. NOTE Install the pumping units, one at a time, in the same position from which removed. (a) To assemble, reverse the procedure used in steps (2), (c) through (h) above, then close the draincock (fig. 4-10). 4-23 (b) Tighten all capscrews, nuts, and screws securely, but not too tight. (c) After the eccentric shaft has been positioned through all eccentrics (17, fig. 4-12) and bearings, tighten locknuts securely, install packing, then tighten all packing glands hand tight. (5) Installation. (a) Position lubricator (without cover installed) on the camshaft housing, and secure with lockwashers and capscrews (fig. 4-10). (b) Reconnect the lubricator drive link (4, fig. 4-11) by installing pin (3). (c) Remove tags and protective covers from oil lines, one at a time, and connect them to their proper pumping unit. NOTE When installing cover, it is necessary that the slots in the adjusting screws be positioned to align with the flats on the adjusting spindles. (d) Position cover gasket (fig. 4-10) on the lubricator housing. Position cover over the housing, with rear edge high enough so that spindle flats and slots in bottom of adjusting screws can be seen and aligned, then move adjusting screw slots to the proper position. Lower the cover into position. Do not drive or force the cover in place. (e) Install cover screws and tighten. If glass hoods were removed for cleaning, position them on the cover correctly, then secure with the clamps and screws. (f) Assure that draincock is closed, then remove oil filler cover and fill with clean oil (LO 55-1925204-12-2). Be sure filter screen is in place in filler neck, and is clean. (g) Prime the lubricator by disconnecting the longest oil line at its engine connector, then turn the hand crank until oil flows from that oil line. Reconnect the oil line at the engine connector. Check for leaks at connections or the bearing packing glands. Check that packing is seated, and gland nuts are hand tight. If leaking at the gland, tighten just enough to stop the leak. (h) The lubricator is now ready for adjustment. (6) Adjustment. (a) With engine running at rated speed, count the number of impulses (indicated by one revolution of the crank handle) per minute; this can be done most accurately with a stop watch, as the impulses for a period of five minutes are counted and divided by five. The particular feeds should deliver the number of drops per minute indicated on table 4-4 TM 55-1925-204-12 Table 4-4. Force Feed Lubricator Drop Count Model 37F16 diesel engine, at 300 rpm) lubrication point Power cylinders (3 lines to each cylinder) Scavenging pump sleeve-lower Scavenging pump sleeve-upper Lubricator drive rocker Thrust bearing Drops per minute 35 28 7 7 28 (b) Next, divide the listed number of drops per minute by the determined number of impulses per minute; this establishes the number of drops per impulse, at which the feeds should be set. (c) With the engine stopped, and the oil at operating temperature, turn the lubricator hand crank one complete revolution, and count the number of oil drops falling into the cup for the particular line being checked. (d) If an adjustment is required, turn the adjusting screw (fig. 4-10) clockwise to decrease, or counterclockwise to increase. (e) Repeat steps (c) and (d) until the number of drops per minute are as required for that feed. (f) Repeat steps (c), (d), and (e) above for each lead, until the lubricator is adjusted to feed correctly. NOTE It is recommended that a check be made to deter4-24 mine if the established number of drops per minute for power cylinders are correct for a particular installation. (g) Remove an exhaust manifold hand hole cover and examine for traces of oil in the manifold. Any traces in excess of between 2 to 3 inches beyond the cylinder wall indicates that the lubricator feed is delivering too much oil. Adjust accordingly, and annotate the change in the lubrication log book. c. Scavenging Oil Transfer Pump 1#5130). This transfer pump, electric motor driven, has a capacity of 3l/2 gpm, and is located on port side of the engineroom at forward bulkhead. Its purpose is to move oil collected by the scraper rings from the force feed lubricator supply to engine cylinder walls, directly to the purifier for removal of carbon before its return to the system for reuse. (1) Removal. (a) Disconnect the 3/8 in. oil line from the pump suction inlet. Tag and disconnect all electrical leads. (b) Remove the motor and pump from its mounting. (2) Disassembly of pump. (a) Separate the motor and pump. (b) Remove two nuts (6, fig. 4-13) and the packing gland (5). TM 55-1925-204-12 Figure 4-13. Scavenging oil transfer pump (#5130) Bearing, ball (2) 7. Screws (8 Brush (2) 8. Cover Motor 9. Nuts 12) PuMotor 10. Armature and shaft Gland, packing 11. Screws 2) Nuts (2) (c) Remove 8 screws (7) and cover (8) (c) Remove brushes (2) then withdraw from pump (4). armature and shaft (10) from frame. (d) Withdraw impeller and shaft. (d) Remove bearings (1). (3) Disassembly of motor. (4) Motor controls. Refer to figure 4-14 and (a) Remove 2 nuts (9) and screws (11). remove and replace parts as required. (b) Remove endbell (12), then remove the opposite endbell. 1. 2. 3. 4. 5. 6. 4-25 TM 55-1925-204-12 1. 2. 3. 4 5 6. 7. 8 9 10. Tip. main contact 11. Spring Finger. main 12. Spring Spring, main finger 13. Spring Spring. helical 14. Finger Contact 15. Contact Spring 16. Spring Contact. heater 17. Finger Coil. relay 18. Diaphragm Contact. relay 19. Spring . Contact. fingers, Figure 4-14. Motor controls. (5) Cleaning, inspection and repair. (e) Inspect brushes for wear. Replace (a) Wash all pump parts in clean fuel oil brushes when less than 3/8 in. extends from holder. and wipe dry. Inspect impeller and shaft for wear or (f) Inspect armature for scoring, or bends. (b) When impeller and shaft is defective, excessive wear. When armature is defective, replace the motor. replace the pump. (g) Clean motor controls with ships (c) Wipe dust and grease from electrical service air, then test components for electrical parts with a cloth dampened in fuel oil, then wipe dry. serviceability. Replace defective components as (d) Inspect bearings for wear, roughness required. in turning, or other defect. Replace defective bearings. (6) Reassembly of motor. Reverse the 4-26 TM 55-1925-204-12 procedure used in step (3) above to assemble the motor. (7) Reassembly of pump. Reverse the procedure used in step (2) above to assemble the pump. (8) Installation. Reverse the procedures used in step (1) above to install the pump assembly on its mount and connect to the oil system. 4-17. Camshaft and Timing System a. General. The diesel engine camshaft is driven by the crankshaft, through a gear train located at aft (drive) end. The camshaft is supported by four camshaft bearings and an end bearing at the drive end. Camshaft bearings are stamped with placement markings so they may be returned to their original position. NOTE If bearing replacement becomes necessary, these markings should be carefully transferred to the new bearings. 1. 2. 3. 4. 5. Cover Gasket Bearing cap Shims Bearing box b. Camshaft Bearing Replacement. The camshaft sleeve bearing assemblies are in halves (lower in box, upper in cap), and come in three sizes depending on location. Shims are used for adjustment of clearance after bearings are hand scraped and fitted. Replace bearing (s) as follows: (1) Preparation. (a) Remove the capscrews securing the camshaft cover to the camshaft lower housing located at right of the astern/ahead handwheel. Lift off the cover. (b) Remove nuts securing the inspection plate located to left of the astern/ahead handwheel. Lift off the inspection plate. (2) Bearing removal. (a) Remove capscrews securing bearing cap (3, fig. 4-15) and bearing box (5). 6. 7. 8. 9. 10. Camshaft Gasket Gasket Rim Nuts Figure 4-15. Camshaft and bearings. (b) Remove bearing cap (3), shims (4), (4) Installation. and bearing box (5). Tag and identify shims for (a) Position bearing box under camshaft. reinstallation. Check one bearing at a time, until the five Lay shims on bearing box and remove tags. are completed. (b) Install bearing cap and secure with (3) Cleaning, inspection, and repair. the capscrews. Tighten screws evenly. (a) Wash bearing halves in clean fuel oil (5) Adjustment. and wipe dry. (a) Place leaf is) of thickness gage 0. (b) Inspect bearing surfaces for cracks, 125 in. wide on camshaft and slide under bearing cap discoloration from overheating, or other defects. Replace and find clearance. a defective bearing assembly when either half is (b) If clearance is between 0. 001 and 0. defective. 0065 in. the adjustment is correct. (c) If a defective bearing is replaced, (c) If clearance is 0.001 in. or less, scrape and fit in a manner similar to that described for change shim stack on both sides as follows: main bearings in paragraph 3-23. 4-27 TM 55-1925-204-12 1. Remove a shim of 0. 025 in. from both sides, then add three 0. 007 shims on each side. 2. Tighten capscrews then remeasure clearance. It should now be between 0. 001 and 0. 0065 inch. If not correct, change shim stack until reading comes within tolerance. 3. Conversely, if clearance reads 0. 010 in., remove a shim of 0. 007 in. from each side to bring clearance within permissible limits. 4. When all shims have been removed and clearance is greater that 0. 0065 in. , replace the bearing. 5. Repeat steps (1) through (5) until all bearings have been checked. c. Gear and Cam Inspection. (1) Camshaft drive gear. (a) Turn engine over slowly with the ratcheting device, and inspect the gear for worn or broken teeth. (b) Report a defective camshaft drive gear to general support maintenance. (2) Camshaft cam lobes. (a) Inspect cam lobes for excessive wear, or roughness of lobe surfaces. (b) Report defective cam lobes to general support maintenance. (c) Reverse the procedures in steps b. (1) (a) and (b) above, then proceed to timing the injection, if required. d. Timing System. The timing (gear train) system begins with the crankshaft drive gear, which drives the idler gear, which, in turn drives the main camshaft gear. The idler gear drives the air distributor by the air distributor intermediate gear, to which is bolted the air timing camshaft gear. Backlash of gears may be checked by referring to table 1-2 for allowable limits. The camshaft gear is composed of a gear rim, gear hub, and cover plate. The hub is securely keyed to the camshaft. The gear rim is locked between the cover plate and hub by means of six studs and nuts through slotted holes in the gear rim. These slotted holes allow the hub and camshaft to be shifted in relation to the gear rim, to adjust the timing of the engine. Adjust engine timing as shown below. (1) Timing the engine fuel injection. (a) Remove timing gear train covers from aft end of the upper base. (b) Use the ratcheting device and turn engine over until the number one piston is at top dead center. (c) Remove cover (1, fig. 4-15) and gasket (2). NOTE If necessary, for a particular condition, the injection timing may be advanced, or retarded, as the condition requires. CAUTION Never change the injection timing by more than 1' at a time, then check engine operation after each such change. Since the firing pressures of the cylinders are affected when the time of injection is advanced or retarded, these pressures must be checked after each such change is made (table 1-4). (d) Remove six cotterpins from nuts (10) on studs in gear rim (9). NOTE The six capscrews securing cover plate to hub may require loosening. before hub and shaft will slip. (e) Loosen the six nuts (10), then holding gear rim (9) stationary, shift hub and shaft in the direction of engine rotation until the chisel mark on cover plate is even with mark for 10 off zero setting for advance. Shift the shaft and hub in the opposite direction to retard. (f) Tighten nuts on studs (tighten capscrews on cover plate, if loosened) then install cotterpins in nuts and studs. (g) Install cover (1) and gasket (2). (h) Install timing gear train covers on upper base. (i) Operate engine and check pressures. (j) Repeat the procedures in steps (a) through (i) until adjustment is correct for the. condition. 4-18. The Engine Electrical System a General. The engine electrical system consists of the instrument panel, with tachometer indicator, fuel pressure gage, oil pressure gage, starting air pressure gage, water pressure gage, and the pyrometer. In addition, there is the safety visual indicator, for sounding an alarm when the oil pressure or water temperature is off the norm. b. Fuel Pressure Gage. (1) Removal. Disconnect fuel line from rear of gage (1, fig. 4-16), remove screws securing the gage to the instrument panel. 4-28 TM 55-1925-204-12 1. 2. 3. 4. Gage, fuel oil pressure 5. Pyrometer Gage, lube oil pressure 6. Tachometer Gage, air pressure 7. Panel, instrument Gage, water pressure Figure 4-16. Instrument panel. c Water, Oil and Air Pressure Gages. Repeat the (2) Cleaning. Wash the gage carefully procedures in subparagraph b. above for the water, oil, with a cloth dampened in clean fuel oil and wipe dry. (3) Test. Use available test equipment to and air pressure gages (2, 3, and 4, fig. 4-16). d. Tachometer Indicator. verify pressure accuracy. Replace a defective fuel pressure gage. (1) Removal. (4) Installation. Install by reversing the (a) Disconnect tachometer drive. procedures in step (1) above. (b) Remove capscrews then lift tachometer (6) from the instrument panel (7). (2) Cleaning. Blow away dirt with ships service air. 4-29 TM 55-1925-204-12 (3) Test and Repair. Test continuity and electrical contacts. Replace a defective tachometer. Repair by replacing a defective sending unit. (4) Installation. Install by reversing the procedures in step (1) above. e. Pyrometer. (1) Test. Use available test equipment to verify scale accuracy of the six thermocouple readouts. Replace a defective pyrometer. (2) Removal. (a) Tag and disconnect the thermocouple leads from rear of pyrometer (5). (b) Remove the eight screws from frame that secures pyrometer to panel (7). (3) Installation. Install the pyrometer by reversing the procedures in step (2) above. 4-19. Flywheel Assembly a. General. The flywheel is keyed to the drive end of the crankshaft, and coupled to the Kingsbury thrust bearing stub shaft. The flywheel jacking device (flywheel turning) is mounted on deck at port side of engine. The flywheel brake shoe is installed on port side, with the air cylinder above the flywheel guard pulling the application lever. The brake air pressure gage indicates available air pressure, and is mounted in line at rear of engine control station. The cam operated pilot air valve controlling the air brake operation is installed on camshaft housing behind the astern/ahead handwheel, and is activated by a cam on handwheel at the stop position. There is a globe shutoff valve in air line for pressure regulating valve to reduce the starting air pressure of 250 psi, to the 125 psi required for the brake application. Relay control is maintained by a pressure regulator. b. Flywheel Jacking (Ratcheting) Device. Use the ratcheting device to turn engine over when performing maintenance, by moving barring arm, after setting ratchet pawl for direction it is desired to turn. Perform maintenance as follows. Figure 4-17. Flywheel jacking device. (1) Disassembly. (a) Remove barring arm from worm. (b) Loosen pin and remove spring. (c) Remove ratchet pawl, then remove worm from bracket. Remove the two ball bearings from the worm. (2) Cleaning, inspection, and repair. (a) Clean all parts removed in clean fuel oil and wipe dry. (b) Inspect spring for weakness, bend, or break. Replace a defective spring. Inspect pin for straightness. Replace a defective pin. (c) Inspect bearings for wear, and smoothness of operation. If worn, or rough, replace. 4 -30 TM 55-1925-204-12 (d) Inspect the ratchet pawl for damaged teeth. Replace a defective pawl. (3) Reassembly. Assemble by reversing the procedure in step (1) above. c. Engine flywheel air brake assembly. (1) Brake lining removal. (a) Close the globe shutoff valve (fig. 418). Figure 4-18. Shutoff value, storage tank, and pressure gage. (b) Disconnect the air hose (fig. 4-19). 4-31 TM 55-1925-204-12 Figure 4-19. Engine air brake cylinder. 4-32 TM 55-1925-204-12 (c) Remove cotterpin, nut, and bolt from brake actuating lever, and move lever and brake lining (5, fig. 4-20) away from flywheel. 1. Hose 5. Lining. brake 12) 2. Eyebolt (2) 6. Nit (121) 3. Spring(2) 7. Screw(12) 4. Nut and cotterpin (2) Figure 4-20. Brake shoe and linkage. (d) Remove nuts (6), screws (7), and lever and cylinder shaft, and secure with nut and cotter brake lining (5). Discard the worn brake lining (5) and pin. Tighten nut (4, fig. 4-20) until spring screws (7), if heads are worn. (3) pulls brake away from flywheel. (e) Remove cotterpin and nut (4) and (e) Connect air hose to air brake spring cylinder, then open globe shutoff valve (fig. 4-18). (3) from eyebolt (2). Inspect spring for d. Brake Air Cylinder. weakness, or other defect. Replace a (1) Removal. defective spring. (a) Close globe shutoff valve (fig. 4-18). (2) Brake lining installation. (b) Disconnect air hose (fig. 4-19). (a) Blow dust from brake shoe with ships (c) Remove cotterpin, nut, and bolt from service air. the actuating lever. (b) Install new brake lining (5) on shoe (d) Back off locknut from turnbuckle, and secure with screws (7) and nuts (6). then turn cylinder counterclockwise until shaft is out of (c) Install spring (3) on eyebolt (2) and turnbuckle. secure with nut and cotterpin (4). (d) Install bolt (fig. 4-19) through actuating 4-33 TM 55-1925-204-12 (2) Disassembly. (a) Remove screws (1, fig. 4-21), lockwashers (2), and clamps (3). 1. 2. 3. 4. 5. 6. C. F. Screw 9. Ring, packing lockwasher 10. Cup Clamp 11. Piston Screw 12. Packing. performed Ring seal 13. Ring. packing Follower 14. Guide Cup 15. Packing, performed Follower 16. Retainer Figure 4-21. Brake air cylinder. (b) Remove screw (4) and ring seal (5) (a) Inspect cups (7 and 10) for from both ends, then remove ends and follower (6). deterioration. Replace a defective cup. Inspect ring (c) Remove cup (7), follower (8), and packing (9 and 13) for pinching or cuts. Replace ring, packing (9). Remove cup (10) and piston (11). defective packings. Remove packings (12). (b) Inspect piston (11) for scoring or (d) Remove ring, packing (13), guide scratches. Replace a defective piston. (14), packing (15) and retainer (16). (c) Replace performed packings (12 and (3) Cleaning, inspection, and repair. Clean all 15). (4) Reassembly. Reverse the procedure in parts in clean fuel oil and wipe dry. step 4-34 TM 55-1925-204-12 (2) (a) through (d) above and assemble the brake air cylinder. (5) Installation. Install the brake air cylinder by reversing the procedure in step (1) (a) through (d) above. e. Cam Operated Pilot Air Valve. (1) Removal. (a) Close globe shutoff valve (fig. 4-18). (b) Disconnect union Figure 4-22. Cam operated pilot air value (fig. 4-22), remove mounting screws, then remove cam operated pilot air valve. (2) Inspection. Inspect the cam operated pilot f. Pressure Regulating Valve. air valve for worn roller, loose arm, or other defect. (1) Removal. Replace a defective pilot air valve. (a) Close the shutoff valve (fig. 4-18). (3) Installation. Install the pilot air valve by (b) Disconnect inlet and outlet air lines. reversing the removal procedures in step (1) (a) and (b) (c) Remove nuts (19, fig. 4-23) from above. studs on bracket (18), then remove body (20). 4-35 TM 55-1925-204-12 1. Nut 8. Retainer 15. 2. Bolt 9. Valve 16. 3. Gasket 10. Packing 17. 4. Diaphragm 11. Gasket 18. 5. Packing 12. Gasket 19. 6. Spring 13. Valve 20. 7. Spring 14. Gasket 21. Figure 4-23. Pressure regulating value. 4-36 Gasket Strainer Retaining ring Bracket Nut Body Cover TM 55-1925-204-12 (d) Remove gasket (14), retaining ring (17), strainer (16) and gasket (15). (e) Remove nuts (1), bolts (2), cover (21), and gasket (3), then remove diaphragm (4). (f) Remove retainer (8), springs (7 and 6), packing (5), then remove nuts, cover and spring from valve (9). (g) Remove packing (10), gaskets (11 and 12), then remove valve (13). Discard all packing and gaskets. (2) Cleaning, inspection, and repair. (a) Clean all parts in clean fuel oil and wipe dry, except the sediment strainers should be blown clean with ships service air. (b) Inspect springs for loss of tension, or breaks. Replace defective springs. (c) Inspect valves for clogged condition or corrosion from moisture. Replace a defective valve. (d) Check the diaphragm for deterioration. Replace a defective diaphragm. (3) Reassembly. Assemble by reversing the procedures used in step (2) (a) through (d) above. Replace all packings and gaskets with new at reassembly. 4-37 (4) Installation. Install be reversing the procedures used in step (1), (a) through (c) above. g. Pressure Gage. (1) Removal. (a) Close shutoff valve (fig. 4-18). (b) Unscrew pressure gage from the line. (2) Cleaning and inspection. (a) Wash the exterior of gage with a cloth dampened in fuel oil and wipe dry. (b) Inspect the gage for damage to case or glass. Look for signs of damage to indicating dial. Replace a defective pressure gage. (3) Test. (a) Install gage in a line with a controlled source of air. (b) Compare reading of dial with the gage on controlled source. If variance is more than 5 psi, replace the gage. (4) Installation. (a) Wipe threads of connection with a sealant such as white lead, then screw gage onto line. (b) Open the globe shutoff valve (fig. 418). TM 55-1925-204-12 CHAPTER 5 MATERIEL USED IN CONJUNCTION WITH THE TUG Section I. AUXILIARY SET 5-1. General a. Component Characteristics. This set consists of the following described components (two sets installed on each harbor tug): (1) Engine, diesel, model 4061A. A four cylinder, 2-cycle, counterclockwise rotation diesel engine, with a governed speed of 1,450 rpm, and rated at 80 brake horsepower. (2) Generator. A dripproof, single ball bearing, stabilized shunt-wound, direct current generator, model I3644, rated at 40 kw, 120 vdc, at 1,450 rpm (4, fig. 5-1). 1. Fire and salvage pump 10. Governor 2. Clutch. priming pump 11 Oil cooler 3. Pump. priming 12. Accessory belt cover 4. Generator 40 kw 13. Fresh water pump 5. Fuel filter 14. Raw water pump 6. Air cleaner 15. Engine blower 7. Hand nut 16. Electric starter 8. Rocker arm cover 17. Fire pump discharge 9. Heat exchanger 18. Clutch lever Figure 5-1. Auxiliary set, three quarter right front vieu'. 5-1 TM 55-1925-204-12 or as a salvage unit in salvage operations through the eductor system. c. Maintenance. Maintenance instructions for the various components are given in the following paragraphs of this section. (3) Fire and salvage pump. A 2-stage horizontally splitcase, all bronze centrifugal pump, connected to the generator shaft through a manually operated friction clutch. The pump has a 5 inch suction; 4 inch discharge (17), and is rated at 500 gpm at 100 psi. (4) Priming pump. An all bronze rotary pump, v-belt driven from main pump shaft, and manually operated through a dry friction type clutch, is used to prime the main pump when necessary. 5-2. Engine (Model 4061A) Accessories a. General. The auxiliary sets are installed in close quarters aboard ship, in an area where the complete unit, can be handily removed with partial disassembly, which includes removal of certain externally mounted accessories. Accessories are listed below. b. Purpose. The basic purpose of this unit, is to furnish electrical power for the vessels electrical system. Its auxiliary use, is as a fire fighting unit, 1. Rocker arm cover 6. Clutch, fire and salvage pump 2. Instrument panel 7. Oil filter 3 Strainer, priming pump 8. Engine generator 4. Belt, priming pump drive 9. Exhaust manifold 5. Fire pump suction Figure 5-2. Auxiliary set, three-quarter left rear view. scavenging, and maintain their efficiency for a reasonable NOTE time before requiring service. This air cleaner is the oil To perform maintenance aboard ship, bath type. remove only those accessories (1) Removal. Unscrew the thumb screw (fig. necessary for access to the item being 53), then lift body off the blower housing carefully to avoid repaired. spilling of oil bath. b. Air Cleaner. The air cleaner is designed to remove foreign matter from the air, pass the required volume of air for proper combustion and 5-2 TM 55-1925-204-12 Figure 5-3. Air cleaner, starter, and fuel filter. 5-3 TM 55-1925-204-12 (a) Tag and disconnect electrical leads (2) Installation. Reverse the procedures used in removal to install the air cleaner, using a new preformed packing for the air cleaner body. c. Fuel Filter. The fuel filter removes foreign matter from the fuel before it enters the fuel pump. (1) Removal. Shut off fuel supply to the engine, then remove fuel filter as follows: (a) Refer to figure 5-3, remove the two fuel lines. (b) Remove the two mounting capscrews, then remove fuel filter from its mounting bracket. NOTE If engine is going in for overhaul, remove the capscrews securing the mounting bracket, instead of those securing fuel filter to the bracket . (2) Installation. (a) Position fuel filter (and bracket) to engine and secure with the capscrews. (b) Install the two fuel lines. (c) Open fuel line to the engine. d. Engine Electrical Starter. (1) Removal. (fig. 5-3). (b) Remove the starter mounting capscrews securing starter to the flywheel housing, then disengage teeth of starter from the flywheel ring gear, and lift starter from the engine. Remove gasket from flywheel housing and discard. (2) Installation. (a) Position a new gasket on starter apeture in the flywheel housing, position the starter drive into flywheel housing, then secure with the capscrews. (b) Remove tage and install the electrical leads. e. Raw Water Pump. This pump supplies water to the heat exchanger. (1) Removal. Shutoff fresh and raw water supply to the engine (table 2-3). Then proceed as follows: (a) Loosen hose clamps (fig. 5-4) and disconnect inlet and outlet raw water lines from the pump. 5-4 TM 55-1925-204-12 Figure 5-4. Raw water pump, lines, and rocker arm cover (1) Removal. Shutoff the fresh and raw water supply to the engine (table 2. 3), and proceed as follows: (a) Drain the engine cooling system. (b) Loosen hose clamps (fig. 5-5) and remove hose connection. (b) Remove mounting capscrews, then lift the raw water pump from the engine. (2) Installation. Install the raw water pump by reversing the procedures in step (1), and tightening the capscrews. f. Fresh Water Pump. The fresh water pump circulates fresh water from the heat exchanger through the engine. 5-5 TM 55-1925-204-12 Figure 5-5. Fresh water pump, lines and governor. (c) Remove three capscrews and lockwashers, then lift the fresh water pump and gasket from front of blower housing. (2) Installation. Install the fresh water pump by reversing the procedures in step (1) above, using new gaskets, and tighten capscrews securing pump to the blower. g. Governor. The hydraulically operated 5-6 TM 55-1925-204-12 governor controls fuel input to keep engine speed near constant under varying loads. (1) Removal. (a) Remove rocker arm cover by unscrewing the hand nuts (fig. 5-4) then lifting rocker arm cover (fig. 5-5), and gasket from the cylinder head. (b) Disconnect fuel rod extension from the injector control tube lever at rocker arms. (c) Remove end of the retracting spring from the throttle control arm (fig. 5-5), then remove cotter pin and pin from the arm. (d) Look at governors left side, at bottom, and disconnect the oil inlet line from the governor. (e) Remove the three screws and lockwashers from cover, and lift cover and gasket off the subcover. Remove the two capscrews and lockwashers from the subcover at the cylinder head. Remove two screws securing subcover to the governor housing. (f) Lift up on the subcover until a definite snap is heard to indicate that the fuel rod and collar have been separated from the terminal lever cross pin. Then, remove the subcover assembly, pulling the fuel rod out of the hole in the cylinder head and throttle control rod mounting bracket. (g) Remove the four capscrews and lockwashers securing governor to the governor drive, then lift governor off the drive housing. Remove the gasket. NOTE If the engine is being disassembled for overhaul, remove the governor drive from blower housing. (h) Remove six capscrews and lockwashers from governor drive, then lift governor drive and gasket from blower housing. (2) Installation. When the governor drive has been removed, proceed as follows: (a) Position a new gasket on blower housing, hold governor drive-in place and install six lockwashers and screws. Do not tighten screws at this time. NOTE If governor drive was not removed, skip (a) above and proceed as follows: (b) Loosen the six governor drive mounting capscrews until there is a little movement available to the housing. (c) Position a new gasket on top of the governor drive housing. (d) Position the governor over the drive housing with the maximum speed adjusting screw toward the cylinder head. Turn the ball head assembly slightly to align splines of shaft with splines of the driven shaft sleeve; then, place the governor shaft straight into the sleeve and position governor on the gasket and drive housing. (e) Install the four governor to drive housing lockwashers and capscrews. Tighten the capscrews to a torque of between 13-17 ft. lbs. 5-7 NOTE Draw nuts down uniformly and after tightening, revolve the drive shaft of the governor drive to check for bmding. Parts must move freely. (f) If the throttle control rod, and mounting bracket was removed earlier, position the bracket with new gaskets on both sides over the fuel rod of the subcover assembly. Position a subcover gasket on the governor housing. (g) Start the fuel rod of subcover through hole in cylinder head, move gasket and bracket up to the head; at the same time push in on the fuel rod knob and lower the subcover down on the governor housing so that the fuel rod enters the slot in the terminal lever cross pin, and the fuel rod collar rests in the front side of the terminal lever cross pin with the flat side of the collar adjacent to the side of the terminal lever. (h) Install the two subcover to governor housing screws and lockwashers. Tighten the screws securely. (i) Install the two lockwashers and capscrews through the flange of subcover, gasket, throttle control rod mounting bracket, and gasket, then thread them into the cylinder head. Tighten the capscrews to a torque of between 7-9 ft. lb. Then, (step (a) and/or (b) above) tighten the governor drive housing capscrews to a torque of between 13-17 ft lb. (j) If removed, install the oil supply line elbow in governor housing, then reconnect the oil inlet line to the elbow. (k) Install the retracting spring on speed adjusting shaft with the hooked end of spring facing out. Install the control lever on the speed adjusting shaft, then install capscrew, lockwasher and nut. Tighten the nut to 7-9 ft. lb. torque. (l) Install throttle control arm (fig. 5-5) over end of control lever, then install the link pin and the cotterpin. (m) Place the straight end of the retracting spring on top of the boss at side of the governor housing, then hook the opposite end of the spring over the control lever. (n) Connect the fuel rod to the injector control tube lever with pin and cotter pin. (o) Pour approximately one pint of engine oil in the top of the governor to provide initial governor lubrication. (p) Install a new gasket on top of the governor subcover, then install cover on top of the gasket and secure with three lockwashers and screws. Tighten the screws securely. (q) Position the control racks and make final adjustments as outlined under "adjustment". h. Fuel Pump. The fuel pump is mounted on the blower just below the blower drive shaft. (1) Removal. (a) Disconnect the fuel lines from the pump. TM 55-1925-204-12 (d) Connect the inlet and outlet fuel lines to the fuel pump. i. Blower. The blower is designed for diesel operation, and supplies fresh air from the air cleaner for combustion and scavenging. (1) Removal. Drain the engine cooling system, then remove governor (g. (1) above) and governor drive. (a) Remove fresh water pump (f. (1) above). (b) Remove the fuel pump (h. (1) above). (c) Disconnect the control wire from the air shut-down valve shaft lever (fig. 5-6), then remove capscrew anchoring the control wire clip to the air housing. (b) Remove the three capscrews with assembled washers, then lift the fuel pump and pump drive coupling fork from the blower. (2) Installation. (a) Position a new gasket on pump body mounting flange, and locate the pump drive coupling fork over the squared end of the drive shaft, with prongs of fork directed away from the pump. (b) Position the fuel pump up against the blower, with the prongs of the drive coupling fork lined up with the slots in drive disc on the blower rotor shaft. (c) Secure pump to blower with three capscrews and assembled washers. Figure 5-6. Blower, and air inlet housing. 5-8 TM 55-1925-204-12 (e) Slide the blower drive shaft cover seal into position against the blower drive gear hub support and tighten the seal clamp. (f) Install the blower drive shaft by pushing the plain end, without squared hole, of the shaft through the blower drive shaft coupling from the rear of the engine, then into the blower drive gear hub. If necessary, rotate the blower rotors slightly to align the splines of the drive shaft with those in the gear hub. Then, install the lock ring in the blower drive cam. (g) Install the flywheel housing small hole cover. (h) Attach control wire clip under the head of the air inlet housing mounting bolt, after gasket, screen, striker plate and air inlet housing have been mounted. Tighten air inlet housing mounting capscrews to a torque of between 16-20 ft lbs. (i) Install the fuel pump (h. (2) above). (j) Install the fresh water pump (f. (2) above). (k) Install the governor (g. (2) above) and drive. (d) Remove the four capscrews and lockwashers, then lift the air inlet housing, gasket, striker plate and air inlet screen and gasket from the blower. (e) Loosen the blower drive shaft cover seal clamp at the blower drive gear hub support. (f) Remove the eight capscrews and plain washers securing the blower to the cylinder block. Slide the blower slightly forward, withdraw the blower drive shaft cover from the seal, then lift the blower away from the cylinder block. NOTE Before installing blower to the engine, check inside of blower for any foreign material, and revolve the rotors by hand to be sure they torn freely. (2) Installation. (a) Place a new blower to block gasket to the cylinder block. Use an approved adhesive to prevent the gasket from shifting when placing the blower against the block. (b) Install a new drive shaft cover seal and seal clamp over the end of the drive shaft cover. (c) Position the blower against the cylinder block. Be careful not to dislodge the blower gasket. (d) Install the eight blower to cylinder block capscrews, and plain washers and tighten the capscrews to 55-60 ft lb. torque. j. Generator and Voltage Regulator. (1) Removal. (a) Remove belt guard (fig. 5-7) mounting capscrews and washers, then remove belt guard. 5-9 TM 55-1925-204-12 Figure 5-7. Belt guard, oil cooler, and engine mounting bolts (b) Tag and disconnect electrical leads from the generator voltage regulator (fig. 5-8), remove two regulator mounting nuts, 5 10 then lift regulator off the mounting bracket. If work is to be done on interior of the engine, remove regulator mounting bracket so the hand hole cover will be accessible. TM 55-1925-204-12 Figure 5-8. Engine generator and voltage regulator. (c) Loosen the generator adjusting bolt and move generator toward' engine block, then lift the drive belt off the pulley. (d) Remove the generator mounting bolts, nuts, and lockwashers, then lift generator away from the engine. (2) Installation. The generator and regulator are installed by reversing the procedures in step (1) above. k. Lubrication Oil Filter. (1) Removal. (a) Drain the engine lubricating system, if the engine is being torn completely down for repairs. 5-11 If only replacing filter, remove drain plug from bottom of adapter housing and drain the filter (fig. 5-8). (b) Tag and remove the two oil lines (inlet and outlet) from filter adaptor and engine block. (c) Remove the four capscrews and lockwashers securing the filter adaptor to the engine block, then lift filter away from the engine. (2) Installation. Install the lubricating oil filter by reversing the procedures in step (1) above. l. Exhaust Manifold ( Water Cooled ). (1) Removal. (a) Drain the engine cooling system. (b) Disconnect exhaust pipe from elbow (fig. 5-9). TM 55-1925-204-12 Figure 5-9. Exhaust pipe and elbow. (c) Loosen hose clamps and remove water return line from front end of exhaust manifold, and the oil cooler (fig. 5-10). 5-12 TM 55-1925-204-12 Figure 5-10. Water cooled exhaust manifold (d) Loosen hose clamps and remove water inlet hose from outlet end of exhaust manifold and the water manifold. (e) If a drain hose is installed on draincock, remove the drain hose. NOTE If the engine is being disassembled for reconditioning (overhaul) the water manifold, and water cooled exhaust manifold can be removed with the cylinder head, by removing the 10 cylinder head hold down nuts. However, for replacing manifold gaskets. proceed as described below. (f) Remove the five retaining nuts and washers from the studs securing the manifold to the engine block. The nut on the stud between the front two legs of manifold will not come off until the others are loosened, and the manifold is pulled away from the cylinder head the thickness of the nut. Remove the manifold. Remove the gasket. (2) Installation. (a) Position new manifold gasket over studs. (b) Lift manifold into position and barely hang it on studs, until the number two washer and nut is started on its stud, then move manifold up to the gasket and tighten nuts to a torque of 30-35 ft lbs. (c) Reconnect inlet and outlet water lines. 5-13 (d) Install drain hose, if used. Fill cooling system. m. Water Manifold. (1) Removal. (a) Drain the engine cooling system. (b) Disconnect and remove water line from exhaust manifold and water manifold (near the instrument panel) (fig. 5-9). (c) Loosen hose clamps and remove the hose connection between water manifold and the thermostat housing at top rear of heat exchanger expansion tank. (d) Remove the 12 nuts and washers that secure the water manifold legs to the cylinder head, then lift water manifold off the engine. Remove the four gaskets. (2) Installation. (a) Position new gaskets over the water manifold studs on cylinder head. (b) Position water manifold on studs, then secure water manifold with washers and nuts. Tighten nuts to a torque of between 25-30 ftlbs. (c) Install hose connection and two hose clamps on front end of water manifold and the thermostat housing, then tighten the two hose clamp screws. TM 55-1925-204-12 (d) Install the hose connection and two hose clamps between water manifold and the exhaust manifold, then tighten hose clamp screws. Fill the cooling system. n. Heat Exchanger and Oil Cooler. The oil cooler core may be removed for inspection and cleaning without removing the heat exchanger housing. See instructions for oil cooler maintenance (para 5-20). (1) Removal. (a) Drain the engine cooling system. (b) Drain the lubrication oil system. (c) Remove the six capscrews and washers securing the oil bypass line (fig. 5-7), then remove the bypass line from oil cooler and the engine. (d) Loosen two hose clamps and remove the raw water hose connection (fig. 5-6) inlet. (e) Loosen hose clamps and remove the water hose connection betweenexhaust manifold and oil coole (f) Loosen the two hose clamps and remove the hose connection between the water manifold and the thermostat housing of heat exchanger expansion tank. Repeat the above at the raw water discharge on port side of heat exchanger. (g) Loosen the two hose clamps securing the suction water line hose connection to the fresh water pump under the governor mounting bracket, and remove the hose connection. (h) Remove the four capscrews and lockwashers from the bosses on rear of expansion tank (fig. 5-6) and the oil cooler housing that secures the heat exchanger to the engine block cover, then lift heat exchanger away from the engine. NOTE Disassembly and repair of the heat exchanger is covered in paragraph 5-20 (2) Installation. When the heat exchanger has been cleaned, repaired, and reassembled it is ready for installation as follows: (a) Lift the assembled heat exchanger into position at front of the engine, install the four washers and capscrews through engine front cover into bosses on the heat exchanger housing. Tighten to a torque of between 25-30 ft lbs. (b) Install hose connections and clamps to all inlet and outlet water lines, including the raw water discharge line, by reversing the procedures in step (1), ( (d) through (g) ) above. (c) Install the oil bypass line by reversing the procedure in (1), (c) above. (d) Fill the engine lubrication system (LO 5-14 (e) Fill the engine cooling system. o. Valve Rocker Cover. (1) Removal. (a) Turn the two hand nuts counterclockwise to loosen. (b) Grasp handle, then lift the valve rocker cover off the cylinder head. Remove the gasket. (2) Installation. Install the valve rocker cover by reversing the procedures in (1) above. 5-3. Cylinder Head a. General The cylinder head is a one piece casting in which the exhaust valves and fuel injectors are installed. The valve and injector operating mechanism, and the injector fuel control mechanism are installed on the cylinder head. Each cylinder has three rocker arms. Two for the exhaust valves, and one for the fuel injector. Each operating unit includes push rods, push rod seats, push rod springs, spring retainers, rocker arm shaft brackets, shaft, bolts, fuel lines, and fuel control rod. b. Removal. When servicing the cylinder head components during regular maintenance procedures, remove only those accessories required for access to the cylinder head, and drain the cooling system to a level below the item to be removed. (1) Accessories. (a) Drain the cooling system as required. (b) Remove the required accessories (para 5- 2), including the rocker arm cover. (c) Disconnect the water manifold from the heat exchanger expansion tank (at the thermostat housing). (d) Disconnect the throttle control rod at the governor. (e) Disconnect the governor fuel rod from the injector control tube lever. (f) Remove governor cover and subcover (para 5-2, g.). (g) Disconnect fuel drain line from the cylinder head. (h) Remove the injector control shaft (fig. 5-11) from the cylinder head. CAUTION Immediately after removing fuel lines from the injectors and fuel manifold, cover all openings to prevent contamination of the fuel system, or damage to fittings . TM 55-1925-204-12 Figure 5-11. Removing injector control shaft and fuel lines. (i) Remove fuel lines from injector and manifold. CAUTION (j) Tag and disconnect electrical leads from the instruments, and lines from pressure gages, then remove the instrument panel. Remove the throttle control rod. Do not set the cylinder head down with bottom flat on bench or floor. The cam followers and injectors project below the bottom surface of the head, and would be damaged. Use blocks for support. (k) Loosen (three or four turns) the two bolts directly below each lifter bracket. These bolts attach the balance weight cover to the front end plate, and the flywheel housing to the rear end plate. They could interfere with cylinder head being lifted off the block. (c) Move the cylinder head to a clear work area for further maintenance. Remove cylinder head gaskets, and oil and water seals. (l) Remove the two capscrews securing the front lifter bracket to the balance weight cover. Also remove the two capscrews securing rear lifter bracket to flywheel housing. c. Disassembly. (1) Fuel injectors. Remove the fuel injectors by removing nut from the injector clamp, then use the injector removing tool (table 4-1) to lift the injector from the cylinder head. (m) Remove the two capscrews securing the heat exchanger vent casting to the balance weight cover, and the two capscrews securing vent casting to the heat exchanger expansion tank, then, remove casting and gasket. (2) (a) Remove fuel line connectors. (b) Remove the studs that secures the valve rocker cover to cylinder head. Cylinder head. (a) Remove the 10 nuts from studs securing cylinder head to the block. (c) Remove the front and rear lifter brackets. (b) Insert lifting hooks into eyes of front and rear lifter brackets; then, raise the cylinder head slowly and uniformly off the studs to avoid stud thread damage. (d) Remove all external fuel oil line fittings. (2) Rocker arms and valves. Remove bolts (fig. 5-12) from brackets, then withdraw shaft from the rocker arms. Backoff locknuts, unscrew rocker arm clevis from the push rods, then remove the rocker arms. 5-15 Figure 5-12. Rocker arms and push rods. (a) Remove guide (fig. 5. 12), then move the cam follower and push rod assembly out from bottom of the cylinder head. Use push rod remover (table 4-1). Repeat for all three remaining valve groups. (b) Compress spring, then snap spring retainer from its groove in the cam follower, and remove the upper spring seat, spring, lower spring seat, and push rod from the cam follower. (c) Compress the valve spring (fig. 5-13), remove the valve lock, spring cap, spring, and spring seat from top of cylinder head. 5-16 Figure 5-13. Exhaust valves on two value, four cylinder head. (d) Remove valve from guide by pushing stem through the guide, then pulling valve out of guide at the bottom of the cylinder head. Tag each valve for identification of guide from which removed, to facilitate installation at reassembly. (a) Wash the cylinder head with clean fuel oil and blow dry with compressed air. (b) Position the cylinder head on its side (fig. 5-14). (3) Valve seat removal (as required). Figure 5-14. Removal of valve seat. (c)Place the collet of remover inside the seat so that the bottom of the collet is flush with the bottom of the seat. (g) Turn T-handler to loosen collet cone, then move the remover into the seat slightly so that the narrow flange at the bottom of the collet is below the valve seat. (d) Hold the collet handle and turn the Thandle to expand the collet cone until the seat is held securely by the remover. (h) Tighten the T-handler of remover, then continue to drive the seat out of the cylinder head. (e) Insert the driver bar of the remover through the valve guide. (4) (f) Tap the bar once or twice to move the seat about 1/16 in. away from its seat in the cylinder head. 5-17 Exhaust valve guide removal. (a) Support the cylinder head, bottom side up, on 2 in. thick wood blocks. (b) Use the valve guide remover (table 4-1) and drive the valve guide (s) out of the cylinder head. d. Cleaning, Inspection, and Repair. (1) Cylinder head. After the cylinder head has been stripped of its components parts, proceed as follows: (a) Clean the cylinder head thoroughly, then brush all gasket surfaces to be sure no bits or pieces cling to the cylinder head. (b) Remove all carbon and dirt from the exhaust passages (ports). (c) Pay particular attention to gummy sludge in push rod bores, or domes of cylinders on bottom of the cylinder head. (d) Inspect the cam follower bores in the cylinder head for scoring or wear. Light score marks may be cleaned up with crocus cloth dampened in fuel oil. Check that maximum diameter of bore in a used head does not exceed 1. 065 inch. Replace a head where bores are excessively worn. (2) Rocker arms, push rods, and valves. Install the valves, push rods and rocker arms by reversing the procedures in C. (2) above. f. Installation. Make a pre-installation inspection of the cylinder head just prior to installation, by checking studs for damaged threads; extruded areas around stud holes; liner height in relation to the cylinder block; that tops of pistons are clean and free of foreign material; no burrs in any bore or counterbore, then check to assure that all push rods are threaded fully into the clevis until end of rod protrudes from top of clevis. (1) Cylinder head installation. (a) Position compression gaskets, water, and oil seals on block, as follows: 1. Position a new gasket on cylinder liners. 2. Position new seal rings in the counterbores of the water and oil holes in cylinder block. 3. Install a new oil seal in the groove at the perimeter of the cylinder block. NOTE CAUTION Never reuse old gaskets and seals. Incorrect placement of new gaskets could block lubricating passages and damage the engine. Thoroughly clean a replacement cylinder head of all rust preventive compound by soaking the head in clean fuel oil, then go over the head and through all of the passages with a soft bristle brush. Blow all oil passages dry with compressed air. (21 Components of cylinder head. (b) Wipe the under side of the cylinder head clean. Insert hoist hooks in the vent holes of the cylinder head, or the eyes of lifter brackets (if installed). (c) Make a final visual check of all gaskets and seals. (d) Lower cylinder head over studs, until the head is about 1/2 inch above the block. (e) Recheck position of all gaskets and seals. (f) Lower head into place. After the head is in place, loosen the lifter bracket-to-cylinder attaching capscrews before installing nuts on studs. If this is not done, the cylinder head may be prevented from seating properly against its gaskets and the cylinder block. (g) Draw the head down gradually and uniformly to insure a good seal. Tighten nuts to a torque of 180-190 ft. lbs. in the sequence shown on figure 5-15. (a) Clean all parts removed from the cylinder head in clean fuel oil, except the fuel injectors. The procedure to be used on fuel injectors is described in paragraph 5-13. (b) Inspect springs for tension, breaks, or bends. Replace a defective valve or push rod spring. (c) Scrape all carbon from stern and valve. Stems should be smooth. and free from scuff marks. Valve faces should be smooth, unpitted, and free of carbon ridges. If any of the above conditions exist, replace the defective valve. e. Reassembly. (1) Fuel injectors. Install the fuel injectors by reversing the procedure in C. (1) above. Figure 5-15. Sequence of tightening cylinder head nuts. 5-18 (2) Accessory replacement. Install all of the accessories removed in b. (1) above by reversing the removal procedure. (a) Fill the lubrication system (LO 55-1925204-12-5). (b) Fill the cooling system. 5-4. Pistons, Connecting Rods, and Piston Rings a. General. The pistons have a protective coating which permits close fitting of the piston. Four grooved rings are placed above the pin as a compression seal, and two oil control ings are placed below the pin to scrape excess lubricating oil from the cylinder wall. The cylinder liners are machined to form a slip fit in the cylinder block. Air inlet ports are located just above center and around the liner circumference. When in place in the engine, a flange at the top of each liner fits into a recess in the cylinder block. b. Removal. (1) Drain the lubrication and cooling systems. (2) Remove necessary accessories to free the cylinder head for removal (para 5-2). (3) Disconnect fuel and raw water lines from the engine. (4) Remove the starter and generator (para 52) from engine. (5) Disconnect the power generator (para 5-29) from the engine. NOTE Slide engine away from generator at least ½ inch to clear dowel pin on generator housing. (6) Position a hoisting device over the engine, place hooks in lifting brackets, remove engine mounting bolts, (fig. 5-7) then lift engine high enough to remove the oil pan. (7) Remove capscrews securing oil pan to the block, then remove oil pan. Remove the oil pump. (8) Use blocks high enough to allow access to the connecting rod bearings and the lubricating oil pump. then lower engine to reset on these blocks. WARNING Keep hoisting device attached and taut to the engine after removing the cylinder head, to avoid engine falling over and possible injury to personnel. (9) (10) Remove the cylinder head (para 5-3). Remove all carbon ridges from the cylinder liner (para 5-5). (11) Remove cotterpins, nuts, and bearing caps from lower end of connecting rod, then push piston and connecting rod out through top of the cylinder (s). NOTE Install connecting rod bearing cap on connecting rod as each one is remon ed to keep bearing halves matched. c. Disassembly. (1) Clamp piston in a soft vise, punch a hole in cap (13, fig. 5-16), and pry the cap from the piston (11). 5-19 1. 2. 3. 4. 5. 6. 7. 8. Nut Cotterpin Bearing cap Lower bearing half Upper bearing half Connecting rod Bolt Sleeve bearing 9. Spray nozzle 10. Oil rings and expanders 11. Piston 12. Sleeve bearing 13. Cap 14. Compression rings 15. Pin, piston 16. Cylinder liner Figure 5-16. Piston, connecting rod,cylinder and rings (2) Remove piston pin (15) and separate rod (6) from piston (11). (3) Drive remaining cap (13) from piston. (4) Remove rings (10 and 14) from the piston. (5) If damaged, remove sleeve bearings (8) from connecting rod (6), and sleeve bearings (12) from the piston (11). d. Cleaning, Inspection, and Repair. (1) Remove all carbon from ring grooves of piston. Grind the end of a discarded ring section and use for scraping carbon from grooves. (2) Clean oil holes in piston bottom with a 3/32inch drill bit in a hand drill. (3) Clean piston thoroughly (inside and out) with fuel oil, and dry with dry compressed air. If gummy deposits resist fuel oil, use solvent Fed Spec P-D-680 and dry with compressed sir. (4) If cylinder liners have been removed (para 55) clean bore of cylinder block, being sure the counterbore at top of cylinder is clean so that cylinder liner will fit properly. NOTE Liners may be cleaned without removal if inspection shows their condition does not warrant removal (see para 5-51. (5) Measurement of pistons and bore sizes in cylinder should be taken at room temperature (70°F). Position a thickness gage leaf of 0. 005 inch between cylinder liner and piston skirt (fig. 5-17). Fit is correct if piston (less ring and pin) slides through the liner of its own weight. If a bind exists, remove piston and examine both piston and liner for burrs. Remove burrs with a flat honing stone. 5-20 Figure 5-17. Measuring piston clearance. (6) Inspect cooling surface on under side of the piston head. A coating of carbon indicates failure of cooling oil supply through the drilled passage in the connecting rod. Clean the orifice at bottom of connecting rod, and the spray nozzle (9, fig. 5-16) at the top to correct the trouble. (8) Fit piston rings into cylinder liner bore (fig. 518) one at a time. To make sure the ring is parallel with top of liner, use a piston to push ring into liner bore. Measure the end gap for compression rings at from 0. 020 to 0. 030 inch (0. 025 to 0. 040 inch for. chrome compression rings). Gap on oil control rings should be between 0. 010 to 0. 020 inch. The gap may be increased to minimum, by clamping a thin, flat, fine mill file in a vise and drawing ring ends across the file. (7) Inspect and measure inside diameter of piston pin sleeve bearings (12, fig. 5-16). If clearance exceeds 0. 010 inch, determine whether pin or bearing is worn. If pin diameter is less than 1. 4990 inch, replace pin. If inside diameter of the sleeve bearing is more than 1. 5030 inch, replace the sleeve bearing. 5-21 Figure 5-18. Measuring piston ring end gap. (9) Check ring side clearance in piston grooves with a thickness gage (fig. 5-19). Ring clearance in grooves should be as follows: (c) Third compression ring................................ ........................ 0.006 to 0.0085 inch. (d) Lower compression ring................................ ........................ 0.006 to 0.0085 inch. (e) Upper oil control ring................................ ....................... 0.0015 to 0.0055 inch. (f) Lower oil control ring................................ ....................... 0.0015 to 0.0055 inch. (a) Upper compression ring ................................ ....................... 0.010 to 0.0125 inch. (b) Second compression ring ................................ ....................... 0.008 to 0.0105 inch. 5-22 Figure 5-19. Checking poston ring side clearance. (10) Fit piston pin into connecting rod sleeve bearing. If pin to bearing clearance exceeds 0. 010 inch, determine which is worn. If pin diameter is less than 1. 4990 inch, replace the pin. If inside diameter of bearing is more than 1. 5020 inch, replace the bearing. (3) Position upper end of connecting rod in line with pin aperture. Lubricate piston pin (15) with clean lubricating oil, and slide it into position. (4) Insert the second cap (13) behind piston pin and tap it into position. (11) Inspect and open hole in orifice at lower end, and holes in spray nozzle at upper end of the connecting rod. Blow dry compressed air through the passages to be sure they are all open. (5) Install oil ring expanders in grooves on skirt of piston, then install oil control rings (10) in grooves over the expanders. (12) Because the connecting rod bearing load is on the upper half, any wear will show only on the upper half. Examine upper bearing halves for scoring, chipping, corrosion, cracking, or the discoloration caused by overheating. Inspect the backs of bearing halves for any. bright spots that indicate halves have been moving in their support, and are unfit for further use. Replace bearings where any of the above defects exist. (6) Install compression rings (14) in grooves at top of piston, putting ring in fourth (bottom) groove first, then up to next groove until all are in place. Move rings in grooves until end gaps are 900 from each other. NOTE Be sure that cylinder liner has been serviced (para 55) before pistons are installed. (13) Inspect journals of the crankshaft. If they are scored, or show the discoloration of overheating, replace the crankshaft (para 5-8). f. Installation. (1) Lubricate surface of piston and rings with clean engine oil, stagger end gaps at 90° around piston, then use ring compressor and compress rings into their grooves. e. Reassembly. (1) If sleeve bearings (8 or 12, fig. 5-16) were removed, install them now. (2) Lower piston rod into liner with the identifying number on rod toward the blower side of the block. Align the connecting rod bearing with the connecting rod journal, and push the piston into the liner (fig. 5-20). (2) Insert a serviceable cap (13) in one end of the piston pin aperture and drive it into position. 5-23 (12) (13) (para 5-29). Install starter and generator (para 5-2). Reconnect the power generator to engine 5-5. Cylinder Liner a. General. The replaceable type cylinder liner is accurately machined and heat treated to provide a long wearing, scuff resistant surface. A flange at the top fits into a counterbore in the cylinder block and rests on a replaceable cast iron insert which permits accurate alignment of the liner. Compression is sealed with an individual laminated compression gasket for each cylinder. The liner is cooled by the waterjacket in block, and by the scavenging air furnished by the blower, through air inlets in liner. NOTE If necessary, the air inlet ports may be cleaned without removing the liner. b. Cleaning the Installed Liner. Figure 5-20. Compressing the piston rings. (1) Remove the cylinder head (para 5-3). (2) Remove the air box handhole covers. (3) Install a cylinder liner hold down clamp (fig. 5-21). NOTE Compressors are not always wide enough to compress six rings of this size at once. If this is true here, compress the bottom pair first, until they have entered the liner, then move compressor to the top four. (3) Wipe clean, then lubricate journal. Position the upper bearing half (5, fig. 5-16) (the one with a short groove at each parting line) in the connecting rod, and position the rod and bearing half on the journal. (4) Note match marks on bearing caps. Install lower bearing half in bearing cap with tang of bearing half in groove of cap. Position the cap and bearing, then install bolts (7) through rod and cap. Torque bolts to 50 ft. lbs. and install new cotterpins. (5) Install remaining pistons in a similar manner. (6) Install lubricating oil pump and screen (para 510). (7) Position a new oil pan gasket on pan, position pan under block, and secure with lockwashers and capscrews. (8) Tighten hoist, remove blocks from under engine, then slide engine to engine mount while guiding it onto pilot pin in generator housing and in position to receive the mounting bolts. Lower engine when in place. (9) Replace the cylinder head (para 5-3) and all accessories removed (para 5-2) in reverse order of their removal. (10) Fill crankcase with engine oil (LO 55-1925204-12-5). Figure 5-21. Cylinder liner hold down clamp. (4) Turn engine over until the piston of the liner whose ports are to be cleaned, is at the bottom of its stroke. (5) Position a cloth on top of piston, to catch carbon removed from liner ridges and ports. Clean all ridges and ports with a suitable tool or a hardwood stick, from the inside of each liner. (11) Fill the fresh water cooling system, after reconnecting fuel and raw water lines to the engine. 5-24 (6) Remove cloth from each piston top carefully so that no carbon falls in cylinder, then remove all chunks of carbon from the air box, and be sure the air box drains are open. (2) Use cylinder liner remover (table 4-1) when removing a cylinder liner. NOTE (7) After cleaning the ports, examine the inside of liners for burrs. Remove burrs by hand with 250 grit emery paper. If you do not remove all burrs, it will lead to early failure of rings and pistons. (8) Remove the hold down clamp, and clean remaining liners in a similar manner. (9) With all hold down clamps removed, install cylinder head (para 5-3) and the air box covers. c. Removal. (1) It is very important that the proper method is followed when removing liners. Do not attempt to push the liner out by inserting a bar in the liner ports and rotating the crankshaft, otherwise the piston may be damaged, or the upper ring groove may collapse. (3) Prior to removing a liner, check measurement of interior of the liner with an inside micrometer (fig. 5-22). Check measurements at room temperature of 70°F. Remove piston and connecting rod (para 54). Figure 5-22. Cylinder liner measurement diagram. 5-25 (4) When necessary, remove liner with tool as follows: cock the lower puller clamp (9, fig. 5-23) on puller rod (1), so rod will slip through the liner. When rod is completely through liner, clamp will seat in a horizontal position. 1. 2. 3. 4. 5. Puller rod Puller weight Puller clamp release Puller clamp, upper Cylinder liner 6. 7. 8. 9. Cylinder block Nut Washer Puller clamp. lower Figure 5-23. Cylinder liner removal. (5) Slide upper puller clamp (4) against top edge of liner. With puller tool in place, strike head of puller rod (1) a sharp blow with puller weight (2) carbon deposits, the liners may be soaked in a hot caustic soda or lye solution long enough to loosen the carbon deposits. (6) Remove cylinder liner from cylinder block. Remove tool from liner, then remove liner insert from counterbore of the block. d. Cleaning and Inspection. (2) Final cleaning may then be accomplished by brushing carbon away from ports. (1) (3) Inspect the cylinder liners for cracks, scoring, poor contact of outer surfaces, flange irregularities, inside diameter, out-of-round, or When fuel oil washing does not remove all 5-26 NOTE taper. Discard liners that are cracked or excessively scored. Honing of liners should be accomplished while liner is in a fixture ( a scrap cylinder block makes an excellent fixture. However, if liner must be honed in the block that must he used when assembling the engine, the engine must be dismantled and thoroughly cleaned to remove all abrasive material. (4) When a liner has been in use for an extended period, the inside surface of the liner becomes very smooth. This is known as a "glazed bore". When seating new rings, this glaze must be removed, even though liner is within dimensional specifications. Before installing the liner in the cylinder block, work a honing tool with a 120-grit stone up and down in liner bore several times, to remove the glaze. This honing will also remove any ridges formed at top of piston travel. e. Installation. (1) Wipe inside and outside of liner clean, and be sure bore in block is also clean. Also, be sure the counterbore in block is clean so the liner insert will fit properly (fig. 5-24). Figure 5-24. Cylinder liner mounted in block. (2) Assure that liner insert is in place on the counterbore. (3) Push the liner into the block until liner flange rests on the insert. If the liner does not slide easily into position, withdraw the liner, rotate it 90° and reinstall it. Do not use excessive force in installing the liner. (4) Clamp the liner in place with a holddown clamp, and measure distance from top of liner to top of block with a dial indicator. The liner flange must be 0. 045 to 0. 050 inch below the surface of the block. However, even though all of the liners are within these specifications, there must not be over 0. 002 inch difference in depth between any two adjacent liners. If the above limits are not met, install the liner in another cylinder and recheck, or use a new liner. 5-6. Flywheel Assembly and Housing a. General. The flywheel is bolted securely to the end of the crankshaft with six bolts and is doweled in two places. Since one of the bolt holes is offset, the flywheel can be attached to the crankshaft in only one-position. Self locking bolts are used to secure the flywheel. A scuff plate is used between bolt heads and the flywheel, to prevent bolt heads from scoring the flywheel. The power generator (Delco Model 1-3644) is directly, connected to the engine flywheel. Doweled into position, a flange on generator shaft is bolted to the flywheel (para 5-29). b. Removal. (1) Disconnect power generator from the engine flywheel (para 5-29). NOTE If the flywheel drive flange, for bolting generator matching flange has an internal spline, remove the drive flange before attaching flywheel lifting tool. (2) Attach flywheel lifting tool with two 7/1614 bolts of suitable length after removing the six flywheel attaching bolts. (3) Attach a chain hoist, or other lifting device to support the flywheel. 5-27 (4) Move the upper end of lifting tool about to assist in loosening flywheel from shaft, then withdraw flywheel from crankshaft and flywheel housing. c. Cleaning, Inspection, and Repair. (1) Wash flywheel with clean fuel oil and blow dry with compressed air. (2) Inspect flywheel face for scoring, overheating discoloration, or cracks. Replace a defective flywheel. (3) Inspect the ring gear for excessive wear or damaged teeth. If ring gear is defective, replace it as described in d. below. d. Ring Gear Replacement. NOTE Be sure bolts are accurately tightened. Never exceed the specified torque. And. never apply compound between two surfaces, where maximum friction is required, such as between crankshaft and flywheel. (6) Mount a dial indicator on the flywheel housing and check runout at flange face. Maximum allowable runout is 0. 001 inch per inch of radius of flange. f. Flywheel Housing. The flywheel housing is a one piece casting mounted against the rear end plate which is attached to the cylinder block, thus providing a cover for the gear train and flywheel. The flywheel housing is counterbored for a lip type oil seal that contacts the crankshaft (para 5-8 b. ). The housing will require little servicing, other than replacement of the oil seal. It will be necessary to remove the housing for this and certain other maintenance operations. (1) To remove the flywheel housing, proceed as follows: (a) Disconnect the power generator (para 529). (b) Remove any accessories attached to the flywheel housing (para 5-2), and drain the lubrication system. NOTE Make note of chamfered teeth so that the replacement ring will be installed with chamfer facing the same direction. (1) Support the flywheel (crankshaft side down) on a solid flat surface of hardwood block, which must be slightly smaller than the inside diameter of the ring gear. (2) Use a suitable drift and hammer to drive ring gear off the flywheel. Work around the circumference to avoid binding gear on the flywheel. (3) Install new ring gear on flywheel as follows: (a)Support the flywheel, ring gear side up, on a solid flat surface. NOTE CAUTION Slide engine away from power generator at least V2 inch to clear dowel pin on generator housing. Do not, under any circumstances, heat the gear over 400°F. , for excessive heating may destroy the original heat treatment. (c) Position a hoisting device over the engine, place hooks in lifting brackets, remove engine mounting bolts (fig. . 5-7), then lift engine high enough to remove the oil pan. (d) Remove capscrews securing oil pan to cylinder block, then remove the oil pan. (e) Position blocks under engine (keep housing free), lower engine to rest on blocks but keep hoist tight at front lifting bracket. (f) Remove two bolts securing rear lifter bracket (mounted on housing) to the cylinder head. This will leave bracket attached to flywheel housing for ease in handling. (g) Remove the flywheel (b. above). (h) Remove the twelve capscrews inside the housing cavity which attach the housing to the idler gear hub, spacer, and cylinder block. Remove the twelve remaining capscrews around the upper portion of the housing, and, the two capscrews that enter from front end plate and thread into the housing. (b) Rest the ring gear on a flat metal surface, with chamfer facing proper direction, then heat the ring gear uniformly with an acetylene torch, keeping the torch moving around the gear to avoid hot spots. (c) Use a pair of tongs to lift the ring gear into position of flywheel. Recheck chamfer direction. (d) Tap the heated gear into place against the shoulder on the flywheel. If the gear can not be tapped into position readily, remove it and apply additional heat. Heed caution above about overheating. e. Installation. (1) Check the extension of the dowel pins from the end of the crankshaft. They must not extend over 0. 500 inch beyond end. (2) Attach lifting device, as in removal above, then hoist flywheel into position on dowel pins of the crankshaft, with bolt holes aligned. (3) Remove flywheel lifting tool. (4) Position drive flange up against flywheel with holes in alignment. (i) With the flywheel housing supported by a hoist attached to the lifter bracket, use a soft hammer and strike the housing on alternate sides to work off the dowel pins and away from the rear end plate, then move housing away from engine. (5) Apply a small quantity of international compound no. 2 (or equivalent) to the threads and contact area of the six attaching bolts. Install and tighten the bolts to a torque of 150-160 ft. lbs. 5-28 (use valve removed from the guide), since worn guides result in improper valve seat contact. If clearance exceeds 0. 006 inch, replace the valve guide (para 5-3). (d) Inspect the valve seat for excessive wear, pitting, cracking, or improper seat angle. Remove a defective seat (para 5-3). Install a new valve seat as follows: (2) Install the flywheel housing by reversing the procedures of removal in step (1) above. 5-7. Valves, Camshaft, and Timing System a. General. Two exhaust valves are provided for each cylinder. The valves are heat treated and ground to the proper seat angle and diameter. Each valve stem is accurately ground to size, and hardened at the end which contacts the rocker arm. Valve seat inserts are pressed into cylinder head permitting accurate seating valves under varying conditions of temperature. Valves and seats are ground to a 30° seating angle. Valve springs are held 'in place by spring caps and tapered two piece locks. Excess oil from rocker arms lubricates the valve stem ends. Valves are cooled by blower air steam. The camshaft lobes move cam followers, which move push rods against the rocker arms, these in turn open the valves and the fuel injector. 1. Clean the valve seat counterbore with solvent Fed Spec P-D-680. Wash the new valve seat in the same solvent, and dry both with compressed air. 2. Inspect counterbores for cleanliness, concentricity, and flatness. Measure the diameter. It should be 1. 626 to 1. 627 inch diameter, and have a depth of 0. 3705 to 0. 3845 inch. The counterbores must be concentric with the valve guides within 0. 003 inch total indicator reading. NOTE b. Valves. If required, use valve seats that are 0. 010 inch oversize on outside diameter. (1) Removal. Remove the valves as described in paragraph 5-3, (cylinder head). (2) 3. Immerse the cylinder head for at least 30 minutes in water heated from 185°F. to 200°F. Cleaning, Inspection, and Repair. 4. Rest the warm cylinder head, bottom side up, on a work bench and position the seat squarely in the counterbore, seating face (30°) up. Install the seat while the cylinder head is still warm, and the seat is at room temperature (70°F. ), otherwise installation will be difficult, and the parts may be damaged. (a) Soak the valves (tagged for identification of port of removal) in clean fuel oil and wipe dry. Remove stubborn carbon with a sharp hardwood stick. Do not scratch or scuff stem or face. (b) Inspect the thoroughly cleaned valves for scuff marks on stem. The faces must be free of ridges, cracks, or pitting. Replace a defective valve. 5. Drive the seat in place with installer (table 4-1) until seated solidly in the cylinder head (fig. 5-25). Grind, or lap seats to valve face as outlined in (3) below. (c) Clean inside of valve guides with brush and fuel oil. Inspect guides for fractures, chipping, scoring, or excessive wear. Check the guide-to valve stem clearance 5-29 Figure 5-25. Installing valve seat. 6. Replace remaining valve seats as necessary, in a similar manner. (3) (d) When valve and seat have a uniform gray appearance, apply a small amount of Prussian blue or white chalk on valve face. Wipe off excess so just a faint trace of blue remains. Insert valve 'and turn valve on seat one complete revolution under slight pressure. If a light ring appears completely around the seat, valve is properly seated. If the ring is not complete, valve and seat are not making complete contact and must be reground until proper measurements are obtained. Reconditioning, or seating new valves. (a) Position cylinder head on workbench, bottom side up. (b) To grind valves, put a small quantity of grinding compound on valve faces. Grind valves with a light, but firm, pressure letting the light valve grinding spring lift the valve grinding tool handle. As soon as the "grinding feel" diminishes, wash valve and valve seat in fuel oil, and examine seat and valve. If valve seat or face has lines, either the valve grinding compound was ground out, or too much pressure was applied, or valve was not lifted off seats often enough during grinding operation. In either case the grinding operation must be repeated. Excess grinding can sometimes be prevented by removing the glaze on the valve seat prior to grinding. This is done by placing a circular piece of fine emery paper, slightly larger than the valve post, over stem of old valve. When valve is placed in position, emery paper comes in contact with valve seat. With a firm steady pressure on valve grinding tool, rotate valve several revolutions. (4) Installation. Install the valves, springs, caps, and locks as described in paragraph 5-3. c. Camshaft and Gear Train. The camshaft is located near top of the cylinder block, on the blower side. The balance shaft is opposite, and, the gear train is located at flywheel end of the engine. The cam and balance gears are driven by the idler gear, which receives its power from the crankshaft timing gear. (1) Removal. While the camshaft itself can be removed without removing the flywheel housing, the following procedure is given in order that the idler gear and bearing will be uncovered for sequential maintenance, along with the bearings and thrust washers of both cam and balance shaft. (c) In grinding valves and seats, finished seat should have contact surface width of no more than 1/8 inch to give good seating. Finished contact surfaces greater than 1/8 inch should be reported to Direct Support Maintenance level. (a) Refer to paragraph 5-2 and remove all accessories necessary to the removal of the front balance weight cover and the flywheel housing, including disconnect of the power generator described in paragraph 5-29 (e) Remove the fifteen capscrews. lockwashers, and plain washers securing the balance weight cover to the cylinder block and front end plate (fig. 5-26). (b) Remove the cylinder head (para 5-3). (c) Remove the flywheel housing (para 56). (d) Remove the heat exchanger (para 5-2). Figure 5-26. Balance weight cover removal and capscrew tightening sequence. (f) Remove the two capscrews attaching the lifter bracket to the cylinder head (if step (b) above has been delayed) then attach lifting device to lifter bracket. (g) Loosen and remove balance weight cover from the gasketed surface. Remove the gasket. 1. 2. 3. 4. 5. 6. 7. 8. Camshaft Cam Bearing, front Capscrew Lockwasher Thrust washer Balance weight Lockwasher 9. 1Nut 10. Plug 11. Key, machine 12. Thrust shoulder 13. Journal 14. Bearing, intermediate 16, Lockring 16. Setscrew (h) Shape a block of wood to fit between the two balance weights, or wedge a clean rag between the cam and balance shaft gears on rear of the engine. (i) Remove capscrews (22. fig. 5-27) then remove the nut retainer (21). 17. Bearing, rear 18. Gear 19. Weight 20. Nut 21. Retainer, nut 22. Capscrew 23, Balance weight 24. 25. 26. 27. 28. 29. 30. 31. Capscrew Balance shaft Bearing Thrust washer Balance weight Lockwasher Nut Thrust shoulder Figure 5-27. Typical camshaft and balance shaft details. 5-31 32. 33. 34. 35. 36. 37. 38. 39. Bearing. rear Gear Weight, integral Nut Retainer. nut Capscrew Balance weight Capscrew (j) Loosen nuts on both ends of the cam and balance shafts. Remove nuts (9 and 30). Do not remove nuts (20 and 35) at this time. hands and rocking in relation to the bearing. If there is any wobble. shake, or end play. the bearing MUST be replaced. If the gear is satisfactory, it is only necessary to check the pre-load before reinstallation (k) Remove the lockwashers (8 and 29). (l) Use two heavy screwdrivers, or pry bars, (one on either side of shaft) between bearing capscrews (4) and the balance weight, to force the balance weights off the shafts. (m) (q) Remove the bolt and washer securing the idler gear to end plate and cylinder block, then lift idler gear, hub, and spacer from the end plate. Remove the two thrust washers (6 and (2) 27) off the hub. Disassembly. (a) Support the cam, or balance shaft, in soft jaws of a bench vise. Be careful not to damage the cams, or thrust shoulders. (n) Remove capscrews (4) and lockwashers (5) from the rear bearings (17 and 32) by inserting a socket wrench through the holes in the webs of the cam and balance shaft drive gears (18 and 33). (b) Remove nut (20 and 35), then use a suitable puller and remove gear from the shaft. If necessary, remove capscrews (24 or 39) and weights (23 or 38). Also, if necessary, remove the machine keys (11) from the shafts. (o) Withdraw the camshaft (1), bearing (17), balance shaft (25), and bearing (32) from the rear end of the cylinder block. (c) Slide the rear bearing (17 or 32) from (p) Remove capscrews (4) and lockwashers (5) from bearings (3 and 26), then withdraw bearings from the front end plate and cylinder block. If the two remaining thrust washers (6 and 27) were not withdrawn with the shafts, remove them at this time. the shaft. (d) Remove the two lockrings (15) from each of the three intermediate bearings (14) and free the two halves. NOTE (e) Disassemble the idler gear as follows: Before removing the idler gear, check the gear, hub, and bearing for any perceptible end play, wobble, or shake by firmly grasping the rim of the gear with both 1. Remove the six bolts (fig. 5-28) and three lockplates which secures bearing retainer to the idler gear. Figure 5-28. Idler gear details and location of parts. 2. Clean the idler gear and bearing assembly with fuel oil and blow dry with compressed air. 3. Position the gear and bearing in an arbor press with bearing cone (inner race) supported on steel blocks. While rotating the gear rim, press the hub out of the bearing. Remove gear from the arbor press, then remove the bearing cones and spacer. NOTE Component parts of the idler gear bearing are mated; therefore, match mark the parts at disassembly to assure return to their original position. 5-32 (d) Start gears on shaft by hand, to align with the keyway, then use driver (table 4-1) to install the gears. 4. Tap the bearing cup (outer race) from the idler gear with a brass drift, alternately at the four notches provided around the shoulder of the gear. (3) Cleaning, inspection, and repair. (a) Wash all parts in clean fuel oil and blow dry with compressed air. Be sure that all foreign matter has been removed from oil passage in camshaft. (b) Examine the cams and journals. If the surfaces are badly scored or worn, replace the shaft. (c) Check the runout at center intermediate bearing with camshaft mounted on the end bearing surfaces. The runout should not exceed 0. 002 inch. (d) Inspect the thrust washers for scoring or wear. Measure clearance between thrust washer and thrust shoulder. With used (removed) parts, the clearance must not exceed 0. 018 inch. (e) Examine the faces of the shaft end bearings and any other surface which comes into contact with the thrust washers. Replace badly marred parts. Slight scratches may be cleaned up with an oil stone. (f) Inspect the bushings in the shaft end bearings. When bushings are worn, or if they have turned in the bearing, replace the end bearings. (g) Check clearance between shaft end journals end bearings. Replace end bearings when clearance is 0. 006 inch or more. (h) Inspect, the intermediate bearings for scoring or wear. Replace the intermediate bearings when badly scored, or clearance is 0. 009 inch. Discard lockscrews with damaged threads. Damaged holes in the cylinder head may be plugged, redrilled and tapped. (i) Wash the idler gear and bearing components in clean fuel oil and dry with compressed air. Inspect as follows: (e) Lubricate the camshaft intermediate bearing journals (13). Then place the two halves of the bearing (14) on a journal and secure the halves together with the two lockrings (15). Install each lockring with the gap over the upper half, with the ends an equal distance above the split line of the bearing. (f) Assemble and preload the idler gear, as follows: 1. Support the idler gear, shoulder down, on the bed of an arbor press and start the bearing cup (fig. 5-28) squarely into the bore of the gear. Then, press the cup tight against the shoulder of the gear, using a steel plate between the ram of the press and the bearing cup. 2. Support one bearing cone, numbered side down, on bed of arbor press and lower the gear and bearing cup down over the bearing cone. 3. Lay spacer ring on face of bearing cone. 4. Place the second bearing cone, numbered side up, in gear and bearing cup against the spacer ring. 5. Position the idler gear hub over the bearing cones so that the oil hole in the hub is 1800 from the gap in the spacer ring. 6. Press the hub into idler gear bearing cones while rotating the gear (to seat the rollers properly between cones), until the face of the hub which will be adjacent to the cylinder block end plate is flush with the corresponding face of the bearing cone. The bearing cones should be supported so as not to load the bearing rollers during this operation. 1. Inspect bearing carefully. When pitting, scoring, or flat spots are noticed, replace the bearing. 2. Check damaged or defective threads. hub and spacer for 3. Examine gear teeth for wear, pitting, or breaks. Also inspect other gears of the train. Replace a defective gear. (4) 7. To check pre-load, mount the idler gear on the engine, after lubricating the bearing with light engine oil. Secure with special washer and bolt to the end plate and the cylinder block. Torque bolt to 80-90 ft. lb. Reassembly. (a) Lubricate the rear cam and balance shaft journals and slide the rear bearings (17 and 32, fig. 527) on each shaft with the mounting flange of the bearing toward the gear end of shaft. 8. Place a steel plate, with matching holes to those in hub, over the idler gear hub and secure to hub with 3 capscrews. Tighten to a torque of 25-40 ft. lb. (b) If removed, install balance weights (23 and 38) on gears and secure with capscrews (24 and 39). 9. Tie one end of a piece of lintless 1/8 inch cord around a 1/8 inch round piece of wood (or soft metal stock). Place the wood between the teeth of the gear, then wrap the cord around the periphery of the gear several times. Attach the other end of the cord to a spring scale. Maintain a straight, steady pull on the scale, 900 to the axis of the hub, and note the pull, in pounds and ounces required to start the gear turning. Make several checks to obtain an average reading. If the pull is within 11/4 lb minimum to 6 lbs 12 ounces maximum and does not fluctuate more than 2 lbs (c) Install machine key (11), if removed. NOTE The left hand helix gear belongs on the camshaft. Right hand helix gear belongs on the balance shaft. 5-33 camshaft into block until cam gear teeth almost engage the teeth of the idler gear. Use care, and avoid damage to the cams. (b) Align the timing marks on the mating gears (fig. 5-29), then slide the camshaft gear into place.. 11 ounces, the idler gear and bearing assembly are satisfactory for use 10. Remove spring scale, cord and stick. Remove steel plate from face of gear. (5) Installation. (a) Insert front end of camshaft into the opening on blower side of the engine block. , Push the Figure 5-29. Gear train and timing marks. L. H. rotation. (c) Secure the camshaft rear bearing (17, fig. 5-27) to the cylinder block with the three lockwashers (5) and capscrews (4). The camshaft gear may be turned to accommodate the capscrews through the holes in the gear web. Tighten the capscrews to a torque of 35-40 ft. lbs. (f) Install the front end cam and balance shaft bearings. Do not hammer bearings into cylinder block, or the thrust washers may be dislodged. Secure the bearings with lockwashers (5) and capscrews (4). Tighten to a torque of 35-40 ft. lbs. (d) Install the balance shaft in a similar manner. (g) Apply grease to the steel face of the remaining thrust washers (6 and 27) and install them so that the steel faces are against the front end bearings (3 and 26). (e) Apply grease to the steel face of each thrust washer (6 and 27). Then place one against the thrust shoulder (31) of each shaft, making sure the steel face is toward the front end bearings. (h) Turn the camshaft intermediate bearings until the holes in the bearings line up with the 5-34 operating mechanism has been disturbed in any way, the valve clearance must be adjusted. Adjust to the cold setting first, to allow for normal expansion of engine parts during the warm-up period. This will insure a valve setting that is close enough to the specified clearance to prevent damage to the engine when it is started. threaded holes in cylinder block. Install the setscrews (16) and tighten to a torque of 15-20 ft lbs. (i) Be sure the machine keys (11) are in shafts. (k) Place a block of wood between the balance weights to block them from turning, then install lockwashers (8 and 29) and nut (9 and 30). Tighten nuts to a torque of 300-325 ft lbs. Remove wood block. (2) (a) Clean any loose dirt from exterior of the cylinder head. then remove the valve rocker cover (para 5-2, o. ). (l) Make one last check to assure that all timing marks are aligned and teeth of gears are meshed correctly, then install front end cover and the flywheel. Tighten balance weight cover capscrews in the numerical sequence shown on figure 5-26. (m) Adjusting valve clearance-engine cold. (b) Place the governor fuel rod in NOFUEL position. (c) Rotate the crankshaft manually, or with the starting motor, until the injector cam follower is fully depressed on the cylinder to be adjusted. Reconnect power generator (para 5-29). (n) Install cylinder head (para 5-3). CAUTION (o) Install accessories (para 5-2). When using a wrench on crankshaft bolt at front of engine to manually turn the engine over. do not turn in a left hand rotation. This will remove the bolt. d. Maintenance and Adjustment of Valve Clearance. (1) General. Smooth, efficient engine operation requires proper valve clearance adjustment at normal operating temperatures. When the cylinder head has been disassembled (para 5-3), or the exhaust valves have been reconditioned or replaced (b. (3) above), or the valve (d) Loosen the pushrod locknut (6, fig. 530). 5-35 1. 2. 3. 4. Injector rocker arm Thickness gage Valve rocker arm Valve stem 5. 6. 7. 8. Upper push rod Locknut Clevis, rod end Fuel lines Figure 5-30. Adjusting the valve clearance. (e) Place a 0. 013 inch leaf of the thickness gage (2) between the valve stem (4) and rocker arm (3). Adjust the pushrod to obtain a smooth "pull" on the thickness gage. (f) Remove the thickness gage. Hold the push rod with a 5/16 inch wrench and tighten the locknut with a l/2 inch wrench. (g) Recheck the clearance. At this time, if the adjustment is correct, the 0. 011 inch leaf will pass freely between valve stem and rocker arm, but the 0. 013 inch leaf will not pass through. (h) Check and adjust the remaining exhaust valves in a similar manner. (3) Adjusting valve clearance-engine hot. (b) Stop engine and check valve clearance, using same method as described in step (2) above, except, if the valve clearance is correct the 0. 008 inch leaf of thickness gage will pass freely through between valve stem and rocker arm, but the 0. 010 inch leaf will not. 5-8. Crankshaft a. General. The crankshaft is a one-piece steel forging, heat treated for strength and durability. The main and connecting rod journals and the oil seal surfaces are induction hardened. Each main bearing journal is 3. 500 inch in diameter. The connecting rod journal diameter is 2. 750 inch. Crankshaft wear is normally associated with bearing troubles. Therefore, when the main or connecting rod bearings are to be inspected, the crankshaft should also be inspected. If the (a) Run the engine until water temperature reaches 140°F. 5-36 crankshaft appears to be in good condition, it is unnecessary to remove the crankshaft to change main bearings (see c. below). b. Crankshaft Oil Seals. An oil seal is used at each end of the crankshaft to retain lubricating oil in the crankcase. (1) Front oil seal removal. (a) Remove the crankshaft pulley (d. below) . (b) Remove the vibration dampener (e below) . (c) Remove the front oil seal by using a small pry and working it out of the crankshaft front cover. Be very careful and avoid any damage to the crankshaft journal, or the oil seat in the cover, (2) Cleaning, inspection, and repair. (a) Clean the oil seat thoroughly, then inspect seat for scoring, or grooves on oil seat surfaces. Replace a defective oil seal. (b) Inspect crankshaft surface of oil seal contact for pitting or burrs. Slight ridges may be removed with 120 grit emery cloth, followed by 240 grit. Rotate crankshaft during this operation, to prevent an out-of-round condition. Use crocus cloth dampened with fuel oil to polish the surface. If this does not perfect the surfaces, replace the crankshaft. (3) Installation. There is a plastic coating on the outside diameter of new seals. Do not remove this coating. If, however the seal is not pre-coated, apply a non-hardening sealant to the periphery of the metal casing. Install as follows: (a) Apply a light coating of grease to the sealing lip, then position seal in seat with lip pointed toward the inner face of front cover (toward engine). (b) Drive seal into seat with a soft face hammer, tapping lightly around the circumference in order that it will be driven in evenly. (c) Remove all excess sealant from cover and seal. (d) Install the cankshaft front cover (f. below). (e) Install the vibration damper (e. below). (f) nstall the crankshaft pulley (d. below). (g) Install the generator drive belt, then replace the belt guard. (4) Rear oil seal removal. (a) Remove the flywheel housing (para 56). (b) Support the rear face of housing on wood blocks. (c) Drive the oil seal out of the housing. (5) Cleaning, inspection, and repair. (a) Clean the oil seat thoroughly, then inspect for scoring or grooves in seat. (b) Inspect surface of crankshaft at point of seal contact for pitting or burrs. Replace a defective crankshaft (g. below) (6) Installation. (a) Support the inner face of flywheel housing on a flat surface. (b) If used, install the spacer or sleeve. NOTE There is a plastic coating on the outside diameter of the current oil seal. Do not remove this coating. If the seal to be used is not pre-coated, apply a non-hardening sealant to the periphery of the metal casing (c) Position the seal with lip pointed toward the inner face (or shoulder of counterbore) of the housing. (d) Drive the seal into the housing by tapping gently with a soft hammer until it is seated in the counterbore, against spacer (if used) or on shoulder in the housing bore. (e) Install the flywheel housing (para 5-6). c. Main Bearings. Main sleeve bearings of the replaceable type are used at each journal. They consist of an upper half carried in the crankcase main bearing support, and a lower half seated in the main bearing cap. The bearing caps are numbered with their position 1, 2, 3, etc. , with matching numbers stamped on the bottom of the crankcase, on blower side. Each bearing cap must be installed in its same original position, and must register with a milled slot in the cylinder block to prevent side-to-side movement when bolted in-place. If main bearing trouble is suspected, remove the oil pan, then remove main bearing caps (one at a time) as outlined below and examine the bearing halves. NOTE All of the main bearing load of the engine is carried on the lower hearing halves, therefore wear will occur on them first Chipping, pitting, scoring. or overheating of the lower halves may be observed by removing hearing caps, one at a time. (1) Removal. When removal of main bearings becomes necessary, but removal of crankshaft is not required, proceed as follows: (a) Disconnect the power generator (para 529). (b) Drain lubrication system and cooling system . (c) Refer to paragraph 5-2 and remove accessories as required in order that engine may be hoisted out of mounting bed and turned up to expose the oil pan. (d) Remove the oil pan (para 5-4 b. (6). (7). (8), and warning). Remove the oil pump. NOTE If there are shims between legs of oil pump and hearing caps, tag for identification and save shims for installation. (e) Remove bolts (6, fig. main hearing caps 1: 5) (one at a time). 5-37 5-31) anti the 1. 2. 3. 4. 5. Bearing half. upper Thrust washer. upper , Gear, crankshaft timing Thrust washer. lower Main bearing cap 6. Bolt, rnain beanng cap 7. Front oil seat 8. Bolt, crankshaft pulley 9. Gear, oil pump drive 10. Crankshaft Figure 5-31. Crankshaft, main, and thrust bearings. (f) To remove all but the rear main upper half, use a /4 inch bolt that is one inch long, with a square head, and the head ground until it is only 1/4 inch thick. Insert this special bolt into the oil hole in journal (fig. 5-32) then turn crankshaft clockwise and roll the bearing half out of position in cylinder block. The head of the bolt must not extend beyond the outside diameter of the bearing half. NOTE two-piece thrust washers are used on each side of the rear main bearing. The lower half of these washers will be removed with the bearing cap. The upper halves can be removed by using a small rod to push on one end of half, and forcing it to revolve around shaft and out. 5-38 Figure 5-32. Removing main bearing upper half( u'ith crankshaft in place NOTE Prior to removing the upper bearing half check bearing-to-journal as described in (3) (c) below. (g) Remove the rear main bearing half by driving on edge of one end with a small rod (fig. 5;33) while at the same time revolving the crankshaft to roll the bearing half out of its position in the cylinder block. Figure 5-33. Removing rear main bearing upper half (with crankshaft in place ). (2) Cleaning, inspection, and repair. (a) Wash bearing half, bearing cap, and journal thoroughly, and wipe dry. (b) Inspect crankshaft journals for scoring or discoloration sign of overheating. Replace a defective crankshaft (g. below). Check back of bearing halves for shiny spots. Shiny spots indicate that bearing is not being held securely in the caps. (c) Check clearance between bearing half and crankshaft journal, before removing the upper half, place a short piece of soft lead wire in lower 5-39 bearing half and reinstall the lower half and the bearing cap. Torque bolts to 190 ft lbs. Remove bolts and bearing cap, then lift wire off the bearing and measure the thickness. If thickness of the flattened piece of wire exceeds 0. 006 inch, replace upper and lower bearing halves. (d) Inspect rear main bearing thrust washers for scoring. Replace defective thrust washers. End thrust, as measured between crankshaft flange and the thrust washer, should be between 0. 004 and 0. 011 inch new, and should never exceed 0. 018 inch. (3) Installation. Upper and lower bearing halves are not alike. Install as follows: (a) Lubricate the crankshaft journal, then take the grooved bearing half drilled for lubrication, and start the plain end, (as opposed to the end with a tang) around the crankshaft journal so that when the bearing half is in place, the tang will fit into a groove in the bearing support. (b) After upper rear main bearing half has been placed, in a manner similar to (a) above, take two of the serviceable thrust washer halves and slide one in each groove along side the upper half. Then, assemble the two lower half thrust washers over the dowel pins in the bearing cap. Install the cap, lubricate the threads of the two bolts, and secure the cap. Do not torque at this time. (c) After all bearings have been checked and replaced if necessary, draw bolts up snug, then rap caps sharply to seat them properly. Tighten to a torque of between 180-190 ft lbs. (d) Install the oil pump on locating dowel pins, secure with four lockwashers and capscrews, then tighten to a torque of 35-39 ft lbs. (e) Use a new gasket and install the oil pan. (f) Refill the engine lubricating system (LO 55-1925-204-12-5). d. Crankshaft Pulley. (1) Removal. Remove beltguard and belt, then proceed as follows: (a) Remove bolt and washer from pulley. (b) Use a gear puller and remove the crankshaft pulley from crankshaft. Withdraw machine key from shaft. (2) Cleaning, inspection, and repair. (a) Clean the pulley in fuel oil and wipe dry. (b) Inspect for cracks, or chips off edges of grooves. Replace defective crankshaft pulley. (3) Installation. (a) Wipe shaft end clean, then position the machine key in keyway. (b) Slide the pulley on the end of the crankshaft. (c) Position the washer on bolt and thread the bolt into the crankshaft, drawing the pulley tight. (d) Tighten pulley retaining bolt as follows: 1. Tighten to 180 ft lbs of torque. 2. Strike the end of bolt a sharp blow with a 2 or 3 lb lead hammer. 3. Tighten to 300 ft lb torque and strike the bolt again. 4. Tighten to a torque of between 290. 310 ft lb. (e) Install belt and beltguard (para 5-2). e. Vibration Damper. (1) Removal. (a) Remove crankshaft pulley (d. above. (b) Remove two of the damper-to-hub capscrews and lockwashers diametrically opposite each other. (c) Reinstall crankshaft bolt, then install puller and move damper enough to loosen the outer cone. Push damper back slightly, then use two thin shank screwdrivers to pry outer cone off crankshaft. CAUTION Do not pound with a hammer, or pry with other tools, in removing the viscous type damper from the crankshaft. To do so will dent the outer housing and cause the flywheel to turn at same speed as outer housing, thus making the damper ineffective. The damper can not be repaired. (d) Slide the vibration damper with damper hub as an assembly off the end of the crankshaft by hand. (e) Slide the inner cone off the crankshaft. CAUTION Do not allow fuel oil to remain on the rubber type vibration damper too long, but blow dry immediately after cleaning. The fuel oil may damage the rubber. (2) Cleaning and inspection. (a) Wash the damper in clean fuel oil and blow dry with compressed air immediately. (b) Inspect the rubber type damper to assure that all rubber is firmly bonded to the metal parts at each side. If the damper has been exposed to fuel oil, lubricating oil, or excessive heat too long, the rubber may have loosened. Inspect for dents in outer housing. Replace a damper with loosened rubber or dents in outer housing. (3) Installation. (a) Coat the lip of crankshaft front oil seal with a light grease. (b) Slide the inner cone (fig. 5-34), tapered end pointing to front end of crankshaft, over the crankshaft and against the seal. Figure 5-34. Typical vibration damper details. (c) If the light and heavy dampers were for any reason removed from the hub, assemble them on hub with flat faces toward each other and on dowel pins and secure with lockwashers and capscrews. (d) Slide the damper and hub as an assembly (long end of hub facing the crankshaft cover) into position on the crankshaft. NOTE Refer to the caution at end of (1) above about hammering on the damper. (e) Slide the outer cone over the crankshaft and into the hub of the damper. (f) Install the crankshaft pulley Id. above). f. Front Cover. (1) Removal. (a) Remove crankshaft pulley (d. above). (b) Remove vibration damper (e. above). (c) When removing the crankshaft, or preparing engine for overhaul, remove the front cover as follows: 1. Remove the seven capscrews, lockwashers, (and flatwashers if installed) securing front cover to front end plate (fig. 5-35). Figure 5-35. Crankshaft front cover details. 2. Remove front cover carefully, by striking it with a soft hammer to free cover from dowel pins, then pulling it straight off crankshaft. 3. Remove the front cover gasket and discard. 4. Inspect the oil seal for damage ordeterioration. Replace a defective oil seal (b. above). (2) Cleaning, inspection, and repair. (a) Wash cover with clean fuel oil and blow dry with compressed air. Remove bits of gasket from all gasketing surfaces. 5-41 (c) Coat the lip of front oil seal lightly with grease, then slide cover over the crankshaft carefully sliding it up to the front end plate. (b) Inspect cover for cracks or other defects. (c) Replace a defective cover. (d) Install flatwashers (if removed) and lockwashers on capscrews and thread them through front cover into front end plate. (3) Installation. (a) Install a new oil seal, if required (b. (e) Tighten the front cover attaching capscrews in the sequence shown on figure 5-36. Tighten 3/8 inch capscrews to a torque of 25-30 ft lbs, and the /2 -inch capscrews to a torque of 80-90 ft. lbs. above). (b) Shellac a new gasket to . the bolting flange of the crankshaft front cover. (f) Install crankshaft pulley (d. above). Figure 5-36. Crankshaft front cover attaching hardware tightening sequence. (d) Remove accessories as necessary (para5-2). (1) Removal. When removal of the crankshaft (e) Disconnect the power generator (para becomes necessary, proceed as follows: 5-29). (a) Clean exterior of engine thoroughly. (f) Remove all engine mounting bolts (fig. 5-7). (b) Drain the cooling system. g. Crankshaft. (g) Attach lifting sling to lifter brackets (c) Drain the lubrication system (LO 551925-205-12-5). 5-42 then hoist engine high enough for access to oil pan and bearing caps. followed by 240 grit for finishing. Then, wet crocus cloth should be used for the polishing operation. (h) Block engine for safety, but leave hoist attached with strain on lifters. 3. If the ridges are greater than 0. 001 inch, the crankshaft must be reground at higher maintenance. (i) Remove oil pan. pump (c. (1) (d) above). and lubricating oil 4. Inspect crankshaft for cracks. Replace a cracked crankshaft. (j) Remove flywheel and housing (para 5- (k) Remove crankshaft front cover If. (1) 5. Inspect the oil pump drive gear (9) for cracks or broken teeth. If cracked, or teeth broken, replace the oil pump drive gear. (l) Remove the connecting rod bearing caps, rods, (para 5-4). 6. Inspect the crankshaft timing gear (3) for cracks. or broken teeth. Replace a defective timing gear. 6). above). (d) Repair a crankshaft by components. Replace a defective crankshaft. (m) Remove the main bearing caps (c. (1). (e) above), but tag them for identification at reinstallation and remove all, at this time. replacing (3) Installation. (n) Remove crankshaft (10, fig. 5-31). NOTE (2) Cleaning, inspection, and repair. If a new crankshaft is to be installed. it must be. or have been. steam cleaned to remove rust preventive compound. and meet the dimensional requirements shown throughout subparagraph 12) above. (a) Clean the crankshaft by removing plugs from crankshaft and thoroughly cleaning all oil passages. (b) Support the crankshaft on V-blocks at the front and rear journals, and check the alignment at the adjacent intermediate journals by using a dial indicator. (a) Install the grooved upper main bearing halves in the cylinder block. NOTE (b) Apply clean engine oil to all crankshaft journals. and place the crankshaft in cylinder block so that the timing gear mark (R or L) meshes with the idler gear mark (fig. 5-29). When runout on adjacent journals is in the opposite direction, the sum must not exceed 0. 003 inch TIR (total indicator reading). When the runout on adjacent journals of the four cylinder crankshaft is in the same direction, the difference must not exceed 0. 003 inch TIR. If the runout at journals No. 2 and 4 is greater than 0. 002 inch, or runout at journal No. 3 is greater than 0. 004 inch, the crankshaft, must be replaced. (c) Install the upper and lower halves of thrust washers on each side of the upper and lower rear main bearing (c. (3) (b) above). (d) Install lower bearing halves in bearing caps, then position bearing caps on like numbered journals. and secure with bolts (6, fig. 5-31) drawn up snug. (e) Rap the bearing caps sharply with a soft hammer, and torque as described in c. (3) (c) above. (c) Inspect journals for ridging caused b'y groove in upper bearing half. If a ridge of 0. 0002 inch exists, it must be removed before the bearings are reinstalled. Proceed as follows: NOTE If the bearings have been properly installed. the crankshaft will turn freely with bolts torqued to specifications. 1. Work a piece of crocus cloth, wet with fuel oil, around the circumference of the journal. Rotate the crankshaft frequently during this process to eliminate an out-of-round condition. (f) Use dial indicator installed at edge of the crankshaft timing gear to measure crankshaft end play (fig. 5-37). 2. If the ridges are greater than 0. 0005 inch, first use 120 grit emery cloth to clean up the ridge, 5-43 (t) Fill the lubricating system (LO 551925204-12-5). (u) Fill the engine cooling system. 5-9. Cylinder Block (Crankcase) a. General. The cylinder block is an integral casting forming the primary structural part of the engine. Transverse members provide rigidity and strength, and ensure alignment of the block bores and bearings under load. The cylinder block is of cast iron, with water jackets extending the full length of the bores, but divided into upper and lower sections which are connected by hollow struts. Water for cooling enters at the bottom of each water jacket and leaves at the top through holes aligned with openings in the cylinder head. The top surface of the cylinder block is counterbored at each water or oil passage to accommodate individual seal rings. b. Cylinder Block Removal. (1) Remove the accessories (para 5-2). (2) Remove the cylinder head (para 5-3). Do not disturb components. Figure 5-37. Checking cranking end play. (g) End play must be within 0. 004 to 0. 014 inch (with new parts), or a maximum of 0. 018 inch with used parts. (3) (para 5-4). (h) Install connecting rod bearings (para 54). Remove pistons, connecting rods, and rings (4) Remove the cylinder liners (para 5-5). (5) Remove flywheel and housing (para 5-6). (i) Install new gasket and flywheel housing (6) Remove camshaft and timing system (para 57). Do not disturb the valves or rocker arms. (j) Install flywheel (para 5-6). (7) Remove the crankshaft (para 5-8 g. (1)), removing and tagging all main bearing halves for identification so that all pieces are reinstalled in their original positions. (para 5-6). (k) Install crankshaft front cover (f. above). (l) Install vibration damper (e. above). (m) c. Cleaning, Inspection, and Repair of Cylinder Block. Install crankshaft pulley (d. above). (n) Install the lubricating oil pump (c. (3) (1) If the cylinder block was removed because of a known defect, proceed to NOTE below and clean up the new cylinder block. Then, proceed to d. below and install the new block. (d) above). (o) Install a new gasket to oil pan bolting flange, then secure oil pan to the cylinder block with lockwashers and capscrews. NOTE Replacement cylinder block assemblies include the numbered main bearing caps and bolts, cylinder head studs and bolts, dowel pins, cylinder liners, and all plugs installed in holes requiring them. But it must be cleaned to remove corrosion and rust preventive compound before it can be installed. (p) Add strain to chain hoist and remove blocks, then lower engine to mounting bed, being careful to allow for dowels on flywheel to line up with power generator mounting flange. (q) Reconnect power generator (para 5-29). (r) Secure engine to bed with mounting bolts (fig. 5-7). (s) Install all removed accessories (para 52). 5-44 (2) Before inspecting the removed block, wash it with clean fuel oil, and blow dry with compressed air. (d) Apply 40 psi air pressure to the cylinder block and maintain pressure for at least two hours. (3) Inspect the water passages for excess scale. When scale exists, reclean with a solvent conforming to Fed Spec P-D-680, then hose down with clean fresh water. Blow dry with compressed air. (e) At the end of test period, examine the cylinder bores, air box, oil passages, crankcase (interior of block), and the exterior of the block for signs of the waterantifreeze mixture, which will indicate the presence of tracks. Replace a cracked block. (4) Reinspect water passages for freedom from scale, then scrape all gasket material from gasket surfaces. (5) (f) After test is complete, turn off the air, remove all plates, drain the block, and blow out all passages with compressed air. Prepare the cylinder block for pressure test as follows: (g) Re-examine the block bores for roughness that requires clean-up. If honing is required, notify GS maintenance. (a) Make five metal plates of 3/16 inch thick material. Make plates 63A/4-inches long and 2inches wide. Mark plate for two holes, to be centered one inch from each end, and one inch from each edge. Where lines cross, use a center punch to start drill, then drill 11/16-inch diameter holes that are 43/ inch from center-to-center. Each plate to fit over two of the cylinder head hold down studs (fig. 5-38). (h) If the cylinder block cleaned up satisfactorily, and is without crack defects, proceed to d. below. d. Installation of Cylinder Block. (1) After cleaning and inspection of the block, clean and inspect engine parts and subassemblies, and, using new parts as required, install them in and on the cylinder block by reversing the sequence of removal in b. above. (2) Install the air box capscrews to a torque of 10-15 ft lb. covers and tighten (3) Fill the engine lubricating system (LO 556115- (4) Fill the engine cooling system. (5) Check for leaks (oil and water). 204-12/1). 5-10. Oil Pump (Engine Lubricating) a. General. The gear type oil pump is mounted on the first and second main bearing caps and is driven by a gear (9, fig. 5-31) on the front end of the crankshaft. In normal operation the pump maintains a pressure of at least 20 psi on the main oil gallery. When pressure exceeds 30 psi, a relief valve in pump opens and oil is bypassed from pressure side to the inlet side of pump. An inlet screen, attached to the oil pump inlet pipe, is immersed in the oil in sump, to screen dirt and other foreign objects from being circulated through the system. Figure 5-38. Typical cylinder block prepared for pressure test. (b) Also, make two covers for the two water holes (for water pump inlet) on blower side of block (fig. 538). Drill and tap one cover for an air line. b. Removal. (c) Use water seal rings in counterbores of water holes on cylinder head, position plates over studs and seal rings. Position main bearing caps on studs and secure with cylinder head holddown nuts. Tighten nuts enough to draw down plates to compress seal rings. (1) Disconnect power generator (para 5-29). (2) Drain the lubricating system (LO 55-1925204- 12-5). (3) Hoist the engine, carefully, to disengage dowel pins on power generator connecting flange. Hoist high enough to give working room to remove the oil pan. NOTE Before installing the last plate. fill water jacket with a mixture of water and one gallon of permanent type antifreeze. then install and tighten the last plate. (4) Remove capscrews and lockwashers securing the oil pan to the cylinder block, remove the pan, then remove the gasket. (5) Remove the capscrews and lockwashers securing the oil pump, regulator body and oil outlet tube and oil inlet tube from bearing caps and the cylinder block. Tag and save any mourting shims for reinstallation in same position from which removed. 5-45 c. Disassemble (Partially) for Repair. (1) Remove screen from the inlet tube. (2) Remove plugs (fig. 5-39) gaskets spring and relief valve from body. 5-46 TM 55-1925-204-12 Figure 5-39. Engine lubricating oil pump. 5-47 (3) Remove covers and gaskets from body. (4) Remove capscrews and lockwashers from cover then remove cover, pin, and sleeve bearings. (5) Remove gears. idler gear support, then remove shaft. Remove keys from shaft. (6) Wash the screen in clean fuel oil and blow dry with compressed air. (7) Use the new parts in the lubricating oil pump service parts kit, to replace similar parts. Discard the old parts. (8) Reassemble by reversing the disassemble procedure. d. Installation. (1) Hold the pump assembly against the main bearing caps so that the idler gear meshes with crankshaft oil pump drive gear (9, fig. 5-31). (2) Complete the installation by reversing the removal procedures in b. above. (3) With engine in an upright position, check that the teeth of crankshaft gear and the idler gear are parallel, then tighten mounting bolts to a torque of 35-39 ft lbs. (4) With engine still in the upright position, check the clearance between idler gear teeth and the teeth of crankshaft gear. It should be between 0. 005 inch and 0. 012 inch maximum. Adjust the clearance, by adding or subtracting shims. (5) Position new gasket on oil pan, install pan and secure with lockwashers and capscrews. Do not tighten capscrews too tight, or you will crush the gasket unnecessarily. (6) Fill lubricating system (LO 55-1925-20412-5). 5-11. Oil Filter a. General. The full flow filter assembly is mounted on engine block by an adapter bracket, which contains a bypass valve that opens at 18-21 psi, to ensure engine lubrication should the filter become clogged. b. Removal. Remove the filter as described in paragraph 5-2. k. c. Service. (1) Disassembly. (a) Remove drain plug (7, fig. 5-40) and drain oil from the filter. 1. 2. 3. 4. Stud Gasket Shell Spring 5. 6. 7. Filter element Washer, nonmetallic Plug, drain Figure 5-40. Lubricating oil filter . 5-48 water enters the cooler and flows through the inside of the tube bundle and out of the cooler to the heat exchanger. The lubricating oil enters the cooler and flows over the outside surface of the tube bundle. The purpose of the oil cooler is to cool the main engine lubricating oil. A bypass valve line is fitted to the oil cooler to provide a path for oil in the event the cooler becomes clogged. Zinc corrosion eliminator plates are located in the heat exchanger to compensate for the electrolytic action of the raw water. b. Removal, Disassembly, Cleaning, Inspection, Repair, Reassembly and Installation. Refer to paragraph 5-20. (b) Remove stud (1), gasket (2), shell (3), and spring (4). (c) Remove and discard filter element (5). (d) Remove the nonmetallic washer from the adaptor. (2) Cleaning. (a) Wash shell (3), stud (1), and spring (4) in clean fuel oil, then wipe dry with a lint free cloth. (b) Wash the bowl of the adaptor with fuel oil to remove all sludge. Blow dry with compressed air. (3) Reassembly. (1) Install a new gasket (2) on stud (1), then insert stud through shell (3). (b) Position spring (4) on stud (1), and slide filter element (5) onto the stud and inside the shell (3). (c) Insert the nonmetallic washer (6) in groove in the adapter. Position shell (3) on the adaptor, and secure with the stud (1). (d) Tighten the stud to a torque of 40-50 ft. lb. d. Installation. Install the oil filter on the engine block as described in paragraph 5-2, k. (2). 5-13. Fuel Injector a. General. The fuel injector meters and injects the exact amount of fuel required to handle the load; it atomizes the fuel and sprays it into the combustion chamber at the high pressure required for efficient injection, and permits continuous fuel flow. The continuous fuel flow through the injector prevents air pockets in the fuel system, and serves as a coolant for those injector parts subjected to high combustion temperatures. b. Removal. (1) Remove rocker arm cover. (2) Remove fuel lines (1 and 4, fig. 5-41). Screw shipping cap over injector inlet and outlet to prevent entrance of dirt. 5-12. Oil Cooler a. General. The lubricating oil cooler is a two pass cooler mounted in a horizontal position. The unit is located on the starboard side of the engine room aft of the heat exchanger. The raw 5-49 1. 2. 3. 4. 5. 6. Fuel line Injector rocker arm Rocker shaft Fuel line Injector clamp Fuel connection 7. 8. 9. 10. 11. 12. Clamp stud Spray tip Injector tube Dowel pin Injector assembly Fuel connection Figure 5-41. Fuel injector mounting. (3) Crank engine in direction of engine rotation until rocker arms for the particular cylinder are on a horizontal plane. (4) Remove two rocker arm bracket bolts and lift rocker arms and brackets up and away from injector. (5) Remove injector clamp (5) nut and lift injector clamp off stud. (6) Lift injector from cylinder head using injector remover (table 4-1}. c. Disassembly. (1) Support the injector right side up in a vise between two blocks of wood. (2) Remove filter caps (3, fig. 5-42). Remove springs (4) and filter element (6). 5-50 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 29. Injector follower Injector body Filter cap Filter spring Gasket Filter element Control rack Dowel pin Seal ring Plunger helix. upper Meter recess Plunger helix, lower Bushing port, lower Valve cage Plunger spring 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Valve stop Spray tip Check valve Valve spring Injector valve Valve seat Spill deflector Bushing port. upper Bushing. plunger Gear retainer Gear retainer nut Gear Plunger Stop pin Figure 5-42. Fuel injector. spring above stop pin (28) and withdraw pin. Allow plunger spring to rise gradually. (4) Remove the plunger follower, spring, and plunger as an assembly. (5) Support the injector bottom side up in a vise between two blocks of wood. Loosen the gear retainer nut (25) with tool (table 4-1). Lift nut away from injector body, being careful not to NOTE New filters should be used when reconditioning fuel injectors. If conditions require the reuse of old filters, be certain that each filter is installed in the same opening and position (right side up) from which it was removed. (3) Compress plunger spring (29). screwdriver, raise Using a 5-51 a vise between two pieces of wood. Start injector rack (7) in rack opening with timing marks up. Place a new seal ring (9) on the injector body. (6) Insert gear (26) in injector body with timing mark on gear registering with the timing marks on injector rack. Place gear retainer (24) in injector body against gear. (7) Insert small end of plunger bushing (23) in injector body with the plunger locating pin aligned with the locating groove in injector body. (8) Place valve seat (20) on finished surface of plunger bushing. Set finished surface of valve (19) on valve seat followed by valve spring (18). Insert lower end of valve stop (15) into opposite end of spring. (9) Place valve cage (14) over valve stop and against valve seat. (10) Set check valve (17) on valve cage and place spray tip (16) over check valve against valve cage. (11) Insert spill deflector (21) into injector retainer nut (25). (12) Being careful to prevent dislodging the spray tip and valve assembly, lower injector nut over spray tip and down against injector body. Screw injector nut in body approximately five full turns. (13) Hold injector, right side up, and tighten nut finger-tight, then torque to 65 foot-pounds. (14) Support injector right side up in a vise between two blocks of wood, and place spring (29) over plunger follower opening in injector body. (15) Insert head of plunger (27) in lower slot of injector follower (1). Align flat on injector plunger with stop pin slot in follower. (16) Position rack in full fuel position and lower plunger and follower into injector body with flat on plunger registering with flat in rack gear. (17) Start stop pin (28) in injector body with lower coil of spring resting on narrow shoulder of stop pin. Depress the follower and push follower stop pin into position. f. Testing. After an injector has been reconditioned, it must be tested prior to placing in service. When in doubt as to condition of an injector, it must be tested to determine if reconditioning is required. Six individual tests are preformed to ascertain: rack freeness, plunger freeness, spray pattern, valve opening pressure, holding pressure, and high pressure. Test fixture tool (table 4-1) is needed to test injector. (1) To test injector, install the injector in test fixture (fig. 5-43) with dowel on underside of injector located in proper hole of fixture. Position the injector support and popping handle support. dislodge the spray tip and other parts resting on the end of the plunger bushing. If the injector has been in service for a long period of time, the spray tip may stick in the injector nut. (6) Carefully lift the spray tip (16), check valve (17), valve cage (14), valve stop (15), spring (18), injector valve (19), and valve seat (20) from bushing (23). (7) If spray tip remained in the injector nut. it may be removed with tool (table 4-1). (8) Remove the spill deflector (21) and seal ring (9) from injector nut. (9) Remove plunger bushing (23), gear retainer (24) and gear (26) from injector body. (10) Withdraw injector control rack (7) from injector body. d. Cleaning, Inspection, and Repair. (1) Wash all injector parts thoroughly in clean fuel oil. and dry with filtered compressed air. All parts must be kept absolutely clean. (2) Check seal ring area of injector body for burns or scratches. (3) Inspect teeth on control rack and control rack gear for wear or damage. If defective, a new rack and gear must be installed. (4) Inspect spray tip and tip of seat of injector nut for carbon deposits. Examine the sealing surfaces of the spray tip and valve parts. (5) Sealing surfaces should be examined with a magnifying glass. Slight imperfections will prevent the injector from operation properly. (6) Clean injector nut with reamer tool (table 4-1). The large shoulder on body of reamer tool fits in the shoulder of the injector nut to keep tool properly aligned. Turn reamer in a clockwise direction to remove carbon deposits. (7) Insert reamer in opening of spray tip. Turn reamer in a clockwise direction to remove carbon deposits. Clean spray tip orifices. Before using the tool, sharpen tip end of wire with stone. (8) Clean plunger bushing and rack openings in the injector body using tools (table 4-1). e. Assembly. (1) Support injector body in a vise between two pieces of wood right side up. (2) Insert a new filter element in each fuel opening. If used oil filters are being reinstalled, be sure each filter is being replaced in the opening from which removed and with the same side up. (3) Place a filter spring in each fuel opening. (4) Place a new gasket over lower end of each filter cap and thread caps into fuel openings. Tighten caps to 75 foot-pounds. (5) Support injector body, bottom side up, in 5-52 1. 2. Injector popping handle Adjusting screw 3. 4. Lock Pump handle Figure 5-43. Injector tester. (2) Connect fuel supply line to inlet side of injector and fuel return line to outlet side. (3) Open both valves and operate pump handle to force all air from the fuel system. Close release valve. (4) Test for rack freeness. Depress injector follower to bottom of travel with popping handle (i, fig. 5-43) then release slowly, at the same time sliding the injector rack back and forth through its full range. The injector rack should move freely, with no trace of binding. If rack does not move freely, loosen the injector nut and turn spray tip. Tighten nut to 65 footpounds and again check the rack. Failure to produce a free rack indicates that damaged or dirty parts have been assembled. To correct this condition, the injector rack must be 5-53 injector nut, a damaged seal ring, or a scored surface on nut or spray tip. A "dribble" or drop at spray tip indicates a leaking valve assembly. (9) Test under high pressure. This test is made to uncover any leaks at injector filter caps, body plugs, or seal rings which did not appear during holding pressure test. Position the injector rack at full fuel and depress injector plunger with popping handle just far enough to close both ports in the bushing. At the same time operate the pump handle to build and maintain a pressure of 1,400 to 2,000 psi. The point at which ports are closed may be ascertained by the fact that the injector spray will change appreciable and a rise in pressure will occur. The popping handle may be held in proper position for this test by means of the handle lock (3) and adjusting screw (2). While maintaining a pressure of 1,400 to 2,000 psi inspect for leaks at the injector filter caps, body plugs and seal ring. g. Installation. (1) Insert the injector into the injector tube with the locating dowel registering with the locating hole in the cylinder head, and with the pin on injector control arm lever registering with injector control rack lever. (2) Place injector clamp over stud and replace washer and nut. Tighten nut to 25 foot-pounds. (3) Position rocker arm assembly and replace rocker arm bolts. Torque bolts to 100 foot-pounds. (4) Connect fuel lines to injector and fuel connections. h. Timing Fuel Injectors. After installation, the injectors must always be timed before the engine is run to insure proper fuel delivery to each cylinder at the correct moment. To insure proper injection timing, the plunger follower of each injector must be adjusted to a certain position in relation to the injector body. If the injectors are not properly timed, the engine operation will be "ragged" and power output reduced. (1) Stop engine and leave throttle in the STOP position. (2) Bar over engine by hand, or by means of the cranking motor until the exhaust valves of the cylinder to be timed are fully opened. (3) Place the stem of the correct injector timing gage (3, fig. 5-44) in the correct timing gage hole in top of injector body (4). completely disassembled, inspected, reassembled and tested. (5) Test for plunger freeness. Depress injector follower and release. A slow return of the follower will denote a sticky injector plunger. Inability to fully depress the follower usually indicates a scored plunger and bushing. Perform this test with the injector rack in three different positions; full fuel, no fuel, and a point midway between these two positions. If a binding plunger is noted, the injector must be completely disassembled, cleaned, inspected, reassembled, and tested. (6) Test for spray pattern. With injector rack in full fuel position, operate pump handle (4) to maintain a fuel pressure of approximately 15 psi. Pop the injector several times by depressing the popping handle, and observe the spray pattern emerging from each orifice. The spray pattern should be uniform. (7) Test for correct valve opening pressure. Place injector rack in full fuel position. Operate pump handle with smooth even strokes and at the same time, observe the pressure gage noting at what pressure the injector sprays fuel. The valve opening pressure should be from 450 to 850 psi on a new injector and from 350 to 850 psi on a used injector. If valve opens at a pressure lower than the above minimums, it indicates damaged or dirty sealing surfaces or a fatigued or worn valve spring. If any of these conditions exist, the injector nut must be removed and the valve parts cleaned, inspected, repaired, reassembled, and tested. (8) Test injector holding pressure. Operate pump handle to bring pressure to a point just below the injector valve opening pressure. Close the shutoff valve and note the pressure on the gage. Check the pressure drop by timing. On a new injector the pressure should drop from 450 to 250 psi in not less than 50 seconds. On a used injector the pressure should drop from 450 to 250 psi in not less than 50 seconds. On a used injector the pressure should drop from 350 to 150 psi in not less than 35 seconds. If the injector fails to hold these pressures, leaks in lines leading to injectors and on the injector itself are indicated. A leak in the injector rack opening indicates excessive clearance between plunger and bushing or between bushing and injector body. A leak around the spray tip or seal ring is usually caused by a loose 5-54 1. 2. 3. 4. Guide follower Injector rocker arm Timing gage Injector body 5. 6. 7. Push rod locknut Push rod, upper Rocker arm clevis Figure 5-44. Timing fuel injectors. (4) Adjust the injector rocker arm (2) by means of the screw adjustment on the upper end of the push rod (6), until the lowest surface of the timing gage head, when rotated, Sill just pass over the top surface of the plunger follower guide (1). Tighten locknut on push rod and recheck with timing gage. The timing gage must be held perpendicular to top surface' of the injector body. 5-14. Fuel Transfer Pump and Lines a. General. The fuel transfer pump is a positive displacement gear type pump, mounted on the aft lower end of the blower. The pump maintains a minimum fuel pressure of 20 psi at the fuel inlet passage. b. Removal. (1) Disconnect fuel pump inlet and outlet connections and move fuel lines away. (2) Remove the three nuts that hold the fuel pump body to engine block and withdraw pump from engine blower. c. Disassembly. (1) Remove the eight capscrews (9, fig. 5. 45) and lockwashers (10) securing fuel pump cover (8) to fuel pump body (4) and withdraw the cover. CAUTION When the above timing operation is carried out on an engine on which an injector has been installed, do not run the engine until after the injector racks have been properly positioned. (5) Adjust the injector control racks according to the procedures laid down in paragraph 5. 16 f 5-55 1. 2. 3. 4. 5. 6. 7. 8. 9. Fork. fuel pump coupling Fuel pump seals Gasket Pump body Drive shaft Driven shaft Drive gear Pump cover Capscrew 10. 11. 12. 13. 14. 15. 16. 17. Lockwasher Ball Valve Pin Spring, helical Gasket Plug Pump drain line Figure 5-45. Fuel transfer pump. (2) Withdraw the driven shaft (6) and gear from pump body as an assembly. Lift drive shaft (5) and gear (7) from pump body. (3) Remove relief valve retaining plug (16), spring (14), pin (located in center of spring), and valve (12). (4) Place pump body between padded jaws of a vise. (5) Remove both seals (2) by driving out with a wooden dowel. (4) Inspect relief valve for burrs or score marks. If defective, install new valve. (5) Inspect finished surfaces of pump cover and body. These parts must be flat and free from burrs and score marks. e. Assembly. (1) Position inner seal (2) in seal recess of pump with sealing edge toward center of pump body. (2) Position outer seal (2) against inner seal with sealing edge away from pump. (3) Clamp pump body in soft jaws of vise with relief valve opening up. Place valve in valve opening with open end up. Insert spring in valve followed by the pin. Place a new gasket (15) over valve retaining plug and replace plug in body. (4) Insert fuel pump drive shaft (5) and gear d. Cleaning, Inspection, and Repair. (1) Wash all parts in clean fuel oil and dry with compressed air. (2) Inspect gears for wear, score marks or nicks. If gears are damaged in any way, replace. (3) Inspect shafts for score marks or wear. If defective, replace. 5-56 Disconnect fuel return line at some point between cylinder head and fuel return line to day tank. Place open end of this line in a container and start the engine. Warm engine and run at 1200 rpm. Measure amount of fuel returned to the container in a 1-minute period. A minimum of V2 gallon should flow from the return line in 1 minute. (7) into pump body as an assembly. Insert driven shaft (6) and driven gear in pump body as an assembly. (5) Apply a thin coating of vinyl, nonadherent type sealer, around outer edge of pump cover finished surfaces. (6) Position cover on pump body and secure with eight capscrews and lockwashers. Tighten bolts to 35 footpounds. (7) Turn fuel pump drive shaft to be sure that parts rotate freely. If bind is noted. tap corner of pump cover with a hammer to relieve binding. f. Installation. (1) Place fuel pump drive coupling over square end of fuel pump drive shaft. (2) Place fuel pump over studs and against fuel pump drive, being certain that drive coupling meets with the square end of the drive assembly shaft. (3) Install lockwashers and nuts. (4) Connect fuel inlet and outlet lines. (5) Check fuel flow of the fuel transfer pump after overhauling. 5-15. Fuel Filter and Strainer a. General. The fuel filter and strainer are essentially the same in construction and operation, therefore they are treated as one in the maintenance instructions. Each has a replaceable filter element which should be renewed after every 500 hours of use. b. Removal. (1) With engine stopped, open drain cock at bottom of filter or strainer shell (fig. 5-46) and remove plug on cover. Empty contents of shell into suitable container. Close drain cock. 5-57 Figure 5-46. Typical fuel strainer (filter) c. Installation. (1) Position a new gasket between filter shell and cover, assemble shell and element to cover and secure with cover nut and gasket. (2) With filler plug removed at top of cover, fill strainer shell with clean fuel oil. (3) Run engine and check for fuel leaks. NOTE In some instances it may be necessary to remove the valve rocker and loosen a fuel line nut in order to bleed trapped air from the fuel system. Be sure the fuel line nut is retightened securely before the valve rocker cover is reinstalled. (2) 5-16. Governor a. General. The hydraulic governor has speed droop stabilization. In operation, oil from the engine lubricating system is forced to an auxiliary oil pump in the governor. The auxiliary pump furnishes oil pressure necessary to actuate the governor mechanism. The governor is connected to While supporting shell, remove cover nut and gasket. (3) Withdraw the shell and strainer element from cover and discard old element. (4) Wash shell in clean fuel oil and install new element. (5) To remove the fuel line between pump and fuel filter, detach tubing connections and lift off fuel line. 5-58 (4) Injector rack may stick or move too hard due to the injector holddown crab being too tight or not properly positioned. This condition can often be eliminated by placing a long punch or screwdriver on the foot of the crab and tapping lightly with a small hammer. (5) Injector rack may stick due to cramping caused by the rack control lever being out of position or cocked. Loosen screws in rack control lever. If this relieves the binding, move the lever on the control tube until the rack control lever no longer cramps the injector rack. Binding of the rack control lever may also be caused by damage to the ends of the adjusting screws or the surfaces which they contact. Correct by filing. After correcting the bind or damage, adjust the rack control lever to proper position. (6) Control tube may stick or turn hard in control tube brackets. Binding due to poor alignment of control tube brackets can be corrected by loosening bracket bolts and realigning brackets. the fuel injectors by a fuel rod or link, attached to a lever on the injector control shaft. Fuel is decreased by action of fuel rod spring and increased by the opposing action of a hydraulic servo-piston inside of a cylinder. Admission of oil to the servo-cylinder is controlled by a pilot valve, which, in turn, is controlled by the flyweights of the governor. The two flyweights are mounted on a vertical shaft and driven through a pair of miter gears from the upper rotor shaft of the blower. Centrifugal force of the flyweights in rotation is opposed by a speeder spring located on the vertical shaft between a spring fork at the top and the arms of the flyweights at the bottom. Compression of the speeder spring, which is controlled by the throttle, determines the speed at which the governor will control the engine. To insure stability (without hunting) of governor operation, speed droop, adjustable in amount, is introduced into the governor system. Adjustable speed droop is achieved through a slotted bracket, attached to the side of the terminal lever, which carries a pin riding in a slot of the floating lever. Moving the droop adjusting bracket (speed adjusting lever bracket) in toward the engine increases governor droop, and out away from the engine, decreases the governor droop. (In starting a cold engine, several cranking periods are required to increase lubricating oil pressure sufficiently to operate the governor and open the throttle so that the engine can start. Starting time can be shortened by pulling out on the fuel rod knob at the front side of the governor, thus, taking control away from the governor. The engine can be stopped regardless of the governor, by pushing in on the fuel rod knob. Considerable force must be exerted to do this as the oil pressure against the servo-piston must be overcome. Besides holding the engine speed constant under varying load conditions, the hydraulic governor acts as an automatic engine shutdown device in case of lubricating oil pressure failure. If the engine fails to supply oil to the governor, the servo-piston will drop, the fuel link will return to the NO FUEL position, and the engine will stop. b. Maintenance and Adjustment. Governor faults are usually indicated by speed variations of the engine, but all speed variations do not necessarily indicate governor faults. Therefore, when improper speed variations appear the following procedures should be carried out: (1) Check load to be sure that speed changes observed are not the result of load fluctuations. (2) If load is uniform, check the engine to be sure that all cylinders are firing properly. (3) Check governor and operating linkage to make sure that no bind exists between governor and engine or the injector control tube on its mounting brackets. NOTE When the injector rack control tube is free of binding and is operating the injector racks properly, the tube will be returned to the NO FUEL position by the tube return spring. When the control tube brackets have been loosened, the adjustments of rack control levers must be checked. (7) Pin in link that connects governor to control tube may be binding in the control tube lever. (8) If speed variations are erratic, but slight, the fault may lie in the governor drive. Excessive backlash in the coupling or the miter drive gears, or too tight a meshing of the latter, may cause this condition. If for any reason, such as worn blower rotor bearings, rubbing of the rotors on the housing, or the load on the flexible coupling between the blower and the engine varies, this variation will be transmitted to the governor as a speed change. The governor will attempt to compensate for this by changing the fuel rod position. No amount of adjustment or work on the governor can correct this condition. c. Governor Adjustment. After installing governor on engine, adjustments enumerated below should be carried out in the order shown. All adjustments, except maximum speed adjustments, are made with engine stopped. Adjustments should be made only after an engine reaches normal operating temperatures. (1) (2) (3) (4) Governor linkage adjustment. Fuel rod adjustment. Position injector control racks. Maximum fuel adjustment (5) (6) Speed droop adjustment. Maximum speed adjustment. (load screw). d. Governor Linkage Adjustment. When the 5-59 limit (2) With linkage in place between governor and throttle, loosen clamp bolt (3, fig. 5-47) in governor speed control lever (2). Using a screwdriver, turn shaft in lever hub clockwise as far as possible. throttle control has been removed from engine, or linkage has otherwise been disturbed, governor linkage adjustment should be checked to determine the correct positions of levers and shafts. Proceed as follows: (1) Move hand throttle to RUN position. 1. 2. 3. Subcap assembly-governor Lever-governor control Bolt-governor control lever 4. 5. 6. Governor case Rod, governor subcap fuel Locknut Figure 5-47. Adjusting fuel rod. (3) Tighten clamp bolt while holding shaft in position. e. Fuel Rod Adjustment. (1) Loosen fuel rod locknut (6) and remove fuel rod knob. (2) Turn locknut (6) so that fuel rod (5) extends 1/16 inch beyond locknut. (3) Replace fuel rod knob against locknut and tighten locknut. f. Position Injector Control Racks. (1) With engine stopped, remove governor cover and replace two screws through the subcap (1) and into the governor case (4) to hold subcap in position. NOTE This step is not necessary on a governor having subcap held in place by two Allen head screws. (2) Remove valve rocker cover. (3) Loosen locknut (5, fig. 5-48) on maximum fuel adjusting (load limit) screw (6). Back screw out flush with outer face of boss. 5-60 1. 2. 3. Collar-governor. subcap, fuel rod Rod, governor subcap. fuel Terminal lever 4. 5. 6. Figure 5-48. Adjusting for maximum fuel. (4) Disconnect fuel rod (6, fig. 5-49) from injector control lever (5). 5-61 Subcap assembly-governor Locknut Screw. governor. load limit 1. 2. 3. 4. Adjusting screw. rack Tube, injector control Adjusting screw. rack control lever (outer) Lever. injector rack 5. 6. 7. Lever. injector control tube Rod. governor, subcap. fuel Governor and drive assembly Figure 5-49. Positioning injector control rack. (5) Adjust rack control lever adjusting screws (1) and (3) on No. 1 injector rack lever (4) (water pump end of engine), so that upper half of lever is straight (not cocked) with respect to lower half. Tighten adjusting screws (1) and (3). (6) Loosen rack control lever screws (1) and (3) on No. 2 injector rack lever (4) to allow 1/8 inch play at lower end of lever. Push and hold No. 1 injector rack to FULL FUEL, or in position. (7) Adjust No. 2 injector rack to FULL FUEL position by turning screws (1) and (3). Turning inner screw (1) clockwise moves the injector rack toward FULL FUEL position. rotation of the injector control tube and will move number one injector rack from the FULL FUEL position. (8) Check injector fuel rod (6) and control tube (2) for binding. Parts must move freely. (9) Hold injector racks in NO FUEL position and adjust clevis on injector shaft end of fuel rod (6) until hold in clevis just slides over pin in lever (5). Replace washer and retaining spring over pin on lever to hold fuel rod in place. g. Maximum Fuel Adjustment. (1) Hold fuel rod (6) in FULL FUEL (full open) position and terminal lever (3, fig. 5-48) firmly against fuel rod collar (1). (2) Turn maximum fuel (load limit) screw (6) NOTE Once FULL FUEL position is reached, do not rotate the inner adjusting screw further, as this will cause 5-62 characteristic which allows engine speed to increase with a decrease in load. Adjustment of speed droop is necessary when governor has-been changed, or if original governor adjustments are disturbed. Proceed as follows: (1) With engine stopped and governor cover removed, loosen droop bracket adjusting bolt (2, fig. 5-50) and move bracket (5) so that bolt is midway between ends of slot in bracket. Tighten bolt. until a 0. 020-inch gap exists between terminal lever and collar on fuel rod (6, fig. 5-49). Tighten locknut (5, fig. 5-48). NOTE Clearance must not exceed 0. 020 inch. Moving the screw too far will prevent full open maximum fuel) position of the injector racks. (3) Replace valve rocker case. h. Speed Droop Adjustment. Speed droop is the governor 1. 2. 3. Rod. governor subcap fuel Bolt Screw. governor high speed stop 4. 5. 6. Locknut Bracket, governor. speed adjusting lever Terminal lever Figure 5-50. Adjusting speed droop. (3) Start and warm engine to operating temperature. Adjust vernier control of throttle so that engine no-load speed, checked with an accurate tachometer, is 1,250 rpm and generator output is 125 volts. (4) Move main switch (circuit breaker) to ON position; this will place full-rated generator load on NOTE The speed droop bracket rides on a shoulder milled in the side of the terminal lever. Hold bracket firmly in place on shoulder when tightening adjusting bolt. If bracket is not positioned in this manner, the bracket will be bent when tightening the adjusting bolt and the governor action will be erratic. (2) Loosen locknut (4) on maximum speed adjusting screw (3) and back out screw 5/8 inch. 5-63 engine. If necessary, again adjust vernier so that full-load speed of generator is 1,200 rpm. (5) Move main switch to OFF position to remove generator load from engine. Note engine speed. If droop is satisfactory. engine speed will now be 1. 250 rpm. If engine no-load speed is too high. stop engine and again loosen bolt (2) and decrease droop by moving bracket (5) out or away from engine. To increase droop, move bracket in or toward engine. Repeat this procedure until engine no-load speed is 1.250 rpm and full-load speed is 1,200 rpm. 1. 2. i. Maximum Speed Adjustment. The maximum speed adjusting screw (4, fig. 5-51) limits travel of governor speed adjusting shaft. This, through linkage, controls the throttle at the control cabinet. Moving the screw in will decrease, and out will increase, the maximum engine speed. This adjustment should be made after the fuel rod, maximum fuel, and the speed droop adjustments have been made. Subcap assembly. governor Governor case 3. 4. Locknut Screw, governor high speed stop Figure 5-51. Setting maximum speed adjusting screw. (1) Loosen locknut (3) and back out maximum speed screw (4), as was done for adjusting the speed droop. Start and warm engine to operating temperature. (2) With no-load on engine, turn throttle vernier and increase the no-load engine speed to 1,300 rpm. With engine running at this speed, turn the maximum speed adjusting screw in until engine speed drops to 1,290 rpm. Tighten locknut (3). (3) Turn throttle vernier back to bring no-load speed to 1,250 rpm. j. Removal. In case of major repairs, or a complete governor change, the governor must be removed from the engine. (1) Remove valve rocker cover, and disconnect governor fuel rod (8, fig. 5-52) from the injector control tube lever (9). 5-64 1. 2. 3. 4. 5. 6. 7. Spring, governor control retracting Bolt, governor control lever Lever, governor control Shaft, governor speed adjusting Clevis pin Link, governor control shaft Bolt, subcap to cylinder head 8. 9. 10. 11. 12. 13. 14. Rod, governor subcap fuel Lever, injector control tube Washer Retainer spring Tube assembly Bolt Governor base Figure 5-52. Hydraulic governor mountings. (2) Slip end of fuel rod off pin in injector control tube lever. (3) Disconnect, at the governor, tube assembly (12) between cylinder block and governor base (14). (4) Remove clevis pin (5) holding governor control lever (3) to throttle control link (6). Separate link from lever. Do not detach lever from governor speed adjusting shaft (4). (5) Remove the three screws and lockwashers holding governor cover and subcap to governor case. (Some models have two Allen setscrews in the subcap holding subcap in position during adjustment). (6) Remove two bolts (7) and lockwashers holding governor subcap to cylinder head. (7) Lift up on subcap assembly until a definite snap indicates that fuel rod has been released from terminal lever within the governor base. Remove subcap assembly, pulling fuel rod (8) out of hole in cylinder head. Remove gasket between subcap and governor case. (8) Remove four stud nuts holding governor assembly to governor drive assembly and lift governor off studs and away from engine. Remove gasket between governor and governor drive. NOTE Handle the governor carefully; especially avoid striking the end of the drive shaft. Such treatment might move the collar on the drive shaft and result in excessive end play of the ball head and shaft. k. Installation (fig. 5-52). (1) Place a new gasket over studs on governor drive housing flange. Set governor assembly on drive flange with opening for oil line into governor pointing in same direction as drive shaft of drive housing. (2) Secure governor assembly to drive housing using a lockwasher and nut on each of the four studs. Draw nuts down uniformly and after tightening, revolve the drive shaft of the governor drive to check for binding. Parts must move freely without bind. (3) If governor cover and subcap are installed remove from governor case. (4) Place gasket on top flange of governor case. (5) Pick up subcap and insert long projecting end of fuel rod through hole in cylinder head and position subcap over governor case. (Secure subcap to case on models having provisions for same). 5-65 (6) Align bolt holes for subcap to cylinder head bolts and replace bolts (7, fig. 5-52) fingertight. (7) Slip fuel rod (8) over pin in control tube lever (9) and secure with washer (10) and spring retainer (11). (8) Place a new gasket on governor cover. (9) Pour l/2 pint of clean lubricating oil over governor mechanism for initial lubrication. (10) Position cover over subcap. Replace the three screws which hold cover to subcap and governor case. Tighten screw holding subcap to governor case and bolts holding subcap to cylinder head. (11) Remove bolt (2) from governor control lever (3). Slip the governor control retracting spring and governor control lever over governor speed adjusting shaft (4). Slip bolt (2) through loop in retracting spring and insert in control lever. Position control lever on shaft and tighten bolt. (12) Start oil line fitting into tee at pressure relief valve and draw up tight enough to be leakproof. b. Removal. Refer to paragraph 5-2, i. (1) for removal instructions. c. Service. (1) Separate the upper section from the lower section. (2) Soak the upper section, including the metalwool element, in clean fuel oil. This will loosen the oil and dust in the element. Empty the oil from the sump, remove the baffle, and wash both with clean fuel oil to remove all sediment. Use a lint free cloth to push through the center tube before the baffle is reinstalled, then fill sump with clean engine oil. (3) Wash the preformed packing that fits between upper and lower section. If the packing is worn, or deformed, replace the packing. (4) Install packing on lower section, and assemble the upper section to the lower oil sump section. d. Installation. Refer to paragraph 5-2, i. (2) for installation instructions. NOTE 5-18. After installing governor on engine and before engine is started for making governor adjustment, the fuel injectors must be properly timed and the exhaust valve clearances carefully checked. If this was accomplished prior to removing the governor it will not be necessary to repeat at this time. (13) Adjust governor according to c. through g. above. Air Inlet (Shutdown) Housing a. General. The air shutdown housing (air inlet) is mounted on the side of the blower, and serves as a mount for the air cleaner. It contains an air shutdown valve that shuts off the air supply and stops the engine whenever abnormal operating conditions require an emergency shutdown. b. Removal. (1) Remove the air cleaner (para 5-2, i. (1) ). (2) Disconnect the control wire from the air shutdown valve lever (fig. 5-6). (3) Remove the six capscrews and lockwashers securing the air inlet housing to the blower, and remove the housing, and gasket from the blower. c. Disassembly. If necessary, the shutdown valve may be disassembled after the housing has been removed from the blower. (1) Refer to figure 5-53 and use a small punch to remove pins from the shutdown shaft. Remove washer from shaft. Remove the seal from the housing. 5-17. Air Cleaner a. General. The oil bath air cleaner is mounted on the air inlet housing to filter dust and dirt from the air before it enters the blower and the engine. It is a cylindrical housing, containing a wire screen element, and an oil sump directly below the element. Air enters at middle of the housing; is deflected downward over the oil sump; then up through the element, where it is again deflected downward through the air inlet housing into the blower. 5-66 Figure 5-53. Typical air shutsown (intlet) housing (2) Remove the pins that secure the shutdown valve to the shaft. (3) Note the position of the air shutdown spring and the valve (for reassembly); then, withdraw the shaft from the housing to release the valve and spring in the housing. Remove seal from the housing. (4) Remove the bolt, lockwasher and plain washer from housing and remove the latch, latch spring, and spacer. d. Cleaning, Inspection, and Repair. (1) Clean all of the parts thoroughly, including the blower screen, with fuel oil, and dry with compressed air. (2) Inspect the parts for wear or damage. The face of the shutdown valve must be perfectly flat to assure a tight seal when it is in the shutdown position. e. Reassembly. Assemble by reversing the procedure in c. above. f. Installation. Install by reversing the removal procedure in b. above; then tighten capscrews to a torque of 16-20 ft lbs. b. Removal. (1) Remove governor from engine and blower. (2) Remove air cleaner and air inlet housing. (3) Remove eight bolts and lockwashers that hold engine front cover to the blower. (4) Remove air box drain tube clip and tube. (5) Remove the 12 bolts and lockwashers which secure the blower assembly to the cylinder block. Remove the special 7/16-14 x 73/4-inch bolt from center of blower front end plate. (6) Move the blower assembly slightly aft to free the gasket between gear cover and blower end plate; then remove the blower from the cylinder block. c. Cleaning, Inspection, and Repair. (1) Inspect blower rotors. Minor abrasions on surface of rotor lobes can be removed. However, if deep marks are noted, replace blower assembly. (2) If there is rubbing and scoring between crowns of rotor lobes and mating rotor lobes, replace blower assembly. (3) Check blower rotors for excessive oil as this will indicate leaky seals and necessitate replacement of blower assembly. d. Installation. (1) Fasten a new gasket to cylinder block at blower pad with shellac. (2) Place blower on cylinder block locating flange and start long bolt through hole in front end plate. Do not tighten this bolt. (3) Install 12 bolts which hold blower assembly to cylinder block and tighten to 50 foot-pounds. 5-19. Blower a. General. The blower designed for efficient diesel operation, supplies the fresh air needed for combustion and scavenging. Its operation is similar to that of a gear type oil pump. Two hollow rotors, each with three lobes, revolve with very close clearance in a housing bolted to the side of the engine. The rotor lobes are made with a twisted or helical form, to provide uniform and continuous displacement of air. 5-67 core and around the lubricating oil core. Raw water, pumped from the sea through the raw water core, removes the heat from the engine coolant and lubricating oil. b. Removal. (1) Drain the fresh water cooling system. (2) Drain the raw water system. (3) Remove four capscrews (17, fig. 5-54) and four lockwashers (18), then remove the raw water inlet elbow (16) from the heat exchanger (5). (4) Replace the 8 bolts which hold front end plate to blower housing. (5) Install air inlet housing and air cleaner. (6) Install governor. 5-20. Heat Exchanger (and Oil Cooler) a. General. The heat exchanger is a liquid-toliquid type which cools both the engine coolant and the engine lubricating oil. The liquid coolant which circulates through the engine enters the top. of the heat exchanger and passes around the raw water 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Electrode assembly Thermostat housing Gasket Thermostat Heat exchanger Retainer Cover Lockwasher Capscrew Gasket 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Seal rings Gasket Core Gasket Cover Elbow Capscrew Lockwasher Gasket Capscrews Cap Figure 5-54. Heat exchanger. (4) Remove the four capscrews securing the thermostat housing (2) to heat exchanger (5), then remove housing (2), gasket (3), and thermostat (4) from the heat exchanger. (5) Remove two hose clamps (17, fig. 5-65) from hose (16) and disconnect fresh water pump suction line from the heat exchanger (5, fig. 5-54). (6) Remove capscrews (9) and lockwashers (8) and disconnect raw water discharge cover (7), then 5-68 outlet tubes (12). Remove bolts (26), lockwashers (25), inlet and outlet tube (12),' and gasket (24) from bypass valve housing (21). disconnect fresh water return line (from manifold to oil cooler) from the heat exchanger (5). (7) Remove capscrews (15, fig. 5-55) and lockwashers (14) from oil line crankcase inlet and 5-69 Figure 5-55. Lubrication oil cooler and fresh water line. 5-70 KEY to fig. 5-55: 1. Gasket 2. Core 3. Gasket 4. Cover 5. Lockwasher 6. Capscrews 7. Capscrews 8. Plug 9. Gasket 10. Spring 11. Valve 12. Tube assembly 13. Gasket 14. Lockwasher 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. (8) Remove all capscrews securing the heat exchanger to the engine, then lift heat exchanger to a suitable work area. (9) Remove the water manifold as follows: (a) Disconnect temperature gage indicator (fig. 5-56). (b) Remove two nuts from studs at the four risers, then lift water manifold from the cylinder head. Remove the four gaskets. Capscrew Hose Hose clamp Elbow Flange Gasket Housing Gasket Lockwasher Gasket Lockwasher Bolt Capscrew Lockwasher Figure 5-56. Typical water manifold mounting. c. Disassembly. (1) Remove raw water components as follows: (a) Remove capscrews (20, fig. 5-54), cover (15), and gasket (14). (b) Remove retainer (6), gasket (10), and rings (11), then pry on flange of core (13) and remove it from the heat exchanger. Remove the electrode assemblies (1) from covers (15 and 7). (2) Remove oil cooler and fresh water components as follows: (a) Remove capscrews (27, fig. 5-55), lockwashers (28), then remove fresh water suction line flange (19) and gasket (20). (b) Remove two capscrews (7), lockwashers (23) and bypass valve housing (21). Then remove gasket (22) from housing. (c) Remove capscrews (6), lockwashers (5), cover (4), and gasket (3). (d) Pull core (2) from the heat exchanger housing, then remove gasket (13). (e)Remove plug (8), gasket (9), spring (10), and valve (11) from oil bypass valve housing (21). d. Cleaning, Inspection, and Repair. (1) Wash all hardware in clean fuel oil and blow dry with compressed air. (2) Clean oil cooler core by directing a jet of steam into the inlet side. Wash the interior with water after steaming, warm the unit to remove all traces of water. (3) If the raw water core, or the water manifold are scaled, clean by soaking in a solvent (FED SPEC P-D680), then blow dry with compressed air. If some scale is still there, use a wire brush and remove all traces. Clean all gasketing surfaces thoroughly. NOTE The manufacturer recommends an alternate procedure, with a mixed scale solvent consisting of 11/3) muriatic acid and (2/3) water to which one-half (1/2) pound of oxalic acid has been added for each 2 1/2 gallons of the solution. Remove the core or manifold when the bubbling and foaming stops. This usually takes from 30 to 60 seconds, then flush thoroughly with clean hot water under pressure. 5-71 secure with capscrews (20). Install electrode assemblies (1) in covers (15 and 7). (c) Install gasket (3) on thermostat housing (2), insert thermostat (4) in housing, then position the housing against heat exchanger (5) and secure with four lockwashers and capscrews. Place cap (21) on heat exchanger (5). f. Installation. (1) Lift heat exchanger into position at front of engine block, and secure with capscrews and bolts as required. (2) Position gasket (19) at cover (15), then place elbow (16) on gasket and secure with lockwashers (18) and capscrews (17). (3) Connect raw water outlet to cover (7). (4) Connect fresh water return from manifold to the oil cooler section. (5) Position hose connection between water manifold and thermostat housing, and secure with two hose clamps. (6) Place a hose connection on elbow (16) and raw water line, and secure with two hose clamps. (7) Place hose (16, fig. 5-55) connection on flange (19) and elbow (18), then secure with two hose clamps (17). Finish connecting up fresh water line to pump in similar manner. (8) Fill the fresh cooling water system. (4) Clean pitted anodes with a wire brush. If replacement is required, remove the anode from the holder, then thread a new anode into the holder. (5) Inspect the component as follows: (a) Inspect all parts for wear, thread or other damage. Replace defective parts. (b) Inspect the thermostat for rust and corrosion that may hold it wide open. Replace a defective thermostat. (c) Inspect the oil bypass valve for wear. Replace worn or defective parts. e. Reassembly. (1) Assemble the oil cooler components as follows: (a) Install gasket (1, fig. 5-55) in back side of housing, then slide core (2) in place. (b) Position gasket (3) on housing, then position cover (4) on gasket and secure with lockwashers (5) and capscrews (6). (c) Place oil bypass valve housing (21) in position, with gasket (22) in place, then secure with lockwashers (23) and capscrews (7). Install valve (11), spring (10), gasket (9), and plug (8) in housing (21). (d) Position gasket (24) in place on housing (21), then place inlet and outlet tube assembly (12) at bypass valve housing, and secure with lockwashers (25) and bolt (26). (e) Place gasket (20) in position on fresh water suction outlet on bottom of heat exchanger (oil cooler) housing, then place flange (19) on gasket and secure with four lockwashers (28) and capscrews (27). (2) Assemble the heat exchanger components as follows: (a) Position gasket (12, fig. 5-54) on heat exchanger (5), slide core (13) into housing, then install gland seal rings (11). Install gasket (10), retainer (6), and cover (7). Secure with lockwashers (8) and capscrews (9). (b) Install gasket (14), cover (15), and NOTE Raw water system will fill when engine is operated. 5-21. Fresh Water Pump a. General. The fresh water pump is mounted on lower forward side of the blower. It is a centrifugal pump for circulating the fresh water from the heat exchanger through the cylinder block, cylinder head, water manifold, and exhaust manifold. b. Removal. Drain the cooling system, then remove the fresh water pump (para 5-2, f (1)). c. Disassembly. (1) Remove end cover from pump housing (6, fig. 5-57). 5-72 1. 2. 3. 4. 5. 6. 7. 8. 9. Coupling Thrower Capscrew Packing Flange Housing Gasket, cover Cup Washer 10. 11. 12. 13. 14. 15. 16. 17. Seal Seal clamp ring Spring guide Spring Impeller Draincock Gasket Shaft Figure 5-57. Fresh water pump. (2) Remove taper pin holding impeller (14) to pump shaft (17), then withdraw impeller (14), spring (13), guide (12), seal clamp ring (11), seal (10), washer (9) and cup (8). (3) Remove the remaining parts only as required. d. Cleaning, Inspection, and Repairs. (1) Clean all of the parts except the shaft and bearing assembly. The sealed type pump shaft bearing must not be immersed in a cleaning fluid since dirt may be washed in, and the fluid cannot be entirely removed. (2) Revolve the pump shaft bearing slowly by hand. If rough spots are detected, replace the shaft (17) and bearing assembly. Replace the seal. A seal replacement kit includes a shaft and bearing assembly, cover and mounting gaskets, packing, and seal assembly. e. Reassembly. (1) Assemble the impeller and seal assembly in reverse order of removal (fig. 5-57). (2) Position the shaft and impeller assembly in the pump housing. (3) Replace the gasket and end cover on the housing, then tighten the capscrews. f. Installation. Install the fresh water pump as described in paragraph 5-2, f. (2). 5-22. Raw Water Pump a. General. The raw water pump is a gear type pump which circulates raw water through one section of the heat exchanger to lower the temperature of the engine coolant in the other section of the exchanger. The pump is mounted on the engine bed at the forward right side of the engine and is belt-driven from the engine drive pulley. b. Seal Replacement (Pump Attached to Engine). Seal parts may be removed and replaced without removing the pump from the engine, as follows: CAUTION Use care not to scratch or burr the lapped surfaces of seal seat, or that portion of the shaft which the seal contacts. (1) Remove five cover screws (24, fig. 5-58), then lift cover (25) and gasket (26) from the pump housing. 5-73 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12 13. 14. Bolt Gear, internal drive Gear, coupling Gear, drive Seal Washer, felt Bearing, ball Shaft Cam Wear plate Seal assembly Housing Capscrew Lockwasher 15. 16. 17 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Bolt, cam Gasket Nut Lockwasher Adaptor Ring, retaining Ring, retaining Key Slinger Screw. machine Cover Gasket Impeller Figure 5-58. Raw water pump. (2) Using two pliers, grasp a blade at each side of the impeller (27), then pull impeller from shaft (8). (3) Insert two wires, each with a hook on the end, between housing and seal assembly (11) with hooks over edge of seal. Pull seal assembly from the shaft. The seal seat and gasket (part of the seal assembly) may be removed in the same manner. (4) With gasket and seat of the assembly in 5-74 relative position (in front of ferrule) slide the new seal assembly over the shaft (8). Be sure that seal ring is snugly in the ferrule and gripping the shaft as it moves into position. The marcel (wavy) washer part of the assembly is then moved up against the flatwasher. (5) Compress the impeller blades enough to clear the cam (9) in housing, as the impeller is pressed on the splined shaft (8). e. Cleaning, Inspection, and Repair. CAUTION Do not wash bearing (7). Wipe clean for inspection with a slightly dampened lint free cloth. (1) Wash remaining parts in clean fuel oil and blow dry. (2) Inspect bearing by holding inner race and revolve outer race slowly to detect possible wear or rough spots. Replace a bearing that is worn, or does not roll freely. (3) Examine all components of the seal assembly (11). Replace the assembly when felt washers or seals are damaged or defective. (4) Examine seal contact surfaces of the shaft. Polish minute scratches away with crocus cloth dampened with fuel oil. (5) Inspect impeller to assure the bond between neoprene and metal is good. If the impeller blades have a permanent set, replace the impeller. (6) Inspect wear plate (10) for burrs. Remove burrs. If wear on plate seems excessive, it may be reversed when the pump is reassembled. NOTE Splined plugs are part of the impeller and are designed to reduce the possibility of foreign material working its way into splines, resulting in excessive wear. (6) Move impeller several revolutions in the direction of normal rotation, in order that blade will be positioned correctly. (7) Install new gasket (26) and cover (25) on pump housing (12), then secure with screws (24). c. Removal. Remove the raw water pump as described in paragraph 5-2, e. (1). d. Disassembly. (1) Remove the impeller and seal assembly (c. above). (2) Mark housing (12) and adaptor (19) for reference at reassembly, then remove capscrews (13) and lockwashers (14) and separate housing from the adaptor. (3) Clamp the drive gear (4) in a soft-jawed vise and remove nut (17) and lockwasher (18) from shaft (8). (4) Remove gear from vise, then, using a suitable puller, remove gear (4) from shaft (8). Remove the key (22) from the shaft (8). (5) Slide seal (5) and felt washer (6) from housing. f. Reassembly. Assemble by reversing procedure in d. above. NOTE Lubricate lips of seals at installation, and install with lip toward bearing. If the seal is spring loaded, the lip faces the impeller. When installing nut (17) on shaft (8), it must be tightened to a torque of 25-30 ft lb. Do not exceed the specified torque. g. Installation. Install according to instructions in paragraph 5-2, e. (2). NOTE Certain pumps, marked with letter X stamped on pump housing between the port flanges, have been assembled without the outer bearing seal 15). When overhauling one of these pumps, the outer seal can continue to be omitted at reassembly. (6) Remove ring (20) from groove in housing. (7) Support housing (12) in arbor press with mounting flange resting on bed of press, and splined end of shaft under the ram. Using a brass rod between shaft and ram, press shaft and ball bearing (7) from the housing. (8) Remove slinger (23) from shaft, or housing. (9) Remove felt washer (6) and seal (5) (not shown) from shaft, or housing. (10) Remove ring (21) from groove in shaft (8), then using an arbor press and a suitable sleeve against the inner race of bearing (7), press bearing off threaded end of shaft. (11) Remove bolt (15) and lift cam (9) from the housing. (12) Lift wear plate (10) off dowel pin. 5-23. Exhaust Manifold, Pipes, and Muffler a. General. The one piece, water-cooled exhaust manifold is cast with an integral water jacket surrounding the exhaust chamber. The diameter of the exhaust chamber increases uniformly from one end to the other where it terminates in a flange to which an elbow and flexible exhaust connection is attached. A portion of the engine coolant is bypassed from the water manifold into the rear end of the jacket, and is discharged from the forward end through a tube into the lower section of the expansion tank of the heat exchanger. A draincock with an attached hose is installed in bottom of the manifold for draining the water jacket. A plug is provided in the bottom of the exhaust outlet elbow for draining moisture condensed from the exhaust gases. b. Removal. Refer to paragraph 5-2, 1. (1) and remove the exhaust manifold. c. Cleaning, Inspection, and Repair. (1) Inspect internal walls for corrosion and scale, and gasket surfaces for grooves, or burrs. (2) Clean away all scale, using a solvent comparable to Fed Spec P-D-680, or the alternate method described for core of heat exchanger in 5-75 (3) Replace broken or worn parts. Replace armature and field coils that fail electrical test. Replace armature assembly if shaft is bent, or scores are deep. e. Reassembly. Assemble by reversing the procedure of disassembly in c. above. f. Installation. Refer to paragraph 5-2, j. (2) and install the generator. g. Test and Adjustment. (1) Remove band at end of generator. (2) Inspect the commutator for sparking, discolored, or dirty condition. (3) Remove brushes as described in step (5) below. then hold a piece of 00 sandpaper against the commutator with a flat piece of wood, while the generator is turning at normal speed. Remove sand and dirt with clean, dry, low pressure air (10 psi). (4) Inspect brushes. Brushes should slide freely in brush holders. Replace oil-soaked or worn brushes. (5) To remove brushes, raise brush spring from brushes, and lift brushes from brush holders. Disconnect flexible pigtails from brush rigging. (6) New brushes must be seated to the commutator to insure proper electrical connection between the armature and the external circuit. Brushes may be seated by installing in brush holders and running in. Better seating will be obtained by "sanding in" the brushes. To "sand in" brushes, wrap a piece of 00 sandpaper, cut to commutator width, around the commutator in the opposite direction to that of normal rotation. Install brushes in brush holder. Set spring tension. Rotate the armature by hand in normal direction until the brush faces fit contour of commutator. Carefully clean dust and sand from commutator ((3.) above). (7) Replace band on generator. paragraph 5-20, d. Remove all gasket material from gasket flanges. Remove all burrs. Replace a defective manifold. (3) Check threads on mounting studs. Replace defective studs. Drive new studs to a torque of 2540 ft lbs. d. Installation. Refer to paragraph 5-2, 1. (2) and install the exhaust manifold. e. Exhaust Pipe and Muffler. The exhaust pipe is connected to the flexible elbow and runs up to the smoke stack where it is connected to the muffler. The flexible pipe is insulated for safety, and is clamped in place throughout its run to the stack. (1) Remove the exhaust pipe when necessary, by disconnecting at elbow of exhaust manifold: remove holding clamps, and disconnect from the muffler. (2) Remove muffler by disconnecting the exhaust pipe, and removing the mounting hardware. (3) Install either by reversing the removal procedure. 5-24. Engine Generator a. General. The battery charging generator is a 24 vdc, 400-watt generator, belt driven from the crankshaft pulley. This generator maintains the starting batteries at a full charge. b. Removal. Refer to paragraph 5-2, j. (1) and remove the generator. c. Disassembly. (1) Remove brush cover band from around end of generator. Lift tension springs from brushes. Slip brushes out of brush holders. (2) Disconnect brush flexible leads and field coil connections from brush rigging. (3) Remove coupling from drive end of generator. Remove endbell from driven end. Remove drive end bearing assembly and generator fan. (4) Remove mounting screws from commutator endbell. Withdraw commutator endbell and armature from generator. (5) Remove bearing from commutator endbell. Pull endbell from armature. (6) Remove brush rigging. (7) Clamp generator housing in vise. Remove pole pieces and field coils by withdrawing mounting screws from generator housing. (8) Press pole pieces from field coils. d. Cleaning, Inspection, and Repair. (1) Clean all components with a solvent conforming to FED SPEC P-D-680. (2) Inspect all components for broken or worn parts. Test armature and field coils for shorts, opens, or grounding. Use a growler or other suitable test equipment (TM 55-506). Replace ball bearings. Inspect armature for bent shaft or damaged commutator. 5-25. Voltage Regulator a. General. This voltage regulator directs the flow of current from the generator (para 5-24) to the batteries at the predetermined rate, until the batteries are fully charged, then reduces (or limits) flow until the load calls for an increase. b. Removal. Refer to paragraph 5-2, j. (1) (b), and remove the voltage regulator. c. Inspection and Test. The following quick checks can be made to determine whether or not the units in the electrical system are operating properly. If not, the checks will indicate whether the generator or regulator is at fault, whereupon proper corrective measures may be taken. A fully charged battery and a low charging rate on ammeter indicates normal voltage regulator operation. To check the current regulator, proceed as follows: (1) Move engine throttle to NO FUEL position, then operate the motor starter about 15 seconds. 5-76 TM 55-1925-204-12 (2) Move throttle to about half speed, then start the engine. With engine running at medium speed, quickly note reading of the ammeter. This reading should be the normal output value for which the current regulator is set. 5-26. Starting Motor NOTE Some vessels may be equipped with engine hydrostarters. If so equipped, refer to TM 55 2990-201-12. (3) Allow the engine to continue running and, as soon as the generator has restored the battery power consumed in cranking, the voltage regulator (if operating normally) will decrease the output until ammeter shows pointer at zero, or barely past zero on the charge side. a. General. The starting motor currently in use on this equipment has a spray type overrunning clutch drive. When the starter push switch completes the electrical circuit, a solenoid is energized and shifts the starting motor pinion into mesh with the teeth of the flywheel ring gear and closes the main contacts within the solenoid. Once engaged, the clutch will not disengage during intermittent engine firing. To protect the armature from excessive speed when the engine does start, the clutch overruns, or turns faster than the armature, which permits the pinion to disengage itself from the tring gear. (4) A fully charged battery and a high charging rate indicates that the voltage regulator is not reducing the generator output as it should. Proceed as follows to determine the cause: (a) Disconnect the field "F" terminal lead from the regulator. This opens the generator field circuit and the output should normally drop to zero. b. Removal. Refer to paragraph 5-2, d. (1), and remove the starting motor. (b) If the output drops to zero with the "F" terminal lead disconnected, the trouble has been isolated to the regulator. c. Disassembly. (1) Raise brush spring (7, fig. 5-59) Lift brushes (6) in holders (8) and wedge in raised position with brush springs. (c) Reconnect the "F" terminal lead, remove the regulator cover, and depress the voltage regulator armature manually to open the points. KEY to fig. 5-59: 1. 2. 3. 4. 5. 7. 8. 9. (d) If the output now drops off, the voltage regulator unit has been failing to reduce the output as the battery came up to full charge. (5) Replace a defective voltage regulator. d. Installation. Refer to paragraph 5-2, j. (2) and install the voltage regulator. 5-77 Solenoid Drive assembly Field winding L.H. Field winding R.H. Armature Spring Holder assembly Thrust washer 10. 11. 12. 13. 14. 15. 16. Leads, electrical Screw & lockwasher Bearing sleeve, intermediate Bearing sleeve, drive end Housing Endbell Bearing sleeve, commutator end TM 5-3610-258-14 Figure 5-59. Starting motor. 5-78 (2) Disconnect electrical leads to brush rigging and commutator endbell (15). (3) Inspect drive spring for break or weakness. Replace a defective drive spring. (3) Disconnect electrical leads (10) to solenoid (1), remove screws and lockwashers (11), and lift solenoid from starter housing (14). (4) Inspect drive for worn gear teeth, or broken parts. Replace a defective drive assembly. (5) Check the solenoid relay for proper operation. If the armature does not snap into position, or winding seems impaired, replace the solenoid. (4) Remove the through bolts from commutator endbell (15) and pull endbell from armature (5). Withdraw armature (5) and drive (2) from housing (14). e. Reassembly. Assemble by reversing the procedure in c. above. (5) Press in on drive end anchor plate of drive assembly and expose pilot screw. Remove pilot screw . (6) Remove drive Remove key from shaft. assembly from armature f. Installation. Refer to paragraph 5-2, d. (2) and install the starting motor. shaft. 5-27. Engine Instrument Panel (7) Remove nuts and insulation washers from field stud, then press stud through the housing. Remove field pole piece mounting screws and slip field windings (3 and 4) from housing (14). a. General. The instrument panel, containing water temperature gage, oil pressure gage, ammeter, starter push switch, and throttle, is mounted at rear of the engine over the flywheel housing. A tachometer is at left, just below the panel. (8) Press pole pieces from field windings. d. Cleaning, Inspection, Test, and Repair. Refer to TM 55-506 and the following instructions: b. Starter Push Switch. (1) Removal. (1) Wipe motor parts clean with solvent FED SPEC P-D680. Inspect commutator end of armature for a good surface. Resurface a defective commutator. (a) Tag and disconnect electrical leads at rear of the instrument panel (fig. 5-60). (2) Test armature and field windings for shorted or open circuits. Replace defective armature or field windings. 5-79 Figure 5-60. Engine instrument panel. (b) Remove locknut nameplate, lockwasher and plain nut, then remove switch from rear panel. (2) Inspection. (a) Inspect glass for crack, and dial for clarity in reading. Replace a gage with broken glass or unreadable dial. (b) Install the gage in place on opposite engine and compare reading. Replace a gage with an inaccurate reading. (2) Inspection. (a) Inspect the switch terminals for corrosion or broken mount. Replace a defective push switch. (b) Check for continuity across terminals while the button is pushed in. If no circuit is indicated, replace the switch. (3) Installation. step (1) above. (3) Installation. Install the starter push switch by reversing the procedure in step (1) above. c. d. Install by reversing the procedure in Water Temperature Gage. (1) Removal. (a) Disconnect the capillary tube and holding clips from the cylinder head. (b) Remove attaching hardware, then remove gage and capillary tube through the panel opening (fig. 5-60). Oil Pressure Gage. (1) Removal. (a) Disconnect, or remove the flexible tube from rear of the oil pressure gage (fig. 5-60). (b) Remove clamp securing the oil pressure gage to rear of the instrument panel, then withdraw the oil pressure gage from front of the panel 5-80 TM 55-1925-204-12 (2) Inspection. (a) Inspect glass and dial for damage or .defect. Replace a defective water temperature gage. (b) Check capillary for damage. Replace a water temperature gage (thermometer, indicating) when capillary is damaged. (3) Installation. Install the water temperature gage by reversing the procedure in step (1) above. (b) Lubricate worm gear and worm wheel gear, for distance of travel, with a light engine oil. Wipe away excess oil. (3) Installation. Check that governor control rod is in NO FUEL position, and that throttle indicator is positioned at STOP, then reverse the procedure in step (1) above to install the throttle. e. Ammeter. (1) Removal. (a) Tag and remove the electrical leads from rear of the ammeter /fig. 5-60). (b) Remove the mounting hardware from rear of the instrument panel, then lift ammeter out of the (2)panel from the front. (2) Inspection. (a) Inspect the glass for cracks, or missing glass, and readability of dial markings. Replace a damaged ammeter. (b) Check the reading accuracy by comparison with the ammeter on the remaining auxiliary set. Replace a defective ammeter. (3) Installation. Install the ammeter by reversing the procedure in step (1) above. 5-28. Batteries a. General. The engines 24 vdc electrical starting system uses four batteries with connectors in series. b. Maintenance. (1) Inspect for cleanliness. Clean batteries and grease terminals to prevent corrosion. (2) Remove battery caps, check water level (1/4 inch above plates), then use hydrometer to test the specific gravity of all cells (TM 9-6140-200-14). c. Removal and Installation. (1) Loosen nuts, then remove all connector cables. (2) Lift old batteries out of box. (3) If necessary, fill new batteries with electrolyte, then install batteries in box. Reconnect all cables on clean terminals, then apply a coating of grease to prevent corrosion. f. Tachometer and Drive Shaft. (1) Removal. (a) Disconnect drive shaft and shaft housing from the tachometer housing (fig. 5-60). (b) Remove drive shaft from the adaptor at the engine rear cover, then remove the adaptor. (c) Remove capscrews and lockwashers securing tachometer to the timing gear cover, then lift housing away from the timing gear cover. Remove the adaptor. (2) Inspection. Inspect the tachometer and drive shaft for visible defects, broken glass, broken or twisted shaft. Replace a defective shaft or tachometer. 5-29. Power Generator (Model I-3644) a. General. The Delco 40-kw, 120-volt dc generator is direct coupled to the General Motors diesel engine. The generator is a six-pole, self excited, compound machine of the single bearing type. b. Maintenance and Adjustment (TM 55-506). (1) Lubricate in accordance with lubrication order 551925-204-12-5). (2) Keep the generator clean inside and out. Wipe all loose dirt from cover before opening. Blow out loose dirt from windings and brush rigging periodically with dry, low-pressure air (25 psi maximum) . (3) Replace brushes when they are worn to 11/4 inch measured on the long side of the brush. New brushes must be sanded to the contour of the commutator. (4) Be sure that brushes move freely in holder, and adjust spring tension to 1.5 to 2 psi of brush contact surface. NOTE At installation be sure that drive adaptor is correctly aligned with the drive shaft. (3) Installation. Install the tachometer and drive shaft by reversing the procedures in step (1) above. g. Throttle. (1) Removal. (a) Disconnect the throttle from the throttle control rod. (b) Remove three machine screws (fig. 5-60) then withdraw throttle from the panel. (2) Inspection. (a) Inspect the spring tension clip of the throttle control, the worm gear and its bushing and the throttle vernier control shaft for excessive wear or other defect. Replace defective components. c. Removal. (1) Remove band (fig. 5-61) between diesel engine flywheel housing and generator and lift clear of generator. 5-81 (2) Remove six bolts which secure generator driving plate to diesel engine flywheel. (6) Lift generator from generator bed, and maneuver generator to passage. (3) Remove all electrical leads to generator. NOTE Mark engine bed shims for repositioning on reinstallation. (4) Remove bolts holding generator housing to flywheel housing. Block the generator in position while removing bolts from generator housing. d. Disassembly. (5) Remove bolts from flange between generator and fire pump. (1) Remove fan and driving disc assembly (12, fig. 562) by removing the 12 mounting bolts (14). 5-82 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Stud insulating sleeve Mounting stud Brush tension spring Brushholder assembly Brush tension arm Brush lead terminal screw Field coil Lifting eye Field pole Main field frame Bolt Fan and driving disc assembly Bolt Bolt 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 23. 26. 27. Fan cover band Screw Brush Plug Sight gage Washer Bolt Bearing Bolt Bearing collar Bearing cap Commutator endbell Bolt Figure 5-62. Delco 40-kw, 120-volt dc generator. (2) Remove commutator cover band. (3) Remove brushes (17). (4) Drain oil by removing plug (18) from sight gage (19). (5) Remove bearing cap mounting bolts (23). (6) Disconnect leads to brush rigging. (7) Remove six endbell mounting bolts (27), and remove commutator endbell (26) by withdrawing in a straight line. Note neutral mark on circumference of endbell and on main field frame. (8) Carefully withdraw armature from main field frame. (9) Do not remove brushholders (4) and mounting studs (2) unless they are to be replaced. (10) Remove three bolts (21) and washers (20). (11) Withdraw bearing (22), using a standard bearing puller. (12) Remove bearing collar (24) and cap (25). e. Cleaning and Inspection ( TM 55-506). (1) Wipe all parts clean with a lint free cloth moistened in solvent conforming to FED SPEC PD-680. 5-83 Figure 5-63. Stud alignment. f. CAUTION Do not saturate windings with solvent. Assembly. (1) Slip bearing cap (25) on commutator end of armature shaft. (2) Check brush tension springs; replace springs that cannot be adjusted to proper tension. (2) Install bearing collar (24) on armature shaft. (3) Inspect brush holder mounting studs, check insulation resistance from stud to frame; replace defective insulating sleeves. When installing new sleeves or studs, avoid cracking sleeves. (3) Press bearing (22) on armature shaft. (4) If brush holder studs were removed, install brush holder assembly and adjust (fig. 5-63). (4) Check ball bearings by holding inner race and turning outer race with fingers. Replace bearing if it binds or sticks. (5) Install commutator endbell (26, fig. 5-62); align marking on endbell with marks on field frame and fasten endbell with bolts (27). (5) Inspect field and armature windings for damaged insulation. Report damage to higher maintenance level or replace generator assembly. (6) Position bearing cap (25) so that holes in bearing cap are over holes in commutator endbell. Insert bolts (23) and tighten. (6) Inspect commutator for pitting or grooving. If commutator is badly grooved, armature must be chucked in a lathe and commutator turned down. After turning, undercut mica to a depth of 1/32 to 3/64 inch. (7) Install fan and drive disc assembly (12) and fasten with mounting bolts (141. (8) Align brush holders (fig. 5-64). 5-84 Figure 5-64. Brush holder alignment. (9) Install brushes and connect wiring to brush rigging. (10) Adjust brush tension (b. above). (11) Lubricate in accordance with lubrication order. g. Installation. Reverse order of removal, making sure bed shims are in same location from which removed. 5-30. Clutch (Model CL208) a General A friction type clutch, with yoke h holder alignment. and shifter collar, places the fire and salvage pump in action. Hub of clutch sets on the generator shaft, with yoke and shifter collar on pump shaft. b. Removal. (1) Remove capscrew from clutch lever (fig. 665), remove capscrews from yoke, then withdraw the clutch operating rod. 5-85 Figure 5-65. Clutch and pump removal. (2) Remove pump from frame (pare 5-31). (3) Slide clutch shifter collar off pump shaft. (4) Remove yoke (10, fig. 5-66) from clutch hub (6), remove setscrew (7) then slide clutch hub off the generator shaft. 5-86 Figure 5-66. Clutch arrangement (Model CL208). 1. 2. 3. 4. 5. c. Nut Bolt Shim Thrust washer Spring 6. 7. 8. 9. 10. Disassembly. to prevent excessive leakage around the pump shaft. The pump is designed with imposed suction impellers providing hydraulic balance, thereby eliminating all thrust strain on bearings. The prime mover drives the pump by means of a twin disc clutch. (1) Remove floating clutch plate (9, fig. 5-66) and thrust washer (4). (2) Remove springs (5), and friction linings. (8). b. Maintenance and Adjustment. The pump packing gland allows a slow water leak, when the pump is running, to provide lubrication between shaft and pump packing. Should packing leak excessively, leakage may be slowed by tightening packing gland nuts while the pump is running. Tighten only enough to bring leakage to a slow drip. Do not stop leakage entirely. d. Inspection. Inspect the friction linings for wear. Replace friction linings that are badly worn. e. Hub and backplate Setscrew, dog point Lining, friction Plate, clutch floating Yoke assembly Reassembly. (1) Position friction linings (8), then install springs (5). (2) Install the floating clutch plate (9) and thrust washer c. (4). Removal. f. Installation. Install by reversing the procedure in b. (1) through (4) above. (1) To remove bearings, it is necessary to remove the bearing housing from the pump. 5-31. Fire and Salvage Pump (2) Remove bearing housing cover (1, fig. removing capscrews. a. General. The fire and salvage pump has a 5 inch suction and a 4-inch discharge. Adjustable packing glands are installed in the pump housing 5-87 567) by 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Bearing housing cover Bearing housing Lantern ring Throat bushing Inserted bearing Impeller, 1st stage Casing, top half Impeller, 2nd stage Case wearing ring Shaft sleeve Packing 12. 13. 14. 15. 16. 17. 18. 19. 20. Bearing housing Bearing adapter Bearing housing cover Shaft Shaft Casing, bottom half Shaft collar Ball bearing Bearing locknut and washer Figure 5-67. Fire and salvage pump. (3) Remove the capscrews holding bearing housings to pump casing. (4) Remove bearing locknut and washer from shaft and withdraw bearing housing, leaving the pump shaft supported on the pump packing. (9) Withdraw bearing housing, with bearing inside, from shaft. NOTE Prior to removing the packing from each packing gland both bearings must be in place and supporting the shaft. NOTE (10) To remove the packing, back off on packing gland and remove the packing from the stuffing box. There is a lantern ring (3) installed in the outer stuffing box under the second ring of packing. There are three rings of packing behind this lantern ring. Prior to removing the inner bearing, replace outer bearing in order that shaft will be supported by at least one bearing. (5) Remove clutch (pare 5-30). (6) Remove the bearing housing cover (14). d. (7) Remove the locknut which holds the bearing in the bearing housing. Cleaning, Inspection, and Repair. (1) Clean bearings thoroughly with fuel oil and dry. Inspect bearings for cracked races or (8) Remove the capscrews securing bearing housing to pump casing. 5-88 (3) Replace inner bearing by pressing bearing on shaft. Position inner bearing housing and replace capscrews. Replace the inner bearing locknut and washer. balls. Bearings which run rough when spun by hand, must be replaced. (4) Replace bearing housing cover. (2) Pack each bearing with grease prior to replacing. (5) To replace outer bearing, press bearing onto shaft and replace locknut. Position outer bearing housing and replace capscrews. Replace outer bearing housing cover. (3) Clean bearing housing thoroughly and inspect for cracks in housing e. Installation. (6) Replace clutch (pare 5-30). (1) To replace packing in shaft stuffing b-ox, make up rings of flax packing the exact size of those removed. When replacing the packing, stagger the ends of the packing, as each turn is placed, to prevent leakage through the ends. NOTE The pruning pump and clutch are not used with these auxiliary sets because the fire and salvage pump is below the salt-water level, and water flows freely to the suction inlet. (2) Replace lantern ring in outer stuffing box after the third turn of packing is positioned, and place [WA turns Of packing on ton of lantern ring. Section II. PUMPS, GENERAL 5-32. Bilge and Ballast Pump a. General. The bilge and ballast pump is a single stage centrifugal pump. It is used to pump the bilges in all below deck compartments. The pump is driven by a 3-hp electric motor. This pump is also used to bring sea water aboard for ballast, pumping it into the fore or after peak tank as aligned by the control valves (table 2-7). It has a priming pump, to lift the bilge water, mounted above and driven by a V-belt and pulley on the end of the motor. b. Removal. (1) Disconnect suction and discharge lines from pump (fig. 5-68). 5-89 Figure 5-68. Bilge and ballast pump removal. (2) Remove bolts holding pump coupling half to motor coupling half. (3) Remove four pump mounting bolts and lift pump from foundation. CAUTION When removing pump from foundation note location of shims on foundation pads so they can be replaced in the same location and position from which removed. c. Disassembly. (1) Remove pump coupling half and key from pump shaft. (2) Remove capscrews (6, fig. 5-69) and remove casing (4) from back head (5). 5-90 Figure 5-69. Bilge and ballast pump. 1. 2. 3. 4. 5. 6. 7. 8. Impeller screw Impeller key Impeller Casing Back head Capscrew Capscrew Impel ler shaft sleeve 9. 10. 11. 12. 13. 14. 15. 16. Pocking Packing gland Inner bearing Shaft Thrust bearing Bearing lock Pump frame Seal cage (3) Remove impeller screw (1) from shaft (12). (4) Remove impeller (3). NOTE Impeller is keyed to shaft: when withdrawing impeller from shaft note the key positions. (5) Remove nuts which hold packing gland (10) against packing (9) and withdraw packing gland. (6) Remove capscrews (7) and withdraw back head from shaft and pump frame (15). (7) Withdraw packing gland from shaft. (8) Remove bearing lock from inner bearing (11) by removing setscrew in bearing lock and withdrawing from shaft. (9) Withdraw inner bearing from shaft and pump frame. (10) Remove thrust bearing (13) in the same manner as the inner bearing. d. Cleaning, Inspection, and Repair. (1) Clean inner bearing and thrust bearing with a cleaning solvent which meets requirements of FED SPEC P D-680. (2) Inspect the bearings for wear. If worn, replace. (3) Inspect impeller shaft sleeve (8) for wear. If worn. remove from shaft by heating surface of sleeve. Replace with new sleeve. Change 1 5-91 TM 55-1925-204-12 NOTE Do not tighten packing gland until pump is running. Tightening the gland without running the pump may seize the packing against the shaft sleeve and cause the sleeve to become grooved and worn. NOTE When replacing sleeve on the shaft it may be necessary to heat the sleeve to slide it into position on the shaft. (4) Inspect wearing ring on the impeller by placing impeller in casing. and check the side play clearance between wearing ring and wearing ring recess in pump casing. Clearance should not exceed .055. to .010-inch total side play. (5) If wearing ring requires replacement, remove ring by heating surface of ring and driving from impeller. If necessary, drill a hole in surface of wearing ring and remove ring by breaking in half. NOTE Be careful not to damage the impeller when removing the wearing ring. f. Installation. (1) Replace pump coupling half on shaft. (2) Position pump on pump foundation using the same shims between pump and foundation. NOTE If a new pump is being installed it will be necessary to realign the entire pump. (3) Check pump alignment by making sure coupling halves meet squarely and on the same plane. (6) Replace by heating the new ring: position on impeller. The new ring will secure itself when it shrinks during cooling. (4) Replace bolts holding pump to pump foundation. and again check pump alignment. (5) Connect coupling halves and replace suction and discharge lines. e. Assembly. (1) Pack thrust and inner bearing with grease in accordance with lubrication order and replace in pump frame. (2) Position pump shaft in pump frame: replace inner bearing lock and packing gland on shaft, but do not tighten bearing lock setscrew. (3) Replace back head on pump frame and tighten capscrews (7). (4) Align impeller on shaft key and slide impeller into place. Replace impeller screw. (5) Replace pump casing and tighten capscrews (6). (6) Check pump by rotating the shaft to make sure it rotates freely. If free, position bearing locks and secure in place. (7) Replace packing by inserting two packing rings, seal cage (16), and then three packing rings. Replace packing gland. (6) Adjust packing with pump running and pumping water. Tighten gland until only a slow drip appears around shaft. Do not stop leakage entirely . 5-33. Priming Pump a. General. To prime a centrifugal pump located above its source of supply necessitates removal of air from pump casing and suction line to draw water up to the pump. Therefore, a priming pump is installed on the suction line of bilge and ballast pump. The priming pump is a water sealed centrifugal type pump which gets its priming water from the sanitary system. The pump is belt-driven from the bilge and ballast motor. The priming pump is mounted on its own foundation above the motor. b. Removal. (1) Remove bolts which hold pump to the foundation. (2) Slip belt off end of pump. c. Disassembly. (1) Remove four nuts (4, fig. 5-70) from bolts holding lobe (8) to body and port plate. Change 1 5-92 1. 2. 3. 4. 5. 6. 7. Packing gland nut Packing gland Packing Nuts, body Gasket, port plate Gasket, lobe Shaft nut 8. 9. 10. 11. 12. 13. Lobe Rotor key Rotor Laminated shim Shaft sleeve Water slinger Figure 5-70. Priming pump. removed and replace in stuffing box. Stagger ends of packing as they are replaced, to prevent leakage through packing butts. (4) Replace packing gland; tighten evenly while turning shaft to prevent packing from binding on shaft. (2) Remove lobe (8) and gasket (6). (3) Remove shaft nut (7) and withdraw rotor from shaft. NOTE All wearing parts are now visible for inspection and no further dismantling is required. e. Assembly. (1) Replace rotor on shaft making sure key (9) aligns in the rotor keyway. (2) Replace shaft nut. d. Cleaning, Inspection, and Repair. (1) Inspect sides of rotor for signs of rubbing and wear. Should inside of rotor be rubbing against port plate, replace laminated shim (11). (2) To remove packing (3) from packing gland (2) 2) remove gland nuts ( 1 ), withdraw gland, and pull packing from stuffing box. (3) Replace gasket (6) against body; replace four bolts and nuts and tighten. f. Installation. (1) Position pump on foundation and place belt over pulley. (3) To replace packing, make up three rings of packing of the same size and length as that 5-93 (2) Replace bolts securing pump to foundation. (3) Adjust belt so that it has 1-inch horizontal slack at a point midway between the two pulleys. (4) Tighten mounting bolts. 5-34. Motor a. Maintenance and Adjustment (TM 55-506). (1) Lubricate in accordance with LO 55-1925204-12. (2) Inspect brushes. Replace brushes worn to one-half normal length. Sand new brushes to contour of commutator. (3) Check brush spring tension. Adjust tension to 13/4 to 21/2 psi at contact surface. 1. 2. 3. 4. 5. 6. 7. 8. 9. Bearing housing outer Screw Gasket Setscrew Bearing housing (inner) Commutator endbell Brush stud Bolt Bilge frame me (4) Check brushes to see that they move freely in holders. (5) Keep commutator clean. b. Removal (1) Disconnect external wiring from motor connection box, and mark for assembly. (2) Remove bolts holding coupling flanges together. (3) Loosen mounting bolts and lift motor from foundation. c. Disassembly. (1) Remove brushes from holders; disconnect wiring from brush holders and mark for assembly. (2) Remove coupling half and key from shaft. (3) Loosen setscrew (4, fig. 5-71) in commutator endbell. 10. 11. 12. 13. 14. 15. 16. 17. Bolt, mounting Hearing housing [inner) Drive endbell Capscrew Screw Rearing housing (outer) Ball bearing Ball bearing Figure 5-71. Bilge and ballast pump motor. (4) Remove commutator endbell mounting bolts (8) and pull commutator endbell (6) from field frame and bearing housing assembly 5-94 (5) Remove drive and endbell mounting bolts (10). and withdraw armature and endbell assembly carefully from field frame. (6) Remove capscrews (13) from drive endbell (12), and pull drive endbell from drive end bearing housing. 5-35. Controller (7) Remove screws (14) from drive end bearing outer housing (15), and remove housing. a. (1) The bilge and ballast pump motor controller is a direct current, single step acceleration type, with thermal overload relay protection. The starting cycle is controlled by a pneumatic timing relay. (8) Pull drive end bearing (16) and bearing inner housing (11) from armature shaft. (9) Remove screws (2) from commutator end outer bearing housing (1), and remove housing. (2) When control circuit is completed by pressing START button, main line contactor operates and the motor is started through the armature resistance. Upon completion of the timing cycle, the timing relay closes its contacts and energizes the coil accelerating relay. The accelerating relay operates and shunts out resistance and permits motor speed to increase to normal running speed. (10) Pull commutator end bearing (17) and inner bearing housing (5) from armature shaft. d. Cleaning and Inspection. (1) Blow loose dirt from windings with clean, dry, lowpressure air. b. (2) Wipe all parts clean using cloth moistened with dry cleaning solvent in comformance with FED SPEC P-D-680. (2) Keep mating surfaces of magnetic coil free of any accumulation to dirt. (3) Inspect contacts for excessive burning or wear. Smooth excessive roughness from copper contacts with a fine file. Do not file silver contacts. Replace contacts worn to one-half original thickness. (4) Inspect commutator for grooving or burring. If commutator cannot be smoothed by taking a light cut in a lathe, replace armature. (4) Check all connections for tightness and cleanliness. (5) Check bearings for roughness when rotated by hand. Replace defective bearings. c. Assembly. (1) (1) Assembly is in reverse order of disassembly. Accelerating Contactor. Replace contacts as follows: (a) Swing arc barriers (2 and 3, fig. 5-72). KEY to fig 5-72 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. (2) Pack new bearings with lubricant in accordance with LO 55-1925-204-12. (3) Adjust brush tension. Replace brush springs that cannot be adjusted to proper tension (a. above). f. Cleaning and Inspection. (1) Keep interior and exterior of enclosure clean. (3) Inspect windings for evidence of short circuit or damaged insulation. If armature windings are defective, replace armature. If field windings are defective, replace motor. e. General. Installation. (1) Set motor in place on foundation. (2) Install mounting bolts; do not tighten. (3) Check coupling alignment. Make sure couplings fit flush all around and are on the same plane. (4) Install bolts in couplings and tighten. (5) Tighten motor foundation bolts. (6) Connect electrical wiring in motor connection box. 5-95 Screw Arc barrier, rh Arc barrier. Ih Side plate, rh Side plate. lh Screw Lockwasher Arc horn Post Contact. stationary Coil relay Contact. movable Spring, helical, Contact Washer Cotter pin Armature Post Support 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. Spring, helical, armature return Screw Lockwasher Contact, movable Nut Guard Support Finger Terminal Frame Clamp Screw Screw Pole face Screw Clamp Magnet coil Terminal post Blowout coil Figure 5-72 Bilge and ballast pump accelerating contactor. 5-96 (d) Installation is in reverse order of removal. (b) Remove screw (6) and arc horn (8), and lift off stationary contact (10). d. Main Line Contactor. (c) Disconnect pigtail from terminal post (36): remove cotter pin, cup washer, and contact spring (13); and lift off movable contact (12). (1) The main line contactor assembly is the same as that of the accelerating contactor (c. above), with the exception that it is a two-pole contactor. (d) Installation is in reverse order of removal. (2) Replacement of contacts (c. (1) above). (2) Replacement of relay coil as follows: (3) Replacement of relay coil (c. (2) above). (a) Disconnect pigtail from terminal post (36), remove cotter pin (15), cup washer (14), and armature return spring ( 19) . Lift off armature assembly (16). e. Overload Relay. (1) Remove screw (10, fig. 5-73) from each end of thermal unit (11) and slip off unit. Installation is in reverse order of removal. Tighten screws securely. (b) Disconnect coil leads at clamp (29) on each side of the coil. (c) Loosen screw (31) and remove pole face (32). Slide coil forward from magnet coil. 1. 2. 3. 4. 5. 6. Contact, stationary Reset and slider Contact, movable Spring Cotterpin Screw 7. 8. 9. 10. 11. 12. Tie bar and slider stop Guide pin Spring Screw Thermal unit Stud Figure 5-73. Overload Relay. (2) Replace latch spring as follows: (a) Remove reset and slider assembly ((2) (b) above). Remove cotter pin (5), spring (4), and contact (3). Installation is in reverse order of removal. (a) Remove thermal unit. (b) Loosen screws (6) holding tie bar and slider stop. Remove reset and slider assembly (2) along with tie bar and slider stop. (c) Remove latch spring 19) from slider assembly and tie bar and slider stop. (b) Remove panel from controller inclosure. Trip thermal unit using slider latch. Remove nut holding stationary contact (1), then unscrew stud (12) from panel. Lift off contact. Installation is in reverse order of removal. 5-36. Fire Pump (3) Replace contacts and springs as follows: a. 5-97 General Description. The pump is a single stage, split case centrifugal pump having a capacity of 300 8pm at 100 psi. The pump is driven by a 25-hp electric motor. Construction of pump is such that it makes a suction on both sides of the impeller and discharges out through the center of the impeller. b. Pump. The pump is fitted with a ball bearing on the extreme ends of the pump frame and with adjustable packing glands on inboard ends where the pump shaft extends through the pump casing. Replaceable wearing rings are installed on the pump impeller. These wearing rings are replaced when the efficiency of the pump decreases and the pump no longer delivers water at its rated capacity. c. Maintenance and Adjustment. The pump is designed with a packing gland that must leak water slowly when the pump is running to provide lubrication between shaft and pump packing. Should the packing leak excessively, the leakage may be slowed by tightening the packing gland while the pump is running. Tighten only enough to bring the leakage to a slow drip. Do not stop the leakage entirely. d Removal. (1) To remove bearing, disconnect motor coupling (fig. 5-74) inlet and outlet lines, and move pump if drive end bearing is to be removed. If thrust end bearing is to be removed pump will not have to be moved. 5-98 TM 55-1925-204-12 Figure 5-74. Fire pump removal. (2) Remove bolts holding pump and motor coupling together. (4) Remove bearing housing cap (3, fig. 5-75, and lift from bearing housing (1). (3) Remove bolts from inlet and outlet flanges and remove pump foundation bolts. 5-99 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Bearing housing Bearing locknut Bearing housing cap Bearing housing cover Fluid deflector Sleeve locknut Shaft sleeve Packing gland Water seal tube Pump casing 11. 12. 13. 14. 16. 16. 17. 18. 19. 20. Pump impeller Wearing ring Casing wearing ring Shaft packing Cage ring Shaft sleeve Sleeve locknut Bearing housing cap Bearing, housing thrust end Housing plug Figure 5-75. Fire pump. (5) Remove capscrews from bearing housing cover and withdraw bearing housing from pump lower half casing. (6) deflector (5) in place and slide bearing housing covers and deflectors from shaft. Remove locknut (2) and bearing from pump (2) Remove packing glands from shaft. shaft. (3) Remove old packing rings from around shaft. Remove cage ring and stuffing box bushing. NOTE When cleaning or replacing bearing, remove one at a time. If pump is being overhauled remove both bearings. (7) (4) Remove setscrew from the shaft sleeve (16) and remove nut and shaft sleeve from shaft. NOTE Thrust bearing is removed in the same way. It may be necessary to apply heat to shaft sleeve in order to remove the sleeve from shaft. Apply only enough heat to expand the sleeve; do not heat the shaft. (8) To remove shaft and impeller, remove bolts and nuts holding upper and lower pump casings together and remove the upper casing. (9) Lift shaft and impeller assembly from pump. (5) Remove impeller from shaft. It may be necessary to heat the impeller to remove from shaft, in which event, heat only enough to expand impeller; do not heat shaft. e. Disassembly. (1) Remove the setscrews which hold fluid f. Cleaning, Inspection, and Repair. (1) Inspect wearing rings on impeller. If wearing rings show signs of scoring, replace them. 5-100 (2) Position casing wearing ring over impeller wearing ring and check for clearance. If clearance exceeds .010 inch, replace wearing rings. (3) To remove impeller wearing ring, heat surface of ring to expand it. Do not heat impeller. Pry wearing ring from impeller. (4) Inspect the surface of the shaft sleeves for scoring. Replace scored sleeves. (5) Remove all old grease from ball bearings with clean fuel oil and wipe dry. Spin each bearing while holding in hand. Bearings that sound rough while spinning will be replaced. (6) Replace impeller wearing ring by heating, positioning on impeller, and allowing to cool. b. Removal. (1) Disconnect external wiring from motor connection box, and mark for assembly. (2) Loosen motor mounting bolts and disconnect coupling between motor and pump. (3) Remove mounting bolts, and lift motor foundation. c. Disassembly. The disassembly of this motor is the same as that discussed in paragraph 5-34 c. d. Cleaning and Inspection. The cleaning and inspection of the motor is the same as that discussed in paragraph 5-34 d. g. Assembly. e. Assembly. The assembly of this motor is the same as that discussed in paragraph 5-34 e. (1) Make sure impeller is positioned on pump shaft with key in place. Grease shaft and slide pump sleeves into position. (2) Replace packing gland (8) and casing wearing rings (13) on each end of shaft, and replace sleeve locknut (6). Tighten shaft sleeve against impeller. (3) Replace bearings on each end of shaft and lock in place with bearing locknut. (4) Position bearings in bearing housing (1) and replace bearing housing cap (3} and cover (4). (5) Position wearing rings (13) in lower casing half, and replace upper casing half. Bolt casing halves together. (6) Fabricate new packing rings and replace in stuffing box. Position three rings of packing, cage ring (15), and then three more rings of packing. f. Installation. (1) (2) (3) (4) (5) Position motor on foundation. Install mounting bolts. Do not tighten. Align coupling; assembly, and bolt together. Tighten foundation bolts. Connect electrical wiring to motor connection box. 5-38. Controller The maintenance on controller is the same as that discussed in paragraph 5-35. NOTE 5-39. Fresh and Salt Water Standby Pump Cut the package by wrapping rings around the shaft and cut, allowing a gap of 1/ inch between packing ends. Stagger ends of packing when replacing. a. General. The fresh and salt water standby pumps are identical in construction and in the maintenance section are treated as one unit. Both the fresh water and salt water pumps circulate water through the propulsion engine heat exchanger or engine to cool the engine, to provide additional circulating water if necessary, or to provide entire cooling should either or both pumps on the engine be cut out of service. The pump is driven by a 7.5-hp, 115-volt dc motor. The pump is a single stage centrifugal pump having a 4-inch suction inlet and a 3-inch discharge outlet. The pump is fitted with two ball bearings, one of which is the thrust bearing. Both bearings are positioned on the same side of the impeller. An adjustable packing gland is installed in the pump housing to prevent excessive leakage around the pump shaft. (7) To adjust packing, turn shaft by hand and tighten packing gland slowly and evenly. Tighten only enough to commence seating packing. h. Installation. Reverse the order of removal and then adjust packing in accordance with b above. 5-37. Motor a. Maintenance and Adjustment (TM 55-506). (1) Lubricate in accordance with LO 55-1925204-12. (2) Inspect brushes. Replace brushes worn to onehalf normal length. Sand new brushes to contour of commutator. (3) Check brush spring tension. Adjust tension to 13/4 to 21/2 psi at contact surface. (4) Check brushes to see that they move freely in holders. (5) Keep commutator clean. b. Maintenance and Adjustment. The pump packing gland must leak slowly when the pump is running to provide lubrication between shaft and pump packing. Should the packing leak excessively, leakage may be slowed by tightening the packing gland nuts while the pump is running. Tighten only enough to bring the leakage to a slow drip. Do not stop the leakage entirely. c. Removal. (1) Disconnect suction and discharge lines from pump (fig. 5-76) . 5-101 Figure 5-76. Fresh and salt water standby pump, removal. (2) Remove cover and bolts holding pump and motor coupling halves together. d. Disassembly. (1) remove (3) Remove pump mounting bolts and lift pump from foundation. 5-102 Remove capscrews (4, fig. 5-77) and the pump casing from pump. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Impeller shaft sleeve Pump casing Casing gasket Capscrews Back head Seal cage Packing Packing gland Liquid deflector Inner bearing Inner bearing seal 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Impeller shaft Thrust bearing Frame shims Bearing lockwasher Bearing cover Bearing locknut Pump frame Impeller Impeller screw Impeller key Impeller shaft sleeve gasket Figure 5-77. Fresh and salt water standby pump. (2) Remove impeller screw (20) from end of shaft. (3) Withdraw impeller (19) from shaft and remove key (21). (4) Remove two nuts from packing gland (8) and slide packing gland against liquid deflector (9). (5) Withdraw back head (5) from pump shaft. (6) Remove pump coupling half from end of shaft and remove shaft key. (7) Slide packing gland from shaft. Remove setscrew from liquid deflector and remove liquid deflector. (8) Remove capscrews from bearing cover (16) and remove cover. (9) Remove bearing locknut (17) and lockwasher (15) from shaft. (10) Remove thrust bearing (13) and impeller shaft as a unit. (11) Remove inner bearing (10) from pump frame. e. Cleaning, Inspection, and Repair. (1) Clean bearings thoroughly with fuel oil and dry. Inspect bearings for cracked races or missing balls. Rotate bearing with air. Bearings which run rough when spun will be replaced. (2) Pack each bearing with grease prior to replacing. (3) Clean bearing housing thoroughly and inspect for cracks. (4) Inspect impeller shaft sleeve (1). If sleeve shows signs of scoring, replace. 5-103 (5) Remove all packing from gland in back head (5). g. Installation. (1) Position pump on foundation and check alignment of coupling flanges. (2) Install pump mounting bolts and again check alignment of coupling flanges. Flanges must meet squarely. (3) Replace coupling bolts and tighten. (4) Reconnect suction and discharge lines. f. Assembly. (1) Replace thrust bearing on shaft. (2) Position new inner bearing seal (11) in pump frame, and slide impeller shaft into position. NOTE 5-40. Motor When positioning shaft be careful not to damage bearing seal. a. General. The motor is a 7.5-hp, 1750-rpm, 115-volt dc motor, flanged directly to the fresh and salt water standby pumps. Ball bearings at each end of motor support the armature and shaft. (3) Slide inner bearing (10) into position on shaft and into pump frame. (4) Replace bearing lockwasher and bearing locknut (17). (5) Replace bearing cover (16) and tighten capscrews which hold cover in place. (6) Replace liquid deflector (9). Tighten setscrew in deflector and check bearings by revolving shaft to see if shaft revolves freely. (7) Slide packing gland onto shaft against liquid deflector. (8) Position back head (5) and impeller (19). Make sure key (21) is properly seated in keyway and in impeller. (9) Replace impeller screw; tighten and replace impeller screw key. (10) Replace pump casing (2) and capscrews (4). (11) Check pump by rotating shaft. Be sure pump does not bind and impeller does not rub against casing side. (12) Replace packing (7) by positioning two rings of packing, seal cage (6), and then three rings of packing. b. Maintenance. The maintenance procedures for replacing bearings, brush holders, coils, insulators, plug springs and washers is the same as for the motor covered in paragraph 5-34. 5-41. Controllers a. General. The fresh and salt water standby pump controller is a dc magnetic type with current limit acceleration. The contacts and springs on the controller are replaceable. b. Maintenance. paragraph 5-35. For maintenance of controllers see 5-42. Fuel Oil Transfer Pump a. General. The fuel oil transfer pump is a DeLaval IMO rotary displacement type pump direct-coupled to a 1750-rpm, 1-hp, 115-volt dc motor. The motor is controlled by dc magnetic type controller operated from a START-STOP switch located in the door of the controller, and an emergency STOP button located at the head of the engine room access ladder. NOTE In replacing packing, stagger the butts of packing rings so leakage will not occur through butts. (13) Slide packing gland into position and tighten gland nuts evenly while rotating pump by hand. Do not overtighten as this may score the shaft. b. Maintenance and Adjustment. (1) Inspect piping connections for leaks. Tighten leaking connections. 2) Check for leakage at pump venthole (18, fig. 578). If leakage appears at venthole, disassemble pump and check mechanical seal. 5-104 1. 2. 3. 4. 5. 6. 7. 6. 9. 10. Idler rotor Pump case, outboard Rotor housing Gasket Pump case, inboard Rotating seal Gasket Stationary seal Spacer Gasket 12. 13. 14. 15. 16. 17. 18. 19. 20. Bolt Oil seal Key Power rotor Ball bearing Snap ring Venthole O-ring Bolt Figure 5-78. Fuel pump, cutaway. c. away from drive motor until clutch jaws are disengaged. Remove coupling spider. (3) Lift pump from mounting. Removal. (1) (2) Disconnect piping from pump. Remove mounting bolts and pull pump 5-105 d. Disassembly. (1) CAUTION Extreme care must be exercised when handling seals to prevent damage to sealing faces, Pull coupling hub from pump shaft. Remove key (14). (2) Remove end cover mounting bolts (12) and pull end cover (11) from rotor shaft. Remove gasket (10). (3) Press oil seal (13) from end cover (11). (4) Carefully withdraw power rotor assembly (6, 8, 9, 15, 16, 17, and 19) from pump. (5) Remove bolts (20) and remove outboard pump case (2) and one gasket (4). (6) Remove idler rotor (1). (7) Remove rotor housing (3) and remaining gasket (4). (8) Remove inboard snap ring (17) from power rotor shaft. (9) Press spacer (9) and bearing (16) from shaft. (10) Remove remaining snap ring and slip stationary seal (8) from power rotor (15). (11) Rotating seal (6) is a separate assembly containing bellows and carbon ring. Work carbon ring out of retainer and off rotor shaft. Normally there will be no need to remove spring and bellows, but if necessary to remove, work rubber bellows off shaft. (4) Place spacer (9) in position on power rotor (15). (5) Pack ball bearings (16) with grease in accordance with MIL-L-15719A. (6) Press bearing (16) on rotor shaft. (7) Install remaining snap ring. (8) Place gasket in position on inboard pump case (5). (9) Install rotor housing (3). (10) Install idler rotors (1). (11) Place gasket (4) on outboard side of rotor housing (3). (12) Install outboard pump case (2) and fasten pump case (2), rotor housing (3), and pump case (5) with bolts (20). (13) Press oil seal (13) into end cover (11). (14) Carefully insert power rotor (15) into pump, and seat spacer firmly against shoulder in case (5). CAUTION Exercise extreme care when inserting power rotor to prevent damage to O-ring (19) when passing it over venthole (18). e. Cleaning and Inspection. (1) Inspect pump rotor for shipping or wear. Replace pump assembly if rotors are defective. (2) Inspect ball bearings for smooth operation. Replace rough or binding bearings. (3) Inspect seals for wear or damage. Replace defective seals. (15) Install gasket (10) on inboard pump case (5). (16) Carefully push end cover (11) over rotor shaft and seat against case (5); fasten with bolts (12). (17) Rotate pump by hand to detect binding. (18) Install key (14) on pump shaft. (19) Press coupling hub on pump shaft. f. Assembly. g Installation. (1) Press rotating seal assembly (6) in place on power rotor (15). (2) Place stationary seal assembly (8) on power rotor as illustrated in figure 5-78. Lap in sealing faces of carbon washer and floating seat. Wipe lapped sealing faces perfectly clean and coat both faces with clean, light oil. (3) Install a snap ring (17) in slot adjacent to stationary seal (8). (1) Install coupling spider in hub on motor shaft. (2) Push pump into position on mounting to permit coupling hub on pump to engage hub and spider on motor shaft. (3) Install pump mounting bolts, do not tighten. (4) Connect fuel lines to pump and tighten. (5) Tighten mounting bolts. (6) Check alignment of coupling (fig. 5-79). 5-106 Figure 5-79. Checking coupling alignment. (5) Remove drive endbell mounting bolts, tap endbell loose from field frame and carefully withdraw armature from field frame. (6) Remove capscrews from drive end bearing cap and pull hearing cap from armature shaft. (7) Carefully pull drive endbell from armature shaft. (8) If brush holders are to be replaced, loosen clamping screw and pull brush holder from mounting studs. (9) Remove locknut and lockwasher from each end of armature shaft. (10) Pull ball bearings from armature shaft; remove inner bearing caps from armature shaft. CAUTION Do not operate pump until alignment tolerances are met. 5-43. Motor a. Maintenance and Adjustment (TM 55-506 ). (1) Lubricate in accordance with applicable lubrication order. (2) Inspect brushes; replace brushes worn to onehalf normal length. (3) Check brush tension; adjust tension to approximately 2 psi of brush contact surface. (4) Inspect commutator; clean dirty commutator with 00 sandpaper. d. Cleaning and Inspection (TM 55-506 ). (1) Wipe parts clean with dry cleaning solvent in conformance to FED SPEC P-D-680. (2) Inspect armature and field windings for damaged insulation. If insulation is defective, replace motor. (3) Inspect brush holders for damage. Replace defective brush holders. (4) Check brush tensioning springs; replace springs that are broken or have lost tension. (5) Inspect commutator for grooving, burning, or high mica. If defects cannot be repaired by taking a light cut in a lathe, or undercutting, replace the motor. (6) Rotate bearings by hand; replace bearings that bind or catch. b. Removal. (1) Disconnect electrical connections from motor, and remove cable from motor connection box. (2) Remove four mounting bolts, and slide motor away from pump until clutch jaws are disengaged. Lift motor from mounting. c. Disassembly. (1) Remove brushes from brush holders; mark electrical connections to brush rigging for replacement upon assembly, and disconnect electric connections from brush rigging. (2) Pull coupling from motor armature shaft.; remove key from shaft. (3) Remove capscrews from commutator end bearing cap and pull bearing cap from armature shaft. (4) Remove commutator endbell mounting bolts, tap endbell loose from field frame, and carefully withdraw endbell from armature shaft. e. Assembly. (1) of 5-107 The order of assembly is the reverse of the order disassembly. (6) Connect motor electrical connections. (2) Pack ball bearings with grease in accordance with applicable lubrication order prior to installation of outer bearing cap. (3) If a new brush holder is installed, position in groove and set brush angle to correspond with angel of original holders. (4) If new brushes are installed, sand to contour of commutator (TM 55-506). (5) Adjust brush tension to approximately 2 psi of contact surface. 5-44. Controller a General. The fuel oil transfer pump controller is a dc magnetic type with current limit acceleration. Depressing the START button energizes the line contact (fig. 5-80) connecting the motor and the series resistors across the line. The coil of the counter electro-motive force contactor is connected across the motor armature. The CEMF (fig. 5-80) contactor is set to pick up at approximately 70 percent of line voltage across the armature as the motor accelerates; the voltage across the armature gradually builds up until it reaches 70 percent line voltage, at which time the CEMF contactor closes; its contacts short out the starting resistors (R1-R2) and connect the motor directly across the line. f. Installation. (1) Place motor on mounting with motor shaft in line with pump shaft. (2) Move motor toward pump to engage clutch. (3) Install motor mounting bolts and tighten. (4) Check coupling alignment (fig. 5-79). (5) Rotate shaft by hand to check for binding. Figure 5-80. Controller, fuel oil transfer pump motor, schematic diagram. contacts when worn to one-half original thickness. (6) Remove accumulation of carbon from arc shields. (7) Check operation of line contactor and accelerating contactor (d and e below). b. Maintenance. (1) Keep interior of controller enclosure clean. (2) Wipe magnetic sealing surfaces clean. (3) Do not lubricate contact tips. (4) Check tightness of all connections. Particularly the connection to overload heater connections. (5) Inspect contacts for excessive burning. Remove excessive roughness from copper contacts with a fine file. Do not file silver contacts. Replace c. Overload Relay. (1) To replace heater, remove screw and washer (13, fig. 5-81) from each end of heater and lift off heater unit. Install new heater in reverse order of removal and tighten screws securely. 5-108 1. 2. 3. 4. 5. 6. 7. Reset spring Cotter pin Nut Washer Cotter pin Contact spring Contact bar 8. 9. 10. 11. 12. 13. 14. Contact Nut Screw and washer Hook Heater unit Screw and washer Latch spring Figure 5-81. Overload relay. (2) To replace overload relay-proceed as follows: (c) Disconnect wiring from overload relay. Mark for reassembly. (a) Disconnect external wiring from controller. Mark for assembly. (d) Remove nuts from mounting studs, and remove screw (101 from rear of panel. Lift off overload relay. (b) Remove four bolts fastening panel to enclosure. Lift panel from enclosure. 5-109 (e) Replace overload relay in reverse order of d. Accelerating Contactor. removal. (1) (f) Replace panel in mounting bolts, and reconnect wiring. enclosure, and 1. 2. 3. 4. 5. 6. 7. 8. Adjustment is performed as follows: install Movable contact Stationary contact Screw and nut Contact post Nut Screw Core Adjusting nut A2 (a) on 9. 10. 11. 12. 13. 14. 15. Tail spring Shaft Armature assembly Hairpin Coil Contact spring Cotter pin Figure 5-82. Accelerating contactor. 5-110 Connect a voltmeter across terminals Al controller panel (fig. 5-80). disconnect pigtail from panel, remove cotter pin (15), cup washer and contact spring (14), and lift off contact. Replace in reverse order of removal. (b) Energize circuit, push START button and observe voltage reading when accelerating contactor closes. This contactor should close at 70 percent of line voltage. Adjust to this valve with adjusting nut (8, fig. 5-82). (2) NOTE Contacts should be replaced in sets and aligned to see that contacts meet squarely. Replacement of contacts as follows: (a) To replace stationary contact (2), remove nut and screw (3) and lift off contact. Replace in reverse order of removal. (b) (c) After contacts are replaced, 'check "Lead Dimension" (L.D.) (fig. 5-83). This dimension should be 1/16 inch, and can be obtained by bending the movable contact at "A." To replace movable contact (1): Figure 5-83. Lead dimensions. (3) Coil replacement as follows: (a) Remove external wiring connections from (b) from enclosure. (c) coil. (d) Remove four mounting bolts and lift panel (e) Remove screw (6) from back of panel and lift coil (13) and core (7) from panel. (f) Slip coil from core. panel. NOTE If coil has been overheated, check all parts for deposits of melted insulation that might interfere with operation of contactor, and remove such deposits. Disconnect electrical connections from Remove hairpin (12, fig. 5-821 and shaft (10) This permits armature (11) to swing away from front of coil (13). (g) 5-111 Replace coil in reverse order of removal. (4) Replacement of ball spring (9) as follows: (d) Install new contactor in reverse order of (e) Install panel in enclosure and reconnect removal. (a) Unhook spring from adjusting screw and armature assembly. (b) Adjust contactor ((1) above). wiring. e. Line Contactor. (5) To replace accelerating contactor as follows: (a) Remove panel from enclosure NOTE The line contactor is similar in construction to the accelerating contactor with the exceptions that it has two sets of main contacts and two normally open auxiliary contacts (fig. 5-84) . ((3) above). (b) Disconnect electrical connections from accelerating contactor. (c) Remove nuts from mounting studs, remove screw (6), and lift accelerating contactor from panel. 1. 2. 3. 4. 5. Nuts Stationary contact Cotter pin Post, movable Line contactor 6. 7. 8. 9. Mounting nuts Contact holder assembly Spring Movable contact Figure 5-84. Auxiliary contacts. 5-112 manufactured by the DeLaval Steam Turbine Company. The pump has a capacity of 175 gpm at 35 psi. The prime mover of the pump is a 10-hp, 1750-rpm, 115-volt dc, electric motor. (1) Replacement of main contacts. Procedure for replacement and adjustment of main contacts is the same as that given in d (2) above. Two sets of main contacts are installed on the line contactor. b. Purpose. The pump is installed against the forward bulkhead of the engine room and can perform the following functions: (2) Coil replacement (d (3) above). (3) Replacement of tail spring as follows: (1) Discharge contents of dirty lubricating oil tank into a container. (a) Unhook tail spring from armature and adjusting screw, and remove. Installation is in reverse order of removal. (2) Transfer oil from the lubricating oil storage tank to propulsion engine crankcase. (b) Set tail spring tension with adjusting nut so that with panel removed from enclosure and inclined 450 backward, the armature will return to its open position when closed manually and released quickly. (4) Replacement contacts as follows: (a) and adjustment of (3) Remove lubricating oil from the engine sump, and send it through Purifier and back to the engine sump. c. Operation. The operation of the pump is as follows: Fluid enters the suction inlet, divides, and flows to the ends of the rotors. At rotor ends it enters the rotor screw forms and is propelled to the central discharge chamber. The rotors are in hydraulic balance. Packing is subject to suction pressure only. A piping connection is made between pump discharge and the pump side of the packing. Fluid is delivered through this pipe from discharge side of pump to the pump side of packing, thereby sealing air leaks. Auxiliary Remove panel from enclosure (c (2) above). (b) Remove cotter pin (3, fig. 5-84) and slide off contact holder assembly (7). Remove spring (8) and stationary contact (2). Replace in reverse order of removal. d. Maintenance. (c) Remove nuts (1) and remove movable contact (9). Replace in reverse order of removal. (1) Inspect all piping connections for leaks. Tighten leaking connections. (d) Adjust "Lead Dimension" (L.D.) to between 3/32 and 1/8 inch by loosening mounting nuts (6) and moving post (4) forward or backward. (5) (2) Check for signs of air leakage at packing gland. If leakage is detected, tighten gland enough to stop leakage. Replacement of line Contactor. See d (5) above. NOTE Leakage at the gland will be indicated by the sound of air being drawn into the pump. f. Emergency Stop Station. (1) Remove cover screws and lift off cover, disconnect electrical connections, loosen cable clamp and withdraw cable, remove mounting screws and lift switch assembly from mounting. (2) e. Removal. (1) Disconnect suction and discharge pump to piping coupling flange (fig. 5-85) by removing six bolts in each flange. Installation is the reverse order of removal 5-45. Lubricating Oil Standby Pump a. General. The lubricating oil standby pump is a model A 322AX250 rotor type pump 5-113 Figure 5-85. Lubricating oil standby pump. (2) Remove three capscrews which hold the coupling half covers together and slide covers out of way. (3) coupling. f. Disassembly. (1) Loosen setscrew from shaft coupling and slide coupling from pump assembly. Remove the grid member from the (2) remove (4) Remove bolts holding pump base to pump bulkhead foundation and move pump to workbench. 5-114 Remove capscrews (1, fig. 5-86) and end cover (2) from pump. TM 55-1925-204-12 1. Capscrews 2. End cover 3. Pump housing 4. Suction inlet 5. Packing gland end cover 6. Capscrews 7. Idler rotor 8. Bushing 9. Packing washer 10. Packing 11. 12. 13. 14. 15. 16. 17. 18. 19. Packing gland nut Packing gland Power rotor Idler rotor Rotor housing Housing spacer ring Discharge outlet Adjusting nut Locknut Figure 5-86. Lubricating oil standby pump, section. (3) Withdraw power rotor (13) and idler rotors (7 and 14) from the rotor housing (15). (4) Loosen packing gland nuts (11) and swing bolt out of way. (5) Withdraw packing gland from pump housing and remove worn packing. (6) Remove capscrew (6) and packing gland end cover from pump housing. (7) Remove bushing (8) from packing gland end cover. g. Cleaning, Inspection, and Repair. (1) Examine power rotor bushing and power rotor at point where rotor revolves in bushing. If bushing shows signs of wear or score marks, replace bushing. (2) Remove all traces of old gasket from both end covers. h. Assembly. (1) Assemble pump in reverse order of disassembly leaving packing out until pump is assembled. (2) Adjust idler rotor adjusting nuts to give rotors a slight pressure against packing gland end cover. NOTE Do not overtighten; to do so will warp idler rotors causing distortion of rotor housing bores. (3) Replace packing with same amount and type as removed. (4) Adjust packing gland nuts (11) finger tight. i. Installation. (1) Install coupling cover on pump shaft and slide coupling into position on shaft. (2) Position pump assembly on foundation and bolt in place. 5-115 (3) Align coupling halves leaving a 1/8 inch gap between coupling halves. (4) Replace gasket that fits between coupling half covers and force lubricant into gap. (5) Install grid member by starting into slots in coupling halves. After grid member is partially started in coupling halves, drive all the way in with a small hammer. (6) Pack grid member with lubricant in accordance with LO 65-1925-204-12-7. (7) Slide covers into position or fasten in place with bolts provided. NOTE Make sure that neoprene seals are squarely seated on hubs and not pinched under cover. (8) Replace gaskets between pump and pipe coupling flanges and bolt in place. 5-46. Motor a. General. The pump is driven by a 10-hp, 115-volt dc electric motor, directly coupled to the lubricating oil pump and mounted vertically above the pump. b. Maintenance. (1) Lubricate in accordance with LO 55-1925-20412-7. (2) Inspect brushes. Replace brushes worn to one-half normal length. Sand new brushes to contour of commutator. (3) Check brush spring tension. Adjust tension to 1 pound. (4) Check brushes to see that they move freely in holders. (5) Keep commutator clean. c. Removal. (1) Disconnect external wiring from motor connection box and mark for assembly. (2) Disconnect coupling (para 5-45). (3) Position a chain fall above motor; rig lifting strap around motor. (4) Remove mounting bolts from motor foundation and swing motor to engine room deck plates. d. Disassembly. (1) Remove capscrews holding fan and motor cover to motor frame. (2) Remove end cover. (3) Remove Allen head setscrew from coupling half, and slide coupling and coupling cover from shaft. (4) Remove key from shaft and withdraw armature (2, fig. 5-87) from motor. 5-116 1. 2. 3. 4. 5. Fan Armature Bearing, front end Motor frame Field, interpole 6. Field main 7. Bearing fan end 8. Brush holder 9. Brush 10. Brush assembly Figure 5-87. Motor, lubricating oil standby pump drive. (5) Remove brush assembly (10) from frame. (6) Remove capscrews holding bearing caps to endbells and remove bearing cap and endbells. (7) Withdraw bearing from endbell. (8) Disconnect brushes (9) from brush assembly (10); release brush spring and lift brush from brush holder (8). e Cleaning, Inspection, and Repair. (1) Blow loose dirt and carbon from windings with clean, dry, low-pressure air. (2) Wipe all parts clean using cloth moistened with drycleaning solvent in conformance with FED SPEC P-D-680. (3) Inspect windings tor evidence of short-circuit or damaged insulation. If armature windings are detective, replace armature. If field windings are defective, replace motor. (4) Inspect commutator for grooving or burring. If commutator cannot be smoothed by taking a light cut in a lathe, replace armature. (5) Check bearings for roughness by rotating by hand; replace defective bearings. f. Assembly. (1) Assembly is in reverse order of disassembly. (2) Pack new bearings with lubricant in accordance with LO 55-1925-204-12-7. (3) Adjust brush tension. Replace brush springs that cannot be adjusted to proper tension. (4) Replace coupling cover and position coupling half in same location from which removed. g. Installation. (1) Using chainfall, set motor in place on foundation. 5-117 (2) Install mounting bolts; tighten only enough to hold motor firm. (3) Align coupling half (para. 5-45 i. ). (4) Tighten mounting bolts and connect electrical wiring to motor. 5-47. Motor Controller a. General. The controller is a magnetic type with current limit (two-step) acceleration. It is actuated by a START-STOP selector switch mounted on the door of the controller inclosure. Protection against overloads is furnished by the manually reset overload relay, which opens its contacts when the current reaches a predetermined percentage above normal, full-load current. The motor cannot be restarted until the overload relay 1. Contact 2. Contact 3. Mounting bolt had been manually reset by pushing the button mounted on the controller door. b. Maintenance. (1) Keep interior and exterior of inclosure clean. (2) Inspect contacts for excessive burning or wear. Smooth roughness from copper contacts with a fine file. c. Removal. (1) To remove the contactor from control panel, first remove fuses from fuse clips and disconnect electrical leads. (2) Remove mounting bolts (3 and 5, fig. 5-88) that hold contactor to controller panel and remove contactor from controller. 4. Capscrew 5. Mounting bolt 6. Spring Figure 5-88. Controller contactor. 5-118 7. Cotter pin and shaft 8. Coil 9. Core d. Disassembly. (1) To remove contacts (1 and 2) from contactor remove screw which holds each to contact post and withdraw from contactor. (2) To remove spring (6) from contactor, unhook spring from boltholes and remove from contactor. (3) To remove coil (8) remove cotter pin and shaft (7) from contactor and swing armature away from coil. (4) Disconnect coil terminal wires. (5) Remove capscrew (4), core (9), and coil (8) from contactor. e. Cleaning, Inspection, and Repair. (1) Inspect springs and replace if spring has lost tension. (2) Wipe all parts clean using cloth moistened with dry cleaning solvent in conformance with FED SPEC P-D-680. (3) Inspect coil windings for evidence of short circuit or damaged insulation. If windings are defective replace coil. (4) Inspect contacts and replace contact shoes that are worn to one-half their original length. f. Assembly. (1) Reassemble all parts in the reverse order of disassembly. (2) Adjust airgap between shoes to 9/16 inch. g. Installation. (1) Position contactor on controller panel and bolt in place with mounting bolts. (2) Connect electrical leads, check all electrical connections for tightness, and install fuses in fuse clips. 5-48. Lubricating Oil Purifier a General. The lubricating oil purifier is a centrifugaldisc type purifier. Included as part of the purifier is the inlet and outlet gear pumps. It is driven by a 1/2-hp, 115-vdc motor, with a start-stop magnetic controller. b. Frame Cover and Inlet Arm. (1) General. The frame cover (fig. 5-89) is hinged to the main frame of the oil purifier and houses the centrifugal discs of the bowl. The inlet arm extends from the main frame, out over the cover, and is clamped to both. Figure 5-89. Lubricating oil purifier. 5-119 (2) Maintenance and Adjustment. (a) When the unit is operating the cover must be clamped tightly in place. (b) If the cover, or inlet arm, leaks, install a new gasket under the cover or an oil seal in inlet arm. Disassembly. (a) For repairs to the check valve (fig. 5-90) in the inlet arm, it is unnecessary to remove covet from the unit. 1. 2. 3. 4. 5. 6. 7. 15. 16. 17. 18. 19. 20. 21. Cover Clamp Priming valve Regulating tube gasket Regulating tube Distributing plug Brake lining Brake bushing 8. Plunger 9. Brake spring 10. Bearing ring 11. Ball bearing 12. Washer key 13. Worm screw 14. Tapered bushing (3) Tapered bushing Point Ball Bottom spring Gasket Sleeve Friction ring Figure 5-90. Oil purifier assembly. 5-120 22. 23. 24. 25. 26. 27. 28. Friction clutch block Helical gear Check valve ball Check valve spring Seal Arm raising spring Seal (b) Loosen cover clamps (1) and raise cover. (c) Remove the cross pin from sleeve which holds ball (24) in place, and check valve spring (25) and ball (24) will drop out. (4) Cleaning, inspection, and repair. (a) Clean all parts thoroughly in a drycleaning solvent which meets requirements of FED SPEC P-D680 and wipe dry with a lint free cloth. (b) Inspect all parts thoroughly. Replace ball check valves that do not seat properly and springs that have lost tension. (5) Assembly. Assembly is in reverse order of disassembly. c. Purifier Bowl. (1) General. The purifier bowl contains the primary parts of the purifier. The bowl is a centrifuge with many discs that revolve separating water and foreign substances from the oil. For the purifier to function properly keep bowl clean. (2) Maintenance and adjustment. (a) To clean bowl apply the brake until bowl has stopped. (b) Remove two cover clamps; remove cover and lock bowl in frame with bowl locking screw on each side of purifier frame. (c) Remove the coupling ring (5, fig. 5-91) and lift bowl top (17) from bowl by lifting at top disc (2). 1. Tubular shaft 2. Top disc 3.Coupling nut 4. Discharge gasket 5. Coupling ring 6. Bowl ring gasket 7. Intermediate discs 8. Bottom disc 9. Bowl shell 10. 11. 12. 13. 14. 15. 16. 17. Figure 5-91. Sectional view of bowl. 5-121 Spindle Locating pin Driving bushing Locating lug Intermediate top disc Driving bushing pin Discharge ring Bowl top NOTE The coupling ring has left-handed threads and must be turned clockwise to remove. (d) Remove tubular shaft (1) and discs as a unit and place in pail of solvent which meets requirements of FED SPEC P-D-680. (e) Scrape bowl shell with scoop to loosen and remove dirt that has collected on periphery. (f) Place disc (wet with solvent) into bowl. (g) Reassemble bowl in reverse order of disassembly. (h) Unlock bowl by loosening locking screws. (i) Start machine without admitting oil and run it dry for 5 minutes. NOTE This will spin all dirt from discs by centrifugal force. (j) Seal with water in accordance with operating instructions and unit is ready for operation. (3) Cleaning, inspection, and repair. (a) To replace discharge ring (16), remove cover from bowl, lock bowl in place and remove coupling nut (3) with special wrench listed in Table 4-1. (b) Lift discharge ring (16) from its seat in bowl top. (c) Replace discharge ring in reverse order of disassembly. (d) Inspect discharge gasket (4) and bowl ring gasket (6) whenever bowl is cleaned. Replace if gasket shows signs of wear. d. Clutch Assembly. (1) General Connection between the prime mover and the centrifuge is made by a friction type clutch which employs clutch blocks installed in a friction hub and worm wheel and gear. This arrangement enables the centrifuge to pick up speed slowly when the motor is started. Top speed of the centrifuge is approximately 7200 rpm. NOTE Disc's are not to be replaced individually. Disc's are dynamically balanced and must be replaced as a unit. (2) Removal. (a) To remove clutch from the purifier, remove pump housing plate from frame. (b) Withdraw the pump assembly from frame and lay carefully on deck, hub up. (c) Lift out friction hub from pump assembly. (3) Disassembly. (a) Remove clutch blocks from friction hub. (b) To remove worm wheel ring (11, fig. 592) from friction ring (12), remove the six screws which hold it in place. (4) Cleaning, inspection, and repair. (a) Inspect clutch blocks for signs of wear and replace those worn excessively. NOTE Clutch blocks may be replaced one at a time; it is not necessary to replace the entire set. (b) Inspect the worm wheel ring and worm shell for signs of wear. If either is worn they may be reversed, end for end, to give double wear. NOTE When either the worm screw shell or the worm wheel ring become worn and need to be reversed, they should both be reversed at the same time. If either has to be replaced, replace both the shell and ring. (5) Assembly. (a) Install worm wheel ring on friction ring. (b) Install the friction blocks in friction ring and install friction hub so that the two driving pins enter between the blocks. (c) Position thrust washer and key on shaft and slide assembled wheel and clutch on shaft. (d) Push assembly tight against thrust washer. Install pump housing. and bolt in place. e. Pumps and Relief Valve. (1) General. There are two gear type pumps installed on the unit. The inlet and the outlet pump. The capacity of the inlet pump exceeds that of the outlet pump. Each pump is provided with a relief valve. (2) Removal. (a) Remove capscrews that hold pump housing plate (4, fig. 5-92) to purifier. 5-122 1. 2. 3. 4. 5. 6. 7. 8. 9. Pump gear Gear plate, outlet Bearing plate Housing plate Bearing key Sleeve, adjusting pinion Bearing locknut Bearing Drive pinion 10. 11. 12. 13. 14. 15. 16. 17. 18. Friction hub Worm wheel ring Friction ring Clutch block Friction ring bushing Drive shaft Gear screw Drive gear Drive shaft bushing 19. 20. 21. 22. 23. 24. 25. 26. 27. Shaft spring Shaft washer Packing Bearing plate Gear plate, inlet Pump gear Idler shaft End plate Adjusting screw Figure 5-92. Pumps and clutches, sectional view. (b) Lay pump, clutch up, on deck and lift clutch assembly. (3) Disassembly. (a) Remove gear screws (16) from drive gears and remove gears. (b) Remove capscrews holding pumps to housing plate and lift pump from plate. (c) With two drive gears removed, the drive pinion (9) with bearing (8) can be removed. (d) To remove bearing from pinion shaft, lift tab on locknut washer and remove bearing locknut (7). (e) To disassemble pump remove four capscrews from pump end plate and end plate (26), gear plates (23 and 2), and gears can be removed. (f) To remove drive shaft (15) pull shaft from pump housing and bushing (18) will withdraw from pump housing. (4) Cleaning, inspection, and repair. (a) Inspect gears and shafts for signs of wear. Replace defective parts. (b) Inspect bearings by spinning while holding in hand. Replace those which run rough. (5) Assembly. (a) Assembly of pump is in reverse order of disassembly. (b) In assembly replace packing rings making sure there is a washer at each end of rings. (c) Install drive gears and pinion gear in reverse order of disassembly. (6) Installation. NOTE The pinion assembly is held to the friction hub by a sleeve and spring on the inside of the housing plate and a screw on the outside of the plate. Proper pinion positioning cannot be done until the assembled plate is fastened properly in the frame. (a) Align holes in housing plate with holes in frame. (b) Check position of two driving lugs on pinion, and line up with slots in friction hub. Position assembly. 5-123 NOTE If the driving lugs enter the slots in the friction hub the housing plate will fit tight against the frame. (c) Tighten capscrews which hold housing assembly to purifier. (d) Adjust pinion for proper mesh against friction hub by turning adjusting screw (27) counterclockwise. This will allow spring to push adjusting sleeve (6) against bearing. Then, turn screw one-quarter turn clockwise and clearance between sleeve and ball bearing is set. f. Bowl Spindle. (1) General. The bowl spindle is a solid shaft unit which turns in roller bearings at the top and in a bronze bushing at the bottom. The worm screw shell is fixed to the bowl spindle and meshes with the helical gear from which it gets its driving force. (2) Removal. (a) To remove the bowl spindle first remove bowl and disc assembly as described in c. (2) above. (b) Remove three capscrews holding bearing cap and bearing (11, fig. 5-90) in place. (c) Remove cap from purifier ant lift entire spindle assembly from purifier. (3) Disassembly. (a) To disassemble spindle, first ;lamp spindle in a vise. Be sure to use a soft material on vise jaws so as not to damage spindle. (b) To remove upper bearing, lift tab from locknut and remove nut and bearing. (c) To remove worm screw (13), lift prong on washer located in one of the slots of the nut. (d) Place a screwdriver in one of the slots of the nuts and tap with a hammer to loosen nut. (e) Withdraw worm screw shell from spindle noting position of key in spindle as worm screw is removed. (4) Cleaning, inspection, and repair. (a) Check ball bearing by spinning while holding in hand. Replace bearings that run rough. (b) Inspect worm screw shell; if teeth show signs of wear, replace worm screw or reverse it, end for end, on reinstallation. NOTE When either the worm screw shell or the worm wheel ring becomes worn and needs to be reversed. They should both be reversed at the same time. If either has to be replaced, replace both shell and ring. (c) Inspect steel point at end of spindle; if worn, replace with a new one. To remove, drive a drift pin into hole in spindle and point will drop out. To replace, dip point in oil and position by tapping on a wooden surface. (5) Assembly. (a) Assembly of spindle is in reverse order of disassembly. (b) Tighten bolt bearing and worm wheel locking nuts tight against their respective shoulders and lock by forcing one of the prongs on the washer into one of the slots in the nut. (6) Installation. Installation is in reverse order of removal. NOTE When spindle is put in frame, care should be taken not to strike the indicator wheel or the worm wheel and to see that it comes to rest upon the steel ball in the bottom screw. Then fasten the top bearing cap securely in place with the three capscrews. g. Brake. (1) General. A brake is installed on the side of the unit for stopping the centrifugal disc. The brake is operated by depressing the plunger (8, fig. 5-90). (2) Removal. To remove brake assembly unscrew bushing (7) from purifier frame. (3) Cleaning, inspection, and repair. (a) Inspect lining and if worn within 1/16 inch of screw in center of brake, remove screw and lift brake lining from brake. Replace with new lining in reverse order of removal. (b) Inspect spring (9) and if spring has lost its tension, replace it. (4) Installation. With brake assembled, screw bushing (7) into position on lubricating oil purifier. h. Speed Indicator. (1) General. The speed indicator is located on front of the frame. Pressing on the speed indicator brings the indicator wheel in contact with the thread on the bowl spindle and actuates a movement of the small plunger for each revolution of the wheel. When running at correct speed the plunger moves 72 times. per minute. This movement can be felt by the end of the plunger protruding through the cap. (2) Removal. (a) Remove spindle as described in f. (2) above. (b) Remove cap and withdraw two springs and small plunger from the outside. (c) Remove wheel and sleeve from inside. (3) Cleaning, inspection, and repair. (a) Remove nut from wheel shaft and inspect shaft, wheel, and sleeve. Should shaft, wheel, or sleeve show signs of wear, replace. (b) Inspect springs and, if tension has been lost, replace them. (c) Reassemble shaft, sleeve, and wheel in reverse order of disassembly. Be sure pin in shaft enters slot in wheel hub; then tighten nut. (4) Installation. (a) Install wheel and sleeve; making sure guide pin on side of sleeve enters slot in frame. (b) Install plunger and springs in reverse order 'of removal and screw cap on tightly with screwdriver. 5-124 i. Bottom Screw. (1) General. The bottom screw, located in the bottom of the frame, supports the thrust bearing for the bowl spindle and it is used to adjust the bowl to its proper height in the cover. (2) Removal. (a) To remove bottom screw, remove bowl and spindle as described in c. and f. above. (b) Drain lubricating oil from frame oil reservoir. (c) Remove locknut from bottom of frame. (d) Remove bottom screw by hand or, if necessary, with the aid of a screwdriver. (e) When removing bottom screw, do not lose steel ball inside, which may come out through the hole in top of screw. (3) Disassembly. (a) To remove parts in bottom screw, drive out the cross pin after which the spring, sleeve, and ball will come out. (b) Remove bushing in top of bottom screw by driving out with a small piece of hardwood. (c) Remove steel point using a punch and hammer. (4) Cleaning, inspection, and repair. (a) Inspect the point for signs of wear, and replace if point shows any wear marks. (b) Inspect sleeve for wear marks and replace if defective. (c) Wipe all parts with a lint free cloth prior to assembly. (5) Assembly. (a) Assemble bottom screw in reverse order of disassembly. (b) Install steel point by dipping in oil and tapping lightly on a piece of wood to seat it. (6) Installation. (a) Installation of bottom screw is in reverse order of removal. (b) With spindle and bowl in place, measure height between coupling ring and top edge of frame bowl casing. Coupling ring on disc should extend exactly 9/16 inch above top edge of frame bowl casing. Should bowl be above or below its proper position, adjust by turning up or down, as necessary, to bring to proper position. (c) Fill oil reservoir with lubricant in accordance with LO 55-1925-204-12-7. (d) Replace bowl cover. j. Heater and Filter Unit. (1) General. The heater and filter unit is installed in close proximity to the purifier. The purpose of the heater is to raise the temperature of the oil being purified to 1800F. The filter unit is a replaceable cartridge type and it removes impurities from the oil which were not removed by the centrifugal purifier. Maintenance and adjustment. (a) Maintenance required is the replacement of cartridges. Replacement is indicated when, because the cartridges are collecting colloidal carbon, resistance to the flow of oil through the cartridge element begins to increase. (b) To replace a cartridge, see operating instructions. (3) Removal. (a) To remove heater elements from heater, disconnect electrical leads to heater. (b) Drain heater and remove bolts which hold heater end covers to heater body. (c) Remove elements from heater assembly. (4) Cleaning, inspection, and repair. (a) Inspect sight glass and lines for signs of leaks. If sight glass leaks, remove retaining rings and replace gasket on sight glass. (b) Tighten all pipe fittings which show signs of leaks. Replace gaskets in pipeline flanges where necessary. (5) Installation. Replacement of parts and installation of heater on purifilter unit, is in reverse order or removal. k. Motor. (1) General. The prime mover of the lubricating oil purifier is a 1/2-hp, 115-volt dc electric motor. The unit is bolted to the side of the purifier frame and is directly connected through the friction clutch to the centrifuge spindle. (2) Maintenance and adjustment. (a) Lubricate in accordance with LO 551925-204-12-7. (b) Inspect commutator and brushes. Clean dirty commutator with 00 sandpaper. Replace brushes worn to one half normal length and "sand in" to contour of commutator (TM 55-506). Adjust brush tension. (3) Removal. (a) Disconnect motor electrical connections. (b) Remove pump housing plate from frame on opposite side from motor, and remove worn wheel and friction clutch. (c) Support motor and remove four screws located inside the frame, which hold motor in place. (d) Remove motor from purifier frame, being careful not to damage drive shaft while withdrawing from frame. (4) Disassembly. (a) Remove screws that hold commutator endbell to motor frame and pull endbell and brush holder from motor shaft. (b) Remove screws which hold drive endbell to motor frame and remove drive endbell and armature assembly. (c) Remove brush holders from commutator endbell; mark position for assembly. (d) Pull drive endbell from armature shaft. (e) If bearings are to be replaced, bend tabs 5-125 (2) on lockwashers back and remove bearing locknuts and lockwashers from armature shaft. (f) Pull bearings from armature shaft. Use bearing puller (TM 55-506). (5) Cleaning and inspection. (a) Blow accumulations of carbon dust and dirt from motor windings with dry, low-pressure (10 psi) compressed air. (b) Wipe all parts with a lint free cloth moistened with cleaning solvent conforming to FED SPEC P-D680. (c) Inspect bearing for roughness. Replace defective bearings. (d) Inspect brushes for chipping and wear. Replace defective brushes (TM55-506). (e) Inspect brush holders. Replace defective brush holders. (f) Inspect motor windings for damaged insulation. Replace motor assembly if windings are defective. (g) Inspect commutator for roughness or pitting. Smooth with sandpaper. If commutator requires turning in a lathe, report fact to higher maintenance level. (6) Assembly. (a) To assemble, reverse order of disassembly. (b) Lubricate new bearing felts in accordance with LO 55-1925-204-12-7. (c) Sand new brushes to contour of commutator. Blow out carbon dust. Adjust brush tension (TM 55-506). (d) After motor is assembled, rotate by hand to determine if armature and shaft move freely. (7) Installation. (a) Position motor on frame and replace the four capscrews and lockwashers that were removed. (b) Replace friction clutch and pump housing (d, above). l. Controller. For controller maintenance, refer to paragraph 5-47. 5-49. Fresh Water and Sanitary System Pump (No. 1892) a. General. This pump (fig. 5-93) is a shallow well reciprocating type piston pump, vee-belt driven by an electric motor. The piston of the pump is in a housing separate from the crankshaft and connecting rod. 5-126 Figure 5-93. Fresh water pump and motor. b. Use. One of these pumps circulates fresh water throughout the vessel, the other controls the sanitary system. Service either pump as follows: (1) Service. Tighten packing by turning the knurled nut (13, fig. 5-94) of the piston rod stuffing box gland clockwise. 5-127 Figure 5-94. Water pump 1. 2. 3. 4. 5. 6. 7. Motor Pressure switch Capscrews Bonnet Valves Valve seat Piston 8. End plate 16. Follower, piston 9. Drain plug 17. Capscrews 10. Lines, water box 18. End cap, frame 11. Packing 19. Connecting rod 12. Cap 20. Adjusting screw, vee-belt 13. Nut, knurled 21. Vee-belt 14. Hinge pin 15. Cross head pin (2) Leaks. If adjusting will not stop leak, remove c. Removal. the knurled nut (13) and replace packing with five rings of new (1) Close fresh water shutoff valve (fig. 5-93). packing. (2) Disconnect electrical leads from motor. (3) Disconnect water inlet and outlet. (3) Belt Adjustment. To tighten, or loosen, belt turn (4) Remove mounting hardware. the adjusting screw (20). (5) Lift pump off mount. NOTE d. Disassembly. Do not tighten belt more than necessary. Just enough to prevent slippage between belt and pulley. 5-128 (1) Connecting rod disassembly as follows: (a) Drain all oil from crankcase. (b) Remove piston rod from follower piston (16). (c) Remove frame end cap (18). (d) Remove capscrews from lower half of connecting rod assembly and withdraw lower half from crankshaft journal. (e) Position crankshaft journal at bottom position and withdraw connecting rod and piston follower (16). (2) Pump piston. (a) To replace leather cups on piston, remove water box end plate (8). (b) Remove piston with a screwdriver inserted in slot. (c) Remove the two leather cups from piston. (3) Valves. (a) To replace valve cap springs, remove capscrew (3) from center of bonnet and lift off bonnet. (b) Remove cotter pins from discharge valves, and remove springs and valves. (c) Remove discharge valve plate. (d) Remove cotter pins from suction valves, and remove springs and valves. e. Assembly. (1) Connecting rod. (a) Replace connecting rod if bearing surface shows signs of scoring or wear. (b) Replace follower piston and connecting rod in crankcase and position connecting rod on crankshaft. (c) Replace lower half of connecting rod. Replace capscrews which hold bearing halves together and torque to 40 foot-pounds. (d) Replace frame and cap. (e) Screw piston rod into piston. (2) Pump piston. (a) Replace leather cups between piston halves. (b) Soak cups in warm water so they will slide into water box cylinder easily. (c) Slide piston into water box cylinder; make sure leather cups are facing correctly as piston slides into place. (d) Position a screwdriver into slot in piston and screw piston back on piston rod. (e) Replace water box end plate. (3) Valves. (a) To replace valve springs, reassemble both suction and discharge valves in reverse order of disassembly. Install new valve springs during assembly. (b) Replace section valves; position a new gasket on water box and replace valve plate. (c) Replace discharge valves and gasket. Replace bonnet and tighten bonnet capscrew. f. Installation. Install by reversing removal instructions. 5-50. Relief Valve a. General. A relief valve is installed on the pump discharge piping to protect the tank and system from undue pressure should the automatic switch fail to function. b. Maintenance and Adjustment. Relief valves are set at the factory, and when replacing a valve, no adjustment is necessary. c. Removal. (1) Disconnect drain line from bottom of relief valve. (2) Unscrew relief valve from pipe line. d. Installation. Reverse the order of removal. 5-51. Air Volume Control a. General. The air volume control prevents waterlogged and airbound tanks, by maintaining proper air volume at all times. The air volume control is connected to the snifter valve on the pump by copper tubing. b. Removal. To replace an air volume control, disconnect the snifter valve and remove air volume control from tank. Replace valves and snifter line. c. Installation. When air volume in tank is not being maintained, install a new air volume control and install line between air snifter valve and air volume control. 5-52. Pressure Switch a. General. An automatic switch is on the water pressure set and maintains the correct amount of water under pressure in the air volume tank. Pressure at which the water is maintained is adjustable by a rheostat on the switch. b. Maintenance and Adjustment. To increase pressure on the system, turn pressure adjusting knob clockwise; to decrease pressure, turn counterclockwise. 5-53. Motor a. General. The water pressure set prime mover is a 1/3hp, 115-volt dc electric motor equipped with pulley and belt drive for driving the water pressure set pump. The motor is controlled through the air volume control and automatic switch. b. Maintenance and Adjustment. (1) Lubricate in accordance with applicable lubrication order LO 55-1925-204-12. (2) Inspect commutator and brushes. Clean dirty commutator with 00 sandpaper. Replace brushes worn to onehalf normal length and "sand in" to contour of commutator (TM 55-506). Adjust brush tension. c. Removal. (1) Disconnect motor electrical connections. (2) Loosen belt adjusting screw (20, fig. 5-94) 5-129 and remove belt. Remove bolts and nuts holding motor mounting and remove motor. d. Disassembly. (1) Remove pulley from rotor shaft. (2) Remove screws holding commutator end-bell to motor frame, and pull endbell and brush holder from shaft. (3) Remove screws securing drive endbell to motor frame, and remove drive endbell and armature assembly. (4) Remove brush holder from commutator endbell; mark position for reassembly. (5) Pull drive endbell from armature shaft. (6) If bearings are to be replaced, bend tabs on lockwashers back and remove bearing locknuts and lockwashers from armature shaft. (7) Pull bearings from armature shaft using bearing puller (TM 55-506). e. Cleaning and Inspection. (1) Blow accumulation of carbon dust and dirt from motor windings with dry, low-pressure (10 psi) compressed air. (2) Wipe all parts with a lint free cloth moistened with cleaning solvent conforming to FED SPEC P-D-680. (3) Inspect bearings for roughness in rotation; replace defective bearings. CAUTION When inspecting bearings, rotate by hand, do not spin with compressed air. (4) Inspect brushes for chipping and wear. Replace defective brushes (TM-506). (5) Inspect brush holders. Replace defective brush holders. (6) Inspect motor windings for damaged insulation. Replace motor assembly if windings are defective. (7) Inspect commutator for roughness or pitting. Smooth with sandpaper. If commutator requires turning in a lathe report to higher maintenance level. f. Assembly. (1) To assemble, reverse order of disassembly. (2) Pack new bearings with grease in accordance with LO 56-1925-204-12. (3) Sand new brushes to contour of commutator. Blow out carbon dust. Adjust brush tension (TM 55-506). (4) After motor is assembled, rotate by hand to determine that armature and shaft are free. g. Installation. (1) Position motor on mounting and secure. (2) Install belt and tighten belt adjusting nut. NOTE Do not overtighten belt. Tighten only enough to eliminate slippage between belt and pulley. 5-54. Rotary Hand Pumps a. General. Three rotary hand pumps are installed in the tug - One in the lubricating oil system (fig. 5-95), one in the fuel oil system, and one in the bilge and ballast system. The pump in the lubricating oil system is used for pumping out the sludge tank contents. The pump in the fuel oil system is used to replenish the fuel oil day tanks, should the fuel transfer pump be out of service. The third pump is installed in the anchor locker to pump out bilge. Their capacity is 10 gpm. 5-130 Figure 5-95. Lubricating oil rotary hand pump. b. Removal. (1) Disconnect suction and discharge lines at the unions (fig. 5-95). (2) Remove nuts and bolts securing pump to the mounting bracket, then remove the pump. NOTE Remove all rotary hand pumps in a similar manner. c. Disassembly. (1) Remove capscrews (4, fig. 5-96) from the cylinder (1). 5-131 1. Cylinder 2. Rotor 3. Head 4. Capscrews 5. Bucket spring 6. Bucket Figure 5-96. Rotary hand pump (typical). (2) (3) Lift head (3) from cylinder (1). Compress spring (5) and withdraw from rotor (2). (4) Lift buckets (6) out of rotor. d. Cleaning, Inspection, and Repair. (1) Inspect sides of buckets (6) for wear. In order to prime and pump efficiently, the buckets, when revolving should fit snugly between head and cylinder. (2) If buckets are worn, with no signs of wear on head or cylinder, replace the buckets. (3) Inspect sides of head and cylinder for wear. When worn, replace the pump. e. Reassembly. Assemble by reversing the procedure of c. above. NOTE If pump is hard to turn after new buckets are installed, remove the head and apply a small amount of fine lapping compound to sides of buckets. Install head and install capscrews lightly. Turn crank a few turns (until pump turns freely), then tighten capscrews a little and turn pump again. Repeat until pump turns freely with capscrews tight. Then, disassemble pump, wash out the lapping compound, and reassemble. f. Installation. Install by reversing the procedure in b. above. Section III. PNEUMATIC EQUIPMENT SYSTEM 5-55. General The pneumatic system of the tug consists of two motor driven air compressors, with storage reservoirs, lines, fittings, and allied instruments and gages. Primary purpose of this system is to provide compressed air for starting, and/or reversing the direction of rotation of the propulsion engine. Each compressor is rated at 34.4 cubic fpm capacity at 250 psi. They are two-stage, with automatic start-stop pressure switches, set with a differential or from 10 to 20 psi. Number 1 compressor has the largest differential, and may be used as the standby, or reserve compressor. Both compressors can be placed on automatic. Two 5-132 TM 55-1925-204-12 safety head valve and unloader diaphragm operating mechanism. WARNING Prior to performing any maintenance work on cylinder head or valves, bleed all air from storage (reservoir) tank or isolate storage tank from compressors by closing stop valve in compressor discharge line. (2) Removal. (a) Disconnect the line leading from centrifugal unloader (fig. 5-97) to unloader diaphragm assembly. storage reservoirs (tanks) of 50 cubic feet, and a whistle reservoir of 5 cubic feet, at 110 psi, is maintained in the system. Other uses: ships service air, and sea chest blow down. Reducing stations are strategically placed. See table 2-2 for control valves, and table 2-11 for alignment. Each compressor is equipped with a centrifugal unloader which enables them to start with no load, and automatically begin compressing as the compressor attains rated design speed. 5-56. Air Compressor a. Cylinder Head. (1) GeneraL The cylinder head houses the high and low suction valves, discharge valves, Figure 5-97. Air compressor. 5-133 TM 55-1925-204-12 (b) Unscrew threaded sleeve from cylinder head and lift out suction valve assembly (1, fig. 6598) and the discharge valve assembly (2) from the cylinder head. (b) Remove the capscrews and lockwashers which hold cylinder head to the cylinder. (c) Lift off the cylinder head. (3) Disassembly. (a) To remove low-pressure control valves, remove capscrews from covers and remove covers. 1. 2. 3. 4. 5. Suction valve assembly Discharge valve assembly Bumper, discharge valve Spring Valve 6. Valve seat 7. Bumper, suction valve 8. Spring, suction valve 9. Valve 10. Valve seat Figure 5-98. Air compressor, low-pressure control valves. (c) To remove high-pressure control valves, remove capscrews from high-pressure cover and unloader. Remove cover and unloader. (d) Unscrew threaded sleeve from cylinder head and lift out suction valve assembly (2, fig. 599) and discharge valve assembly (1) from cylinder head. 5-134 TM 55-1925-204-12 1. 2. 3. 4. 5. Discharge valve assembly Suction valve assembly Valve seat Valve Spring 6. Bumper suction valve 7. Valve seat 8. Valve 9. Spring 10. Bumper discharge valves Figure 5-99. Air compressor, high pressure control valve. (e) To remove diaphragm from unloader body, remove screws (1, fig. 6-100) from highpressure diaphragm unloader and remove cover (2). 5-13S TM 55-1925-204-12 Figure 5-100. High-pressure diaphragm unloader 1. Screw, cover 2. Diaphragm cover 3. Diaphragm 4. Unloader body 5-136 TM 55-1925-204-12 (f) Remove diaphragm (3) from unloader. (4) Cleaning, inspection, and repair. (a) Clean each valve assembly thoroughly in solvent conforming to FED SPEC P-D-680. (b) See that each spring has enough life to snap valve disc back on its seat quickly. Replace weak springs. (c) Inspect valve surfaces for wear. Do not attempt to grind valves. Worn parts of valve assemblies will be replaced. (d) Examine the diaphragm (3; fig. 5-100) for cracks or signs of deteriorated material. Replace defective diaphragm. (e) Examine all gaskets removed from lowpressure and high-pressure control valves. Replace with new gaskets if worn or show signs of leaking. (5) Assembly. (a) Position diaphragm (3) on unloader body and replace cover (2) and screws (1). Tighten screws. (b) Replace high-pressure and low-pressure control valves in their respective positions in the cylinder head and assemble (fig. 5-98 and 5-99). (c) Replace threaded sleeves and covers on low-pressure control valves and unloader and replace cover on high-pressure control valves in same position from which removed. (6) Installation. (a) Position a new gasket on cylinder. (b) Replace head (fig. 5-97). Align gasket and replace capscrews which hold head in position. Tighten to 35 foot-pound torque. 6. Pistons and Connecting Rods. (1) General. The compressor has two pistons, the larger of the two is the low-pressure piston, and the smaller is the high-pressure piston. The connecting rods and connecting rod bearings of the two pistons are the same. The connecting rod bearings are the insert type and require no scraping or shimming when installing new bearings. (2) Removal. (a) To remove the piston and connecting rod, remove the cylinder head (a. (2) above). (b) Remove the six capscrews from the inspection plate (fig. 5-97) on the side of the compressor block and remove the plate. (c) Working through the inspection plate opening remove nuts from connecting rod bearing caps (7, fig. 5-101) and remove lower half of bearing cap and bearing shell. 5-137 TM 55-1925-204-12 Figure 5-101. Air compressor. 1. 2. 3. 4. 5. Low-pressure valve cover Safety valve Loadless starting diaphragm assembly Cylinder head Flywheel and pulley 6. 7. 8. 9. (d) Force connecting rod and piston upward and withdraw from compressor block. High-pressure connecting rod Connecting rod bearing cap Centrifugal unloader Low-pressure connecting rod (e) Remove both connecting rods and pistons in this manner. 5-138 TM 55-1925-204-12 (c) Compress piston rings with a ring compressor. (d) Lower bearing end of connecting rod into cylinder and tap piston into the cylinder making sure connecting rod bearing hits squarely on the crankshaft journal. (e) Replace the connecting rod bearing cap and tighten to 40 foot-pounds. (f) Replace both connecting rods and pistons in the above manner. (g) Replace inspection plate on block. (h) Replace cylinder head; tighten bolts to 35 foot-pound torque. (i) Replace line leading from centrifugal unloader to diaphragm unloader (fig. 5-97). c. Drive Belts. (1) General. There are three drive belts which transfer power from motor to compressor. These belts come in matched sets. When replacing, always replace complete set. (2) Maintenance and adjustment. Do not run belts under excessive tension. Adjust for '/2 inch firm slack in a belt at a point midway between the motor and compressor pulleys. Adjust by loosening motor mounting capscrews (fig. 5-102) and moving motor in direction necessary to provide required slack. Belts are replaced by loosening motor mounts and sliding motor toward compressor enough to permit removal of belt. Install new belts and adjust. Always realign pulleys after belts have been adjusted. (f) Remove the cylinder from case by removing the six capscrews securing it. (3) Disassembly. (a) Clamp connecting rod in a vise, piston up. (b) Remove rings from piston, noting that the compression ring is on top, scraper ring, next (there are two scraper rings on the high pressure piston) and the oil ring, at bottom. (4) Cleaning, inspection, and repair. (a) Remove old oil from ring grooves and clean all oilholes in piston. (b) The connecting rod bearing load is on the upper shell only. Any wear, therefore, will appear on examination of the upper shell. Check for scoring, chipping, corrosion, cracking, or signs of overheating. Inspect backs of bearing shells for bright spots. Bright spots indicate that shells have been moving in their supports and are unfit for further use. Replace bearing shells if any of the above conditions exist. (5) Assembly. (a) Clamp connecting rod in a vise, piston up. (b) Replace rings on piston. Install new rings whenever, the compressor is overhauled. Position oil ring first, then scraper ring (high pressure piston has two scraper rings), and uppermost compression ring. (6) Installation. (a) Position a new gasket between cylinder and case. Replace cylinder and tighten bolts. (b) Position upper bearing shell in connecting rod. 5-139 TM 55-1925-204-12 Figure 5-102. Motor removal and belt adjustment. d. Air Intake Silencer. (1) General The air filter silencer (fig. 5-97) is a dry tape which filters the intake air going to the compressor. The filter removes all dust from the air, thus, prolonging the life of the compressor. (2) Maintenance and adjustment. (a) Keep filter silencer clean. (b) Remove filter silencer by removing nut on end of silencer and withdrawing silencer from silencer stud. (c) Clean filter screen with compressed air. If filter is extremely dirty wash in soapy water solution, rinse off with fresh water and allow to dry thoroughly prior to replacing. (d) Replace filter silencer on compressor. WARNING Never clean the filter silencer with gasoline or other explosive materials. e. Switch Replacement and Adjustment. (1) Replacement of snap switch. (a) Remove pressure switch cover screws and lift off cover. (b) Disconnect electrical connections from snap switch. Mark for reassembly. (c) Remove. snap switch mounting screws. (d) Installation is in reverse order of removal. (2) Replacement of pressure switch assembly. WARNING Do not attempt to replace pressure switch with air pressure on system. Shut off air valves at tanks. (a) Slowly back off coupling nut at air line connection to pressure switch and allow residual air in gage and switch line to bleed off. (b) Disconnect air line from pressure switch. 5-140 TM 55-1925-204-12 (1) Lubricate in accordance with LO 55-1925204-12-4. (2) Inspect brushes. Replace brushes worn to one-half normal length. Sand new brushes to contour of commutator. (3) Check brush spring tension. Adjust tension to 13/4 to 21/2 psi of contact surface. (4) See that brushes move freely in holders. (5) Keep commutator clean. b. Removal. (1) Disconnect external wiring from motor connection box, and mark for reassembly. (2) Loosen mounting bolts and remove drive belts from motor pulley. (3) Remove mounting bolts, and lift motor from foundation. c. Disassembly. The disassembly of this motor is the same as that discussed in paragraph 5-34. d. Clean and Inspection. The cleaning and inspection of the motor is the same as that discussed in paragraph 5-34. e. Assembly. The assembly of this motor is the same as that discussed in paragraph 5-34. f. Installation. (1) Position motor on foundation (fig. 5-102). (2) Install mounting bolts; do not tighten. (3) Install drive belts on pulleys. (4) Check pulley alignment with a straightedge. (5) Adjust belt tension by positioning motor on slotted foundation. (6) Tighten mounting bolts. (7) Connect electrical wiring to motor connection box. 5-59. Controllers The maintenance on controller is the same as discussed in paragraph 5-35. (c) Remove cover and disconnect electrical connections to switch; mark for reinstallation. (d) Remove mounting nuts from recesses in switch assembly housing. (e) Installation is in reverse order of removal. Check air connections for leaks after pressure switch installation. (3) Pressure switch adjustment. (a) Turn adjusting screw clockwise to raise the pressure. (b) Turn adjusting screw counterclockwise to lower the pressure. NOTE Moving pressure switch adjustment up or down changes the differential between ON and OFF. Select the mean average nearest the desired setting. 5-57. Air Tanks and Lines a. General. The starting air tanks (reservoirs) in the forward end of the engine room are air-fed directly from the air compressors. The air tanks in addition to providing starting air for the engine also serve as general usage air storage reservoirs. b. Maintenance and Adjustment. (1) Air (reservoirs) tanks and piping system must be leak free at all times or the compressor will run unnecessarily. (2) To check for leaks, brush a soapy water solution on suspected areas and leaks will be indicated by soapy bubbles. This method will detect even the smallest leaks. (3) Leaks in threads of pipe can be repaired by detaching fitting, removing all the old white lead from threads, applying fresh white lead, and retightening fittings. (4) Report any leaks in air storage tanks to higher maintenance level immediately upon detection. 5-58. Motor a. Maintenance and Adjustment. Section IV. ANCHOR WINDLASS-CAPSTAN SYSTEM 5-60. General a. Anchor Windlass (MARKEY TYPE VEV16 ). The anchor windlass is fully described, and operating procedures are outlined in paragraph 222. b. Capstan. The capstan is described and the operating procedures are outlined in paragraph 223. 5-61. Anchor Windlass (Markey Type VEV-16) a. Maintenance and Hand Brake Adjustment. (1) Lubricate in accordance with LO 55-1925204-12-7. (2) Adjust the hand brake for lining wear as follows: (a) Back the two inner adjusting nuts (fig. 5-103) away from the boss. 5-141 TM 55-1925-204-12 Anchor windlass brake arrangement Figure 5-103. Anchor windlass brake arrangment. 5-142 TM 55-1925-204-12 (2) Remove brakeband from each eyebolt, then lift band away from the drum. (3) Position new brakeband around drum, with boss on the eyebolts, then secure with the two outer adjusting nuts. 14) Adjust new brakeband as described in a. (2) above. c. Bearing and Seal Removal. (1) Remove motor (para. 5-6i6). (2) Drain oil from gear box (fig. 5-104) (LO 551925.204-12-7). (b) Turn the brake handwheel until brake lining is as far away from the drum as it will go. (c) Tighten the two outer adjusting nuts equally toward brake actuating worm, until there is but 1/8 inch air gap clearance between drum and brake band. (d) Tighten the two inner adjusting nuts snugly up to their boss. b. Brake band Replacement. (1) Remove the two outer adjusting nuts (fig. 5-103) from the eyebolt. Figure 5-104. Anchor windlass motor and gear box (3) With coupling removed, remove nuts and washers securing bearing retainer and seal, then remove bearing retainer and 3eal. (4) Remove drive end plate and gasket in a similar manner. 5-143 TM 55-1925-204-12 (8) Remove nuts securing cover plate to the gear box, then remove cover plate. (9) Working through drive end and bottom of the gear box, remove bolt (11, fig. 5-105) and keeper plate (12), then pull gear (13) off shaft. (5) Remove pinion shaft, bearing, pinion gear, and the other bearing from gear box. (6) Remove seal from bearing retainer. (7) Press or pull a bearing off each end of the pinion shaft. 1. 2. 3. 4. 5. Brakeband Capscrew Locknut Bearing Washer 6. 7. 8. 9. Retainer Bearing Drive end plate Bearing Figure 5-105. Anchor windlass, Type VEV-16. 5-144 10. 11. 12. 13. Retainer and seal Bolt Keeper plate Gear TM 55-1925-204-12 bearings and seals by reversing the procedures in c. above. 5-62. Motor For maintenance of the anchor windlass motor see paragraph 5-66. 5-63. Control For maintenance of the anchor windlass control see paragraph 5-68. 5-64. Master Switch For maintenance of the anchor windlass master switch see Figure 5-106 and paragraph 5-67. (10) Remove bearing (7). (11) Remove capscrews (2), retainer (6), locknut (3), and washer (5). Then, remove bearing (4) from its cage. d. Cleaning, Inspection, and Repair. (1) Wash all parts in clean fuel oil and wipe dry. (2) Inspect the bearings for wear or roughness in rotation. Replace a defective bearing. (3) Repack bearings with lubricant (LO 551925-204-12-7), then lay aside carefully until reassembly. e. Bearing and Seal Installation. Install 5-145 TM 55-1925-204-12 Figure 5-106. Anchor windlass and master switch. (2) Lubricate in accordance with LO 55-1925204-12-4. c. Worm Shaft Thrust Bearing Replacement. (1) To remove the worm shaft thrust bearing, first drain lubricating oil from capstan gearbox by opening drain (fig. 5-107). 5-65. Capstan (model R6293) a. General. The capstan is an all purpose pulling machine with a vertical winch head which t used for handling manila lines, or for warping. b. Maintenance. (1) Keep all moving parts free from corrosion. 5-146 TM 55-1925-204-12 Figure 5-107. Capstan. 1. 2. 3. 4. 5. 6. Capstan Key Capstan shaft Grease fittings Gearbox bushings Worm wheel rim 7. Oil level plug 8. Oil drain plug 9. Worm gear 10. Magnetic brake 11. 10-hp, dc motor (2) Remove the six capscrews from the bearing end cap and remove end cap. (3) Remove the bearing holding nut from worm gear shaft. (4) Remove the nine capscrews from worm housing cover and pull cover away from housing about /4 inch. NOTE Moving the cover in this way will loosen thrust bearing, and bearing can now be removed. 5-147 TM 55-1925-204-12 in either direction, energizes solenoids in the brake which in turn removes pressure on brakeshoes. b. Maintenance and Adjustment. (1) Lubricate in accordance with LO 55-1925204-12-4. (2) Inspect brushes for wear. Replace brushes worn to one-half normal length. Sand new brushes to contour of commutator. (3) Check brushes for freedom in brush holders. Brushes should slide freely in holders. Clean and free brushes that stick in holders. (4) Inspect commutators for cleanliness and wear. Clean dirty commutators, using 00 sandpaper if necessary. (5) Adjust brush tensions to 1t/2 to 21/: psi spring scale pull. (6) To adjust motor brake release spring pressure, turn adjusting nut (8, fig. 5-108) conterclockwise. (5) Pull bearing from worm gear shaft. CAUTION Do not spin bearings with compressed air. (6) Replace bearing if bearing runs rough when spun, while holding in hand. (7) Assembly is in reverse order of disassembly. Replace housing cover and bearing cap gaskets, if necessary, on assembly. (8) Fill capstan gearbox with lubricant in accordance with LO 55-1925-12-4. 5-66. Motor and Brake a. General. The motor is a 10-hp, 115-volt dc motor capable of turning at 1750 rpm in either direction. The motor drives the capstan through a series of worm, pinion, and bevel gears all of which are contained in the capstan gearbox. The motor is equipped with a dry-type shunt brake which remains set until such time as current is applied to motor. Application of current to rotate the motor Figure 5-108. Motor brake, capstan. 1. End plate 2. Rotating disc 3 Stationary disc 4. Pressure plate 5. Housing 6. Manual release and wear indicator 7. Cover plate 8. Adjusting nut 9. Spring 10. Coil 11. Hub (7) Compensate for lining wear by turning slotted stud in center of adjusting nut (8) counterclockwise. This adjustment is necessary when indicator (6) points to position marked ADJUST on cover plate (7). c. Removal. (1) Disconnect wiring from motor. (2) Position a chain fall and support motor and brake assembly. (3) Remove six capscrews which hold motor to adaptor plate. 5-148 TM 55-1925-204-12 (8) Assemble the unit on the motor in reverse order of disassembly. (9) Adjust brake (b). (6) above). (4) Withdraw motor from adaptor plate and lower motor to engine room deck plates. d Replacement of Roller Brakes. (1) Remove bearing cat, ,. removing capscrews and lockwashers. NOTE After unit has operated a few times, adjust to ON position on indicator with current off. 5-67. Master Switch a. General. A master switch (controller) is located near the capstan on the main deck. The switch provides five points of acceleration for both inhaul and outhaul. An emergency stop switch is provided on the master switch to stop the motor in an emergency by deenergizing the line contactors and the brake contactors. The emergency switch should never be used for normal stopping, because it causes motor to come to a sudden stop and results in hard wear on the brake. b. Maintenance and Adjustment. (1) Keep moving parts free from corrosion. (2) Do not apply paint to emergency stop switch shaft, or master control lever shaft. These controls must operate freely. NOTE To remove the bearing on the commutator end of motor it will first be necessary to remove the brake from the motor. (2) Pull bearings from motor frame one at a time. (3) Test bearings for roughness of rotation while holding in hand. Replace defective bearings. (4) Pack bearings with lubricant in accordance with LO 55-1925-204-12-4. (5) Replace bearings in motor frame in reverse order of removal. e. Replacement of Brushes. (1) To replace brushes remove the four capscrews from each of the access covers and remove cover. (2) Blow loose dirt and carbon dust from motor windings and vicinity of brushes with clean, dry, low-pressure air. (3) Inspect brushes for freeness of movement in brush holders. Replace brushes worn to one-half their original length. (4) Inspect commutator for grooving. If commutator is deeply grooved report fact to higher maintenance level. (5) Check brush springs for proper tension. Replace springs that have lost tension. (6) Replace access covers on motor frame. f. Repair of Shunt Brake. (1) Back off the four socket head capscrews and free the housing (5) from the end plate (1), (2) Back off six setscrews and remove brake assembly from motor. (3) Disconnect lead wire connections from coils. (4) Withdraw brake assembly from motor frame. (5) To remove rotating disc drive gear from motor shaft, loosen setscrew from gear and pull gear from shaft. (6) Inspect coil for damaged insulation, open circuits, and shorts. Replace defective coils. (7) Inspect brake linings for wear. Replace linings worn to 1/8 inch thick as follows: (a) Drill out old rivets and remove linings. (b) Check discs for wear, distortion, and cracks. Replace defective discs. (c) Position new linings and rivet securely in place. CAUTION In the event of water leaks into the switch inclosure, do not operate the equipment until it has been thoroughly dried. (4) Inspect contacts and springs. Replace contacts worn to one-half original thickness. Replace springs that have lost tension. c. Disassembly. (1) Remove cover from switch housing. (2) Disconnect electrical connections to switch mounting board. (3) Remove mounting bolts from end of mounting board and lift board and switch assemblies from housing. d. Cleaning, Inspection, and Repair. (1) Inspect the switch housing for signs of leaks. If there is evidence of leakage through gaskets or seals, replace as required. (2) Inspect contacts for burning and wear. Dress excessive roughness from copper contacts with a fine file. Do not file silver contacts. Replace worn contacts. NOTE When replacing contacts, replace both the stationary and movable contacts. (3) To replace contacts and springs(a) Remove cotter pin, washer, and spring (4, fig. 5-109) and lift movable contact (3) from pin. 5-149 1. 2. 3. 4. 5. 6. Spring, contact arm Contact, stationary Contact, movable Spring, contact finger Seal Gasket, right side 7. 8. 9. 10. 11. Gasket, bottom Gasket, left side Gasket, top Resistor, tube, heater Seal, rubber Figure 5-109 Master switch control assembly 5-150 the forward and reverse directions. The panel also provides overload and under voltage protection. b. Maintenance. (1) Keep control panel inclosure clean and dry. (2) Inspect contacts for burning and wear. Dress excessive roughness from copper contacts with a fine file. Do not file silver contacts. Replace contacts. (3) Check contact spring tension. Replace springs that have lost tension. (4) Inspect relay coils for evidence of overheating, check control circuit resistor in series with coils where overheating is evidenced. Replace defective resistors and coils. (5) Check all electrical connections for cleanliness and tightness. Tighten loose connections and clean dirty connections. (b) Remove nuts and washers from threaded post of stationary contact (2) and withdraw contact from mounting board. (c) Installation is in reverse order of removal. (4) To remove resistor(a) Remove mounting screw securing resistor to mounting board. (b) Disconnect electrical leads to resistor. (c) Withdraw resistor from switch housing. (d) Installation is in reverse order of removal. e. Assembly. (1) Assembly is in reverse order of removal. (2) Check each electrical connection for tightness prior to replacing the cover on switch assembly. 5-68. Control a General. The control (panel) is installed with the capstan motor and switch to provide one step armature shunting and three steps of straight series connections in both NOTE Overload heater connection resistance is critical, keep these connections tight. (6) Check resistor bank connections. Clean and tighten loose or dirty connections. Section V. HEATING SYSTEM 5-69. General The heating unit of the system is a sectional type cast iron steam boiler, containing a tankless domestic hot water heater fired by a burner (fig. 5110) mounted on the front of the boiler. This unit is automatic, and is rated at 450,000 btu per hour. Controls consist of a stack switch to provide safety combustion control; a low water cutoff to provide an automatic shutdown feature, and an aquastat to control the domestic hot water when the boiler is not used for heating the vessel. 5-151 Figure 5-110. Heating boiler burner unit and mounting. (2) Cleaning. (a) Keep outside of boiler clean at all times. (b) After six months of operation, clean firebox and all parts in contact with hot gases of all accumulations of soot and carbon. 5-70. Heating System a. Boiler. (1) Draining and filling. Once each month drain approximately one gallon of water from the bottom drain of the boiler, then fill until the water gage shows full. 5-152 threads of nipple with white lead, then install new relief valve by turning it clockwise until tight. (b) Inspect the observation doors for breaks, tears, or other defect. Remove and replace a defective door. b. Burner and ignition. (1) Removal. (a) Remove cover (19, fig. 5-111). (3) Boiler repairs. Inspect, and repair by replacing the following items when defective: (a) Inspect the safety relief valve operation by moving the lever out away from valve body while the boiler is at work. If steam does not escape, shutdown the boiler, vent all steam and replace the defective safety relief valve by turning it counterclockwise until it is free of the nipple. Fill Figure 5-111. Oil burner assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Conduit Motor Fan Upper housing Coupling Lockwasher Capscrew Fuel pump Tube Combustion manifold 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Elbow Gasket Front bushing Lower housing Base nipple Locknut Base Rear bushing Cover Oil burner nozzle Strainer 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. (b) Disconnect electrical connections in cable (40) from electrodes (39). Adaptor Indicator Bracket Plate Connector Nipple Support Tube Elbow Insulating elbow Shutter 33. 34. 35. 36. 37. Dial Screw Rod Knob Transformer, ignition 38. Clamp 39. Electrode 40. Cable (d) Loosen setscrews remove thumbscrew and slip adjusting bracket from fuel connection. (c) Disconnect fuel line connector (26) at slide adjustment bracket (24). (e) 5-153 Remove screws, and lift off cover plate (25). (a) Lubricate (f) Remove nipple (27). (g) Withdraw the ignition and sleeve assembly from lower housing (14). (2) Disassembly. (a) Unscrew nozzle (20) from nozzle adaptor (22). Remove nozzle strainer (21). Remove stem from nozzle. (b) Loosen setscrew in clamp (38) and carefully withdraw electrodes (39). (3) Cleaning and inspection. (a) Clean nozzle strainer in clean fuel oil. (b) Wash all nozzle parts thoroughly in drycleaning solvent in conformance with FED SPEC P-D-680. in accordance with LO 551925-204-12. (b) Inspect ac and dc brushes on motor/converter. Replace brushes worn to one-half normal length. (c) Clean lint and debris from fan. (d) Inspect fuel pump for evidence of leakage. Tighten any loose screws. NOTE Do not disassemble motor/converter or fuel pump in the field. Replace defective units. (3) Removal of motor and fan. (a) Disconnect electrical connections from NOTE Deposits in slots and orifice are difficult to remove, the deposits are varnish and gum formed by the oil under operating conditions. A round tooth pick is an ideal cleaning tool for removing these deposits. motor. (b) Remove mounting screws and withdraw motor and fan assembly from upper housing (4, fig. 5-111). (4) Removal of fuel pump. (a) Disconnect fuel inlet and outlet lines from fuel pump (8). (b) Remove mounting capscrews (7) and lockwasher (6). Withdraw fuel pump and flexible coupling (5) from upper housing. (c) Remove setscrew from coupling (5) and pull coupling from fuel pump shaft. (5) Installation. Installation is in reverse order of removal ((1 above). d. Stack Switch. (1) General. The stack switch, located on the smokepipe at the rear of the boiler, provides complete safety combustion control for the oil burner. It provides automatic lockout in case of flame or ignition failure, and automatic recycling in case of power failure (does not lock out). CAUTION Never use a material harder than wood to clean nozzles. Use of harder materials will result in permanent damage to the nozzles. (c) Clean electrodes with solvent in accordance with FED SPEC P-D-680. Examine electrodes for cracked porcelain or badly burned tips. Replace defective electrodes. (4) Assembly. (a) Assembly of nozzle is in reverse order of disassembly. Tighten stem securely in nozzle tip. Seat nozzle securely to nozzle adaptor. (b) Slip electrodes into mounting clamp and tighten clamp. (c) Insert sleeve assembly into housing to edge of manifold. (d) Install nipple (27) and connector (26). (e) Set cover plate in position on housing and fasten with thumbscrew, screws, and washers. (f) Install adjusting bracket over fuel connection, and insert thumbscrew into cover plate through slot in adjusting bracket. Do not tighten. (g) Set adjusting bracket so that pointer is aligned with position A on cover plate. Tighten thumbscrew. c. Fuel Pump, Blower Motor, and Fan. (1) General. The oil burner fan (3, fig. 5-111) and fuel pump (8) are driven by the motor/converter (2), which, in addition to driving these units, furnishes ac voltage to the transformer from which 10,000 volt ignition voltage is supplied to the electrodes. The fan is mounted on the motor shaft, and the fuel unit is driven through a flexible coupling (5). (2) Maintenance and adjustment. WARNING After extended period of shutdown, test operation of stack switch before placing heating unit in operation. (2) Test. (a) Remove screws from mounting flange and withdraw stack switch from smoke pipe. (b) Start the heating unit and measure time intervals from burner ignition to shutdown. (c) If burner does not shutdown within 2 minutes, turn heating unit supply switch OFF, replace stack switch ((5) below) and repeat test. (d) If burner does shutdown automatically within 2 minutes, wait 5 minutes after shutdown then install stack switch in mounting and fasten with mounting screws. This test indicates that ignition and flame failure features are operative. (e) Press reset button, burner should ignite. (f) Allow boiler to heat, then place heating unit supply switch in OFF position. (g) Place heating unit supply switch in ON position. Unit should not start for several minutes 5-154 temperature by controlling the heating unit. The thermostat is mounted on the bulkhead of the crews quarters. (2) Removal. When replacement of unit is necessary, remove cover by loosening screw at bottom of cover. Disconnect electrical lead wires and tag for reassembly. Remove mounting screws and lift thermometer from bulkhead. (3) Installation. Install by reversing removal procedures. g. Maintenance and Adjustments. (1) Burner. Need for adjustment is indicated by a rumbling or pulsating sound, or smokey stack gases. To adjust the burner: (a) Set air inlet shutter (32, fig. 5-111) to one-half open mark. (b) View flame through the observation door on front of boiler, and adjust the air shutter until the flame is light orange in color. (c) If flame is proper color and the burner still smokes, a dirty or clogged nozzle is indicated. Remove burner and clean nozzle (b. above). (2) Fuel filter. Once a month during continuos operation, remove and clean the fuel filter as follows: (a) Remove nut (fig. 5-110) from top of the fuel oil filter. (b) Lower bottom (bowl) of filter, then lift out the filter element. (c) Clean the filter element thoroughly in clean fuel oil, then blow dry with low pressure air. (d) Assemble the filter by placing a new gasket on bowl, then reversing the order of removal in (a) and (b) above. (until stack switch thermostatic element cools). This test indicates that power failure feature is operative. (3) Maintenance and adjustment. (a) After 6 months operation remove stack switch and clean soot from exterior of thermostatic element. (b) Remove cover and inspect contacts; clean dirty contacts by drawing a piece of crocus cloth between them. (4) Removal. (a) Disconnect electrical connections; mark for installation. (b) Loosen conduit clamp and withdraw cable. (c) Remove rounting screws and withdraw switch assembly from smoke pipe. (5) Installation. (a) Place stack switch in position on smoke pipe; fasten with mounting screws. (b) Inspect electrical cable through conduit clamp and tube. Tighten clamp. (c) Connect electrical wiring and tighten securely. (d) If new switch assembly is installed carry out test procedure in (2) above. e. Aquastat. (1) General. The aquastat controls the firing of the boiler during summer months when the boiler is being used only for heating domestic hot water. (2) Maintenance and adjustment. To adjust aquastat to provide hot water at desired temperature, turn adjusting setscrew clockwise to raise and counterclockwise to lower temperature. f. Thermostat. (1) General. The thermostat maintains temperature of crew's quarters at an even and comfortable NOTE Replace the filter element at least once annually. Section VI. VENTILATING SYSTEM 5-71. General The five ventilating blower units of the system supply and exhaust air to/from crew quarters, galley, and the engineroom. Four of the units (para. 5-72) are of the centrifugal type, while the fifth (para 5-74) is an axial type unit. Maintenance for the units are similar, except for the controller (s), covered in the applicable paragraph. 5-72. Centrifugal Blower Assembly a. General. The centrifugal blowers (figure 5-112) have differing air displacement requirements of from 1,050 to 1,600 cfm, and the motor power varies from 1/2 to 31/2 hp, depending on their location and duty. 5-155 Figure 5-112. Typical centrifugal blower assembly. b. Removal. (1) Tag (1) Loosen setscrew securing fan hub to and disconnect motor shaft. electrical (2) Remove motor mounting capscrews securing motor to the motor support. (3) Move motor carefully away from the housing until fan hub frees motor shaft, then lift fan from the housing. Fully withdraw motor from the motor support and place it on a workbench. connections. (2) Remove duct connecting hardware (fig. 5112) from inlet and outlet ducts at blower housing. (3) Loosen locknuts and nuts securing housing mounting brackets, then use a lifting device to remove motor and housing from the frame. c. Disassembly. 5-156 (4) Remove end bell covers from motor, disconnect brush electrical leads, then lift brushes from brushholders. (5) Remove mounting screws from commutator end bell, then remove end bell and brushholder from motor shaft. (6) Remove screws from drive end bell, then carefully push armature through field frame, and remove drive end bell and armature from the frame. (7) Disconnect internal electrical leads, then remove field coils from pole piece. (8) Pull drive end bell from armature shaft. (9) Remove brushholders from the commutator end bell, marking position for reassembly. (10) Bend tabs on lockwashers back, remove bearing locknuts and the lockwashers from armature shaft. (11) Use a puller to remove bearings from the armature shaft (TM 55-506). d. Cleaning, Inspection, and Repair. (1) Blow accumulation of carbon dust and dirt from field coils with dry low pressure (10 psi) compressed air. (2) Dampen a clean lint free cloth in a solvent conforming to FED SPEC P-D-680, then wipe all parts free of dust and dirt. (3) Inspect bearings for wear, or roughness of rotation. Replace a worn or defective bearing. (4) Inspect brushes for chipping, or excessive wear. Replace worn or defective brushes. Note that brush springs give proper tension. Replace worn, weak, or defective springs. (5) Inspect brushholders for cracks or deformation. Replace defective brushholders. (6) Inspect windings of field for damaged insulation, shorts (TM 55-506), and leaks. Replace defective field, or coil. (7) Check that armature is not shorted. Inspect the commutator for roughness, pitting, or excessive wear. Replace a defective armature. e. Reassembly. f. Installation. (1) Position motor and fan on foundation housing. (2) Install the mounting hardware. Do not tighten. (3) Connect inlet and outlet ducts to the housing. (4) Tighten mounting hardware. (5) Reconnect all electrical connections. g. Replacement of START-STOP Switches. (1) Remove as follows: (a) Remove cover screws and lift cover off housing. (b) Tag and disconnect the electrical leads. (c) Remove mounting screws, then lift switch from the housing. (2) Install as follows: (a) Position new switch in housing over the mounting holes and secure with the mounting screws. (b) Reconnect electrical leads to terminals and remove tags. Tighten terminals securely. (c) Position switch cover and secure with the cover screws. (3) Replace START-STOP buttons as required. 5-73. Controller a. General. All centrifugal type blowers are controlled by a magnetic starter; a START-STOP station, and an emergency STOP station. The closing of the START button closes the circuit to the magnetic coil of the line contactor, causing the contacts to close. The magnetic coil circuit is maintained by an auxiliary contact on the line contactor after the START button has been released. Pressing the STOP button at the START-STOP station, or at the emergency STOP station, breaks the circuit to the magnetic coil of the line contactor, causing it to open and stop the motor. When the motor is running, current passes through the heating element of an overload relay in the controller. Excessive current will cause the normally closed contacts of this relay to open, breaking the circuit to the line contactor magnetic coil, thus stopping the motor. These contacts, once opened, must be reset by pressing the RESET button on the controller panel. Insufficient voltage will also cause the line contactor to drop out. The controllers for the exhaust blowers have an added feature of speed control. Turning the dial switch towards SLOW causes resistance to the armature circuit and reduces the motor speed. b. Cleaning, Inspection, and Repair. (1) Keep interior of controller clean by blowing out with dry, low pressure compressed air. (2) Inspect contacts for pitting or burned points, and contact spring tension. Replace defective contacts or springs. (3) Check arcing contacts to see that they NOTE Pack bearings with grease in accordance with LO 551925-204-12. (1) Assemble by reversing the order of disassembly. (2) Sand new brushes to contour of the commutator, then blow out carbon dust and sand. Adjust brush tension (TM 55-506). To 11/2 to 21/2 oz Spring Scale pull. NOTE After installing fan hub on shaft, rotate by hand to determine that fan is squarely mounted, and does not rub the housing. 5-157 (1) Deenergize circuit at power panel, tag and open the switch, then remove fuses from the power supply panel. (2) Tag and disconnect all electrical connections at the controller. (3) Remove mounting screws, then lift controller from mounting. e. Installation. Install by reversing the removal procedure. 5-74. Axial Blower Assembly a. General The engineroom exhaust ventilating blower, and axial flow type, driven by a 4 hp, 115volt dc, 1. 750 rpm motor, is rated at 9,000 cfm, and mounted vertically on the overhead of the fidley (fig. 5-113) and exhausts into the stack. close first and open last. Shim graphite contacts to compensate for normal wear. (4) Check all connections for tightness and clean contact surfaces. (5) Check magnet coil for overheating. If the magnet coil overheats, measure resistance of the 365 ohm control resistor. Replace a shorted resistor. Check magnet coil for shorted turns. Replace a defective coil. c. Adjustment of Contacts. (1) Check that contacts are touching when the magnet is still open 1/4 inch at top of armature. (2) When opening is less then l/4 inch, replace the contacts. d Removal. 5-158 Figure 5-113 Axial blower assembly (looking up ) for engineroom exhaust. b. Motor and Fan Assembly. CAUTION WARNING Accumulation of corrosion or dirt in axial flow blowers must be prevented. Such an accumulation will impede fan rotation and damage the equipment. (b) Keep all moving parts free of corrosion, dust, dirt, or debris. Keep blower housing clean and free of corrosion. (c) Inspect commutator and brushes. Clean Before attempting repair or adjustment of ventilating blowers, deenergize circuit at power panel, tag switch, and remove fuses, to avoid injury of personnel. (1) Maintenance and Adjustment. (a) Lubricate in accordance with LO 551925-20412. 5-159 (c) Untact weld of three braces from bottom mounting flange, then lower housing to grating in fidley (fig. 5-113). (3) Disassembly. (a) Remove screen assembly from bell housing. (b) Remove hood screws, and remove hood (1, fig. 5-114). a dirty commutator with 00 sandpaper. Replace brushes worn until less then l/2 inch protrudes from holder. Sand new brushes to contour of the commutator. Adjust brush tension (TM 55-506). (2) Removal. (a) Tag and disconnect external wiring from the motor. (b) Remove nuts and bolts from upper mounting flange of blower housing. 1. 2. 3. 4. 5. Hood Cotter pin Nut Upper grease supply tube Capscrews 6. 7. 8. 9. 10. Lower grease supply tube capscrews Access door Lower grease drain Upper grease drain Figure 5-114 Axial blower assembly, sectional view. (c) Remove cotter pin (2) and castellated nut (3) from fan shaft. (d) Pull fan from motor shaft. (e) Remove key which holds fan in position on shaft. (f) 9, and 10). (g) housing. 5-160 Loosen nuts on grease tubes and drains (4, 6, Unscrew grease tubes and withdraw from fan (b) Insert motor into fan housing and fasten with mounting capscrews. (c) Install grease tubes and slip conduit and outlet box into position and make connections. (d) Install key in armature shaft. and press fan on shaft. (e) Lock fan in place with castellated nut and cotter key. (f) Rotate fan by hand to detect binding or rubbing. (g) Install hood on fan and fasten with capscrews. (h) Tighten nuts on all grease tubes, and install screen on bell housing. (6) Installation. (a) Hoist fan assembly into position on fan foundation and fasten with mounting bolts and nuts. (b) Make electrical connections in outlet box. c. Replacement of START-STOP Switches. For replacement of switches, refer to paragraph 5-72. g. 5-75. Controllers a. General. The 4-hp engineroom exhaust blower motor is controlled by a magnetic controller with automatic starting acceleration control and manual speed control. Closing the START switch closes the circuit to the magnet coil of the line contactor, which operates to close the line contactor. The circuit to the magnet coil is maintained, when the START button is released, by an auxiliary contact on the line contactor. The closing of the line contacts energizes the motor through the starting resistance and closes the circuit to the coil of the accelerating contactor. The contacts of the accelerating contactor close in sequence. The motion is delayed by a mechanical retarding mechanism, so that resistance is shunted from the motor circuit in steps, until full voltage is applied. The speed of the motor can be reduced by turning the dial switch toward SLOW; this inserts resistance into the armature circuit of the motor. When the motor is running, the motor current passes through the heating element of an overload relay. Excessive current will cause the normally closed contacts of this relay to open, breaking the circuit to the magnet coil of the line contactor and stopping the motor. To start the motor after tripping from overload, the RESET button on the face of the controller panel must be pushed. b. Maintenance. For maintenance procedures refer to paragraph 5-73. (h) Support motor and remove two capscrews (5). Remove motor from fan housing. (i) Remove brush access covers from motor frame. (j) Remove brushes from brush holders. Disconnect electrical connections from brush holders. (k) Remove bearing caps from motor endbells. (l) Bend tabs of lockwasher back and remove bearing locknut. NOTE The bearing is push fit on the motor shaft and a puller should be used to remove bearing. (m) Remove bearing from endbell. (n) Remove bolts which hold commutator endbell to motor frame and remove endbell. Remove drive endbell in same manner as commutator endbell. (o) Push armature through field frame, and motor is disassembled. (4) Cleaning and inspection. (a) Blow accumulations of carbon dust and dirt from motor windings with dry, low-pressure (10 psi) air. (b) Wipe all parts with a lint free cloth moistened with cleaning solvent conforming to FED SPEC PD-680. (c) Inspect bearing for roughness in rotation; replace defective bearings. CAUTION When inspecting bearings, rotate by hand, do not spin with compressed air. (d) Inspect brushes for chipping and wear. Replace defective brushes. (TM 55-506). (e) Inspect brush holders. Replace defective brush holders. (f) Inspect motor windings for damaged insulation. Replace motor assembly if windings are defective. (g) Inspect commutator for roughness or pitting. Smooth with sandpaper. If commutator requires turning in a lathe, report fact to higher maintenance level. (5) Assembly. (a) Assemble motor in reverse order of disassembly. NOTE After motor has been assembled there should be approximately 1/64-inch shaft end play. Make sure shaft turns freely by hand. 5-161 Section VII. WATER SUPPLY SYSTEM located just forward of the heating boiler on port side of the engineroom. c. Fresh Water System. The pressure tank and pump of the fresh water system is identical to that of the sanitary system, but is located aft of the heating boiler on port side of the engineroom. 5-77. Water System a. General Water closets are located in the officer and crew (fig. 5-115) wash rooms, with lavatories (wash basins) and shower placement as shown (typical). Lavatories are also placed in the captain and chief engineers staterooms. 5-76. General a. General The water supply system of the vessel is a combination fresh and salt water system that utilizes salt water for the sanitary disposal from water closets, and fresh water for lavatory, shower, water dispenser (cooler), and galley. A fresh (potable) water storage tank of 2,756 gallons is located in the lazarette. b. Sanitary System. A pressure tank of 42 gallon capacity draws salt water from the sea chest on port side of the engineroom amidships, with a piston type reciprocating pump controlled by a pressure switch to maintain 40 psi pressure on the system. The pressure tank and pump are 5-162 Figure 5-115. Typical wash room fixture placement. 5-163 (4) Water tanks. The two peak tanks (ballast) and the fresh water storage tank must be drained and cleaned periodically. Proceed as follows: (a) Open drain valves at bottom of tanks and inspect water for traces of scale or other impurities. (b) If the inspection shows need for draining, close salt water shutoff valve at sea valve; close fresh water shutoff valve at main storage tank, then open drain valves. Vents at top of tanks must remain open at all times. (c) After tanks are drained, flush tanks with fresh water, then repeat examination for sediment. When tank drain releases no sediment, close valves and refill tanks. b. Cleaning, Inspection, and Repair. (1) Water closets. (a) Inspect the lines, valves, and flush float for leaks, or corrosion. (b) Remove corrosion with a stiff brush, and/or solvent conforming with FED SPEC P-D680. (c) Replace defective line, valve, or flush float by closing valve in water supply at the pump, then unscrewing the defective item to replace it with a new one. (d) Repair leaking valves by replacing the rubber valve seat, or if leak is at line, remove valve and paint threads with new white lead, then reinstall the valve, or other leaking fitting. (2) Lavatories and Showers. Use similar methods described in (1) (a) through (d) above. (3) Water dispenser (cooler ). The water cooler is installed on port side of the mess room at frame 26. Inspect, clean, and repair as follows: (a) Inspect cleanliness, then check effectiveness of water supply and drain facilities. Clean out clogged drain. (b) Check that all electrical connections are free of corrosion and tightened securely. (c) Report a defective water cooler to general support maintenance. NOTE Before draining fresh water storage tank, be sure a supply of fresh water is available at dock. (d) Close storage tank shutoff valve first in main water line, open tank vent, then open drain valve at bottom of tank. Recheck flow for sediment. (e) Flush the storage tank until clean, then refill as in (c) above. (5) Tank repair. Replace, or seal, leaking fittings and pipe. Notify general support maintenance when tanks require test or replacement. Section VIII. FOOD PREPARATION SYSTEM (a) Remove screws securing cover to 5-78. General There is a complete galley aboard the vessel, to accommodate a full crew of sixteen persons. The galley equipment consists of a range, refrigerator, freezer, and a coffee urn. Each unit will be described in the subparagraphs of paragraph 5-79. 5-79. Galley Equipment a. Galley Range. The galley range is of cast iron construction, containing a range top and oven in one unit. The range is fired by an oil burner unit mounted on front. The burner oil supply comes from a 30 gallon day tank mounted on overhead of engineroom casing. Perform maintenance as follows: (1) Cleaning, inspection, and repair. Repairs to the range consist of repairs to the burner and blower unit, including the motor ( (3) below). (a) Keep the exterior of the range clean and free from accumulations of dirt and grease. (b) Lubricate the burner blower motor in accordance with LO 55-1925-204-12-8. (c) Periodically, remove nut (10, fig. 2-31) and lift the cylindrical strainer out of unit. Clean the strainer in clean fuel oil and blow dry with dry low pressure (10 psi) compressed air. (2) Replacement of START-STOP switch. switch housing. (b) Tag and disconnect electrical leads from switch terminals. (c) Remove the two screws securing switch to housing then lift switch out of the housing. (d) Installation of new switch is in the reverse order of removal ( (a) through (c) above). (3) Burner assembly. Remove and install the burner assembly as follows: (a) Tag and disconnect electrical leads from motor. (b) Turn off fuel control valve in line from day tank. (c) Disconnect fuel line at connector (5). (d) Remove four screws (12) then pull burner assembly from the range. (e) Install by reversing the procedures in steps (a) through (d) above. (4) Motor removal, repair, and installation. (a) Remove burner assembly ( (3) above). (b) Loosen setscrew securing fan to motor shaft. (c) Remove the sheet metal screws securing motor to the burner assembly housing and front plate 5-164 TM 55-1925-204-12 (a) Remove the cover mounting screws from the rotary switch, then tag and disconnect the electrical leads from switch terminals. Remove switch mounting screws and lift the rotary switch from the urn. (b) Tag and disconnect electrical leads from the immersion heater. (c) Remove mounting screws from heater mounting plate, then withdraw element from the coffee urn. Remove the gasket. (3) Cleaning, inspection, and repair. (a) Keep exterior and interior of coffee urn clean. (b) Inspect the rotary switch for free movement and good contacts. Test for continuity. Replace a defective switch. (c) Inspect the immersion heater for corrosion, or burned through 'element. Test for continuity. Replace a defective immersion heater. (4) Reassembly. Assemble in reverse order of disassembly. Install new gasket under element mounting plate. (5) Installation. Install by reversing the removal procedure, (1) above. c. Refrigerator. The refrigerator is located at, forward starboard side of the. galley. It is equipped with a temperature and defrost control switch. The motor and compressor is located in a compartment below the refrigerator. Inspect and service as follows: (d) Remove nuts from motor mounting then lift motor from blower housing. (e) Inspect motor armature and brushes for wear or other defect. Replace worn brushes if motor is otherwise serviceable. Replace a defective motor. (f) Installation is in reverse order of removal in steps (a) through (d) above. Be sure fan is squarely on shaft. (5) Blower fan removal and installation. (a) Remove motor ( (4) above). (b) Remove defective fan from blower housing. (c) Insert new fan in the housing. (d) Install motor and burner ( (4) above). (6) Fuel oil metering control valve. Remove and install a replacement fuel oil metering control valve as follows: (a) Remove burner assembly ( (3) above). (b) Remove fuel connection (5) and pipe from control valve (9). (c) Remove control valve (9) from blower housing. (d) Install new control valve to blower housing. (e) Reinstall pipe and fuel connection (5) to the control valve. (fl Remove nut (10) and strainer from control valve. Clean strainer, if necessary, then replace strainer and secure with nut (10). (g) Install burner assembly ((3) above). b. Coffee, Urn. The coffee urn is a stainless steel electrically operated urn, with a three element heating unit controlled by a three position rotary switch to select desired heat level. The heating element is replaceable. (1) Removal. (1) Cleaning and Inspection. (a) Clean the refrigerator evaporator lines after a frost buildup is noted, by turning control switch to "defrost". When the frost softens, wipe it away with a clean cloth. Scrape stubborn ice away, with a blunt edge, to avoid damage to lines or finish of the interior surfaces. (b) Clean the compressor unit (fig. 5-116) with ships service air to remove dust and dirt from coils of the condenser; the compressor, motor, and their mounting platform. Use a clean lint free cloth dampened in clean fuel oil to wipe residual grease and dirt from the unit. (a) Disconnect electrical plug from power. (b) Shutoff water control valve, drain the urn, then disconnect water line from the coffee urn. (c) Lift urn from table and move to a suitable work area. (2) Disassembly. 5-165 Figure 5-116. The refrigerator compressor unit, (c) Inspect the V-belt drive for deterioration or maladjustment. Replace a defective V-belt. Adjust a loose belt to prevent "burning". (d) inspect the motor for bearing type, then lubricate in accordance with LO 55-1925-204-12-8. (e) Wash inside of the refrigerator with a solution of baking soda and cold water to remove any stale food odors. (2) Belt adjustment and replacement. (a) Loosen motor mounting hardware and move motor toward the compressor. Remove the Vbelt. 5-166 compressor unit is located in the engineroom, near the refrigerator compressor unit. The unit is provided with an automatic cycling device to maintain constant storage temperature; a temperature selector; a warning device to indicate undue temperature rise in the storage compartment, and a thermal overload cutout with automatic reset for the motor. (b) Install new V-belt on pulleys, move motor away from compressor until V-belt will depress only l/4 inch midway between pulleys, then tighten motor mounting hardware. d. Freezer. The freezer contains 18 cu ft of space for frozen food; will maintain an average temperature of -5°F. to -2°F. without load, when the ambient temperature is 120°F. (fig. 5-117). The Figure 5-117. Freezer for cold storage of food. (1) Cleaning and inspection. Perform the cleaning and inspection as described for the refrigerator in c. (1) above. (2) Belt adjustment and replacement. Perform similar procedures as described in c. (2) above. 5-167 Section IX. MAIN ELECTRICAL SYSTEM into the circuit breaker and is designed to trip. the breaker when the source of voltage falls. It is so constructed that the breaker cannot be closed until a The main control panel (fig. 2-5) of the electrical minimum voltage between dropout and 80 percent system is located in the engineroom, just forward of the voltage is available. main propulsion engine. It provides the controls, the b. Maintenance and Adjustment. instruments, resistors, circuit breakers, switches and the (1) Remove load from undervoltage release overload relays, trips, or under voltage release devices to be cleaned. necessary to control the vessels electrical system. It (2) Remove capscrews securing door on contains switching contactors necessary to parallel the which circuit breaker is mounted, and open the door. ships service generators and to switch the power (3) Clean all dust from undervoltage requirements to shore power; individual circuit overload release and moving parts. protection by means of the air circuit breakers on front (4) Lubricate moving parts with a few drops of the control panel; a ground detector for testing power of light oil to prevent any binding in operation. and lighting circuits for accidental grounds, and an (5) Because of the construction of the alarm system. It is a dead front panel, with all undervoltage release device no adjustment is connections made from the rear of the panel. necessary. WARNING 5-83. Overload Trip Attachment Before performing maintenance on the main control panel components, all a. General. The overload trip device trips the precautions must be taken to assure circuit breaker whenever the current in the circuit safety, and deck must be dry. Use test exceeds the overload setting. instruments, and work from front of b. Maintenance and Adjustment. panel when possible, to avoid injury. (1) Remove load to overload trip to be Always secure load to instrument cleaned. undergoing maintenance as directed (2) Remove capscrews which hold door on in the maintenance paragraphs below. which circuit breaker' is mounted, and open door. (3) Clean all dust from overload trip and 5-81. Circuit Breakers moving parts. (4) To adjust the trip. setting, loosen the a. General. The circuit breaker installed on calibrating knob, place the pointer at the desired setting, the main panel performs two basic functions: to carry and retighten the calibrating knob. the rated current, and to interrupt currents at or below the interrupting capacity. The first function is performed 5-84. Shunt Trip by the main contacts which are made of copper and heavily silver plated to produce low contact resistance. a. General The shunt trip is mounted on the right side To perform the second function and protect the main of the breaker and is used for tripping the breaker by contacts, arcing contacts are provided. These contacts means of a pushbutton. mate first in closing, and break last in opening, thus b. Maintenance and Adjustment. bearing the full force of any arc formed during the (1) Remove load to shunt trip to be cleaned. opening or closing operation. (2) Remove capscrews which hold door on which circuit breaker is mounted, and open door. b. Maintenance and Adjustment. (3) Clean all dust from shunt trip and (1) The safety of personnel and protection moving parts. of vital equipment often depends on correct functioning of circuit breakers. Breakers must be kept clean and NOTE operate freely. The shunt trip coil is immediately cut (2) Secure load to circuit breaker to be out of the circuit when the breaker cleaned. opens. (3) Remove capscrews securing door on (4) Because of the simplicity of construction which circuit breaker is mounted, and open door. no adjustment is necessary. (4) Clean all dust from circuit breaker and moving parts. 5-85. Auxiliary Switches (5) Lubricate moving parts with a few drops of light oil. a. General. The rotary type auxiliary switches are composed of a rotor, mounted on the main operating 5-82. Undervoltage Release Device shaft of the breaker, which rotates with the shaft. b. Maintenance and Adjustment. a. General. The undervoltage release is built (1) Remove load to auxiliary switch to be cleaned. 5-80. General 5-168 (3) Remove mounting screws and ammeter from switchboard. (4) Inspect ammeter. If damaged or not operating prior to removal, replace. (5) Position ammeter on panel, secure with mounting screws. (6) Connect wires in proper location and tighten the terminals. (2) Disconnect wires from switch. Tag wires for proper reinstallation. (3) Remove mounting screws from switch plate and withdraw switch. (4) Clean all dust from the switch and moving parts. (5) Inspect contacts. If pitted, replace. (6) Remove screw holding contact to contact arm and lift off contact. (7) Position a new contact in plate and tighten mounting screw. Reinstall wires in their proper location. 5-86. Bell Alarm Switch a. General The bell alarm switch, mounted on the main panel, indicates when the circuit breaker has been automatically tripped by energizing a bell alarm. b. Maintenance and Adjustment. (1) Remove load from bell alarm switch. (2) Disconnect wires from switch. Tag wires for proper reinstallation. (3) Remove mounting screws from switch plate and withdraw switch. (4) Clean all dust from switch and moving parts. (5) Inspect switch; if damaged or broken, replace. (6) Position switch on panel and tighten mounting screws. (7) Reinstall wires in their proper location. 5-87. Voltmeter a. General The voltmeter, mounted on the main panel, indicates available voltage 5-89. Disconnect Switch a. General. The disconnect switches on the switchboard are used to connect and disconnect the generators from the control panel. b. Maintenance and Adjustment. (1) Remove load from disconnect switch to be removed. (2) Detach wires from disconnect switch. Tag wires for proper reinstallation. (3) Remove mounting screws and lift disconnect switch from panel. (4) Clean all dust from switch and moving parts. (5) Inspect switch; if damaged or burned, replace. (6) Position disconnect switch on switchboard and tighten mounting screws. (7) Position wires in proper location and tighten terminals. 5-90. Indicator Lamps and Fuses a. General. Lamps indicate when power is available from the generators; when there is a ground in the electrical system or when power is available from the shore connection, the lamps are protected by catridge type fuses b. Maintenance and Adjustment b. Maintenance and Adjustment (1) Remove lenses from blown lamps by turning counterclockwise (2) Remove lamp by turning counterclockwise (3) Place a new lamp in holder and tighten by turning clockwise. Replace the lens and tighten by turning clockwise (4) Use a fuse puller to remove blown fuses (5) Use a fuse puller to insert new fuses of the same amperage rating (1) Remove load from voltmeter to be removed (2) Disconnect wires from voltmeter. Tag wire for proper reinstallation (3) Remove voltmeter from panel mounting screws and (4) Inspect voltmeter; if damaged or not operating prior to removal, replace 5-91. Battery Charging Panel (5) Position voltmeter on panel and secure with mounting screws a. General. The battery charging panel, located in the upper engineroom, is used to charge the general alarm batteries without disconnecting the batteries from the alarm circuit. b. Removal. (1) Place the power panel switch (23, fig. 25) in OFF position. (2) Remove rheostat wheel (6, fig. 5-118) (6) Connect wires in proper location and tighten terminals 5-88. Ammeter a. General. The ammeter on the main switchboard indicates the current load on the generator b. Maintenance and Adjustment (1) Remove load from ammeter to be removed (2) Disconnect wires from ammeter. Tag wires for proper reinstallation Loosen two screws and swing panel door (8) open 5-169 1. 2. 3. 4. Voltmeter Ammeter Battery selector switch Trickle charge switch 5. Main switch 6. Rheostat wheel 7. Battery volt switch 8. Panel door Figure 5-118. Battery charging panel. (3) Disconnect two wires from voltmeter (1). Tag wires for proper reinstallation. Remove three mounting screws from face of voltmeter and lift out voltmeter. (4) Disconnect two wires from the ammeter (2). Tag wires for proper reinstallation. Remove three mounting screws from face of ammeter and lift out ammeter. (5) Disconnect wires from battery selector switch (3). Tag wires for proper reinstallation. Remove mounting locknut and lift out battery selector switch. (6) Disconnect wires from the battery volt switch (7). Tag wires for proper reinstallation. Remove mounting locknut and lift out battery volt switch. (7) Disconnect wires from trickle charge switch (4). Remove the mounting screws and lift out charge switch. (8) Disconnect wires from main switch (5). Remove mounting screws and lift out main switch. (9) Disconnect three wires from reverse current relay. Tag wires for proper reinstallation. Remove mounting screws and lift out reverse current relay. (10) Disconnect four wires from resistors at rear of the panel. Tag wires for proper reinstallation. Remove mounting screws and lift out resistors. (11) Disconnect two wires from rheostat. Tag wires for proper reinstallation. Remove mounting screws and lift out rheostat. (12) Remove and replace blower fuses. Be sure to replace fuses with proper amperage rating. c. Cleaning, Inspection, and Repair. (1) Inspect the voltmeter (1). If voltmeter was not operating prior to removal or is damaged, replace. (2) Inspect the ammeter (2). If ammeter was not operating prior to removal or is damaged, replace. (3) Inspect battery selector switch (3); if damaged, replace switch. 5-170 (4) Inspect battery volt switch (7); if not operating before removal or is damaged, replace. (5) Inspect trickle charge switch (4); if damaged, replace. (6) Inspect the main switch (5); if damaged, replace. (7) Inspect rheostat; if not operating prior to removal or it is damaged, replace. (8) Inspect resistors; if broken or damaged, replace. d. Installation. (1) Position voltmeter (1) in battery charging 'panel and tighten three mounting screws. Replace two wires in their proper location and tighten terminals. (2) Position ammeter (2) in battery charging panel and tighten three mounting screws. Replace two wires in proper location, and tighten terminals. (3) Position battery selector switch (3) in battery charging panel and tighten mounting locknut. Replace the wires in proper location and tighten terminals. (4) Position battery volt switch (7) in battery charging panel and tighten mounting locknut. Replace wires in proper locations and tighten terminals. (5) Position trickle charge switch (4) in battery charging panel and tighten two mounting screws. Replace two wires in proper location and tighten terminals. (6) Position main switch (6) in battery charging panel and tighten two mounting screws. Replace two wires in proper location and tighten terminals. (7) Position reverse current relay in battery charging panel and tighten mounting screws. Replace three wires in proper location and tighten terminals. (8) Position resistors in rear of panel and tighten mounting screws. Replace four wires in proper location and tighten terminals. (9) Position rheostat in battery charging panel and tighten mounting screws. Replace two wires in proper location and tighten terminals. (10) Replace all. blown fuses. Be sure replacement fuse is the same amperage rating as the blown fuse. (11) Close panel door (8) and tighten two screws. (12) Replace rheostat wheel (6). (13) Place switch, power panel (23, fig. 2-5) in the ON position. radio, telephone, searchlight, lighting port and starboard main deck, towing lights, and radio direction finder. b. Maintenance and Adjustment. (1) Remove and replace blown fuses with new fuses of the same amperage rating. (2) To remove and replace defective switches proceed as follows: (a) Place the navigation lighting panel switch (25, fig. 2-5) in the OFF position. (b) Open the navigation light panel door and remove mounting screws from the defective switch. Disconnect wires. Tag wires for proper reinstallation. Lift out switch. (c) Replace switch and tighten mounting screws. Place the wires in proper location on new switch and tighten terminals. (d) Close the navigation light panel door. (e) Place the navigation lighting panel switch (25) in the ON position. 5-93. General Lighting Panel a. General. The general lighting panel is located in the athwartship passageway, main deck, frame 21, at center of ship (fig. 2-17). Individual switches and fuses are provided for the circuits supplied from the main panel (18, fig. 2-5). b. Inspection and Repair. (1) Remove and replace defective fuses with fuses of same amperage as those removed. (2) To remove and replace defective switches proceed as follows: (a) Place the general lighting switch (18, fig. 2-5) at OFF. (b) Open the door of the general lighting panel, remove mounting screws from the defective switch, tag and disconnect the electrical leads, then remove switch from the panel. (c) Position new switch on panel then install mounting screws. Remove tags and install electrical leads to switch. Tighten all connections. (d) Close panel door. (e) Move lighting switch (18, fig. 2-5) to ON. (f) Replace fuses and switches on minor panels in a similar manner. 5-94. General Alarm 5-92. Navigation Light Panel a. General. The general alarm consists of four vibrating bells, 3-eight inch, and one 10-inch. They are battery operated by a 24-volt system maintained at full charge by the battery charging panel (para 5-91). The alarm is controlled by a contact maker No. 60-17 type C located in the pilothouse. The eight inch bells are located one in crew quarters, one in galley, and one in athwartship passageway. The 10-inch bell (fig. 5-119) is located in the engineroom. a. General. The navigation light panel is located in the pilothouse. Individual fused switches in the panel control the air whistle, pilothouse lighting, 5-171 Figure 5-119. Engineroom general alarm beel b. Removal. (1) Tag electrical leads (fig. 5-119). (1) Use low pressure compressed air (10 psi) and blow dust and dirt from the bell assembly components within housing. and disconnect the (2) Remove mounting screws, then lift bell assembly off the mounting plate. (2) Inspect vibrating clapper for bends or other defect. Inspect all electrical terminals for corrosion. c. Disassembly. (1) Remove capscrew, then lift bell off the (3) Test continuity of all electrical circuits assembly. (4) Repair by replacing a defective bell (2) Remove cover screws, then lift cover off the vibrator. assembly. (3) Remove screws from junction box cover, then lift cover from the junction box. e. Reassembly. procedure in c. above. d. Cleaning, Inspection, and Repair. Assemble by reversing the f. Installation. Install by reversing the procedure in b. above. 5-172 Section X. STEERING SYSTEM 7L/2 hp, 115 volt dc unit equipped with electric brake 5-95. General b. Removal This steering gear is a Rapson slide constructed combination electro-hydraulic and hand-hydraulic type, with the ram group mounted athwartship on the after end of the main deck. The electrohydraulic power unit with the control mechanism is mounted under the main deck at the forward end of the engineroom. The handhydraulic unit is mounted in the steering console, which is located in the pilothouse (1) Secure all electrical power to steering system and tag all switches, to prevent injury to personnel working on the steering hydraulic pump drive motor, then tag and disconnect electrical leads from motor (2) Disconnect the two coupling halves between motor and pump 5-96. Motor and Brake (3) Remove coupling half from motor shaft, then remove key (18, fig. 6-120). a. General The hydraulic pump drive motor is a 5-173 Figure 5-120. Motor and brake. 1. Winding, motor field 2. Coil, interpole 3. Bearing, ball 4. Ring, insulation 5. Brush 6. Holder 7. Spring 8. Armature and shaft 9. Bearing, ball !0. Sleeve 11. 12. 13. 14. 15. 16. 17. 18. 19. 5-174 Spring Lining, end plates Coil, magnetic brake Disk assembly Disk assembly Lining assembly Disk, rotating Key Capscrews (3) Check the follow-up cable between ram and the differential unit. Keep all slack out of this cable by adjusting the turnbuckles on starboard side of the engineroom. b. Operating Inspection of Rudder Travel. (1) Start the steering unit (para 2-14). (2) Check the rudder travel from hard over to hard over. The rudder should travel 900; 45°on either side of the amidship position. If necessary, adjust the rudder travel to these limits by use of the adjusting stops located at the differential control unit (fig. 5-121). (4) Remove the hardware securing motor to the frame. c. Maintenance, Adjustment, and Repair. The maintenance, adjustment, and repair of this motor and brake is similar to that described in paragraph 5-66. d Installation. Install by reversing the removal procedure. 5-97. Differential Control (and Hydraulic Pump) a. Maintenance. (1) Lubricate in accordance with LO 551926204-12-3. (2) Inspect piping, and fittings for oil leaks. Replace fittings when leak cannot be stopped by tightening the fitting. NOTE Check rudder travel at the rudder, or the rudder post. Do not use the angle indicator (10, fig. 2-1) on console in pilothouse as the reference for this check. 1. Locknut 2. Adjusting screw Figure 5-121. Rudder travel stop adjustment screws. 5-175 (1) Secure the steering system and tag al switches to prevent operation of power unit while working on the ram (3) Check the time it takes for rudder to travel the 90° by using a stop watch. If the time of travel is greater than 12 seconds, notify general support maintenance (2) Open the valve (13, fig. 5-122) to prevent pressure being inadvertently applied to the hydraulic ram c. Hydraulic Ram Packing and Grie Fitting Replacement 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Cotterpin(4) Nut (8 Nut (4) Stud (4) Cotterpin 14) Nut (4) Capscrew (8) Lubrication fitting (2) Capscrew(4) Capscrew (12) Lubrication fitting 12. Valve, plug 13. Valve, aircylinder 14. Retainer, packing 15. Preformed packing 16. Pin, tiller shoe 17. Lubrication fitting 18. Cotterpin (2) 19. Lubrication fitting (2) 20. Bearing, sleeve 21. Shoe, tiller 22. Bearing, sleeve Figure 5-122. Hydraulic ram assembly. (3) Remove nuts and lockwashers securing the packing retainer (14) then move retainer away from cylinder. (4) Use a packing hook to remove old packing from end of cylinder. (5) Install preformed packing (15) with small diameter of rings pointing away from the cylinder, then use retainer to move packing into cylinder. (6) Install a second preformed packing (15) with small diameter of rings away from the cylinder, and use the retainer to move packing into cylinder. (7) Position retainer (14) against packing, install lockwashers and nuts, then tighten nuts handtight. Be sure retainer is square with cylinder end. (8) Repeat steps (2) through (7) above on the opposite ram. (9) After both rams have been repacked, close valve (13), then start the steering system (para 214). (10) Use the power steering unit to operate the rudder. Observe packing being checked-i.e., if rudder is turning right, pressure is being applied to right ram. Tighten nuts around retainer evenly until all leaking stops. (11) Vent the system, then repeat procedures of (10) above. Continue venting and tightening 5-176 (b) Disconnect hydraulic lines from the pump. (c) Remove mounting hardware, then lift pump from the frame of control unit. (2) Disassemble the pump only as far as required to perform the maintenance described in the following steps: (3) Replace a drive end bearing (8, fig. 5123) as follows: procedures until both rams travel smoothly, and all leaking around packing has stopped (12) Secure the steering system until further notice, and remove tags. d. C Hydraulic Pump. (1) Secure the system and tag all electrical switches to prevent operation of power unit while working on pump, then remove pump as follows: (a) Disconnect the two coupling halves (between motor and pump). 5-177 1. 2. 3. 4. 5. Pin {7) Valve Bearing (2) Pin (7) Ring, floating 6. 7. 8. 9. Slipper (7) Plunger (7) Bearing (2) Seal, encased Figure 5-123. Hydraulic pump. 5-178 10. 11. 12. 13. Spindle Nut (12) Seal, oil guide rod Spindle nut not scored, replace all seven plungers in a similar manner. Replace a pump with scored cylinders. (a) Remove coupling half from spindle (10), then lift key out of spindle. (b) Remove six nuts (11) and lockwashers securing drive and cover, then remove cover. (c) Remove the encased seal (9) from cover. (d) Remove bearings (8 and 3) from the housing. (e) Install a new seal in cover, after dipping seal in oil and wiping away excess, then applying a light coating of sealing compound to face of the case before pressing it into the cover. (f) Be sure that replacement bearings (8 and 3) are lubricated in accordance with LO 551925204-12-3, then installed in housing. (g) Replace cover and secure with six lockwashers and nuts (11). (4) Replace opposite end bearings as follows: (a) Remove six nuts (11), spindle nut (13), and cover from housing. (b) Remove bearings (8 and 3). (c) Be sure that bearings are lubricated in accordance with LO 55-1925-204-12-3. Install new bearings, then replace cover and secure with six lockwashers and nuts (11). (d) Install nut (13) on spindle (10). (5) Replace as follows: (a) Dismantle pump as in step (3) above, then remove male and female halves of the floating ring (5). Do this by lifting floating ring from pump housing, then driving pin (4) out of plunger (7) and lift plunger from lower half of floating ring (5). J Replace the plunger with a new one then install pin (4). (c) Install male half of the floating ring, then reassemble pump in reverse of disassembly. (6) Install the pump by reversing the procedure in step (1) above. e. Control Differential. (1) Lubricate in accordance with LO 55-192520412-3. (2) Remove and disassemble components only so far as necessary to replace bearings, bushings, gears, cams, shafts, pins, and/or couplings. NOTE Install new gaskets to replace those removed at disassembly. 5-98. Steering Console, Hand Pump, and Valves a. General. The steering console (stand) located in pilothouse, houses the hand hydraulic pump, valves, and pipe fittings necessary for control of the system, and acts as a mount for the steering wheel. The steering wheel is equipped with a clutch latch for disengagement of the wheel when control of the steering is turned over to aft steering station, or the trick wheel in the engineroom. b. Hand Hydraulic Pump. The hand hydraulic pump provides a means of developing hydraulic pressure manually for operation of the steering gear rams should the electro-hydraulic unit fail. (1) Removal. (a) Close changeover globe valve (3, fig. 5124) on side of steering console (fig. 5-125). (b) Disconnect hydraulic piping from pump. (b) Before replacing the plunger as above, carefully inspect plunger cylinder for scoring. If 5-179 4. Safety relief valve 5. Elbow 1. Tee 2. Check valve 3. Globe valve Figure 5-124. Valve and fittings. 5-180 TM 55-1925-204-12 1. Screw, machine 2. Clutch, manual engaging 3. Setscrew. manual drive clutch. 4. Key, machine Figure 5-125. Steering console. (c) Remove bolts from pump mounting bracket and the lower pump and gear assembly, then remove pump from console. (d) Pull gear from pump shaft. (e) Remove key (10, fig. 5-126) from pump shaft (9). 5-181 1. 2. 3. 4. 5. 6. 7. 8. 9. Gasket Bearing Bolt, socket head Key, machine Ring, eccentric Rotor set, pump Retainer, bearing Seal, encased Shaft 10. 11. 12. 13. 14. 15. 16. 17. Key, machine Ring, pilot Washer, thrust Pin Spring Collar Washer Capscrew Figure 5-126. Pump, hand, hydraulic. (d) Inspect bearings for looseness as sign of wear, or rough turning of rollers. Replace defective bearings. Pack bearings in accordance with LO 551925-20412-3. (e) Inspect shaft for wear at bearing surfaces, or bend in length. Replace a defective shaft. (f) Inspect collar for wear, spring for weakness or break, and the thrust washer for a deformed face. Replace a defective collar, spring, or thrust washer. (4) Reassembly. Assemble by reversing the disassembly procedure. (5) Installation. Install by reversing the removal procedures. c. Steering Valves. Repair the steering valves and piping, by replacing fittings and valves as required, and proceed as follows, (1) Removal (a) Tag and disconnect all switches and/or fuses to prevent operation while working on the hydraulic system. (b) Disconnect any line at a union, near the valve or other fitting to be removed. (2) Disassembly. (a) Remove capscrews (17) and pump cover, then remove gasket (1). (b) Remove thrust washer (12), pin (13), collar (15), and spring (14). Remove washer (16) then withdraw shaft (9). (c) Remove seal (8) from housing, then remove retainer (7) and roller bearings (2). (d) Remove socket head bolt (3), ring, eccentric (5), and rotor set (6) from shaft (9), then remove key (4). (e) Remove pilot ring (11) as required. (3) Cleaning, inspection, and repair. (a) Wash all parts in clean fuel oil and wipe dry with a lint free cloth. (b) Inspect all parts for gummed rings or buildup, or for excessive wear. Use a blunt piece of hardwood to scrape accumulated gummy rings off of eccentric ring or rotor set. Replace worn or defective parts. Use new gasket at reassembly. (c) Inspect oil seal (8) for deterioration, or signs of leaking. Replace a defective seal. 5-182 (c) Unscrew the valve or fitting. (2) Inspection. Inspect operation of all components frequently. Lubricate in accordance with LO 551925-204-12-3. (2) Installation. Install valve or fitting by reversing the removal procedures. Seal all threads with a sealing compound. (3) component. d. Steering Console. The steering console components require little if any maintenance other than cleaning and inspecting for leaks of the hydraulic lines. On rare occasions a bearing, bushing, or gear may require replacement. Never disassemble farther than the defective part. Repair by replacing a defective 5-99. Gear Boxes, Universal Joints, and Couplings a. General. Miter gear boxes, universal joints, and couplings provide the change of direction necessary to control the rudder from the pilothouse steering console. Figure 5-127 outlines the use of these items between console and differential control. (1) Cleaning. Keep the interior of console clean by use of low pressure compressed air, or with a lint free cloth dampened with FED SPEC P-D-680 solvent. 1. 2. 4. 4. Repair. Universal joint Gear unit, 3-way Universal joint Coupling 5. Coupling 6. Coupling 7. Universal joint Figure 5-127. Gears, universal joints, and couplings. 5-183 b. Miter Gear Boxes. The three types of miter gear boxes are illustrated on figures 5-128, 5-129, and 5-130. Maintenance and adjustment as follows: Figure 5-128. Miter gear box, L. H. 1. 2. 3. 4. 5. 6. Bolt, machine Screw, machine Bolt, machine Gear, bevel Key, machine Bearing 7. Lubrication fitting 8. Key, machine 9. Shaft 10. Bearing 11. Retainer, bearing 5-184 Figure 5-129. Miter gear box, R. H. 1. 2. 3. 4. 5. 6. 7. Bolt, machine Retainer, bearing Bearing Key, machine Shaft Bolt, machine Gear, bevel 5-185 8. Key, machine 9. Bearing 10. Shaft 11. Key, machine 12. Lubrication fitting 13. Screw, machine 1. 2. 3. 4. 5. 6. 7. 8. Figure 5-130. Miter gear box, differential Bolt, machine 9. Screw, m-chine Coupling 10. Bolt, machine Key, machine 11. Key, machine Gear, bevel 12. Retainer, bearing Key, machine 13. Bearing Bearing 14. Shaft Retainer, bearing 15. Lubrication fitting Shaft (c) Remove bolts _(1) and cover from housing, then remove machine screw (2) and lockplates from gears (4). (d) Pull shaft (9) from gears and housing, then lift gears (4) out of housing. (e) Remove bearing retainers 11l), then remove remaining bearing (6 or 10). (f) Remove keys (5) from shafts (9). (g) Remove lubrication fittings (7) as necessary. (4) Cleaning, inspection, and repair. (a) Wash all pats in clean fuel oil and wipe dry. (1) Lubrication. Lubricate in accordance with LO 55-1925-204-12-3. (2) Removal of miter gear boxes. (a) Tag and lockout all switches to prevent operation while working on miter gear boxes. (b) Remove couplings (4, 5, 6, fig. 5-127) and universal joint (7) from both shafts of gearbox. (c) Remove the four bolts, lockwashers, and nuts from mounting flange (figs. 5-128, 5-129, or 5-130) of miter gear box, then lift gear box from its mounting bracket. (d) Remove all remaining miter gear boxes in a similar manner. (3) Disassembly. (a) Remove key (8, fig. 5-128) from shaft (9). (b) Remove bolts (3), and covers, then remove bearings (6 or 10). 5-186 corrosion, arcing, or loose connections. Replace defective contacts or fingers. (3) Repair as follows: (a) Loosen the four thumbscrews swing the eyebolt out of the way, then remove cover from the master control switch. (b) Test movement of contacts and fingers. (c) Tag and cut out electrical power to the steering system, then disconnect electrical leads from defective contacts. (d) Install new contacts (or fingers) then reconnect electrical leads. Tighten all screws securely. c. Adjustment. (1) Keep moving parts free from corrosion. (2) Do not apply paint to master control switch shaft or the lever. These controls must operate freely. (3) Keep cover fastened tightly to avoid moisture getting inside. CAUTION In event water leaks into switch enclosure, do not operate the equipment until the switch has been thoroughly dried. (4) Inspect contacts for excessive burning or wear. Smooth the excessive roughness from the copper contacts with a fine file. Replace contacts worn to one-half the original thickness. (b) Inspect gears for chipped teeth, breaks, or wear. Inspect shafts for wear. Inspect bearings for flat spots, or roughness. (c) Repair by replacing defective components. NOTE Repack bearings, or pack new bearings in accordance with LO 551925-204-12-3 before reassembly. (5) Reassembly. Assemble by reversing the removal procedure. (6) Installation. Install be reversing the removal procedures. (7) Adjustment. (a) Shim under gear box, on top of mounting bracket, at one or more corners, to reduce strain on the universal joints. (b) Extend coupling over key to lengthen the universal joint. 5-100. Aft Steering Control Station a. General. The after steering control station consists of the master control switch, engine order telegraph, and one station of the intercommunicating telephone system. b. Cleaning, Inspection, and Repair. (1) Keep the station clean at all times. Frequently remove cover and use low pressure air to blow dust and dirt from the master control switch. (2) Inspect the contacts and fingers for Section XI. NAVIGATION EQUIPMENT properties of the gyroscope in combination with the rotation of the earth and the effect of gravity produce this result. (2) Maintenance. Crew and organizational maintenance for the gyrocompass is limited to fuse, lamp resistor, and capacitor replacement. Terminals and sockets may be replaced or repaired in an emergency, and gaskets replaced when required. (3) Preventive maintenance checks and services, and troubleshooting. Refer to TM 55-6605261-15 for all PMCS and troubleshooting procedures. c. Radar. (1) General. This tug is equipped with a radar system type AN/SPN-18. The indicator is located in pilothouse; antenna is atop the mast, and the power unit is in a locker portside aft of pilothouse. (2) Maintenance. Crew and organizational maintenance of the radar system is limited to inspection, cleaning, test, and adjustment. Refer to TM 11-5840-214 for all of the authorized procedures. 5-101. General The effective navigation equipment aboard the vessel consists of magnetic compass, gyro compass, and the radar system with auxiliary equipment such as the radio direction finder and the fathometer. 5-102. Navigation Equipment a. Magnetic Compass. (1) General The magnetic constellation type compass, located in the pilothouse, indicates the tugs magnetic heading. (2) Cleaning and inspection. (a) Inspect the glass cover. If cracked, notify general support maintenance. (b) Keep the compass and stand clean and free of all foreign matter. (c) Check amount of fluid in the compass. If there is no fluid, or if the fluid is low, notify general support maintenance. b. Gyro Compass. (1) General. The Mark 27 Gyro compass contains a gyroscope controlled in a manner to make it seek and continuously align itself with the meridian and thereby point to true north. The 5-187 Section Xll. SEARCHLIGHT EQUIPMENT 5-103. General The purpose of the searchlight equipment is to provide illumination for shore lines, buoys, obstructions, other vessels and the like during night operations, or periods of poor visibility. The tugs are equipped with a 12-inch incandescent searchlight. The optical system is housed in a watertight drum type housing (fig. 5-131) with a watertight door. The optical system consists of 1,000-watt megul base lamp and socket; a parabolic primary reflector constructed of silvered glass approximately 12 1/2 inches in diameter, and a spherical shaped secondary reflector of alzak surfaced aluminum, 4 inches in diameter. The drum is mounted on a base and yoke assembly of corrosion resisting silicon aluminum castings. The base contains bronze bearings, and a bronze floating stop which allows approximately 360° of horizontal rotation. The searchlight may be elevated or depressed 450 from the horizontal. A single lever (3, fig. 2-1) in the pilothouse controls both vertical and horizontal movement. 5-188 Figure Figure 5-131. Searchlight atop pilot house. 5-189 c. Replacement of Primary Reflector. (1) Open door (8, fig. 5-132) and remove lamp (4) from its base. 5-104. Searchlight a. Removal. (1) Remove nut at end of control rod (fig. 5131). (2) Withdraw control rod by pulling it down into the pilothouse. Lay aside carefully, pending installation. (3) Tag and disconnect electrical leads from control box, loosen locknut, then withdraw electrical leads from pedestal (base). (4) Remove capscrews and lockwashers securing pedestal to roof of pilothouse, then lift searchlight from the pilothouse roof. b. Installation. Install by reversing the removal procedure. KEY to fig. 5-132: 1. Clamp, reflector 2. Pin, hinge 3. Lens 4. Lamp 5. Reflector, secondary 6. Setscrew 7. Setscrew (2) 8. Door 9. Clamp, lens 10. Flange, lens seating 11. Lockwasher 12. Screw 13. Gasket 5-190 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 26. Locknut, knurled Knob, adjusting Base and yoke assembly Control lever assembly Handwheel clamp Oil fitting Cable Drum Reflector, primary Pad Lockwasher Screw Figure 5-132. Searchlight, cross section. 5-191 (2) Remove screws (25), lockwashers (24), and clamps (1) that secure reflector (22) against pads (23) at rear of drum. (3) Lift defective reflector (22) out carefully to avoid damage to adjusting mechanism on lamp base. (4) If pads (23) are damaged, scrape them off and replace with new pads of same thickness. Fasten new pads in place with shellac. (5) Carefully position new reflector on pads (23), and secure with clamps (1), lockwashers (24), and screws (25). NOTE Tighten all screws gradually and evenly to prevent strain on reflector. Tighten screws only until the reflector, when grasped with two hands along the edge, can be rotated under the clamps. CAUTION Clamps must not be too tight, or reflector breakage is possible due to expansion from heat. Reflector must not be loose enough to permit movement due to normal vibration of the vessel. (6) Install lamp in its base then close door. d. Replacement of Lens. To replace a cracked or broken lens, proceed as follows: (1) Remove pins (2, fig. 5132) from hinge, loosen thumbscrews (fig. 5-131) and move door clamps, then lift door (8, fig. 5-132) off the drum. (2) Remove screws (12), lockwashers (11), clamps (9), and the damaged lens (3). (3) Scrape old lens cement and cork pad out of lens seating flange (10). (4) Apply a few drops of shellac on seating flange (10) of door frame, opposite the screw holes for lens clamps (9). (5) Press a new cork pad into place on shellac, and allow shellac to dry. (6) After pad is seated, refill seating flange groove with cement and smooth to a thickness of approximately 1/16 inch. (7) Lay a new lens on cemented pad and press down evenly and firmly. (8) Replace clamps (9), and secure with lockwashers (11) and screws (12). Tighten screws carefully to produce even pressure on glass at all points. (9) Scrape excess lens cement off both sides of door surface, and clean both sides of lens. (10) Install door on drum, replace hinge pins (2), then secure door with clamps and thumbscrews. e. Maintenance and Adjustment. (1) Lubricate in accordance with LO 55-192520412. (2) Keep electrical connections tight, and free of corrosion. (3) If the lens fog, indicating presence of moisture inside housing drum, open door and wipe all parts dry. Operate lamp with door opened slightly to permit warmed moist air to escape. Continue operating lamp until interior of drum housing is completely dried, then close and fasten door. (4) Keep moving parts free from corrosion. Do not screw threads or bearing surfaces. (5) Clean primary reflector and lens weekly with water and detergent applied with a soft cloth. CAUTION Never use coarse or abrasive material to clean searchlight reflectors. (6) To adjust the searchlight beam focus, proceed as follows: (a) Loosen setscrews (6, fig. 5-132), and remove secondary reflector (5). (b) Project the searchlight beam on a vertical surface located 30 or 40 feet from the searchlight. (c) Loosen knurled locknut (14). (d) Move lamp socket assembly forward and/or backward with adjusting knob (15) until the smallest and most clear image of the filament is produced on vertical surface of target. Tighten knurled locknut (14) securely.. (e) Install the secondary reflector (5) on its mounting, loosen two setscrews (7) and twist the reflector sideways slightly until two spots of light appear on the target. The spots will not be of equal intensity, the weaker spot will be caused by the secondary reflector. (f) Adjust the secondary reflector up or down until the centers of the spots are on the same horizontal line. (g) Move the secondary reflector to or from the lamp until the two spots on target appear to be the same size. Twist the secondary reflector sideways until the spots on target coincide, then tighten all setscrews. Section Xlll. FIRE FIGHTING EQUIPMENT 5-105. General The fire fighting system is described in paragraph 4-2a. Operation of the system appears in paragraph 2-19. Maintenance of the system appears in paragraph 5-106 below. 5-106. Fire Fighting Equipment a. Portable Fire Fighting Equipment. The portable system consists of eight 15 pound and four 4 pound hand extinguishers (fig. 5-133)positioned about the vessel. 5-192 Figure 5-133. Typical portable extinguisher position. (1) Inspection. Inspect and operate (para 219 b. ). (2) Replacement. Replace an empty extinguisher with a full one. NOTE Never place an empty extinguisher on its mounting bracket without first marking it prominently as discharged. Notify organizational maintenance so that they may test and refill at first opportunity. b. Fixed Fire Fighting Equipment. (1) Removal. Remove the fixed fire fighting cylinders, or piping, as follows: (a) Disconnect cable from pull box (fig. 5134) at remote control lever (fig. 5-135) by removing cotter pins and pin from lever. 5-193 Figure 5-134. Pull box (activation ). 5-194 Figure 5-135. Remote control lever release. (b) Remove ring nut coupling that secures discharge control head to cylinder valve. (c) Lift control head from cylinder valve. (d) Unscrew flexible hose that connects control head to discharge lines from control head. (e) Remove hardware securing cylinder to mounting rack then lift cylinder from rack. (f) Remove remaining cylinders in a similar manner. Remove pipe and fittings as required. (2) Installation. Install cylinders by reversing the removal procedures in (1) above. (3) Siren (warning). (a) Test siren (para. 2-19). (b) Remove and replace a defective siren as follows: 1. Disconnect CO, line from siren. 2. Remove mounting hardware, then lift siren from frame. 3. Position new siren on frame, and secure with mounting hardware. 4. Test new siren (para 2-19). 5. Remove test air line, then connect CO2 line to siren. (4) Pull box (activator). Replace a broken glass in pull box (after use) as follows: (a) Remove the two cover screws and lower cover. (b) Scrape old glass from frame and clean grooves. (c) Install new glass in cover and secure in place, then lift cover to proper position, and secure with the two cover screws. Section XIV. RADIO TELEPHONE SYSTEM 5-107. General The AN/SRC-32 is a Marine Radio Set similar to the Raytheon Model RAY-75A-3C marine radio telephone. This set provides AM communications within the frequency limits of 2,000 KHz thru 6,000 KHz on 10 crystal controlled channels. 5-108. Radio Telephone System The inspection, test, repair, operation, and maintenance of the AN/SRC-32 Marine Radio Set is covered in TM 11-5826-68915. Section XV. WHISTLE/ HORN SYSTEM house to the lever of the pilot valve at whistle. Air is stored in a 5 cubic foot tank, with pressure established at 110 psi. The electric whistle/horn is controlled by a switch from the pilot house. 5-109. General The tug is equipped with an air whistle, and an electrically operated whistle/horn, both mounted on mast (fig. 5-136). The air whistle is operated by a lanyard running from pilot 5-195 Figure 5-136. Air whistle and electric horn. 5-196 5.110. Whistle/Horn System (b) Examine valve piston for wear, or excessive play in valve. Replace a worn or defective valve piston. a. Air Whistle. (1) Removal. (c) Check valve spring for deformation, breaks, or weakness. Replace a defective spring. (a) Shut off air valve at whistle tank. (b) Disconnect air line (fig. 5-136) from valve, then disconnect lanyard from lever. (d) Inspect diaphragm for loose fit, or other deformation. Replace a defective diaphragm. (c) Remove four nuts, lockwasher, and bolts securing air whistle to mounting bracket, then lift air whistle off the bracket. (4) Reassembly. Assemble by reversing the removal procedure, using new gaskets and 0 rings in all positions. (2) (5) Installation. Install by reversing the removal procedure. Disassembly. (a) Unscrew the two air whistle bells from the b. Whistle/Horn. diaphragms. (b) Loosen clamp diaphragms from the frame. screws, then remove (1) Removal. (a) Tag and disconnect electrical leads (fig. 5- (c) Unscrew pilot valve from frame. 136). (d) Remove valve cap, then remove valve spring and valve piston. Remove the valve cap gasket. (b) Remove bolt, lockwasher and nut, then remove the electric horn. (e) Remove pin securing lever to the pilot valve, then remove lever. (3) (2) Installation. Install by reversing the removal procedures. Cleaning, inspection, and repair. (a) Wash all parts in clean fuel oil and wipe dry. Section XVI. LIFE BOAT DAVIT (1) Lubricate lifeboat davit and handling equipment in accordance with LO 55-1925-204-121. 5-111. General The life boat davit is the single radial arm type H20, manufactured by the Welin Davit and Boat Division of Continental Copper and Steel Company. It has a bevel gear mounted with a gear ring for hand turn-out and turn-in. The bevel gear assembly is mounted on the davit pedestal. The hoisting winch (hand crank) is secured to the davit arm. It has a 1,750 pound working load, and is equipped with a hand operated manual brake for lowering the life boat. Turning the hand crank on hoisting winch will lift the boat free of stowage, and operating the turn-out will swing the boat free of the vessels side. By releasing the locking pawl on the hoist winch, the boat can be lowered away by means of the handbrake. The hoisting tackel consists of a six inch double sheave with an upset swivel shackle at davit head and a six inch single sheave with becket and a Raymond quick-release hook. (2) Clean davit and associated equipment frequently, to prevent buildup of dirt, grease, or grime. b. Inspection. (1) Inspect condition of wire rope on winch drum and hoisting tackle for broken strands, or kinking. If broken strands, or kinks, notify general support maintenance. (2) Inspect teeth in ring gear of davit, and bevel gear of turn-out assembly for broken or chipped teeth. If teeth are broken, or show evidence of excessive wear, notify general support maintenance. (3) Inspect weldment of wire rope fair lead (mounted on davit arm) for cracked weld, and bent or binding sheave. If noted, notify general support maintenance. 5-112. Lifeboat Davit a. Maintenance. 5-197 APPENDIX A REFERENCES A-1. Fire Protection TB 5-4200-200-10 A-2. Lubrication C9100IL LO 55-1925-204-12/1 LO 55-1925-204-12/2 LO 55-1925-204-12/3 LO 55-1925-204-12/4 LO 55-1925-204-12/4 LO 55-1925-204-12/5 LO 55-1925-204-12/7 LO 55-1925-204-12/8 TB TC 15-17 A-3. Painting TB 746-93-4 Hand portable fire extinguishers for Army users. Fuels, Lubricants, Oils and Waxes Tug, harbor, diesel, 1,200 hp, steel, 100 foot, Design 3006 Engine, diesel, marine (Fairbanks-Morse 37-F-16) Steering Device, electric motor driven (American Engineering Model 51/4" Ram) Air Compressor (2), motor driven, (Quincy Model D340) Capstan, motor driven (New England Trawler Equipment Co. Model RG293) Auxiliary Set (Generator and Fire and Salvage Pump) (GM Engine 4061A, Delco Generator 1-3644, Patterson Pump 4LSBB, and Kraissl priming pump 25-9RS). Lubricating Oil Purifier, motor driven, (DeLaval Steam Turbine Co Model 45-28). Windlass, motor driven, marine (Markey Marine Co. Model VEV-16) Pump and Motor Models A313 A143 and 322 AX250. In service Testing of Engine lubrication oil. Painting of Vessels. A-4. Radio Suppression and Electronics Components TM 11-483 TM 11-1302 TM 11-1502 TM 11-5820-286 TM 11-5820-364 TM 11-5820-689-15 TM 11-5825-299 TM 11-5840-214 Radio Interference Suppression LORAN AN/SPN-7 LORAN AN/SPN-7 Radio AN/SRC-8 Radio AN/SRC-6 AN/SRC-32 Radio Direction Finder AN/SRD-8 Radar AN/SPN-18 A-5. Maintenance TB TC-15-15 TB 55-1900-201-12/1 TB 55-1900-202-12/1 TB TC-11 TM 38-750 TM 9-6140-200-14 TM 9-6140-200-14 TM 55-501 TM 55-506 TM 55-507 TM 55-1925-204-20P A-6. Shipment and Storage TB 740-93-4 Treatment of Cooling water in Marine Diesel Engines. Application of Non-slip walkway compound, Harbor Tugs. U. S. Army Floating Craft Maintenance. Arc Welding on Water-Borne Vessels The Army Maintenance Management System (TAMMS) Operator, Organizational, direct, general support and depot i-rantenance of Storage Batteries, Lead Acid Type Operator, Organizational, direct, and general support maintenance of Storage Batteries, Lead Acid Type Harbor Craft Crewman's Handbook Marine Electrical and Refrigeration Equipment Floating Craft Preventive Maintenance Organizational Maintenance Repair Parts and Special Tools List for Tug, harbor, diesel, 1,200 hp, steel, 100 foot, design 3006, Hull Nos. LT1936 Through LT1977 and LT2202. Preservation of Vessels for Storage A-1 A-7. Destruction of Army Materiel TM 750-244-3 Procedures for Destruction of Equipment to Prevent Enemy Use A-8. Operations TB TC-16 Standard Tug Boat Signals A-9. Cleaning Fed Spec P-D-680 Metal Cleaning Solvent for Army Use A-2 TM 55-1925-204-12 APPENDIX B OPERATOR/BOAT SET LIST COMPONENT OF END ITEM, BASIC ISSUE ITEMS, ADDITIONAL AUTHORIZATION AND EXPENDABLE SUPPLIES AND MATERIEL LISTINGS Section I. INTRODUCTION B-1. General. a. This Appendix for Tug, Harbor, Design 3006, Flight one, is intended as an aid in identification, procurement, requisitioning, assembly, storage and issue of component of end item, basic issue items, additional authorization items and expendable supplies and materiel aboard the vessel. b. The boat set will be issued initially complete by the US Army Troop Support Command (TROSCOM). c. Requisitions for replacement of component items will be submitted to the managing activity having issue responsibility. d. When watercraft are transferred or returned to an inactive status, the boat set will be complete and turned in with the vessel. B-2. Format. a. Sectional. Introduction. The items in this group are components which when affixed to the hull, comprise an end item. These may or may not be removed from the end item for transportation before, during or after operation. But, no matter which, they must be on board the end item for issue or turn in. b. Section II. Components of End Item (COEI). The items in this group are components which may be removed from an end item but which must be on board in order to make the end item complete. However, COEI are addressed in two ways for the operator/crew, so the COEI list in the end item operator's manual identifies: (2) Items identified as on-board spares. This list is for authorization of these items. All on-board spares are listed in the COEI under the separate header "onboard spares." c. Section III. Basic Issue Items List (BIIL). Basic Issue Items (BII) are items (common/special tools, repair parts, Test, Measuring and Diagnostic Equipment (TM&DE), publications, first aid and safety related) required by the crew to enable it to carry out its assigned mission. d. Section IV. Components of End Item (COEI) onboard repair/spare parts, special tools. e. Section V. Damage Control Equipment. Damage control is the temporary and immediate action taken when damage occurs on or to a vessel. f. Section VI. Expendable Supplies and Materiel List (ES&ML). Are expendable and bulk items required by the crew to operate the end item and to enable the crew to perform their assigned maintenance functions. B-3. This appendix does not constitute authorization for excessing or disposing of any operating equipment, supplies or on board spare parts which are currently on board or marked for this vessel. Excess items will be exhausted by normal attrition. B-4. Composition of appendix. The component listing within each section is in alphabetical sequence by item name, with additional descriptive information required for identification. (1) Spare/repair parts that are removed from the major end item and separately packaged or stowed for transportation or movement. This list is for information only. Change 6 B-1 TM 55-1925-204-12 APPENDIX B. OPERATOR/BOAT SET LIST-Continued B-5. Abbreviations AC ................................ ................ Alternating Current AMP ................................ ............. Ampere(s) BA ................................ ................ Ball BX ................................ ................ Box CHG ................................ ............. Charge CIRC ................................ ............ Circumference CL ................................ ................ Coil NC ................................ ................ Can CO ................................ ................ Container CO ................................ ................ Carbon Dioxide CRES ................................ ........... Corrosion Resistance DC ................................ ................ Direct Current DIA ................................ ............... Diameter DR ................................ ................ Drum DRVN ................................ ........... Driven EA ................................ ................ Each ELEC ................................ ............ Electric FT ................................ ................. Foot GAL ................................ .............. Gallon HP ................................ ................ Horse Power IN ................................ .................. Inch LB ................................ ................. Pound LG ................................ ................ Long LP ................................ ................. Liquid Propane MDL ................................ .............. Model MTD ................................ .............. Mounted NC ................................ ................. National Course OZ ................................ ................. Ounce PR ................................ ................ Pair QTY ................................ .............. Quantity REC ................................ .............. Recoverability RL ................................ ................. Reel SE ................................ ................ Set SL ................................ ................. Spool SO ................................ ................. Shot U/I ................................ ................. Unit of Issue V ................................ ................... Volt W................................ ................... Watt(s) W/O ................................ .............. Without Section II COMPONENTS OF THE END ITEM LIST (COEIL) NSN CTA 50-935 CTA 50-935 CTA 50-935 CTA 50-935 CTA 50-935 DESCRIPTION U/I QTY U/I QTY EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA 1 1 1 4 1 1 1 8 1 1.2 16 1 1 2 2 Direction Finder Set Frequency Meter Radar Set Radio Set Compass Magnet Section III BASIC ISSUE ITEMS LIST (BIIL) NSN 6625-00-519-2998 2040-00-377-8603 2040-00-194-1797 4210-00-142-4949 6605-00-240-5599 5120-00-293-0665 6660-00-075-6666 6140-00-263-4603 6140-00-635-3824 6135-00-050-0915 6135-00-050-3280 6350-00-256-9062 6650-00-530-0974 3940-00-892-4561 3940-00-926-3724 DESCRIPTION Ammeter, Portable, DC.: Type 1-0-500 CW, w/case Anchor, Danforth, 300 lb., A-1i 5707 (81349) Anchor, Marine, Fluked 800 lb. A-15707 (81349) Ax, Fire, Pick Head, 6 lb. GGG-A-926 Type A (81348) Azimuth Circle, 7 1/2": 124 (50967) Bar, Wrecking, 30" Ig: GGG-G-101 (81348) Barometer, Aneroid, 3257A (80063) Battery, Storage: engine starting; 6 volt; W-D-191, type 7d (81348) Battery, Filler, Jug Type 75 (72853) Battery: battle lantern BA-23 (80063) Battery: emergency light: BA-200N (81350) Bell, Ships, 30 lb., B-674 (81349) Binocular, 7 x 50: B-13656, Type M17A1 (81349) Block, Double: 3/4" Wire Rope GGG-B-490 Type 2 (81348) Block, Double: 1" rope GGG-B-490 Type 2, Iron (81348) B-2 Change 6 TM 55-1925-204-12 Section III (Continued) BASIC ISSUE ITEMS LIST (BIIL) NSN 3940-00-879-2133 7210-00-282-7950 6545-00-911-1300 7330-00-078-5706 7350-00-251-8746 7330-00-262-2323 7330-00-241-8168 4240-00-678-5268 7330-00-550-7592 6145-00-791-3233 5210-00-229-3054 5210-00-221-1921 7240-00-256-7700 7240-00-965-4427 7240-00-160-0441 7240-00-160-0440 5120-00-529-4124 4010-00-188-9003 4010-00-262-2586 7105-00-269-8463 7110-00-273-8782 5110-00-554-7345 5110-00-236-3272 5110-00-234-1944 5110-00-222-2117 5130-00-203-6424 6645-00-238-9054 6645-00-290-2233 5120-00-240-5630 6645-00-224-8631 7310-00-935-6675 7330-00-680-2762 5935-00-504-3260 7240-00-161-1150 7240-00-161-1147 7240-00-161-1143 7210-00-281-6751 6680-00-242-9229 7350-00-935-6635 7350-00-223-7760 5110-00-188-2524 5110-00-293-0460 5110-00-224-7058 5180-00-541-1644 7110-00-290-9131 5136-00-357-7494 5136-00-357-7504 7330-00-272-2488 7330-00-190-5190 7350-00-641-6050 5210-00-266-7038 6605-00-025-7005 7330-00-205-3154 7330-00-267-4141 7330-00-205-3155 5130-00-853-4480 5130-00-889-9004 5133-00-293-0983 3414-00-165-4136 7330-00-243-3408 4210-00-270-4512 4210-00-202-7858 4140-00-255-7798 2040-00-815-4792 7110-00-286-3798 DESCRIPTION Block, Single: 3/4" Wire Rope GGG-G-490 Type 3 Style 2 RIG 25 (81348) Blanket, Wool, O.D. B-844 (81349) Blanket, Set, Medical Board, Food Chopping: LLL-B-568 (81348) Bowl, Eating: Plastic: LT-48 (81348) Bowl, Mixing: 5 1/2 QT: B-2054 (81349) Bowl, Mixing: 7 1/2 GAL, w/cover, B-2054 (81349) Breathing apparatus: Oxygen: B-51254 (81349) Butchers Steel: 10" Lg; GGG-C-746 (81348) Cable, Shore Power, W/Lugs MIL-C-915 (81349) Caliper, Micrometer; 0"-6" OD; GGG-C-95 (81348) Caliper, Micrometer; 2'-12" ID, GGG-C-105(81348) Can, Flammable, Waste, 10 gal. RR-C-114 (81348) Can, Ash & Garbage, 10 gal w/o Cover. RR-C-82 (81348) Can, Ash & Garbage, 24 gal w/o Cover. RR-C-82 (81348) Can, Ash & Garbage, 32 gal w/o Cover. RR-C-82 (81348) Carrier, Battery, Hand, C-19482 (81349) Chain, Anchor, 1" Dia(105 Fathoms) S-2603-860341 (80064) Chain, Anchor (Shot 90 Ft) S2603-860341 (80064) Chair, Folding, Metal; AA-C-291 (81348) Chair, Straight, W/Arms; Aa-C-293 (81348) Chisel, Cape, 1/4"x 6 3/4" GGG-C-313 (81348) Chisel, Cold, 3/4" x 6 1/2" GGG-C-313 (81348) Chisel, Cold, 1" x 8" GGG-C-313 (81348) Chisel, Half Round, 1/4" x 5 1/2" GGG-C-313 (81348) Chisel, Power Hammer GGG-C-330 (81348) Chronometer, Size 35, C-2536 (81349) Chronometer Case, U/W Size 400F533787A (80064) Clamp, "C", Heavy Duty, 4", GGG-C-401 TRype 1 Class A (81348) Clock, Marine, Mech. 8 Day, 6" Dial, 12 Hr C-1 194 (81349) Coffee Maker Set, MIL-C-28515 (81349) Colander, 11QT; RR-K-260 (81348) Connector, Receptacle, electrical; Cover, Can, Ash & Garbage; 10 gal RR-C-82 (81348) Cover, Can Ash & Garbage, 24 gal; RR-C-83 (81348) Cover, Can Ash & Garbage, 32 gal; RR-C-82 (81348) Cover, Mattress; DDDC-628 (81348) Counter, Rotary, 0-5000 RPM, 107(57163) Cruet, Condiment: DD-T-101 (81348) Cup, Drinking, Plast, 10 oz LT-148 (81348) Cutter, Bolt; 36 Ig. GGG-C-740 (81348) Cutter, Pipe: 1/8to 2"; GGG-C-771 (81348) Cutter, Wire Rope, HYD, Hand; GGG-C-800 (81348) Cutter & Flaring Set, tubing; GG-C-744 (81348) Desk, Flat Top, AA-D-1 91 81348) Die & Tap Set, Thread Cutting, NC, GGG-T-330 (81348) Die & Tap Set, Thread Cutting, NF, GGG-T-330 (81348) Dipper, Kitchen; RR-D-400 (81348) Dishpan, Round, RR-D-450 (81348) Dispenser, Sugar; 12 oz; DD-T-101 (81348) Divider, Mechanics, O-ring; GGG-D-351 (81348) Divider Set, Navigation, S-2407H533623 (80064) Double Broiler, 3 qt.; RR-B-500 (81348) Double Broiler, 8 qt.; RR-B-500 81348) Double Broiler, 11 qt.; RR-B-500 (81348) Drill, Electric 3/8", AC/DC WD-661 (81348) Drill, Electric 1/2", AC/DC WD-00661 (81348) Drill Set, Twist, 29 EA GGG-C-751 Type 2 Class A (81348) Drilling Machine, Upright; MIL-D-80038 (81349) Ega Beater, 11 5/8" LG; RRE-300 (81348) Extnguisher, Fire, CO2 5 lb., 0-E-910 (81348) Extinguisher, Fire CO215 lb., 0-E-910 (81348) Fan, Circulating, Bracket, 115 VDC 12" Dia. Fender, Marine: 5" x 24" Fendaire (81348) Filing Cabinet, Steel, 5 Drawer Change 6 B-3 U/I QTY EA EA SE EA DZ EA EA EA EA FT EA EA EA EA EA EA EA FT FT EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA SE EA SE SE EA EA EA EA SE EA EA EA EA EA SE EA EA EA EA EA EA EA 2 32 1 1 2 1 1 1 1 75 1 1 2 2 1 2 1 630 630 6 2 1 1 1 1 2 1 1 2 1 2 2 1 2 1 2 32 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 4 8 10 6 1 TM 55-1925-204-12 Section III (Continued) BASIC ISSUE ITEMS LIST (BIIL) NSN 8345-00-935-0445 8345-00-926-6803 8345-00-935-0446 8345-00-926-6805 8345-00-935-0447 8345-00-926-9218 8345-00-926-9987 8345-00-935-0448 8345-00-935-0449 8345-00-926-6810 8345-00-926-9988 8345-00-935-0450 8345-00-935-0444 8345-00-926-6001 8345-00-935-0451 8345-00-935-0452 8345-00-935-0453 8345-00-926-6812 8345-00-926-0454 8345-00-926-6002 8345-00-926-6814 8345-00-935-0455 8345-00-935-0456 8345-00-926-6004 8345-00-935-0457 8345-00-935-0458 8345-00-656-1446 8345-00-656-1434 8345-00-375-0221 8345-00-935-3120 8230-00-264-8261 9150-01-131-3323 9150-01-131-3324 9150-01-131-3325 7330-00-634-4653 7340-00-223-7791 7340-00-241-8169 7240-00-230-2416 7240-00-527-9868 7240-00-233-4482 4240-00-052-3776 2040-00-238-9060 7330-00-243-3418 3415-00-243-1456 4930-00-287-5419 5120-00-892-5485 5120-00-224-4111 5120-00-203-4656 5130-00-190-6442 5120-00-243-2957 3950-00-937-7978 2040-00-268-9250 4720-00-293-7874 4720-00-202-6482 4720-00-288-8532 4210-00-202-8188 4210-00-078-9170 7310-00-702-7025 6545-00-922-1200 6545-00-168-6893 7340-00-223-7771 7340-00-223-7769 7340-00-223-7766 DESCRIPTION Flag "A" size 6; F-2692 (81349) Flag "B" size 6; F-2692 (81349) Flag "C" size 6; F-2692 (81349) Flag "D" size 6; F-2692 (81349) Flag "E" size 6; F-2692 (81349) Flag "F" size 6; F-2692 (81349) Flag "G" size 6; F-2692 (81349) Flag "H" size 6; F-2692 (81349) Flag "I" size 6; F-2692 (81349) Flag "J" size 6; F-2692 (81349) Flag "K" size 6; F-2692 (81349) Flag "L" size 6; F-2692 (81349) Flag "M" size 6; F-2692 (81349) Flag "N" size 6; F-2692 (81349) Flag "O" size 6; F-2692 (81349) Flag "P" size 6; F-2692(81349) Flag "Q" size 6; F-2692 (81349) Flag "R" size 6; F-2692 (81349) Flag "S" size 6; F-2692 (81349) Flag "T" size 6; F-2692 (81349) Flag "U" size 6; F-2692 (81349) Flag "V" size 6; F-2692 (81349) Flag "W" size 6; F-2692 (81349) Flag "X" size 6; F-2692 (81349) Flag "Y" size 6; F-2692 (81349) Flag "Z" size 6; F-2692 (81349) Flag, National: Union Jack: 1'10" x 2'8"; DDD-F-416 (81348) Flag, National: U.S.; 2'4" x 4'6"; DDD-F-416 (81348) Flag Set: semaphore; M113; F-40055 (81349) Flag Transportation Corps MIL-F-26 (81349) Flashlight Fluid, Hydraulic, MIL-H-46170B Fluid, Hydraulic, MIL-H-46170B Fluid, Hydraulic, MIL-H-46170B Food Turner: 8 in.; F-21662 (81349) Fork, Food Preparation: 15 in. Ig; MULU-1081.5 (81349) Fork, Table: plain; 24 per box; RR-F-450 (81348) Funnel: 1/2 qt; w/spout; F-1 0814 (81349) Funnel: 1 qt; wistrainer; RR-F-800 (81348) Funnel: 1 gal; galvanized; F-10814 (81349) Goggles: plastic; safety; GG-G-531 Grapnel, Marine: 15 lb; G-613 (81349) Griddle Plate: 13 1/2 x 25"; RR-G-681 (81348) Grinder: bench mtd; elec, dc; 1/3 hp; W-G-656 (81348) Gun, Fluid,-Direct Delivery: 30 oz; GGG-0-591 (81348) Hammer, Carpenter: 1 lb; GGG-H-86 (81348) Hammer, Hand: 1 lb; GGG-H-86 (81348) Hammer, Hand: 3 lb; GGG-H-86 (81348) Hammer, Pneumatic: portable; DD-H-1 16 (81348) Hammer, Sledge: 10 lb; GGG-H-86 (81348) Hoist, Lever and Ratchet: 1,000 lb. 515-8521-001 (93601) Hook, Boat, Wood 10'; H3496 (81349) Hose Assembly: nonmetallic; 1/2 x 50'; ZZ-H-500 (81348) Hose Assembly: nonmetallic; 3/4" x 50'; ZZ-H-611 (81348) Hose Assembly: nonmetallic; 1 1/2" x 50'; ZZ-H-601 (81348) Hose, Fire, Cotton, Ruber 2 1/2" x 50'; ZZ-H-451 (81348) Hose, Fire, Polyester Fiber 1 1/2" x 50'; ZZ-H-451 (81348) Hot Plate, 2 Burner, AC/DC WH-640 (81348) Kit, First Aid, 12 Unit Kit, First Aid, Life Raft Knife, Cook's 12 in; GGG-C-746 (81348) Knife, Paring: 3 1/2"; GGG-C-746 (81348) Knife, Slicing GGG-C-746 (81348) B-4 Change 6 U/I QTY EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA SE EA EA EA EA EA EA EA BX EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 qt 1 gal 5 al 2 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 2 2 2 2 2 4 2 1 2 2 1 1 1 TM 55-1925-204-12 Section III (Continued BASIC ISSUE ITEMS LIST (BIIL) NSN 7340-00-291-0625 7340-00-060-6057 7340-00-241-8170 7330-00-248-1153 6230-00-783-6252 4940-00-384-0466 4220-00-200-0538 1940-00-204-3894 1095-00-270-6019 6230-00-255-0166 6230-00-782-0643 6220-00-224-6237 6620-00-553-1125 6620-00-553-1123 6530-00-783-7810 7125-00-680-2764 4930-00-223-3379 4930-00-253-2478 4930-00-223-3389 1370-01-074-0591 6850-00-270-9986 5120-00-221-2731 5120-00-224-9443 7210-00-531-6476 7210-00-530-3730 7210-00-205-3585 7240-00-233-6013 7240-00-233-6025 8465-00-238-3344 4210-00-287-1948 4210-00-288-6857 4210-00-274-8545 6625-00-241-9979 4930-00-266-9182 4930-00-262-8868 7330-00-205-3151 7240-00-160-0455 7330-00-205-3164 7330-00-485-9672 7330-00-205-3150 7330-00-238-3805 7330-00-238-8316 8345-00-935-0495 8345-00-935-0401 8345-00-926-6023 8345-00-935-0490 8345-00-935-0491 8345-00-935-0492 8345-00-935-0493 8345-00-926-9214 8345-00-935-0494 8345-00-935-0405 7210-00-268-8675 7210-00-292-2326 1095-00-726-5820 7350-00-195-4763 7350-00-249-5165 5120-00-239-8251 7330-00-245-1224 7330-00-205-4146 DESCRIPTION Knife, Steak Scimitar: 10 in; GGG-C-746 (81348) Knife, Steak: table; RR-F-450 (81348) Knife, Table: RR-F-450 (81348) Ladle, Kitchen: 8 oz; U-1 0815(81349) Lantern, Electric, 6V, wlrelay 1500 (81349) Leak Detector, Refrigerant Gas Prestolite 18R17 (36346) Life Preserver, Vest, Adult MIL-L-18045 (81347) Life Raft, 15-Man Line, Throwing Device; MIL-L-45505A, Type 2 (81349) Light Marker, Distress: life jacket; L-573 Type II, Class 1 (81349) Light Marker, Distress, Rail, 815119724, Symbol 289 (80064) Light, Nav. Clear, Emergency Light, Nav. Red, Emergency; 1008 (46576) Light, Nav. Green, Emergency, 1008 (46576) Litter, Stokes, Rigid; L117 (81349) Locker, clothing; steel, 18"w, 78"h, 24" deep; Lubricating Gun: hand; 9 oz; Lubricating Gun: hand; 16 oz; G-3859 (81349) Lubricating Gun: hand; 28 oz; 7556 (57733) Marker, Location Marine, MK58 MOD1, P/N 3139741 (10001) Marker, Sea Fluorescent, MIL-S-17980 (81349) Marline spike: 8 in; M-1 5926 (81349) Marline spoke: 14 in; M-1 5926 (81349) Mattress, Bed; Cotton Felt; 4 x 26 x 72 1/2, VM-81 (81348) Mattress, Bed, Cotton Felt, 4 x 31 x 78, VM-81 (81348) Mattress, Bed, Inner Spring, VM-96 (81348) Measure, Liquid; 1 Qt; RR-M-190(81348) Measure, Liquid; 1 gal; RR-M-190 (81348) MegaPhone, Hand; 18" M-1263 (81348) Nozzle, Hose, Foam 1 1/2, MIL-N-12279 (81349) Nozzle, Fire Hose, 1 1/2", 3 Position MS39110-2 (96906) Nozzle, Fire Hose, 2 1/2", 3 Position MS39110-3 (96906* Ohmmeter: 0 to 1000 meg ohms resistance; AM-21 B/U (80058) Oiler, Hand; 8 oz; GG-O-591 (81348) Oiler, Hand: flexible spout; 1 pt; GGG-O-591 (81348) Opener, Can, MTD, FF-0-601 (81348) Pail, Utility, Metal, 3 1/2 Gal, RR-P-30 (81348) Pan, Baking & Roasting, 13 1/4 x 9 1/2 x 2 1/4, RR-P-54 (81348) Pan, Baking & Roasting, 24 x 12 x 3 P3852 (81349) Pan, Cake, Round, 9" Dia 1 3/8 Deep 12 in. Box RR-P-62 (81348) Pan, Frying, 18" RR-P-89 (81348) Peeler, Potato, P-20583 (81348) Pennant: signal "0"; F-2692 (81349) Pennant: signal "1 "; F-2692 (81349) Pennant: signal "2"; F-2692 (81349) Pennant: signal "3"; F-2692 (81349) Pennant: signal "4"; F-2692 (81349) Pennant: signal "5"; F-2692 (81349) Pennant: signal "6"; F-2692 (81349) Pennant: signal "7"; F-2692 (81349) Pennant: signal "8"; F-2692 (81349) Pennant: signal "9"; F-2692 (81349) Pillow, Bed VP-356 (81348) Pillowcase, Bed DDD-P-351 (81348) Pistol, Pyrotechnic, AN-MB 247642 (10001) Pitcher, Syrup, 20 Oz. DD-T-101 (81348) Pitcher, Water 2 Qt RR-P-386 (81348) Pliers, Lineman 8 in. GGG-P-471 (81348) Pot, Cooking, 6 qt w/cover; C-1 588 (91349) Pot, Cooking, 14 qt w/cover; RR-B-500 (81348) Change 6 B-5 U/I QTY EA BX BX EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA BX EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA 1 1 1 2 6 1 16 2 1 1 6 4 4 4 1 12 1 1 1 2 1 1 1 12 4 4 1 1 1 1 2 2 1 1 1 1 4 4 2 1 2 2 1 1 1 1 1 1 1 1 1 1 16 32 1 2 2 1 2 1 TM 55-1925-204-12 Section III (Continued BASIC ISSUE ITEMS LIST (BIIL) NSN 7330-00-263-8505 6675-00-191-1514 5120-00-245-2776 5120-00-595-9305 5110-00-449-7313 4930-00-263-9886 4240-00-368-6149 2040-00-288-2866 4220-00-275-3157 6675-00-191-1509 5130-00-857-8526 7330-00-240-2134 7330-00-240-2137 7330-00-153-9760 4120-00-832-6219 5120-00-293-3309 2040-00-222-3729 6605-00-224-7735 7350-00-641-8951 7350-00-240-7068 7350-00-641-8950 7350-00-240-7069 8345-00-174-0453 8345-00-264-6081 8345-00-276-9516 8345-00-285-5963 8345-00-285-5962 7520-00-162-6178 5110-00-161-6909 5110-00-221-1085 7210-00-171-1099 7331-00-184-0089 1370-00-629-2336 5850-00-407-6671 3439-00-930-1638 7330-00-254-4791 7340-00-223-7800 7340-00-241-8171 7340-00-240-7080 7340-00-205-1421 7340-00-205-3341 7340-00-205-3340 5110-00-634-8596 7110-00-634-8596 6645-00-250-4680 7520-00-298-7043 6680-00-242-9229 5210-00-221-1882 5210-00-526-0752 6630-00-074-0394 6630-00-531-1968 6630-00-171-5126 4910-00-379-0376 6625-00-132-1196 6685-00-276-0071 (81348) 6685-00-255-9981 5180-00-357-7514 5180-00-926-3552 5180-00-629-9783 5180-00-356-4614 7310-00-272-7891 7330-00-616-0997 3433-00-264-6206 DESCRIPTION Pot, Cooking, 24 qt w/cover; RR-B-400 (81348) Protractor: plastic, 3 arm, JAN P-90 (81350) Puller, Fuse, no 3, P-1 8488 (81349) Puller, Mechanical gear, 0 to 8 in, P-1 8488 (81349) Punch Set: gasket cutting; HP7 (45225) Pump, Dispensing, Hand: rotary; F-152 (61178) Respirator; Air Filter: R-3308 (81349) Ratguard; Galv. 2 x 36", MIL-G-2767 (81349) Ring Buoy, Floating, 30" OD w/line MIL-R-16847 (81349) Rule, Parallel: 18 in., navigators; GG-R-118(81348) Sander, Disc, Electric, Portable: ac/dc; 00-S-90 (81348) Saucepan: 2 qt; w/cover; S-40044 (81349) Saucepan: 7 1/2 qt; w/cover; S-40044 (81349) Scoop, Kitchen: RR-S-131(81348) Screwdriver, Dross Tip: 8 in.; KP 2B (11728) Screwdriver, Flat Tip: 10 in.; RR-S-121 (81348) Sea Anchor: 36 x 7Oin.; MM-1-562 (81348) Sextant, Marine: S-2387 (81349) Shaker, Pepper: 3 oz; DD-T-101 (81348) Shaker, Pepper: 6 oz; RR-K-260 (81348) Shaker, Salt: 3 oz; DD-T-101 (81348) Shaker, Salt: 6 oz; S-1979(81349) Shape, Day, Maritime: ball; black; S-7003-921620 (80064) Shape, Day, Maritime; ball; black & white, MIL-S-29108 (81349) Shape, Day, Maritime, ball, black & red S-7003-921620 (80064) Shape, Day, Maritime, Black & White, Horiz, CG169 (81340) Shape, Day, Maritime, Double, Frustrum, Red CG169(81340) Sharpener, Pencil: F-S-58 (81348) Shears, General Purpose: GGG-S-278 (81348) Shears, Metal cutting, straight cut, GGG-S-291 (81348) Sheet, Bed: DDD-S-182 (81348) Sifter, Flour: RR-S-345 (81348) Signal, Illumination, ground, red star, parachute, M126A1 P/N 8797968(19203) Signal Lamp: Aldis type; SE-11 (80063) Soldering Gun: elec; trigger operated; 450 (11103) Spatula, Steel: 14 in; GGG-C-746 (81348) Spoon, Basting: 21 in; U-10815(81349) Spoon, Dessert: 24 in box; RR-F-450 (81348) Spoon, Food Service: 15 in. RR-S-617 (81348) Spoon, Slotted: serving: RR-S-617(81348) Spoon, Table: cres; 24 in box; RR-F-450 (81348) Spoon, Tea: cres; 24 in box; RR-F-450 (81348) Stamp set, Metal, Numbering 1/4" 1-9 Stool, Revolving: wood; AA-S-700 (81348) Stop Watch: 60 sec dial; I gg-S-164(81348) Stencil Sert: marking letters; 1 in; RR-S-714 (81348) Tachometer, Mechanical: 107 (37163) Tape, Measuring; 3/4" x 100'; GGg-T-106 (81348) Tape, Tank: measuring; 50 ft; 14075(37163) Test Kit, Chromate: 121 H (71881) Test Kit, Oil Condition: T-19467 (81349) Tester, Battery, Electrolyte Solution: GG-T-258 (81348) Tester, Cyl Comp Tester, Electric Thermometer, Self-Indicating, Liquid-In-Glass: meat; GG-T-315 EA Thermometer, Self-indicating, Liquid-In-Glass; oven; GG-T-351 (81348) Threading Set, Pipe: 1/8 to 1 in; GGg-T-581 (81348) Tool Kit, Air Conditioner: SC 5180-97-CL-E49 (19097) Tool Kit, General Mechanic: marine; SC 5180-97-CL-E28 (19099) Tool Kit, radio: TK-61-SR (88058) Toaster, Electric: ac/dc; 4 slice; W-T-550 (81348) Tongs, Food Serving: T-40097 (81349) Torch Outfit, Oxygen-Acetylene: SM9-4-3433-A06 (00000) B-6 Change 6 U/I QTY EA EA EA EA SE EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA 1 1 1. 1 1 1 2 6 6 1 1 2 2 2 1 1 1 1 2 1 2 1 2 1 1 1 1 2 2 2 64 1 12 EA EA EA EA BX EA EA BX BX SE EA EA SE EA EA EA EA EA EA EA EA 1 1 1 1 1 2 2 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 EA SE SE EA EA EA EA SE 1 1 1 1 1 1 1 TM 55-1925-204-12 Section III BASIC ISSUE ITEMS LIST (BIIL) NSN Description U/I Qty 3439-00-542-0531 Torch Kit, Soldering: LP.: JT25(70785) EA 1 7350-00-195-7334 Tray, Mess. Compartmented: T-46 (81349) EA 10 7350-00-823-7301 Tray, Service, plastic: T-43259 (81349) EA 2 6675-00-190-5867 Triangle, Plastic, 30 to 60 Dog. 10 In. Lg; GG-T-671 (81348) EA 2 6675-00-190-5862 Triangle, Plastic, 45 Deg. 8 In. Lg. GGT-671 (81348) EA 2 7350-00-680-0645 Tumbler, Plastic, 8 Oz., 12 In. Box, L-T-800 (81348) DZ 2 7430-00-254-4321 Typewritier, non-portable, 11 In. Carriage EA 1 5120-00-221-1117 Vise, Machinist's; 5 In. Jaw: GGGV-410 (81348) EA 1 6625-00-519-2499 Voltmeter: Portable; DC; MR53W750DCW (81 349) EA 1 6605-00-273-6985 Weight, Sounding; 7 LB.: S-3717 (81349) EA 1 8465-00-254-8803 Whistle, Ball w/Lanyard; W-1 053 (81349) EA 16 5120-00-277-1484 Wrench, Pipe: Adjustable; 8 In.; GGG-W-651 (81348) EA 2 5120-00-277-1486 Wrench, Pipe: Adjustable; 14 In.; GGG-W-651 (81348) EA 2 5120-00-277-1461 Wrench, Pipe: Adjustable, 18 In.; GGG-W-651 (81348) EA 2 5120-00-277-1462 Wrench, Pipe: Adjustable, 24 In.; GGG-W-651 (81348) EA 2 5120-00-293-0316 Wrench, spanner, 1 1/2" to 3", GGG-W-665 (81348) EA 6 7920-00-579-8484 Wringer, Mop w/Bucket, RRR-M-1075 (81348) EA 2 Change 7 B-7 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN Description U/I Oty *Air Compressor, Quincy Md 1 D340 3030-00-246-0194 Belts, V; Matched set of 3 8B5-3 (78323) SE 1 5977-00-413-2045 Brush, Electrical, contack; 10131 (213810) EA 4 4820-00-148-5511 Diaphragm. Compressor; Assembly 1823AX (49576) EA 1 4310-00-375-2543 Ring Set, Piston: H.P. 4425STD (49576) EA 1 I 4310-00-871-2306 Ring Set, Piston: L.P. 4405STD (49576) EA 1 5945-00-417-9952 Tip, Contact, Main Line: 129-13 (53635) Engine, Detroit Diesel Model 4061 A EA 2 5340-00-363-8200 Anode, Heat Exchanger: 8515850 (27462) EA 2 3120-00-662-8425 Bearing, Sleeve: Connecting Rod; 5192895 (72582) EA 1 3120-00-663-8992 Bearing, Half Set Sleeve: Crankshaft Main; 5192874 (72582) EA 1 3120-00-517-8329 Bearing, Sleeve: Piston Pin, Connecting Rod; 5125248 (72582) EA 2 3030-00-288-3572 Belt, V: Generator Drive; 5155911 (72582) EA 2 5977-00-391-0635 Brush, Battery: Charging Generator; 1906911 (16764) EA 2 5977-00-237-1596 Brush, Electric; Motor; 1906906 (89619) EA 4 2910-00-377-5548 Filter, Element, Fuel Fitlter: 5573261 (70040) EA 4 2940-00-141-9026 Filter, Element, Lubricating Oil Filter: N50 (81321) EA 4 5330-00-383-4041 Gasket: Oil Cooler, Inner; 5150155 (72582) EA 1 5330-01-117-5877 Gasket: Oil Cooler, Outer; 5154215 (72582) EA 1 5330-00-354-3768 Gasket: Oil Cooler, Lower; 5112401 (72585) Gasket: Oil Cooler, Upper; 5159447 (72585) EA 2 EA 1 2930-00-363-8178 B-8 Change 7 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN Description U/I Qty 5330-00-363-8659 Gasket: Valve Rocker Cover; 5150328 (72582) EA 2 2815-00-379-4302 Gasket Set: Cylinder Head; 5193117 (72582) EA 1 5330-00-841-5964 Gasket Set: Oil Filter Cover Nut; 5574130 (70040) EA 2 2930-00-767-0508 Kit, Impeller and Seal: 5194860 (725820) EA 1 5330-00-354-1235 Packing, Preformed: Fresh Water Pump Inlet 5159457 (72582) EA 1 5330-00-030-3219 Packing Material: Priming Pump 25-9-7 (34294) EA 2 2910-00-698-2936 Parts Kit, Injector Tip: 5228213 (72582) EA 1 2815-00-362-9385 Retainer, Spring: Exhaust Valve 5150291 (72582) EA 2 2815-00-288-0695 Ring Set, Piston: compression, Cornplete for 1 Piston; 5193477 (72582) EA 1 5330-00-588-5359 Seal, Plain: Raw Water Pump Bearing, 5195101 (72582) EA 1 5330-00-579-6799 Seal, Plain: Raw Water Pump Bearing, Small: 5195020 (72582) EA 1 5330-00-154-5358 Seal, Plain: Encased Crankshaft Oil NT7770PC5 (72915) EA 1 5330-00-282-5906 Seal, Plain: Encased Crankshaft Oil, Rear; 5114335 (72582) EA 1 5360-00-249-5903 Spring, Helical: Battery Charging Generator Brush, 1910033 (16764) EA 2 5360-00-664-4216 Spring, Helical: Compression Exhaust Valve; 5150289 (72582) EA 2 5360-00-597-3278 Spring, Helical: Starting Motor Brush; 8D064 (04741) EA 2 6620-00-277-3497 Thermostat, Flow Control: 5172141 (72582) EA 1 2815-00-127-3055 Valve, Oil Pump, Relief: 515324 (72582) EA 2 Valve, Poppet Engine: Exhaust w/Locks; 5193666 (72582) EA 2 EA 8 2815-00-516-5915 Generator Set Delco Model 1-3644 5977-00-232-5335 Brush, Electrical Contact 5367065 (72560) Change 7 B-9 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN 5360-00-366-3873 Description Spring, Helical Torsion Holder Brush 5310593 (72560) U/I Qty EA 4 Fire and Salvage Pump Patterson Model 4LSBB 3120-00-287-8594 Bearing, Sleeve L.H. 25854LH (55139) EA 1 4320-00-379-0232 Ring, Pump Case Bronze 25852 (65177) EA 2 4320-00-379-2034 Sleeve, Pump RH 1315-27RH (65177) EA 1 Bilge and Gallast Pump Fairbanks Morse Co. Fig. 5531 3110-00-144-8519 Bearing, Ball: Commutator End A058996 (58275) EA 1 3110-00-293-9302 Bearing, Ball: Drive End; 03003-000 (21335) EA 1 3110-00-112-4711 Bearing, Ball Annual Inner; 1104KL (21335) EA 1 3110-00-227-3824 Bearing, Ball Annual Outer; N104KL (21335) EA 1 3030-00-529-0359 Belt, V; Priming Pump Drive; A68 (24161) EA 1 5877-00-228-7935 Brush, Electrical Contact: Motor; 17068 (21387) EA 4 5970-00-950-9840 Bushing, Electrical: Brush Holder Stud 19751 (21387) EA 4 4320-00-366-7738 Gasket; Priming Pump, Body; D5632XP (42280) EA 1 4320-00-379-2042 Gasket; Priming Pump, Lobe; D8963XP (42280) EA 1 5330-00-379-2060 Gasket; Pump, Impeller screw; T3A3-9B (10613) EA 1 4320-00-417-9696 Packing; Priming Pump; PK234 (42280) EA 2 4320-00-379-2061 Shaft, Impeller: Pump, Ind. Sleeve; T3A4W (21387) EA 1 6110-00-312-5200 Spring, Helical: Armature Return; 374DlOX1 (56365) EA 2 6110-00-312-5190 Spring, Helical: Contact Block; 1855X13 (56365) EA 1 6110-00-200-7000 Spring, Helical: Pneumatic Timer; 2055X26 (56325) EA 1 B-10 Change 7 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS 5360-00-312-5191 Spring, Helical: Movable Contact, 1864X13 (56365) EA 1 6110-00-413-2445 Contact Electrical: Stationary Contact; 1475X41(53635) EA 2 6110-00-312-5189 Spring, Helical: Tail; 1476X18 (81487) EA 1 5360-00-347-2510 Spring, Helical: Torsion; E38902-2 (21387) EA 1 Capstan New Englans Trawler Model R6293 5930-00-379-2226 Contact, Electrical, Movable D6325-14 (76727) EA 2 5930-00-379-2227 Contact, Electrical, Stationary D6325-13 (76727) EA 3 5905-00-379-2228 Resistor, Tube Heater D6323-55 (76727) EA 1 1 Engine, Diesel Fairbanks Morse Co. Model 37P16 2815-00-362-5768 Cartridge, starting: 50 per box; 16FM117C (21387) EA 2815-00-362-5790 Cartridge, Holder: YLA-3093A (21387) EA 2940-00-493-2496 Filter, element, Cellulose: 6826-818-33 (13800) EA 6 2940-00-460-3222 Filter, Element, Fuel Oil: 1116GFIR14GW BM 33286 (15434) EA 2 4330-00-081-2119 Filter, Element, Granite: 6825-818-88 (13800 EA 6 2910-00-765-0322 Filter, Injector: YLA 351C (21387) EA 1 2815-00-362-6388 Gasket: Air Starting, Bottom; YLA1 549C (21387) EA 1 5330-00-362-6394 Gasket: Air Starting, Cage, YLA5877B (21387) EA 1 2815-00-673-2174 Gasket: Air Starting, Cage/Bushing;: YLA1645B (21387) EA 1 5330-00-362-6415 Gasket: Camshaft Housing, Large YLA3532B (21387) EA 1 5330-00-362-6416 Gasket: Gear Housing Cover; YLA3533B (21387) EA 1 5330-00-362-6419 Gasket: Camshaft Housing, Breather Cover; YLA4586B (21387) EA 1 Change 7 B-10.1 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN Description U/I Qty 5330-00-362-6417 Gasket: Camshaft Housing, cover to Cam Gear Cover; YLA4112B (21387) EA 1 5330-00-362-6418 Gasket: Camshaft Housing, to Gear Housing: YLA4113B (21387) EA 1 5330-00-362-6390 Gasket: Relief Valve, Cage: LYA290A (21387) EA 1 5330-00-362-6391 Gasket: Relief Valve, Cover; YLA4059A (21387) EA 1 5330-00-362-6361 Gasket: Crankshaft, Cover; YLA1991 A (21387) EA 2 2815-00-362-5778 Gasket: Core Hole Cover; YLA4067A EA 2 2815-00-362-6400 Gasket: to Cylinder; YLA632A (21387) EA 1 2815-00-363-1407 Gasket: Head, Cooling Water Pipe; YK213C (21387) EA 2 2910-00-362-6255 Gasket: Fuel Injector, Spring Housing; YLA6184B (21387) EA 2 2910-00-362-6252 Gasket: Fuel Injector, Tip; YLA6178D (21387) EA 2 5330-00-773-1855 Gasket: Fuel Filter, Bag; 1116KR1R (44256) EA 2 2940-00-202-2349 Gasket: Fuel Oil Filter, Cover; 111 5Y11 R (44256) EA 2 5330-00-362-6542 Gasket: Fuel; Oil Supply Pump Bracket; Y8LA4447B (21387) EA 1 5330-00-362-6538 Gasket: Fuel Oil, 0.002 In. Thick; RAC157A (21387) EA 2 5330-00-455-7091 Gasket: Fuel Oil, 0.005 In. Thick, RAC157B (21387) EA 1 5330-00-362-6539 Gasket: Fuel Oil, 0.0015 In. thick, RAC157C (21387) EA 1 5330-00-362-6540 Gasket: Fuel Oil Supply Pump Suction and Discharge; RBC15 (21387) EA 2 2815-00-362-6392 Gasket: Handhole Cover; YLA407B (21387) EA 4 5330-00-362-6251 Gasket: Injector Nozzle, Fuel Filter; 16103825 (21387) EA 2 5330-00-363-4905 Gasket: Lubricating Filter Lid; 10912 (13800) EA 1 2815-00-376-1068 Gasket: Oil Pump, Bearing Plate; C7JB1097A (21387) EA 1 B-10.2 Change 7 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN Description U/I Qty 2990-00-362-6592 Gasket: Oil Pump, Cover: CJB3851A (21387) EA 1 5330-00-362-6366 Gasket: Piston Cooling Pipe; YLA4043B (21387) EA 1 5330-00-375-4188 Gasket: Safety Valve Cage Fitting Plug; CADD8682A (82796 EA 2 2910-00-217-0200 Injector Assembly, Fuel: Incl Tip; NR201YLAGNE (82796) EA 2 2910-00-509-8257 Needle Injection Valve: Fuel; w/Sleeve; 16106108 (21387) EA 2 5330-00-362-6218 Packing: Manifold Stuffing Box; CKB1332A (21387) EA 4 5330-00-365-1868 Packing, Preformed: Fuel Oil Filter; 1116ZA1R (44256) EA 1 5340-00-362-0449 Protector: Heat Exchanger, Zinc 4Z3R106 (51900) EA 2 2815-00-343-2626 Ring, Cylinders: Piston Scrapper YLA4025 (21387) EA 3 2815-00-362-6376 Ring, Piston: Compression and Oil; YLA8T (21387) EA 5 5330-00-363-2123 Seal: Fuel Oil Supply Pump; RBC119A (21387) EA 1 5330-00-449-4263 Seal: Oil, Shaft; 15024 (54641) EA 1 5330-00-362-6403 Spring, Helical, Compression Relief Valve: YLA1455A (21387) EA 1 2910-00-377-2357 Tank, Fuel Noxxle: Injector; YLA204N (21387) EA 2 4710-00-451-2734 Tube, Water, Cooling: Cylinder to Head; YLA212A (21387) EA 2 5310-00-595-7709 Washer: Spring Tension, Fuel Injector Nozzle Body: QQ-C-576, Annealed EA 4 YJA6382A (21387) Pump Fairbanks Morse Co. Fig. 5874 5977-00-097-0685 Brush, Electrical Contact: Motor 10120SOS4508 (21387) EA 4 5330-00-030-3194 Gasket: Pump, Impeller; G2A166al (21387) EA 2 5330-00-030-3193 Gasket: Pump Casing; G2A157C (21387) EA 1 Change 7 B-10.3 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN Description U/I Qty 4320-00-034-8277 Impeller, Pump: G2A1G (21387) EA 1 4320-00-034-8280 Ring, Water Seal: 14M10A (21387) Fresh and Salt Water Standby Pump Fairbanks Morse Co. Fig. 5532 EA 4 5977-00-413-2045 Brush, Electrical Contact: Motor EA10131 (21387) EA 4 5330-00-366-8527 Gasket: Pump, Impeller shaft Sleeve; T4B166A (21387) EA 1 4320-00-797-3665 Impeller, Pump: C3B1H (21387) EA 1 4320-00-417-9252 Seal; Grease: Pump Bearing; N05J (21387) EA 2 4320-00-600-3299 Shaft, Impeller, Pump: Incl T4B4AQ (21387) EA 1 Fuel Oil Transfer Pump DeLaval Steam Tubin Co, Model A313A143 4320-00-114-0967 Gasket:Pump, End Cover; S1123AV (16712) EA 1 5330-00-599-0711 Packing, Preformed: Pump, Oil Seal; S1123AW (167120 EA 1 5977-00-280-4673 Brush, Electrical Contact SP54637 (95402) EA 2 5330-00-097-4241 Seal: Pump, Inner; S1146A (16712) EA 1 5330-00-179-0890 Seal: Oil Pump, Outer; N051X215 (73680) EA 1 Heating Boiler Crane Co. Model SO-30-9 5977-00-090-1421 Brush, Electrical: Motor, DC; SA681-2 (35662) EA 2 4530-00-030-3113 Electrode, Oil Burner; Ignition; 50291 (14959) EA 2 4530-00-034-8101 Nozzle, Oil Burner, Pressure: 52631 (14959) EA 1 Boiler Heating Way-Wolff Model 4536-12E 5977-00-538-6818 Electrode Set (49937) Ml 05-1 EA 2 4330-00-277-3273 Filter, Element, Fluid, Pressure 2230F1 (15472) EA 1 B-10.4 Change7 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN Description U/I Qty 5330-00-641-4108 Gasket: Fuel Filter: Head Unit A7-213-042 (1542) EA 1 5330-00-375-3334 Gasket: Fuel Filter: Head to Sump A28-213-040 (15472) EA 1 5330-00-593-2428 Gasket: Fuel Pump Strainer Cover P1873 (64294) EA 1 4730-00-097-0530 Nozzle: w/ilp and Strainer 40X 45DEG (49937) EA 1 Lubricating Oil Purifier DeLaval Separator Co. Model 45-28 4330-00-319-4769 Block Wood, Friction, Clutch; 14989 (71871) EA 4 5977-00-391-2231 Brush, Electrical: 8100097ABP9 (03511 ) EA 2 4330-00-709-0698 Element, Filter: Oil, C44PB (73370) EA 6 5330-00-030-3177 Gasket: Filter Cover; 11913 (73370) EA 3 4330-00-859-4160 Gasket: Purifier Bowl, Small; 149813 (71871) EA 1 4330-00-097-4230 Glass, Gage: Slight Oil and Temperature; 18280 (71871) EA 1 2940-00-317-2522 Lining, Brake, Bowl; (71871) EA 1 4330-00-603-4276 Packing, Preformed: Pump Drive; EA 4 4330-00-805-9656 Ring: 4996 (71871) EA 1 5330-00-213-0323 Ring: Inlet Seal; 10853 (71871) EA 2 4330-00-097-5859 Spring, Helical, Compression: Pump EA 2 16699 (71871) Relief Valve; 15818 (71871) Pump, Rotary, Power Driven DeLaval Model A322AX250 5977-00-280-8436 Brush, Electrical Contact: Motor; 54566 (08219) EA 4 5330-00-030-3208 Gasket: Packing Box and Outboard Over; S823EC (16712) EA 2 5905-00-347-3923 Resistor: Controller; Starting S5S200A11 5A3Q000 (89025) EA 1 5977-00-239-9189 Brush, Electrical, Contact: 1/8 H.P. Motor; 54437 (08219) EA 4 5977-00-280-8436 Brush, Electrical, contact 7 1/2 H.P. Motor; 54566 (08219) EA 4 Change 7 B-10.5 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN Description U/I Qty 6105-00-323-9804 Boil, Interpole, Motor: 7 1/2 H.P. 38068-324C4-2 (08219) EA 1 5330-00-626-2038 Gasket: Control Drum Cover: MD16-516A (98523) EA 1 5330-00-305-6627 Gasket: Hydraulic Ran; Pump Flange MD14-257C (98523) EA 1 5330-00-626-2039 Gasket: Hydraulic Ran; Supply Tank Cover Plate; MD12-713B (02128) EA 2 5330-00-078-9767 Packing, Preformed: Ran Cyl; 431 (73680) EA 2 5930-00-296-6673 Switch, Push Button: Start-Stop; 601-2-7 (89025) EA 1 6105-00-049-8139 Winding, Motor field: 7 1/2 H.P. Motor; 39854-324-2 (08219) Ventilating Fan Motors and Controller EA 1 5977-00-422-4640 Brush, Electrical Fan motor; 99542000A (30190) EA 6 5977-00-379-0257 Brush, Electrical Fan Motor; 99602000A (30190) EA 4 Water Pressure Set Deming Model, Fig. 1892 4320-00-073-2127 Gasket, Crankcase Cover 0007223 (16859) EA 1 3030-00-073-3603 Belt, V: Pump Pullery; 0024894 (16859) EA 1 4320-00-073-2139 Valve, Relief; 0004428 (16859) EA 1 4320-00-074-7373 Gasket Set, Pump; 00193212 (15859) EA 1 Windlass New England Trawler Eqp Model D6340 5977-00-280-8346 Brush, Electrical, Contact: Motor; 54566 (08129) EA 4 3950-00-301-5948 Lining, Brake; Hand, w/Rivets B6462-10 (76727) EA 2 3040-00-575-0737 Lining, Fiction: Motor Brake, w/Rivets B6462-10 (76727) EA 2 Miscellaneous Items 2090-00-809-4640 Blade, Windshield Wiper: N56-10 (81100) EA 2 5920-00-252-2018 Fuse, Cartridge: 3AMP, 250 DC; 500 V AC; F15A250V6A (81349) EA 15 B-10.6 Change 7 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN Description U/I Qty 5920-00-686-9548 Fuse, Cartridge: 10 AMP, 250 V. DC; OTM10 (71424) EA 15 5920-00-543-0673 Fuse, Cartridge: 15 AMP, 15 V; F15A250V15A (81349) EA 15 5920-00-263-0621 Fuse, Cartridge: 100 AMP, 150 V; DC; 500 V, AC; F19A250V100A (81349) EA 15 6240-00-143-3049 Lamp, Incandescent: 115 V, DC; CP0002AB 963076) EA 24 6240-00-043-7464 Lamp, Incandescent: Search-Light; 500 2, DC; 500T20-21-115V (08108) EA 1 Special Tools Populsion Engine Fairbanks-Morse Model 37F16 5120-00-362-6619 Drill: Injection Valve Tip Cleaning; YKA4324F (21387) SE 1 2815-00-363-2284 Gauge: Injection Setting; TD2727A (23187) EA 1 5120-00-362-6621 Guide: Connecting Rod, w/Clamp; YLA4353B (21387) EA 1 5120-00-362-6620 Guide; Piston Ring; YLA3693A (21387) EA 1 5120-00-522-2880 Puller: Injection Pump; TD2728B (21387) EA 1 5120-00-363-0956 Wrench, Packing Gland CHB1080A (21398) EA 1 5120-00-415-2378 Wrench, Box, Air Start Pipe; GGGW641 (81348) EA 1 5120-00-363-0960 Wrench, Scavenging Pump; YK400 (21387) EA 1 5120-00-362-6627 Wrench, Cylinder Stud YLA1644A (21387) EA 1 5120-00-219-8400 Remover Valve Spring; J3270 (33287) EA 1 5220-00-387-9581 Injector Timing Gauge (1.460)) J-1 853 (33287) (Not in TM) EA 1 5180-00-219-8407 Tool Set, Fuel Pump; J1508-02 (33287) SE 1 5120-00-152-2420 Wrench; Bowl Coupling; 21930 (71871) EA 1 5120-00-494-1915 Wrench, Cyl Head Stud Nut 1928-01 (33287) EA 1 5120-00-591-2685 Wrench, Fuel Pump: U/O Water Pump; J4242 (33287) EA 1 Change 7 B-10.7 TM 55-1925-204-12 Section IV. COMPONENTS OF END ITEM (COEI) ON-BOARD REPAIR/SPARE PARTS SPECIAL TOOLS NSN Description U/I Qty DeLaval Oil Purifier Tools 4330-00-163-0159 Clamp, Lifting, Bowl Top 7575 (71871) EA 1 5120-00-213-0460 Drift, For Steel Point 3425 (71871) EA 1 4330-00-213-0425 Scoop Cleaning: Bowl Shell 7331 (71871) EA 1 5120-00-670-8085 Wrench, Spanner: Bowl Nut 14943 (71871) B-10.8 Change 7 TM 55-1925204-12 Section V. DAMAGE CONTROL EQUIPMENT NSN Description U/I Qty 5140-00-587-5558 Box, Tool EA 1 5110-00-188-2524 Cutter, Bolt EA 1 5120-00-223-1016 Punch, Drive Pin EA 1 5110-00-277-4592 Blade, Hacksaw BD 1 5110-00-289-9657 Frame, Hacksaw EA 1 5120-00-223-7396 Plier, Slip Joint EA 1 5110-00-228-3161 Hatchet, Half EA 1 5110-00-236-3273 Chisel, Cold, Hand EA 1 5120-00-237-6985 Screwdriver, Flat Tip EA 1 5120-00-222-8852 Screwdriver, Flat Tip EA 1 5120-00-239-8251 Pliers EA 1 5110-00-239-8253 Pliers, Diagonal Cut EA 1 5120-00-277-4244 Wrench, Adjustable, 10" EA 1 5120-00-277-1486 Wrench, Pipe, 14" EA 1 5120-00-270-4309 Wrench, Pipe, 36" EA 1 5110-00-293-0089 Shears, Metal Cutting EA 1 5120-00-293-0665 Bar, Wrecking EA 1 5120-00-224-1390 Bar, Wrecking, Pinchpoint, 1 1/2" X 5' EA 1 5120-00-240-5328 Saw, Hand (Cross Cut, 26") EA 1 4210-00-142-4949 Axe, Fire, Pickhead EA 1 B-11 Change 7 TM 55-1925-204-12 Section V (Continued) DAMAGE CONTROL EQUIPMENT NSN DESCRIPTION U/I QTY EA EA EA LB LB PC PC RL EA 1 1 1 5 5 1 1 1 3 551 0-00-260-8953 5510-00-260-8958 5510-00-260-8962 5510-00-260-8966 5510-00-260-8969 5510-00-260-8949 5510-00-260-8973 Maul, Ships, 5 lb Hammer, Machinists, 2 lb Hammer, Carpenter Nail, Common, 8d Nail, Common, 16d Canvas, 12 ox, 25" x 12' Rubber Sheet, 36" x 6' x 1/8" Marlin Flashlight 3 Cell, Waterproof Plug, Wood Soft Large Small 1" 0" 2" 0" 3" 0" 5" 1" 7" 3" 10" 7" 8" 4" Length 3" 4" 8" 10" 10" 12" 10" EA EA EA EA EA EA EA 10 10 10 10 10 2 5 5510-00-2683479 5510-00-268-3485 5510-00-268-3481 Wedge, Plug, Tapered, Hardwood Thickness Width 2" 2" 4" 2" 3" 3" Length 8" 8" 12" EA EA EA 5 5 5 55100-268-3475 5510-00-2683476 Wedge, Shoring, Tapered, Hardwood Thickness Width 1 1/2" 2" 1 1/2" 3" Length 12" 12" EA EA 5 5 EA EA 5 3 EA EA 2 2 5120-00-255-1476 5120-00-061-8546 Lumber, Shoring (Softwood) 5510-00-220-6178 5510-00-501-7146 4"x4"x8' 2"xlO"xl2' Wedge, Jointing and Breaking 5120-00-224-9486 5120-00-224-9487 3/4"x 1 1/2"x 6' 2" x 2" x 10' PUBLICATIONS LUBRICATION ORDER LO 55-1925-204-12-1 LO 55 LO 55 -2 LO 55 LO 55 -3 LO 55 LO 55 -4 LO 55 -5 -6 -7 -8 TECHNICAL BULLETIN TB TC 11 TB TC 15-15 TB TC 15-17 TBTC 16 TM 55-244-3 TM 55-2943 TM 55-2961-1 TM 55-3720-1 TM 55-3749-1 TB 55-1900-102-12/1 TB 55-1900-202-12/1 TB 55-3761-1 TECHNICAL MANUAL TM 55-3750 TM 55-1925-204-12 TM 55-1925-204-20P TM 55-6605-261-15 *U.S. GOVERNMENT PRINTING OFFICE: 1996 - 755-025/40273 B-12 Change 6 TM 55-1925-204-12 Section VI. EXPENDABLE SUPPLIES AND MATERIAL LIST NSN 7520-00-281-5911 6135-00-050-0915 6135-00-050-3280 6135-00-120-1020 7510-00-889-3494 7920-00-291-8305 7920-00-240-6358 7920-00-240-3407 8020-00-889-7920 8020-00-889-7918 8020-00-889-7917 7920-00-772-5800 7920-00-240-7174 7920-00-291-5815 5130-00-293-0263 4240-00-174-1365 7520-00-240-5503 5940-00-195-9689 4020-00-240-2160 4020-00-204-2164 7230-00-576-4934 6830-00-584-3041 7930-00-880-4454 5345-00-881-5449 5345-00-187-3420 5345-00-881-5452 7920-00-224-8308 4210-00-223-9877 4020-00-174-3031 7920-00-267-1218 6240-00-155-8655 6240-00-143-3119 6240-00-143-3124 6240-00-330-0139 4020-00-240-2185 7220-00-238-8852 7920-00-171-1148 7540-00-530-3769 7930-00-266-7137 7930-00-205-0442 7920-00-205-1711 4020-00-231-9013 4020-00-752-8879 4020-00-542-3308 7501-00-161-6215 7930-00-579-8532 8520-00-129-0803 3439-00-188-6986 3439-00-188-6988 7920-00-269-4639 7510-00-283-0612 7510-00-290-2026 7510-00-266-6694 5970-00-644-3167 DESCRIPTION U/I QTY Basket, Waste paper RR-B-181 (81348) EA 4 Battery, Battle Lantern BA-23 (80063) EA 12 Battery, Emergency Light, BA-200N (81350) EA 16 Battery, Flash Light,m BA-30 (80063) EA 8 Binder, Loose Leaf, B-43064 (81349) EA 1 Broom, Upright; Corn H-B-71 (81348) EA 4 Brush, Dusting, Bench H-B-190 (81348) EA 2 Brush, Dusting, Floor H-B-651 (81348) EA 2 Brush, Paint, 1" EA 4 Brush, Paint, 2" EA 4 Brush, Paint, 3" EA 4 Brush, Sanitary H-B-481 (81348) EA 2 Brush, Scrub, H-B-1490(81348) EA 2 Brush, Wire, Curved Handle H-B-178 (81348) EA 4 Brush, Wire, Rotary Wheel H-B-771 (81348) EA 2 Canister, OBA 929000 (40912) EA 2 Clipboard, File, LLL-A-650(81348) EA 2 Clip, Electric, 3 1/2" Ig. P-P-10921 (80249) EA 4 Cord, Cotton, 5/16 1200' coil T-C-571 (81349) CL 1 Cord, Cotton, 1 ?4" 200' coil L-1 145 (81349) CL 1 Curtain, Shower, 48" w x 72" Ig. CS 48 x 72 (19099) EA 6 Cylinder, Replacement, Propade BB-G-110 (81348) EA 1 Dishwashing Compound Hand P-D-410 (81348) GL 4 Disk, Abrasive, NO 24 P-D-455 (81348) EA 2 Disk, Abrasive, NO 36 P-D-455 (81348) EA 2 Disk, Abrasive, NO 60 P-D-455 (81348) EA 2 Dust Panb RR-D-800 (81348) EA 2 Foam Liquid, Fire Exiting OF555 (81348) EA 6 Halyard, 3/8 dia 220' Ig, 18 Strand H-226 (81349) CL 1 Handle, Mop, Wood, NN-H-101 (81348) EA 4 Lamp, Incandescent 40W W-L-101 (81348) EA 18 Lamp, Incandescent 60W W-L-101 (81348) EA 18 Lamp, Incandescent 100 W W-L-101 (81348) EA 18 Lamp, Incandescent, 12V, ALDIS, Lamp A-139-1 (81348) EA 2 Marline, Hemp, 20 lb Coil, TR-650 (81348) CL 1 MAT, Floor, Rubber, 18" w 29" Ig. ZZ-M-46 (81348) EA 5 Mop Head, Cotton, TM-561 (81348) EA 4 Paper, Toilet, 96 Rolls per case UUP-556 (81348) CS 2 Polish, Metal, P-P-556 (81348) GN 2 Powder, Scouring, P-S-311 (81348) CS 1 Rags, Wiping, 50 lb Bale DDD-R-30X (81348) BE 1 Rope, Manila, 2 3/4" 1200' coil T-R-605 (81348) CL 1 Rope, Nylon, 4" 600' coil RL 1 Rope, Nylon, 6" 600' coil RL 1 Ruler, Wood 12" Lg GG-R-791 (81348) EA 2 Soap, Laundry 100 lb Drum P-S-579 (81348) DR 1 Soap, Toilet 144 Per Box P-S-617 (81348) BX 1 Solder, Acid Core 5 lb spool QQ-S-571 (81348) SL 1 Solder, Rosin Core 5 lb spool QQ-S-, 71 (81348) SL 1 Squeegee Window 8 g19. ZZ-S-666 (81348) EA 1 Tape, Masking 1" PPP-T-42 (81348) EA 6 Tape, Masking 2" PPP-T-42 (81348) EA 6 Tape, Masking 3" PPP-T-42 (81348) EA 6 Tape, Plastic, Electrical 3/4" HH-1-510 (81348) EA 12 *U.S. GOVERNMENT PRINTING OFFICE. 1992 - 654-028/60309 Change 6 B-13/(B-14 Blank) TM 55-1925-204-12 NSN 4320-00-114-0967 5330-00-030-3205 4320-00-034-8384 5977-00-280-4673 5330-00-097-4241 5330-00-097-4242 5977-00-090-1421 4530-00-030-3113 4530-00-034-8101 4330-00-319-4769 5977-00-391-2231 4330-00-709-0698 5330-00-030-3177 4330-00-859-4160 4330-00-097-4230 2940-00-317-2522 4330-00-603-4276 4330-00-805-9656 5330-00-213-0323 4330-00-097-5859 5971-00-090-1191 5330-00-030-3208 5905-00-347-3923 5905-00-098-6136 5977-00-238-9189 5977-00-090-1191 6105-00-323-9804 5330-00-626-2038 5330-00-305-6627 5330-00-626-2039 5330-00-078-9767 5930-00-296-6673 6105-00-049-8139 5977-00-379-0252 5977-00-379-0257 4320-00-073-2127 3030-00-073-3603 4320-00-073-2139 4320-00-074-7373 5977-00-090-1191 3950-00-301-5948 6110-00-575-0737. 2540-00-713-8359 5920-00-252-2018 5920-00-364-7879 NOUN/MFR CODE PART NUMBER U/M Gasket: pump, end cover; (16712) S1123AV ea Gasket: pump, rotor housing; (16712) S1123BC ea Packing, Preformed: pump, oil seal; (16712) S1 123AW ea Brush, Electrical Contact (95402) 38794A ea Seal: oil pump, inner; (16712) S1146A ea Seal: oil pump, outer; 116712) S1146AA ea Heating Boiler Crane Co. Model SO-30-9 Brush, Electrical: motor, dc: (35662) SA681-2 ea Electrode, Oil Burner: ignition; (14959) 50291 ea Nozzle, Oil Burner, Pressure: (14959) 52631 ea Lubricating Oil Purifier DeLaval Separator Co. Model 45-28 Block, Friction, Clutch: (71871) 14989 ea Brush Set, Electrical: (03511) 8100097ABP9 ea Element, Filter: oil, (73370) C44PB ea Gasket: filter cover; (73370) 11913 ea Gasket: purifier bowl, small; (71871) 14913 ea Glass, Gage: sight oil and temperature; (71871) 18280 ea Lining, Brake, Bowl: (71871) 15733 ea Packing, Preformed: pump drive; (71871) 16699 ea Ring: 171871) 4996 ea Rig: inlet arm seal; (71871) 10853 ea Spring, Helical, Compression: pump relief valve; 15818 ea (71871) Pump, Rotary, Power Driven DeLaval Model A322AX250 Brush, Electrical Contact: Motor; (08219) 54566 ea Gasket: packing box and outboard cover: (16712) S823EC ea Resistor: controller: starting; (89025) S5S200A115A3200ea Resistor: fixed, wire wound, controller: accelerator and line controller: (89025) 1000-194-2005 ea Brush, Electrical, Contact: 1/8 hp motor; (89930) 54437 ea Brush, Electrical, Contact: 7½ hp motor; (08219) 54566 ea Cdl, Interpole, Motor: 7½ ,'2 hp; (08219) 38068-324C4-2 ea Gasket: control drum cover; (02128) MD16-516A ea Gasket: hydraulic ram: pump flange; (02128) MD14-257C ea Gasket: hydraulic ram; supply tank cover plate; (02128) MD12-713B ea Packing, Preformed: ram cyl; (73680) 431 ea Switch, Push Button: start-stop; (89025) 601-2-7 ea Winding, Motor Field: 71/1 hp motor; (89930) 39854-324C4-2 ea Ventilating Fan Motors and Controller Brush: fan motor; (30190) 99542000A ea Brush: engineroom fan motor; (30190) 99602000A ea Water Pressure Set Deming Model, Fig 1892 Gasket, Crankcase Cover (16859) 0007223 ea Belt, V: Pump Pulley (16859) 0024894 ea Valve, Relief 116859) 0004428 ea Gasket Set, Pump (16859) 0019312 ea WINDLASS NEW ENGLAND TRAWLER EQUIPMENT MODEL D6340 Brush, Electrical, Contact: motor (08219) 54566 ea Lining, Brake: hand, w/rivets; (72088) D6366-2 ea Lining, Friction: motor brake, w/rivets (082191 B6462-10 ea Miscellaneous Items Blade, Windshield Wiper: (81100) N56-10 ea Fuse, Cartridge: 3 amp, 250 v, dc; 500v ac; (96906)MS90088-7 ea Fuse, Cartridge: 10 amp, 250 v, dc: (71424) OMT10 ea Change 1 B-21 QTY 1 2 1 2 1 1 2 2 1 4 2 6 3 1 1 1 4 1 2 1 4 2 1 1 4 4 1 1 1 2 2 1 1 6 4 1 1 1 1 4 2 2 2 15 15 AUTH TM 55-1925-204-12 NSN 5920-00-543-0673 5920-00-263-0621 6240-00-143-3049 6240-00-143-7464 5120-00-363-6619 2815-00-363-2284 5120-00-362-6621 5120-00-362-6620 5120-00-522-2880 5120-00-363-0956 5120-00-415-2378 5120-00-363-0960 5120-00-362-6627 5120-00-219-8400 4910-00-690-8452 5180-00-219-8407 5120-00-152-2420 5120-00-494-1915 5120-00-591-2685 4330-00-163-0159 5120-00-213-0460 4330-00-213-0425 5120-00-317-2518 NOUN/MFR CODE PART NUMBER Fuse, Cartridge: 15 amp, 150 v; (81349) Fuse, Cartridge: 100 amp, 150 v, dc; 500 v, ac: (81349) Lamp, Incandescent: 115 v, dc; (63076) Lamp, Incandescent: searchlight; 500 2, dc; (08108) Special Tools Propulsion Engine Fairbanks-Morse Model 37F16 Drill: injection valve tip cleaning; (21387) Gauge: injection setting; (23187) Guide: connecting rod, w/clamp; (21387) Guide: piston ring; (23187) Puiler: injection pump; (23187) Wrench, Packing Gland (21387) Wrench, Air Start Pipe (21387) Wrench, Scavenging Pump (21387) Wrench, Cylinder Stud (21387) Recover, Injector: valve spring; (33287) Test, Diesel Engine: fuel rack adjusting; injector timing and valve setting; (98798) Tool Set, Fuel Pump; (33287) Wrench: bowl coupling; (71871) Wrench, Box: cyl head stud nut; (33287) Wrench, Fuel Pump: u/o water pump; (33287) DeLaval Oil Purifier Tools Clamp, Lifting, Bowl Top (71871) Drift. For Steel Point (71871) Scoop, Bowl Shell (71871) Wrench, Spanner: bowl nut (71871) U/M QTY ea 15 F19A250V100A ea 1-1864-2 ea 500T20-21-115V ea 15 24 1 YLA4324F TD2727A YLA4353A YLA3693A TD2728B CHB1080A 16FM 19P532 YK400 YLA1644A J4824-01 se ea ea ea ea ea ea ea ea ea 1 1 1 1 1 1 1 1 1 1 201 J1508-02 21930 1928-01 J4242 ea se ea ea ea 1 1 1 1 1 7575 3425 7331 14943 ea ea ea ea 1 1 1 1 F15A250V15A AUTH Section V. ANICILLIARY ITEMS LIST NSN 2040-00-377-8603 2040-00-194-1797 4210-00-142-4949 6685-00-537-9173 6135-00-050-0915 6135-00-050-3280 6140-00-263-4603 6350.00-256-9062 4010-00-188-9-03 6645-00-224-8631 5935-00-504-3260 7110-00-290-9131 4210-00-270-4512 4210-00-202-7858 4140-00-255-7798 7110-00-286-3798 2040-00-268-9250 4210-00-202-8188 4210-00-078-9170 6230-00-828-6398 6230-00-782-0643 6220-00-224-6237 6220-00-553-1125 6220-00-553-1123 7125-00-680-2764 4210-00-288-6857 4210-00-274-8545 4220-00-275-3157 DESCRIPTION Anchor, Danforth: 300 lb; A-15707 (81349) Anchor, Marine, Fluked 800 lb; A-15707 (81349) Ax, Fire, Pick Head. 6 lb; GGG-A-926, type I11(81348) Barometer: aneroid 3257A (80063) Battery: battle lantern BA-23 (80063) Battery: emergency light; BA-200N (81350) Battery, Storage: engine starting; 6 volt; W-D-191, type 7d (81348) Bell, Ships: 30 lb; B-674 (81349) Chain: anchor; 1 in. dia: (105 fathoms) S-2603-860341 (80064) Clock: marine; mech 8 day, 6 in. dial, 12 hr; C-1194 (81349) Connector, Receptacle, electrical; Desk, Flat Top; Extinguisher, Fire, CO ,: 5 lb; O-E-910 (81348) Extinguisher, Fire, CO,: 15 lb; O-E-910 (81348) Fan, Circulating, Bracket; 115 V. D/C, 12 in. dia.; Filing Cabinet: Steel, 5 drawer; Hook, Boat: wood; 10 ft; H-3496 (81349) Hose. Fire, Cotton, Rubber: 21/i in. x 50 ft; ZZ-H-451 (81348) Hose, Fire; Polyester Fiber: 1/2 in. x 50 ft; ZZ-H-451 (81348) Lantern: elec; 6 v; with relay; 1500 (86796) Light Marker: distress; rail; L-2648 (81349) Light: navigation; clear; emergency; Light: navigation; red; emergency; 1008 (46576) Light: navigation; green; emergency; 1008 (46576) Locker, clothing; steel, 18" w, 78" h, 24" deep; Nozzle, Fire Hose, Water: 1 /2 in.; 3 position; N-12314 (81349) Nozzle, Fire Hose, Water: 21/= in.; 3 position; N-12314 (81349) Ring Buoy, Lifesaving: 30 in. od; w/line; R-168;47 (81349) B-22 Change 1 U/M QTY AUTH EA EA EA EA EA EA EA EA FT EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA 1 1 4 1 12 16 8 1 630 5 1 1 4 8 10 1 2 4 2 6 6 2 1 1 12 2 2 6 TM 55-1925-204-12 NSN 4020-00-184-9797 7110-00-634-8596 5120-00-293-0317 DESCRIPTION Rope, Manila: 3 in. circ; 200 ft coil; DWG 900-9215, PN13 (80064) Stool, Revolving; 30 in; Wrench, Spanner: 1'/i to 3 in; W-10442 (81349) ELECTRONIC EQUIPMENT Direction Finder Set Frequency Meter Radar Set Radio Set (Lifeboat) Radio Set (Ocean Operation) Radio Set (Ship to Shore) Change 1 B-23/(B-24 Blank) U/I QTY CL EA EA 3 2 4 CTA 50-935 CTA 50-935 CTA 50-935 CTA 50-935 CTA 50-935 CTA 50-935 APPENDIX C MAINTENANCE ALLOCATION CHART (MAC) Section I. INTRODUCTION incipient failure by measuring the mechanical or electrical characteristics of an item and comparing those characteristics with prescribed standards. C. Service. Operations required periodically to keep on time in proper operating condition, i.e., to clean, to preserve, to drain, to paint, or to replenish fuel, lubricants, hydraulic fluids, or compressed air supplies. D. Adjust. To maintain within prescribed limits, by bringing into proper or exact position, or by setting the operating characteristics to specified parameters. E. Align. To adjust specified variable elements of an item to bring about optimum or desired performance. F. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipments used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared. G. Install. The act of emplacing, seating, or fixing into position an item, part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system. H. Replace. The act of substituting a serviceable like type part, subassembly, or module (component or assembly) for an unserviceable counterpart. I. Repair. The application of maintenance services (inspect, test, service, adjust, align, calibrate, or replace) or other maintenance actions (welding, grinding, riveting, straightening, facing, remachining, or resurfacing) to restore serviceability to an item by correcting specific damage, fault, malfunction. or failure in a part, subassembly module (component or assembly}, end item, or system. J. Overhaul. That maintenance effort (service/action) necessary to restore an item to a completely serviceable/operational condition as prescribed by maintenance standards (i.e., DMWR) in appropriate technical publication. Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition. C-1. General a. This section provides a general explanation of all maintenance and repair functions authorized at the various maintenance levels. b. Section II designates overall responsibility for the performance of maintenance functions on the identified end item or component and the work measurement time required to perform the functions by the designated maintenance level. The implementation of the maintenance functions upon the end item or component will be consistent with the assigned maintenance functions. c. Section III lists the special tools and test equipment required for each maintenance function as referenced from Section II. d. Section IV contains supplemental instructions or explanatory notes for a particular maintenance function. C-2. Explanation of Columns in Section II a. Column 1. Group Number. A number is assigned to each group in a top down breakdown sequence. The applicable groups are listed on the MAC in disassembly sequence, beginning with the first group removed. b. Column 2. Functional Group. This column contains a brief description of the components of each numerical group. c. Column 3. Maintenance Functions. This column lists the various maintenance functions (A through K). The lowest maintenance level authorized to perform these functions is indicated by a symbol in the appropriate column. Work measurement time standards (the active repair time required to perform the maintenance function) are shown directly below the symbol identifying the maintenance level. The symbol designations for the various maintenance levels are as follows: C-Operator or crew. O- Organizational maintenance. F--Direct support maintenance. H-General support maintenance. D- Depot maintenance. The maintenance functions are defined as follows: A. Inspect. To determine serviceability ot an item by comparing its physical, mechanical, and electrical characteristics with established standards through examination. B. Test. To verify serviceability and detect C-1 maintenance function the item is to be used with. The letter is representative of columns A through K on the MAC. b. Maintenance Category. This column shows the lowest level of maintenance authorized to use the special tools or test equipment. c. Nomenclature. This column lists the name or identification of the tools or test equipment. d. Tool Number. This column lists the manufacturer's code and part number, or Federal Stock Number of tools and test equipment. C-4. Explanation of Columns in Section IV a. Reference Code. This column consists of two letters separated by a dash, entered from column 5, Section II. The first letter references the remark and the second letter references a maintenance function, column 3, A through K, to which the remark applies. b. Remarks. This column lists information pertinent to the maintenance function being performed, as indicated on the MAC in Section II. K. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurement (hours/miles etc.) considered in classifying Army equipment/components. d. Column 4. Tools and Equipment. This column is provided for referencing by code the special tools and test equipment, (sec III) required to perform the maintenance functions (sec II). e. Column 5. Remarks. This column is provided for referencing by code the remarks (sec IV) pertinent to the maintenance functions. C-3. Explanation of Columns in Section III a. Reference Code. This column consists of a number and a letter separated by a dash entered from column 4 on the MAC. The number references the special tools and test equipment requirements and the letter represents the specific (1) G R O U P (2) Functional group Section II. MAINTENANCE ALLOCATION CHART (3) Maintenance functions A N U M B E R B C D I N S P E C T T E S T S E R V I C E A D J U S T C 0.2 C 0.3 C 0.2 C 3.0 .. .. .. .. C 0.5 C 0.1 C .. C 0.2 .. .. C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 C C C 0.2 E G H A L I G N F C A L I B R A T E I N S T A L L R E P L A C E C 0.8 C 0.3 C .. H 16.0 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. H 18.0 C 2.0 C 3.0 C 0.2 .. .. .. .. .. .. .. O 10.0 .. .. H 10.0 .. .. .. .. C 0.5 .. .. C 0.2 .. .. .. .. C C .. .. .. .. C 0.1 C 0.1 C 0.2 C 0.2 C .. .. .. C 0.5 C 0.5 C 0.5 .. 0.5 .. .. .. .. .. .. C C C 0.3 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.5 .. .. C 2.0 C 0.6 C 2.0 F 0.3 C 1.0 C C C 1.5 C 3.5 C 2.6 C 3.5 C 1.0 C 2.0 C 0.5 H 4.0 H 4.0 H 4.0 C 2.0 H 2.0 C C C 2.3 H H (4) Tools and equipment (5) Remarks .. ...... A-E, A.J .. ...... B-H .. .. 1-H 2-H 3-H 4-H 5-H 6-H C-H, D-H 7-I, 8-I 9-1 E-D 10-I, 11-I F-B I J K R E P A I R O V E R H A U L R E B U I L D 01 GROUP-PROPULSION ENGINE 0101 ENGINE, DIESEL, FAIRBANKSMORSE MODEL 37F16 Cylinder Head 0102 Piston, Rod, and Rings 0103 Cylinder and Sleeve assembly 0104 Fuel System Fuel Transfer Pump Fuel Priming Pump Fuel Injection Pump Control Fuel Injector Fuel Filter Relief Valve Governor and Controls Governor Controls C-2 C H 6.0 320.0 C H 4.0 6.0 .. .. .. .. .. .. .. H .. .. .. G-D INDEX Paragraph Page Paragraph Page Bearings, main (GM engine} ............................... 5-8c Rearing replacement camshaft......................... 4-17b Hell alarm switch ................................ ............... 5-86 Bilge and ballast and the fire and salvage system operation .................. 2-20 Bilge and ballast pump ................................ ...... 5-32 Bilge and ballast system control valves............... 2-2t Operation................................ ..................... 2-20b Block cylinder (crankcase, ................................ ... 5-9 Blower (engine)................................ ................... 5-2i Maintenance................................ ...................... 5-19 Blower motor and fan................................ ........5-70c Blower assembly, centrifugal.............................. 5-72 Controller ................................ ....................... 5-73 Boiler................................ ............................... 5-70a Bottom screw................................ ..................... 5-48i Bowl purifier................................ ...................... 5-48c Bowl spindle ................................ ..................... 5-48f Box air receiver................................ ................. 4-14e Boxes miter gear................................ .............. S-99b Brake................................ ............................... 5-48g Brake air cylinder................................ ............. 4-19d Brake assembly engine, air............................... 4-19c Brake motor and................................ ................ 5-96 Brake motor and (capstan)................................ . 5-66 Breakers circuit................................ .................. 5-81 Breather, crankcase................................ ........... 3-17 Burner and ignition................................ ........... 5-70b Burner operation................................ ............... 2-21c A Access, hull assembly................................ ........ 3-27 Adjustment, governor IGM engine).................... 5-16c Administrative storage ................................ ......... 1-6 After steering station controls............................. 2-2d Operation ................................ ...................... 2 14d Maintenance................................ ................. 5-100 Aids engine starting ................................ ........... 3-15 Air brake assembly engine................................ 4-19c Air brake cylinder ................................ ............. 4-19d Air cleaner ................................ ......................... 5-2b Maintenance................................ ................... 5-17 Air compressor ................................ .................. 5-56 Cylinder head................................ ............... 5-56a Pistons and connecting rods......................... 5-56b Drive belts ................................ ..................... 5-56c Air intake silencer................................ ......... 5-56d Air compressor controls ................................ ..... 2-21 Air compressor operation................................ ..2-15c Air distributor ................................ ................... 4-14b Air inlet housing ................................ .......... 5-2i(1)(d) Maintenance................................ ................... 5-18 Air receiver (Box) ................................ ............. 4-14e Air scavenging pump ................................ ......... 3-16 Air start header ................................ ............... 4-14 d Air starting check valve ................................ ...... 3-6e Air starting system ................................ ............. 4-14 Air tanks and lines ................................ ............. 5-57 Air valve, cam operated pilot............................ 4-19e Air volume control ................................ ............. 5 ·51 Air whistle ................................ ...................... 5-110a Alarm, general ................................ ................... 5-94 Alarm, switch bell................................ ............... 5-86 Alarm system, operation of general................... 2-17f Ammeter................................ ............................ 5-88 Anchor and chain................................ .............. 3-27i Anchor windlass................................ ................. 5-61 Motor ................................ ............................. 5-62 Control ................................ ........................... 5-63 Master switch ................................ ................. 5-64 Data ................................ ............................ 1- 10g Operation ................................ ....................... 2-22 Attachment, overload trip ................................ ... 5-83 Auxiliary set component characteristics............. 5-1 a Auxiliary set engine controls and instruments...... 2-2f Auxiliary set operation................................ ........ 2-11 Auxiliary switches ................................ .............. 5-85 Axial blower assembly................................ ........ 5-74 Controllers................................ ....................... 575 3-66 5-59 1-2 2-3 2-35 5-187 3-47 4-31 4-33 5-2 5-66 5-133 5-133 5-137 5-139 5- 140 2-13 2-37 4-11 5-9 5-66 4-15 3-47 4-15 3-23 4-10 5-141 4-35 5-129 5-197 5-171 5-169 2-43 5-169 3-66 5-140 5-145 5-145 5-145 1 -5 2-58 5-168 5-1 2-6 2-23 5-68 5-158 5-161 5-37 4-27 5-169 2 48 -5-89 2-21 2-48 5-44 5-8 5-67 5-154 5-155 5-157 5-152 5-125 5-121 5-124 4-15 5-184 5-124 4-33 4-31 5-173 2-148 5-168 3-53 5-153 2-58 C Calibration ................................ ........................... 1-7 Cam operated pilot air valve ............................. 4-19e Camshaft and timing system (propulsion engine) 4-17 4-27 Camshaft bearing replacement (propulsion engine)................................ ....... 4-17b Camshaft, and timing system (GM engine) Valves................................ .............................. 5-7 Valves................................ ............................ 5-7b Camshaft and gear train................................ ..5-7c Adjusting valve Clearance .............................. 5-7d Capstan (Model R6293)................................ ..... 5-65 Motor and brake................................ ............. 5-66 Master switch ................................ ................. 5-67 Control ................................ .............................. 5-68 Capstan operation ................................ ............. 2-23 Centrifugal blower assembly .............................. 5-72 Controller ................................ ....................... 5-73 Chain, anchor and ................................ .............3-27i Charging panel, battery................................ ...... 5-91 Check valve, air starting................................ ..... 3-6e Chests, sea................................ ....................... 3-29c Circuit breakers ................................ ................. 5-81 Cleaner, air................................ ........................ 5-2b Maintenance................................ ................... 5-17 Clutch (model CL208)................................ .........5,30 Clutch assembly ................................ .............. 5-48d Coffee urn and immersion heater operation........ 2-29 B Ballast pump, bilge and................................ ...... 5-32 5-89 Batteries ................................ ............................ 5-28 5-81 Battery charging panel................................ ....... 5-91 5-169 Tabulated data ................................ ............ 1-10m 1-7 Bearing, (Kingsbury) thrust ................................ 3-25 3-64 Hearings, connecting rod ................................ ... 3-7c 3-27 Bearings, main................................ ................... 3-24 3-61 I-1 1-2 4 35 4-27 5-29 5-29 5-30 5-35 5-146 5-148 5-149 5-151 2-59 5-155 5-157 3-66 5-169 3-23 3-77 5-168 5-2 5-66 5-85 5-122 2-62 Paragraph Page Paragraph Page Maintenance................................ ................. 5-79b Cold, operation in extreme................................ . 2-34 Compass, gyro ................................ .............. 5-102b Compass magnetic ................................ ........ 5-102a Component characteristics of auxiliary set ................................ .................... 5-1a Compressed air system data............................ 1-10e Operation................................ ........................... 2-15 Compression relief valve, cylinder....................... 3-6f Compressor, air ................................ ................. 5-56 Cylinder head................................ ............... 5-56a Pistons and connecting rods......................... 5-56b Drive belts ................................ ..................... 5-56c Air intake silencer................................ ......... 5-56d Connecting rod, bearings, rings, and cylinder sleeve, piston................................ 3-7 Connecting rod bearings................................ .... 3-7c Connecting rods, and piston rings (GM engine) pistons................................ . 5-4 Console, steering................................ ............. 5-98d Control, air volume ................................ ............ 5-51 Control [anchor windlass!................................ ... 5-63 Control (capstan) ................................ ............... 5-68 Control differential................................ ............ 5-97e Control panel, operation main electrical............ 2-17g Control reverse ................................ ................. 4-14c Control station, aft steering .............................. 5-100 Control valves for bilge and ballast system.......... 2-2t Controller (air compressor) ................................ 5-59 Controllers (axial blower) ................................ ... 5.75 Controller (bilge and ballast pump)..................... 5 35 Controller (centrifugal blower) ............................ 5.73 Controller (fire pump) ................................ ......... 5-38 Controller (fuel oil transfer pump)....................... 5-44 Controller motor (lubricating oil standby pump) .. 5-47 Controller (purifier motor) ................................ . 5-481 Controller (stand by pumps)............................... 5-41 Controls and instruments ................................ ..... 2-2 Controls and instruments for auxiliary set engine................................ .......... 2-2f Controls at after steering station......................... 2-2d Controls for air compressor................................ 2-21 Controls for fire and salvage system .................. 2-2p Controls for fresh Hater system........................... 2-2r Controls for fuel oil system................................ . 2-20 Controls for heating system ............................... 2-2k Controls for lubricating oil system ...................... 2-2q Controls for ran and fresh water engine cooling system........................... 2-2n Controls for ventilation system .......................... 2-2m Controls pilot house engine................................ 2-2b Controls pilot house navigation .......................... 2-2a Controls propulsion engine room........................ 2-2e Cooler lubrication oil heat exchanger.................. 3-23 Cooler oil ................................ ........................... 5-12 Cooler water dispenser ................................ ...... 2-28 Cooling system operation engine ....................... 2-18 Couplings gear boxes universal joints and.......... 5-99 Cover front................................ .......................... 5-8f Cover, valve rocker................................ ............ 5-20 CO 2 fire extinguishing equipment operation................................ ........................ 2-19 Crankcase breather (propulsion engine)............. 3-17 Crankshaft (propulsion engine) .......................... 3-24 Crankcase (cylinder block) (GM engine)............... 5.9 Crankshaft (GM engine)................................ ..... 5-8g Crankshaft pulley................................ ............... 5-8d Front cover ................................ ......................... 5-8f Front oil seal................................ .................. 5-8b(1) Main bearings................................ ..................... 5-8c Rear oil seal ................................ .................. 5-8b(4) Vibration damper ................................ ............... 5-8e Crankshaft, main bearings, and crankcase explosion valves (propulsion engine).............................. 3-24 Criteria, equipment serviceability.......................... 1-4 Cylinder, air brake................................ ............ 4-19d Cylinder block (crankcase) (G M engine}.............. 5-9 Cylinder compression relief valve (propulsion engine)................................ .......... 3-6f Cylinder and Sleeve (propulsion engine)............ 4-13 Cylinder head (GM engine) ................................ .. 5-3 Cylinder head and valves (propulsion engine}...... 3-6 Cylinder liner (GM engine) ................................ ... 5-5 Cylinder sleeve and scraper rings (propulsion engine)................................ 3-7d Cylinder sleeve, piston, connecting rod, bearings, rings and (propulsion engine)..... 3-7 5-165 2-66 5-187 5-187 5-1 1-5 2-35 3-24 5-133 5-133 5-137 5-139 5-140 3-25 3-27 5-19 5-183 5-129 5-145 5-151 5-179 2-43 4-13 5-187 2-21 5-141 5-161 5 95 5-157 5-101 5-108 5-118 5-126 5-104 2-1 5-14 2-48 3-53 3-61 5.44 5-42 5-40 5-41 5-37 5-37 5-37 5-40 3-61 1-2 4-33 5-44 3-24 4-8 5-14 3-20 5-24 3-29 3-25 D Damper, vibration ................................ .............. 5-8e Data, tabulated ................................ .................. 1-10 Battery charging control panel..................... 1-10m Fixed fire extinguisher system....................... 1-10n Galley equipment ................................ ......... 1-10o Heating unit................................ .................... 1-10j Lifeboat Davit................................ ............... 1-10p Main electrical control panel ......................... 1-101 Propulsion................................ ..................... 1-10c Pumps ................................ ........................... 1-10i Tug ................................ .............................. 1-10b Ventilation system ................................ .........1-10k Davit, lifeboat................................ ................... 5-112 Deep freeze unit operation.............................. 2-27 Description................................ ....................... 1-8 Destruction of army materiel to prevent enemy use1-5 Diesel engine starting (GM 4-71) .................. 2-11b Difference in models................................ ......... 1-9 Differential control................................ .............5-97e Differential control land hydraulic pump)......... 5-97 Disassembly (cylinder head)............................ 5-3c Disconnect switch................................ .............. 5-89 Dispenser, water................................ .......... 5-77b(3) Distributor, air ................................ .................. 4-14b 2-6 2-3 2-13 2-18 2-20 2-17 2-10 2-19 2-16 2-16 2-3 2-1 2-4 3-61 5-49 2-61 2-46 5-183 5-41 5-40 1-3 1-7 1-7 1-7 1-6 1-7 1-7 1-3 1-5 1-3 1-6 5-197 2-61 1-2 1-2 2-23 1-3 5-179 5-175 5-15 5-169 5-164 4-11 E Eductor system................................ ................ 3-28h Electrical system operation ................................ 2-17 Electrical starter, engine................................ ..... 5-2d Electrical system, the engine.............................. 4-18 I-2 3-72 2-38 5-4 4-9R Paragraph Page Paragraph Page Emergency fuel shutoff reset lever....................... 3-8 Engine air brake assembly................................ 4-19c Engine controls and instruments for auxiliary set................................ ................ 2-2f Engine cooling system operation........................ 2-18 Engine, diesel, model 4061A.............................. 5-1a Engine electrical starter................................ ...... 5-2d Engine fresh water pump................................ ... 3-18 Engine, general, propulsion................................ 4-12 Engine generator ................................ ............... 5-24 Engine instrument panel ................................ .... 5-27 Engine (model 4061A) accessories...................... 5-2 Engine oil pressure pump............................. 2-13c(4) Engine order telegraph repair............................ 3-28f Engine raw water pump ................................ ..... 3-19 Engine room controls, propulsion....................... 2-2e Engine starting aids ................................ ........... 3-15 Engine, starting the 4-71 diesel........................ 2-11b Engine, stopping the auxiliary set..................... 2-11d Equipment, galley ................................ .............. 5-79 Range, galley ................................ ............... 5-79a Coffee urn................................ ................... 5 -79b Refrigerator................................ ................... 5-79c Freezer................................ ......................... 5-79d Equipment, navigation ................................ ..... 5-102 Tabulated data ................................ ............. 1-10d Equipment Serviceability Criteria (ESC) ............... 1-4 Equipment, special tools and ............................... 4.4 Equipment, tools and ................................ ........... 4.3 Errors, reporting of................................ ............... 1-3 Exchanger, (water cooling) heat......................... 3-21 Exhaust manifold, pipe and muffler (GM engine) 5-23 Exhaust manifold, water cooled (GM engine)...... 5-21 Exhaust system (propulsion engine)................... 4-15 Exhaust valve guide removal (GM engine)...... 5-3c(4) Explosion valves crankcase (propulsion engine)................................ ......... 3-24 Extinguishers, hand ................................ ......... 2-19b Extreme cold. operation in................................ .. 2-34 Extreme heat. operation in................................ . 2-35 Flywheel jacking (ratcheting) device (propulsion engine)............................ 4-19b Forced feed lubricator................................ ........ 4-16 Forms and records, maintenance......................... 1-2 Frame cover and inlet arm ............................... 5-48b Freezer................................ ............................ 5-79d Fresh and salt water standby pumps.................. 5-39 Fresh water and sanitary system pumps ............ 5-49 Relief valve ................................ ..................... 5.50 Air volume control ................................ .......... 5-61 Pressure switch................................ .............. 5-62 Motor ................................ ............................. 5-53 Fresh water pump (GM engine)........................... 5-2f Maintenance................................ ..................... 5-2 Fresh water pump, (propulsion engine).............. 3-18 Fresh water system controls ............................... 2-2r Fresh water system operation............................ 2-24 Front cover ................................ ......................... 5-8f Front oil seal................................ .................. 6-8b(1) Fuel filter ................................ ............................ 5-2c Fuel filter and relief valve................................ ... 3-14 Fuel filter and strainer ................................ ........ 5-15 Fuel injection pump................................ ............ 3-11 Fuel injection timing ................................ ..... 4-17d(1) Fuel injector (GM engine)................................ ... 5-13 Fuel injector (nozzle)................................ .......... 3-12 Fuel injectors ................................ ................. 5-3c(1) Fuel oil pump operation ................................ ... 2-12d Fuel oil system controls ................................ ..... 2-20 Fuel oil system operation ................................ ... 2-12 Fuel oil transfer pump ................................ ........ 5-42 Fuel pressure Gage................................ ......... 4-18b Fuel priming pump................................ ............. 3-10 Fuel pump, blower motor, and Fan.................... 5-70c Fuel pump (GM engine) ................................ ..... 5-2h Fuel shutoff reset lever emergency....................... 3-8 Fuel transfer pump................................ ............... 3-9 Fuel transfer pump and lines.............................. 5-14 Fuses, indicator lamps and ................................ 5-90 3-32 4-31 2-6 2-46 5-1 5-4 3-54 4-8 5-76 5-79 5-2 2-31 3-71 3-57 2-4 3-47 2-23 2-24 5-164 6-164 5-165 5-165 5-167 5-187 1-4 1-2 4.4 4.3 1-2 3-58 5-75 5-11 4-16 5-17 3-61 2-48 2-66 2-67 G F Fan, fuel pump blower motor and...................... 5-70c Filter and strainer, fuel ................................ ....... 5-15 Filter, fuel ................................ .......................... 5-2c Filter, oil (GM engine) ................................ ........ 5-2k Maintenance................................ ...................... 5-11 Filter unit, heater and................................ ........ 5-48j Fire and salvage pump................................ ....... 5-31 Operation................................ .......................... 2-11c Fire and salvage system ................................ ...2-20c Fire and salvage system controls....................... 2-2p Fire fighting equipment, general....................... 5-105 Fire fighting system................................ ............ 4-2a Fire pump ................................ .......................... 5-36 Fixed fire extinguisher operation....................... 2-19a Fixed fire fighting equipment.......................... 5-106b Flywheel assembly (propulsion engine).............. 4-19 Flywheel assembly and housing (GM engine) ................................ ..................... 5-6 4-30 4-15 1-2 5-119 5-167 5-101 5-126 5-129 5-129 5-129 5-129 5-5 5-1 3-54 2-20 2-59 5-41 5-37 5-4 3-44 5-57 3-39 4-28 5-49 3-40 5-15 2-28 2-17 2-24 5-104 4-28 3-36 5-154 5-7 3-32 3-32 5-55 5-169 Gage fuel pressure................................ .......... 4-18b 4-28 Gage pressure................................ ................. 4-19g 4-37 Gages water, oil and air pressure...................... 4-18c 4-29 Galley equipment................................ ............... 5-79 5-164 Galley range................................ ................. 5-79a 5-164 Coffee urn................................ .................... 5-79b 5-164 Refrigerator................................ ................... 5-79c 5-164 Freezer................................ ......................... 5-79d 5-167 Galley range................................ .................... 5-79a 5-164 Operation................................ ....................... 2-25 2-60 Gear backlash (engine model 37F16)................ 1-10r 1-7 Gear boxes miter ................................ ............. 5-99b 5-184 Gear boxes universal joints, and couplings......... 5-99 5-183 General (air compressor system) ........................ 5 55 5 132 General alarm................................ ..................... 5.94 5 171 Operation................................ ..................... 2-17F 2-43 General lighting panel................................ ........ 5-93 5-171 General methods used to obtain proper suppression4-8 4-6 General operation of auxiliary equipment........... 2-10 2-23 Generator and voltage regulator.......................... 5-2j 5-9 Generator, engine (GM)................................ ..... 5-24 5-76 5-154 5-57 5-4 5-11 5-48 5-125 5-87 2-24 2-53 2-18 5-192 4-1 5-97 2-48 5-193 4-30 5-27 I-3 Paragraph Page Paragraph Page Inlet header water................................ .............. 3-20 Inlet (shutdown) housing, air .............................. 5-18 Inspecting and Enticing the equipment................. 4-2 Inspection of the hull................................ ...........4-2c Installed fire extinguisher operation.................. 2-19a Instructions lubrication ................................ ......... 3-2 Instrument panel engine................................ ..... 5-27 Instruments and controls................................ ...... 2-2 Intercommunicating telephone system ............. 3-28g Interference suppression components.................. 4-9 Generator (model 1-3644)................................ .. 5-29 5 81 Governor (GM engine) ................................ ....... 5-2g 56 Maintenance................................ ................... 5-16 5-58 Adjustment................................ .................... 5-16c 5-59 Governor (propulsion engine)............................. 3-13 3-42 Grease fitting replacement. hydraulic ram packing and............................. 5-97c 5 176 Guide removal exhaust valve......................... 5-3c(4) 5-17 Gyro Compass................................ ............... 5-102b 5 187 Operation ................................ ....................... 2 32 2 63 J H Hand extinguishers ................................ .......... 2-19b Hand lubrication pump................................ ..... 3-16e Hand pumps rotary ................................ ............ 5-54 Hand pump, steering console and valves........... 5-98 Hand steering pilothouse control....................... 2-14c Header air start................................ ................ 4-14d Head and valves cylinder................................ ..... 3-6 Header, water inlet................................ ............. 3-20 Head (GM engine) cylinder................................ ... 5-3 Heater and filter unit................................ ......... 5-483 Heat exchanger and oil cooler............................ 5-2n Maintenance................................ ................... 5-20 Heat exchanger (oil cooking) (propulsion engine)................................ ......... 3-23 Heat exchanger (water cooking) (propulsion engine)................................ ......... 3-21 Heating system................................ .................. 5-70 Boiler ................................ ........................... 5-70a Burner and ignition ................................ ....... 5-70b Fuel pump, blower motor and fan .................. 5-70c Stack switch ................................ ................. 5-70d Aquastat................................ ....................... 5-70e Thermostat................................ .................... 5-70f Heating system operation................................ ... 2-21 Heating system controls................................ ..... 2-2k Heating system general................................ ...... 5-69 Heat, operation m extreme................................ . 2-35 Hoisting the anchor................................ ............ 2-22 Housing air inlet (shutdown)............................... 5-18 Housing and flywheel assembly ........................... 5-6 Hull and accessory items, miscellaneous ........... 3-28 Hull assembly access ................................ ........ 3-27 Hull inspection ................................ ................... 4-2c Hydraulic governor................................ ............. 5-16 Hydraulic pump................................ ................ 5-97d Hydraulic pump, and differential control ............. 5-97 Hydraulic ram packing and grease fitting replacement.............................. 5-97c Jacking device flywheel ratcheting.................... 4-19b 2-48 3-50 5-130 5-179 2-35 4-15 3-20 3-57 5-14 5-125 5-14 5-68 4-30 K Kingsbury thrust bearing................................ .... 3-25 3-64 L Lamps and fuses educator................................ . 5-90 Lavatories and showers............................... 5-77b(2) Lifeboat davit................................ ................... 5-112 Lifeboat davit general................................ ....... 5-111 Lighting panel general................................ ........ 5-93 Light panel navigation................................ ........ 5-92 Liner cylinder ................................ ....................... 5-5 Lines air tanks and................................ ............. 5-57 Lowering the anchor ................................ ......... 2--22 Lubricating oil purifier system ...................... 2-13c(5) Maintenance................................ ................... 5-48 Lubricating oil standby pump ....................... 2-13c(3) Maintenance................................ ................... 5-45 Lubricating oil system controls ........................... 2-2q Operation................................ ....................... 2-13 Pump operation................................ ............. 2-13c Lubrication instructions ................................ ........ 3-2 Lubrication oil cooler (heat exchanger)............... 3-23 Lubrication off pump, (propulsion engine) .......... 3-22 Lubrication pump hand ................................ .....3-16e Lubricator, forced feed................................ ....... 4-16 3-61 3-58 5-152 5-152 5-153 5-154 5-154 5-155 5-155 2-55 2-10 2-151 2-67 2-58 5-66 5-27 3-66 3-66 4-3 5-58 5-177 5-175 5-169 5-164 5-197 5-197 5-171 5-171 5-24 5-141 2-58 2-31 5-119 2-30 5-113 2-19 2-28 2-30 3-1 3-61 3-59 3-50 4-19 M Magnetic compass................................ ..........5-102a Main bearing (GM engine)................................ ...5-8c Main bearings (propulsion engine) ..................... 3-24 Main electrical system, general ......................... 5-80 Operation................................ ..................... 2-17g Maintenance checks and services, preventive ................................ ............. (table 4-2) Maintenance checks and services preventive ................................ ............. (table 3-1) Maintenance forms and records........................... 1-2 Maintenance repair parts................................ ...... 4-5 Manifold, water ................................ ................. 5-2m Manifold, water cooled exhaust.......................... 5-21 Master switch (anchor windlass) ........................ 5-64 Master switch (capstan) ................................ ..... 5-67 Miscellaneous hull and accessory items............. 3-28 Miter gear boxes................................ .............. 5-99b Model R7293 Capstan ................................ ....... 5-65 Motor and brake................................ ................. 5-66 Master switch................................ ..................... 5-67 Control ................................ ........................... 5-68 Models, difference in................................ ............ 1-9 Motor and brake (capstan)................................ . 5-66 Motor and brake................................ ................. 5-96 Motor (air compressor) ................................ ...... 5-58 5-176 I Identification and instruction plates .................. 1-10a Ignition, burner and................................ .......... 5-70b Immersion heater operation ............................... 2-29 Indicator lamps and fuses ................................ .. 5-90 Indicator, speed ................................ ............... 5-48h Indicator, tachometer ................................ ....... 4-18d Injection pump, fuel (propulsion engine)............. 3-11 Injector, fuel (CM engine)................................ ... 5-13 Injector {nozzle) fuel (propulsion engine)............ 3-12 Injectors, fuel ................................ ................. 5-3c(1) Inlet arm and frame cover ................................ 5-48b 3-57 5-66 4-1 4-3 2-48 3-1 5-79 2-1 3-72 4-6 1-3 5-153 2-62 5-169 5-124 4-29 3-39 5-49 3-40 5-15 5-119 I-4 5-187 5-37 3-61 5-168 2-43 4-5 3-2 1-2 4-4 5-13 5-11 5-145 5-149 3-66 5-184 5-146 5-148 5-149 5-151 1-3 5-148 5-173 5-141 Paragraph Page Paragraph Page Motor ( anchor windlass)................................ ... 5 -62 Motor (bilge and ballast pump)........................... 5-34 Motor (fire pump) ................................ .............. 5-37 Motor (fresh water and sanitary system pumps .. 5-53 Motor (fuel oil transfer pump) ............................. 5-43 Motor (lubricating oil purifier) ............................ 5-48k Motor (lubricating oil standby pump) .................. 5-46 Motor controller (lubricating oil standby pump) ................................ .............. 5-47 Motor (standby pumps) ................................ ...... 5-40 Motor, starting ................................ ................... 5-26 Movement, preliminary preparation for ............... 2-3b Muffler, exhaust manifold, pipe and.................... 5-23 Operation, heating system ................................ . 2-21 2-55 Operation in extreme cold................................ .. 2-34 2-66 Operation in extreme heat................................ .. 2-35 2-67 Operating inspection of rudder travel................ 5-97b 5 175 Operation, immersion heater.............................. 2-29 2-62 Operation, lubricating oil system ........................ 2-13 2-28 Operation, main electrical control panel ........... 2-17g 2 43 Operation, potable water system........................ 2-24 2-59 Operation, power hoisting the anchor and chain2-22b 2-58 Operation, power lowering the chain and anchor2-22c 2-58 Operation, refrigerator................................ ........ 2-26 2-61 Operation, searchlight................................ ........ 2-30 2-63 Operation, steering system ................................ 2-14 2-33 Operation, steering system trick wheel............. 2-14b 2 35 Operation, ventilation system............................. 2-16 2-38 Operation, water dispenser (cooler).................... 2-28 2 61 Operation, windshield wiper............................... 2-31 2-63 Operation of auxiliary set (generator and pump). 2-11 2-23 Operation of electrical system............................ 2-17 2-38 Operation of general alarm system ................... 2-17f 2 43 Other pilothouse controls................................ ....2-2c 2-3 Overload trip attachment................................ .... 5-83 5-16B 5-145 5-94 5-101 5-129 5-107 5-125 5-116 5-118 5-104 5-77 2-22 5-75 N Navigational light control panel operation......... 2-17e 2-42 Maintenance................................ ...................... 5-92 5-171 Navigation equipment ................................ ...... 5-102 5-187 Navigation equipment, general......................... 5-101 5-187 Nozzle, fuel injector................................ ............ 3-12 3-40 O Oil and water pump drive ................................ .. 3-16f 3-51 Oil cooler ................................ ........................... 5-12 5-49 Oil cooler and heat exchanger............................ 5-2n 5-14 Maintenance................................ ................... 5-20 5-68 Oil cooler (heat exchanger) lubrication ............... 3-23 3-61 Oil filter (GM engine)................................ .......... 5-2k 5-11 Maintenance................................ ................... 5-11 5-48 Oil pressure pump, engine........................... 2-13c(4) 2-31 Oil pump, engine lubrication............................... 3-22 3-59 Oil Pump (engine lubricating)............................. 5-10 5-45 Oil purifier, lubricating ................................ ........ 5-48 5-119 Oil purifier system, lubricating ...................... 2-13c(5) 2-31 Oil seal, front ................................ ................. 5-8b(1) 5-37 Oil seal, rear ................................ .................. 5-8b(4) 5 37 Oil standby pump, lubricating............................. 5.45 5-113 Oil system, operation of fuel............................... 2-12 2-24 Oil system, lubricating operation ........................ 2-13 2-28 Oil transfer pump, fuel ................................ ....... 5-42 5-104 Oil transfer pump, scavenging (#5130)..............4-16c 4-24 Operating pressures (engine model 37F16)....... 1-10t 1-7 Operating procedures ................................ .......... 2-3 2-21 Operating procedures, general............................. 2-1 2-1 Operating temperatures (engine model 37F16). 1-10u 1-7 Operation, air compressor................................ .2-15c 2-37 Operation, aft steering station.......................... 2-14d 2-35 Operation, burner................................ ..............2-21c 2-58 Operation, capstan - ................................ ......... 2-23 2-59 Operation, compressed air system..................... 2-15 2-36 Operation, coffee urn................................ ......... 2-29 2-62 Operation, deep freeze unit................................ 2-27 2-61 Operation, engine cooling system ...................... 2-18 2-46 Operation, fuel oil pump................................ ... 2-12d 2-28 Operation, fuel oil system ................................ .. 2-12 2-24 Operation, galley range................................ ...... 2-25 2-60 Operation, gyrocompass................................ .... 2-32 2-63 P Packing and grease fitting replacement, hydraulic ram............................... 5-97c 5-176 Parts, maintenance repair................................ .... 4-5 4-4 Panel, battery charging................................ ...... 5-91 5-169 Panel, engine instrument ................................ ... 5-27 5-79 Panel, general lighting ................................ ....... 5-93 5-171 Panel, navigation light................................ ........ 5-92 5-171 Pilot air valve, cam operated............................. 4-19e 4-35 Pilothouse controls, other................................ ....2-2c 2-3 Pilothouse engine controls................................ . 2-2b 2 -3 Pilothouse navigation controls........................... 2 -2a 2-1 Pipe and muffler, exhaust manifold.................... 5-23 5-75 Piston, connecting rod, bearings, rings, and cylinder sleeve (propulsion engine)................... 3-7 3-25 Pistons, connecting rods, and Piston rings (GM engine) ................................ ..... 5-4 5-19 Power generator (Model 1-3644)........................ 5-29 5-81 Power hoisting the chain and anchor, operation2-22b 2-58 Power lowering the chain and anchor................ 2-22c 2-58 Portable fire extinguishers................................ 2-19b 2-48 Portable fire fighting equipment....................... 5-106a 5-192 Post operation ................................ ..................... 2-9 2-23 Potable water system operation......................... 2-24 2-59 Preliminary preparation for movement ............... 2-3b 2 22 Pressure gage ................................ .................. 4 19g 4-37 Pressure gage, fuel................................ ........... 4 18b 4-28 Pressures, operating (engine model 37F16)...... 1-10t 1-7 Pressure regulating valve................................ .. 4-19f 4-35 Pressure switch ................................ ................. 5-52 5-129 Preventive maintenance checks and services (table 3-1) 3-2 Preventive maintenance checks and services (table 4-2) 4-6 I-5 Paragraph Page Paragraph Page Priming pump (bilge and ballast pump) .............. 5-33 Propeller and shaft................................ ............. 3-26 Propulsion data................................ ................. 1-10c Propulsion engine, general................................ . 4-12 Propulsion engine room controls........................ 2-2e Pulley, crankshaft ................................ .............. 6-8d Pump, air scavenging ................................ ........ 3-16 Pump-and lines, fuel transfer ............................. 5-14 Pump and relief valve ................................ ...... 6-48e Pump, bilge and ballast................................ ...... 6-32 Pump drive, oil and water................................ .. 3-16f Pump, engine fresh water ................................ .. 3-18 Pump, engine lubrication oil ............................... 3-22 Pump, engine raw water................................ ..... 3-19 Pump, (engine) raw water ................................ .. 5-21 Pump, engine oil pressure............................ 2-13c(4) Pump, fire................................ .......................... 5-36 Pump, fire and salvage ................................ ...... 5-31 Pump, fire and salvage ................................ .....2-11c Pumps, fresh and salt water standby.................. 5-39 Pumps, fresh water and sanitary system............ 5-49 Relief valve................................ ........................ 5-50 Air volume control ................................ .............. 5-51 Pressure switch ................................ ................. 5-52 Motor ................................ ................................ . 5-53 Pump, fresh water (GM engine).......................... 5-21 Pump, fuel injection ................................ ........... 3-11 Pump, fuel oil transfer................................ ........ 5-42 Pump, fuel priming................................ ............. 3-10 Pump, fuel transfer ................................ .............. 3-9 Pumps, general, data................................ ........ 1-10i Pump, GM engine, fuel ................................ ...... 5-2h Pump, hand lubrication ................................ .... 3-16e Pump, hydraulic................................ ............... 5-97d Pump, lubricating oil standby ....................... 2-13c(3) Maintenance................................ ...................... 5-45 Pump oil (engine lubricating).............................. 5-10 Pump operation lubricating oil system............... 2-13c Pump operation of fuel oil ................................ 2-12d Pump. priming {bilge and ballast pump) ............. 5-33 Pump, raw water (engine) ................................ .. 5-2e Maintenance................................ ...................... 5-21 Pumps, rotary, hand ................................ .......... 6-54 Pump, scavenging oil transfer........................... 4-16c purifier bowl ................................ ...................... 5-48c Purifier, lubricating oil ................................ ........ 5-48 Purifier system, lubricating oil ...................... 2-13c(5) Pyrometer................................ ........................ 4-18e Radio interference suppression General methods used to attain........................ 4-8 Interference suppression components............... 4-9 Replacement of suppression components...... 4- 10 Testing of radio interference suppression components................................ 4-11 Radio telephone system................................ ... 5-107 Radio telephone system, general..................... 5-107 Range operation, galley................................ ..... 2-25 Maintenance................................ ................... 5-79 Raw and fresh water engine cooling system controls....................... 2-2n Raw water pump, engine................................ .... 3-19 Raw water pump (GM engine)............................ 5-2e Maintenance................................ ................... 5-22 Rear oil seal ................................ .................. 5-8b(4) Regulating valve, pressure................................ 4-19f Regulator, voltage................................ ............... 5-2j Maintenance................................ ................... 5-25 Receiver (box), air................................ .............4-14e Records, maintenance forms and......................... 1-2 Refrigerator ................................ ...................... 5-79c Operation................................ ....................... 2-26 Release device, under voltage............................ 5-82 Relief valve................................ ........................ 5-50 Relief valve, cylinder compression ...................... 3-6f Relief valve, fuel filter and................................ .. 3-14 Relief valve, pumps and................................ ....5-48e Relief valve, safety................................ ............. 3-6d Removal of windshield wiper............................ 3-28b Repair of engine order telegraph....................... 3-28f Repair parts, maintenance................................ ... 4-5 Replacement of suppression components.......... 4-10 Reporting of errors................................ ............... 1-3 Reset lever, emergency fuel shutoff...................... 3-8 Reverse control................................ ................. 4-14c Reversing ahead from astern............................... 2-8 Reversing astern from ahead............................... 2-7 Rings piston, connecting rod and....................... 3-7b Rings piston (GM engine) ................................ .... 5-4 Rocker arms and valves................................ . 5-3c(2) Rocker cover, valve ................................ ........... 5-20 Rod bearings connecting................................ .....3-7c Rotary hand pumps ................................ ........... 5-54 Rudder travel................................ ................... 5-97b 6-92 3-66 1-3 4-8 2-4 5-40 3-47 5-66 6-122 5-89 3-51 3-54 3-59 3-57 5-4 2-31 5-97 5-87 2-24 5-101 5-126 5-129 5-129 5-129 5-129 5-72 3-39 5-104 3-36 3-32 1-5 5-7 3-50 5-177 2-30 5-113 5-45 2-30 2-28 5-92 5-4 5-72 5-130 4-24 5-121 5-119 2-31 4-30 4-6 4-6 4 -6 4-7 5-195 5-195 2-60 5-164 2-16 3-57 5-4 5-73 5-37 4-35 5-9 5-76 4-15 1-2 5-lfi5 2-61 5-168 5-129 3-24 3-44 5-122 3-23 3-69 3-71 4-4 4-6 1-2 3-32 4-13 2-23 2-23 3-25 5-19 5-15 5-14 3 27 5-130 5-175 S Safety relief valve ................................ .............. 3-6d 3-23 Salt water standby pumps, fresh and ................. 5-39 5-101 Salvage by eductor ................................ .......... 3-28h 3-72 Salvage pump, fire and................................ .....2-11c 2 24 Salvage pump, fire and................................ .......5 31 5 87 R Radar ................................ ............................. 5-102c 5-187 I-6 Paragraph Page Paragraph Page Sanitary system pumps, fresh water and............ 5-49 Operation ................................ ....................... 2-2s Relief valve................................ ..................... 5-50 Air volume control ................................ .......... 5-51 Pressure switch................................ .............. 5-52 Motor ................................ ............................. 5-53 Scavenging oil transfer pump (#5130)............... 4-16c Scavenging pump, air ................................ ........ 3-16 Scope................................ ................................ .. 1-1 Scraper, cylinder sleeve and rings...................... 3-7d Screw, bottom................................ ................... 5-48i Sea valves, strainers, and sea chests................. 3-29 Searchlight ................................ ...................... 5-104 Searchlight equipment, general........................ 5-103 Searchlight operation................................ ......... 2-30 Seat removal, valve ................................ ....... 5-3c(3) Servicing the equipment, inspecting and.............. 4-2 Shaft, propeller and................................ ............ 3-26 Showers, lavatories and............................... 5-77b(2) Shunt trip................................ ........................... 5-84 (Shutdown) housing, air inlet.............................. 5-18 Sleeve, cylinder and scraper rings...................... 3-7d Speed indicator................................ ................ 5-48h Special tools and equipment................................ 4-4 Spindle bowl ................................ ..................... 5-48f Standby pump lubricating oil .............................. 5-45 Start header air-................................ ............... 4-14d Starter, engine electrical................................ ..... 5-2d Starting aids engine................................ ........... 3-15 Starting, ahead from a stop................................ .. 2-4 Starting motor................................ .................... 5-26 Starting system, air ................................ ............ 4-14 Starting the 4-71 diesel engine......................... 2-11b Station, aft steering control .............................. 5-100 Station operation, aft steering .......................... 2-14d Steering console................................ .............. 5-98d Steering console hand pump, and valves........... 5-98 Steering system operation................................ .. 2-14 Steering system tack wheel operation.............. 2-14b Steering valves ................................ ................. 5-98c Storing system, general ................................ ..... 5-95 Motor and brake................................ ................. 5-96 Stopping the auxiliary set engine...................... 2-11d Stopping the engine................................ ............. 2-6 Stopping the steering system....................... 2-14a(2) Storage, administrative ................................ ........ 1-6 Strainer, fuel filter and................................ ........ 5-15 Strainers, (raw water)................................ ....... 3-29d Stuffing boxes (propeller shaft)......................... 3-26b Switch, bell alarm ................................ .............. 5-86 Switch, disconnect................................ ............. 5-89 Switch, master (capstan) ................................ ... 5-67 Switch, pressure ................................ ................ 5-52 Switches, auxiliary ................................ ............. 5-85 Telephone system, radio................................ .. 5-107 Temperatures, operating (engine model 37F16)1-10u Testing fuel injector................................ ........... 3-12f Testing of radio interference suppression components. 4-11 Motor test................................ ..................... 4-11a Component check ................................ ........ 4-11b Thermometers ................................ .................. 3-20f Thermostats (Thermometer) ............................. 3-20f The engine electrical system.............................. 4-18 Thrust bearing (Kingsbury)................................ . 3-25 Timing system ................................ ................. 4-17d Timing system, valves, camshaft and .................. 5-7 Adjusting valve clearance............................... 5-7d Camshaft and gear train................................ ..5-7c Valves ................................ .............................. 5-7 b Timing system, camshaft and ............................ 4-17 Timing the fuel injection ............................... 4-17d(1) Tools and equipment ................................ ........... 4-3 Tools and equipment, special............................... 4-4 Torque limits (engine model 37F16)................. 1-10q Transfer pump and lines, fuel............................. 5-14 Transfer pump, fuel................................ .............. 3-9 Transfer pump, fuel oil................................ ....... 5-42 Travel, rudder ................................ .................. 5-97b Trick wheel operation, steering system............. 2-14b Trip attachment, overload ................................ .. 5-83 Trip, shunt ................................ ......................... 5-84 Troubleshooting (table 3-3)................................ .. 3-4 Troubleshooting (table 4-3)................................ .. 4-7 5-126 2-20 5-129 5-129 5-129 5-129 4-24 3-47 1-1 3-29 5-125 3-75 5-190 5-188 2-63 5-17 4-1 3-66 5-164 5-168 5-66 3-29 5-124 4-4 5-124 5-113 4-15 5-4 3-47 2-22 5-77 4-10 2-23 5-187 2-35 5-183 5-179 2-33 2-35 5-182 5-173 5-173 2-24 2-23 2-35 1-2 5-57 3-77 3-66 5-169 5-169 5-149 5-129 5-168 5-195 1-7 3-42 4-7 4-7 1-7 3-58 3-58 4-28 3-64 4-28 5 29 5-15 5-29 5-29 4-27 4-28 4-3 4-4 1-7 5-55 3-32 5-101 5-175 2 35 5-168 5-168 3-10 4-6 U Universal joints, couplings and gear boxes......... 5-99 5-18 Under voltage release device............................. 5-82 5-168 Urn, coffee................................ ....................... 5-79b 1-165 V Valve air starting check................................ ...... 3-6e 3-23 Valve, cam operated pilot air............................. 4-19e 4-35 Valve, cylinder compression relief....................... 3-6f 3-24 Valve guide removal exhaust......................... 5-3c(4) 5-17 Valve pressure regulating................................ .. 4-19f 4-35 Valve, relief................................ ........................ 5-50 5-12 Valve rocker cover................................ ............. 5-20 5-14 Valve safety relief ................................ .............. 3-6d 3-23 Valve seat removal ................................ ........ 5-3c(3) 5-17 Valves camshaft and timing system ..................... 5-7 5-29 Valves................................ ............................ 5-7b 5-29 Camshaft and gear train................................ ..5-7c 5-29 Maintenance and adjustment of valve clearance 5-7d 5-35 Valves cylinder head and................................ ..... 3-6 3-20 Valves, hand pump steering console and........... 5-98 5-179 Valves, rocker arms and ................................ 5-3c(2) 5-15 Valves, sea................................ ...................... 3-29b 3-77 Valves steering................................ ................. 5-98c 5-182 Ventilation system data................................ .....1-10k 1-6 Controls ................................ ........................ 2-2m 2-16 Operation................................ ....................... 2-16 2-3 Vibration damper ................................ ............... 5-8e 5-40 Voltage regulator ................................ ............... 5-25 5-76 Voltage regulator and generator.......................... 5-2j 5-9 T Tabulated data................................ ................... 1-10 1-3 Tachometer, indicator ................................ ...... 4-18d 4-29 Tank repair (water)................................ ....... 5-77b(5) 5-164 Tanks and lines, air................................ ............ 5-57 5-141 Tank, water ,................................ ................ 5-77b(4) 5-164 Telephone system, intercommunicating3-28g372 I-7 Paragraph Page Paragraph Page Voltmeter................................ ........................... 5-87 Lavatories and showers............................ 5-77b(2) Water dispenser (cooler) .......................... 5-77b(3) Water tanks................................ .............. 5-77b(4) Tank repair ................................ .................. 5-77b(5) Water pump (propulsion engine) fresh............... 3-18 Water pump (propulsion engine) raw ................. 3-19 Water supply system general............................. 5-76 Water system ................................ .................... 5-77 Water closets................................ ............... 5-77b(1) Water system operation, potable........................ 2-24 Water tanks................................ ................. 5-77b(4) Wear limit tolerance (engine model 37F16).......1-10s Whistles air ................................ .................... 5-110a Whistle/horn system ................................ ........ 5-110 Windlass, anchor................................ ............... 5-61 Motor................................ ................................ . 5-62 Control ................................ .............................. 5-63 Master switch................................ ..................... 5-64 Windshield wiper operation................................ 2-31 Windshield wiper removal................................ 3-28b Wiper operation, windshield............................... 2-31 5-169 5-164 5-164 5-164 5-164 W Water closets................................ ............... 5-77b(1) 5-164 Water cooled exhaust manifold.......................... 5-21 5- 11 Water cooling heat exchanger............................ 1-21 3-58 Water dispenser................................ ........... 5-77b(3) 5-164 Water dispenser (cooler) operation .................... 2-28 2-61 Water inlet header ................................ ............. 3-20 3-57 Water manifold ................................ ................. 5-2m 5-13 Water oil and air pressure gages...................... 4-189 4-29 Water pump drive oil and................................ .. 3-16f 3-51 Water pump (GN1 engine) fresh ......................... 5-2f 5-5 maintenance................................ ................... 5-21 5-72 Water pump (GM engine) raw............................ 5-2e 5-4 maintenance................................ ................... 5-22 5-73 I-8 3-54 3-57 5-162 5-162 5-164 2-59 5-164 1-7 5-197 5-197 5-133 5-145 5-145 5-145 2-63 3-69 2-63 TM 55-1925-204-12 Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A N U M B E R 0105 Air Starting System Air Distributor Reverse Control (Ram) Air Start Header Air Receiver (box) Engine Starting Aids 0106 Air Scavenging Pump System Crankcase Breather Pump, Oil, Hand 0107 Cooling System Pump, Fresh Water Pump, Raw Water Water Manifold (Header) Thermostats Heat Exchanger Anodes 0108 Exhaust System Manifold Silencer and Pipes 0109 Force Feed Lubricator System Drive Assembly Carrier Arm Assembly Pumping Unit 0110 Engine Lubrication System Oil Pump Oil Cooler 0111 (3) Maintenance functions Camshaft and Timing System Camshaft B C G H A L I G N F C A L I B R A T E I N S P E C T T E S T S E R V I C E I N S T A L L R E P L A C E A D J U S T C 0.3 C 0.1 C 0.2 C 0.2 C 0.1 C 0.1 C 0.3 C 0.1 C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.5 C 0.2 .. .. .. .. C 0.4 .. .. .. .. C 0.2 C 0.3 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.0 C 2.0 C 3.0 O 2.0 C 0.2 H 8.0 .. .. C 1.0 C H 2.0 3.0 C H 1.4 3.2 C 4.1 C 3.5 C 2.5 C 1.0 C H 12.0 16.0 C 1.0 C 0.1 C 0.1 C 0.1 C 0.1 C 0.2 C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. C 0.2 C 0.2 .. .. .. .. C 0.5 C 0.1 C 0.5 C 0.5 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.0 C 1.0 C 1.0 C 0.5 H 3.0 C 0.2 C 1.5 C 1.5 C 2.0 C 1.0 C 8.0 C 0.1 C 0.1 C 0.3 C 0.1 C 0.1 C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. C 0.2 C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. O 0.3 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. H C 4.0 6.0 H O 10 0 16.0 H C 1.0 1.5 H F 0.7 1.0 C C 0.8 1.3 C C 1.0 1.5 C 0.1 C 0.1 C 0.2. C 0.2 .. .. .. .. .. .. .. .. C 0.2 C 0.5 .. .. .. .. .. .. .. .. C 1.0 .. .. C 1.5 .. .. C 0.7 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 2.8 H 3.0 .. .. H 8.0 C 3.4 H 3.4 .. .. Bearings Gears and Cams Timing System C 0.3 C 0.2 .. .. .. .. .. .. C 0.4 D E C-3 (4) Tools and equipment (5) Remarks .. .. 12-I, 13-I H-C .. .. 14-I, 15-H I J K R E P A I R O V E R H A U L R E B U I L D H 3.0 H 3.0 I-A H 3.0 H 1.5 C 3.0 C 4.2 C 2.0 H 3.5 .. .. F 2.5 .. .. J-D 16-H K-D TM 55-1925-204-12 Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A Engine Electrical System Instrument Control Panel Pyrometer Meters 0113 Tachometer Upper Base (Crankcase) 0114 Flywheel Assembly Jacking Device Engine Air Brake Assembly Brake Lining Air Cylinder Air Pilot Valve Pressure Regulating Control Valve Pressure Gage 0115 Crankshaft Main Bearings Crankshaft Main Bearings 0116 Lower Base 0117 Thrust Bearings {Kingsbury) 0201 02 GROUP- PROPELLER AND SHAFT Propeller Bearings 0202 B C T E S T S E R V I C E A D J U S T C 02 C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.2 .. .. C .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. O .. .. .. C 0.3 C 0.2 C .. .. .. .. .. .. C 0.1 .. .. C 0.1 .. .. C 0.1 C 0.1 C 0.3 C 0.3 C 0.2 C 0.1 .. .. C 0.4 .. .. C 0.2 C 0.2 C 0.3 C 0.3 C 0.3 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 I N S P E C T N U M B E R 0112 (3) Maintenance functions Shaft, Propeller Stuffing Boxes 0301 03 GROUP- HULL ASSEMBLY Hatches 0302 Doors 0303 Port Lights C 0.1 .. .. O 0.1 D E (4) Tools and equipment G H A L I G N F C A L I B R A T E I N S T A L L R E P L A C E .. .. C 0.4 .. .. C .. .. .. .. .. .. C 0.1 C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. H 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. O 0.6 C 0.5 C .. .. H 24.0 C 1.0 H 8.0 C 4.0 C 1.0 C 0.5 C 1.0 C 0.9 C 0.3 O 0.8 C 0.8 H 1.0 H 1.3 .. .. C .. C 0.2 H 4.0 C 0.4 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. H 40.0 C 16.0 H 40.0 H 20.0 .. .. .. H 30.0 .. C 8.0 H 32.0 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. H H H 40.0 16.0 24.0 H 4.0 H H H 16.0 24.0 32.0 .. .. .. .. .. .. .. .. .. .. .. C 0.2 C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. H 8.0 C 0.8 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.0 C 0.5 C 0.5 C-4 I J K R E P A I R O V E R H A U L R E B U I L D C 8.0 H 10.0 C 0.5 C 0.5 H 6.0 (5) Remarks C 1.5 C 1.0 C 0.5 C 0.5 L-A, L-D .. M-D TM 55-1925-204-12 Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A N U M B E R 0304 Sea Valves 0305 Piping 0306 Strainers 0307 Sea Chests 0308 Items: Windshield Wipers Intercom Devices Telegraph and Indicator Eductor System 0401 04 GROUP - AUXILIARY SET AND RELATED SYSTEMS: Engine Assembly, Diesel Cylinder Head Pistons and Connecting Rods Ring Sets Cylinder Liner Bearings Flywheel Assembly and Housing Valves, Camshaft, and Timing Systems Valves, Guides Seats and Springs Camshaft and Gear Train Crankshaft Main Bearings Cylinder Block 0402 (3) Maintenance functions Lubricating Oil System Oil Pump Oil Filter Oil Cooler B C D I N S P E C T T E S T S E R V I C E A D J U S T C 0.2 C 0.3 C 0.1 C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. C 0.2 C 1.0 C 0.1 C 0.1 C 0.2 C 0.2 .. .. .. .. C 02 .. .. C 0.3 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 E J K R E P A I R O V E R H A U L R E B U I L D (5) Remarks N-H G H A L I G N F C A L I B R A T E I N S T A L L R E P L A C E .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. H 4.0 H 2.0 C 0.3 C 0.2 C 0.3 C 0.3 C 0.2 .. .. .. .. C 0.5 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.5 C 1.2 .. .. .. .. C 0.5 C 1.4 C 1.3 C 0.5 C 1.0 .. .. .. .. .. .. .. .. .. .. .. .. C 0.5 C 0.2 .. .. .. .. C 0.2 C 0.1 .. .. C 0.3 .. .. .. .. .. .. .. .. .. .. .. .. C 0.4 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F 16.0 C 2.0 C 1.0 C 1.0 C 4.0 C 2.0 C 2.3 C 8.0 C 2.4 C 1.5 H 24.0 H 4.0 .. .. .. 17-H .. .. 18-H, 19-H 20-H .. .. .. 21-H C 0.1 .. .. .. .. C 0.3 .. .. .. .. .. .. C 1.6 C 2.8 .. .. C 0.2 .. .. .. .. C 0.5 .. .. .. .. C 2.4 .. .. .. .. .. .. C 0.1 C 0.1 C 0.2 C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.2 .. .. .. .. .. .. .. .. .. .. C 0.5 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 4.0 C 20.0 C 10.0 O 6.0 C 4.0 C 8.0 C 0.2 C 0.1 C 0.1 .. .. .. .. .. .. C 0.2 C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 6.0 C 0.2 C 6.0 C 8.0 C 0.2 C 6.0 C-5 I (4) Tools and equipment H 6.0 C 5.0 H 3.0 C 1.5 H C 6.0 H 8.0 O-D 22-H, 23-H 24-H, 25-H 26-H, 27-H 28-H Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A N U M B E R 0403 Fuel System Fuel Injectors Fuel Transfer Pump Fuel Filter and Strainer Governor, Hydraulic Controls 0404 Air Intake System Air Cleaner Air Inlet (Shutoff) Housing Blower Assembly 0405 Cooling System Heat Exchanger Thermostat Housing Thermostat Oil Cooler Fresh Water Pump Raw Water Pump Water Manifold 0406 Exhaust System Manifold (Water Cooled) Muffler and Pipes 0407 Electrical System Generator Voltage Regulator Starting Motor Storage Batteries 0408 (3) Maintenance functions Instrument Control Panel Thermometer, Indicating Gage, Oil Pressure Ammeter Tachometer B C D I N S P E C T T E S T S E R V I C E A D J U S T C 0.1 C 0.1 C 0.1 C 0.1 C 0.2 C 0.2 .. .. .. 0.2 O 0.2 .. .. C 0.2 C 0.1 C .. C 0.3 .. .. C 0.1 .. .. C 0.1 C 0.2 E G H A L I G N F C A L I B R A T E I N S T A L L .. .. .. .. .. .. C 0.5 C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.2 .. .. .. .. .. .. .. .. .. C 0.1 C 0.3 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.3 C 1.3 C 0.1 C 0.1 C 0.1 C 0.1 .. .. .. .. .. .. .. .. C 0.1 .. .. .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.4 C 0.4 C 0.3 C 1.0 C 1.5 C 1.5 C 0.1 C 0.1 .. .. .. .. C 0.1 C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.8 C 1.0 C 1.2 C 1.3 C 0.1 C 0.1 .. .. .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.0 O 1.4 C 1.0 C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.2 C 0.2 C 0.1 .. .. .. .. .. .. .. .. .. .. C 0.2 .. .. C 0.1 C 0.2 .. .. C 0.1 C 0.1 C 0.1 C 0.1 C 0.3 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.5 C 0.4 C 0.5 C 0.3 0 0.5 C 0.4 C 0.3 C 0.3 C 0.3 C-6 I J K R E P L A C E R E P A I R O V E R H A U L R E B U I L D C 1.0 C 1.0 C 0.2 C 1.0 C 0.5 C 1.0 C 1.3 C 0.5 H 1.5 C 0.8 C 2.0 F 1.5 C 0.6 P-H .. 29-H .. 30-I, 31-I H 2.0 .. H 2.8 C 1.5 C 2.0 (5) Remarks H 1.0 H 1.6 C 0.2 C 1.5 (4) Tools and equipment H 1.5 H 1.6 Q-D Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A N U M B E R 0408 Instrument Control Panel (Cont'd) Drive Starter Push Switch 0409 Generator, (Delco 1-3644) Rotor Brushholders Frame Support and Housing Drive Clutch (CL208) 0410 Fire and Salvage Pump 0501 05GROUP-PUMPS, GENERAL Bilge and Ballast Pump (#5531) Priming Pump Motor Controller 0502 Fire Pump (#58741 Motor Controller 0503 Fresh and Raw Water Standby Pump (#5532) Motor Controller 0504 Fuel Oil Transfer Pump (#A313A148) Motor Controller 0505 Lubricating Oil Standby Pump (#A322AX250) Motor Controller 0506 (3) Maintenance functions Lubricating Oil Purifier B C D I N S P E C T T E S T S E R V I C E A D J U S T C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.2 .. .. .. .. C 0.3 .. .. .. .. .. .. .. .. .. .. C 0.3 .. .. .. .. C 0.3 C 0.2 C 0.1 .. .. .. .. .. .. C 0.2 C 0.2 C 0.1 C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 C 0.3 C 0.2 C 0.2 .. .. C 0.3 C 0.2 .. .. C 0.1 C 0.1 C 0.1 E (4) Tools and equipment G H A L I G N F C A L I B R A T E I N S T A L L R E P L A C E .. .. .. .. C 0.4 .. .. .. .. .. .. .. .. C 0.3 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.4 C 0.3 C 6.0 C 2.0 C 0.3 C 1.6 C 0.5 C 1.0 C 4.0 C 0.2 C 0.2 C 0.2 C 0.2 C 0.2 C 0.2 C 0.2 .. .. .. .. C 0.1 .. .. .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.2 C 0.2 .. .. C 0.1 C 0.1 C 0.1 .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.1 C 0.1 C 0.1 C 0.2 C 0.2 .. C 0.1 C 0.1 C 0.1 .. .. C 0.1 .. .. .. .. .. .. .. .. C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 .. .. C 0.2 C 0.1 C 0.1 C 0.1 C 0.2 .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. C-7 I J K R E P A I R O V E R H A U L R E B U I L D C 8.0 H 2.0 C 0.4 C 1.9 H 20.0 C 6.0 H 16.C C 4.0 C 1.0 C 1.0 .. .. C 4.0 C 1.0 C 0.5 C 6.0 C 1.5 C 1.5 C 0.7 C 6.0 C 1.5 H 16.0 .. .. .. .. .. .. C 1.0 C 0.5 .. .. C 1.0 C 1.0 C 0.7 H 8.0 H 2.0 .. .. .. .. .. .. .. .. .. .. .. .. C 1.0 C 0.5 .. .. C 1.0 C 1.0 C 0.7 H 6.0 H 1.5 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.0 C 0.5 .. .. C 1.0 C 1.5 C 1.0 C 0.7 H 1.4 H 6.0 J 1.5 H 2.0 H 2.0 (5) Remarks Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A N U M B E R 0506 Lubricating Oil Purifier (Cont'd) Frame Cover and Inlet Arm Purifier Bowl Clutch Assembly Pump and Relief Valve Bowl Spindle Brake Speed Indicator Bottom Screw Heater and Filter Unit Motor 0507 (3) Maintenance functions Controller Fresh Water System Pump (#1892) Relief Valve Air Volume Control Pressure Switch Motor 0508 Rotary Hand Pumps 0601 06 GROUP- PNEUMATIC EQUIPMENT Air Compressor Cylinder Head Pistons and Connecting Rod Valves Drive Belts Switches, Pressure Air Intake Silencer 0602 Lubrication System 0603 Tanks and Lines 0604 Motor 0605 Controller B C D I N S P E C T T E S T S E R V I C E A D J U S T C 0.1 C 0.1 .. .. .. .. .. .. .. .. C 0.2 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C .. .. C 0.3 .. .. .. E (4) Tools and equipment G H A L I G N F C A L I B R A T E I J K I N S T A L L R E P L A C E R E P A I R O V E R H A U L R E B U I L D .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.4 C 0.2 C 0.6 C 0.2 .. .. 32-I .. .. .. .. 33-I, 34-I 35-I, 36-I 37-I .. .. C .. C 3.2 .. .. .. C 0.1 C 0.1 C 0.1 C 0.1 .. 0.2 C 0.1 C .. .. .. .. C 0.2 .. .. .. .. .. .. C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 2.0 C 1.0 C 1.0 C 1.0 C 0.2 C 2.0 C 2.0 .. C 3.0 C 2.0 C 2.0 C 1.0 H 3.0 .. 38-I C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.2 .. .. .. .. .. .. C 0.1 .. .. C 0.1 C 0.1 C 0.1 C 0.2 C 0.2 C 0.2 .. .. .. .. .. .. .. .. C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.0 C 0.5 C 0.5 C 0.5 C 1.0 C 2.0 C 1.0 H 6.0 .. 39-I C 2.0 C 2.0 H 3.0 C 0.3 C 0.1 C 0.2 C 0.2 C 0.1 C 0.1 C 0.1 C 0.2 C 0.2 C 0.1 C 0.1 C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.1 .. .. C 0.2 .. .. C 0.2 C 0.1 .. .. C 0.1 C 0.1 C 0.2 C 0.2 C 0.1 C 0.1 C 0.2 .. .. .. .. C 0.5 C 0.1 .. .. .. .. .. .. .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 2.0 C 0.5 C 2.0 C 1.0 C 0.1 C 0.2 C 0.5 .. .. H 8.0 C 2.0 .. .. C 3.0 C 0.5 H 10.0 C-8 C 1.0 C 2.0 C H 3.0 C 1.0 C 2.0 C 2.0 C 3.0 C 1.0 (5) Remarks H 3.0 .. R-I Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A N U M B E R 0701 07 GROUP- ANCHOR WINDLASS CAPSTAN Anchor Windlass Handbrake 0702 Capstan Motor Control Master Switch 0801 08 GROUP-HEATING SYSTEM Heating Boiler Burner and Ignition Motor and Fan Assem. Fuel Unit (Pump) Exhaust System Fuel System Controls 0901 09 GROUP--VENTILATING SYSTEM Centrifugal Blower Assembly Motor Starter Switch Controller 0902 (3) Maintenance functions Axial Blower Assembly Motor Starter Switch Controller 1001 10 GROUP-WATER SUPPLY SYSTEM Water Closet 1002 Lavatory and Shower 1003 Water Cooler (Dispenser) 1004 Tanks B C D I N S P E C T T E S T S E R V I C E A D J U S T C 0.2 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 .. .. C 0.1 .. .. .. .. .. .. C 0.1 C 0.2 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 H 0.3 .. .. .. .. .. .. .. .. .. .. O 0.2 C 0.2 C 0.1 C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.2 E (4) Tools and equipment G H A L I G N F C A L I B R A T E I J K I N S T A L L R E P L A C E R E P A I R O V E R H A U L R E B U I L D .. .. .. .. .. .. .. .. C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. F 8.0 C 2.0 F 8.0 C 6.0 .. .. O 2.0 O 8.0 C 1.0 0 8.0 C 8.0 C 4.0 O 4.0 C 0.4 C 0.2 C 0.1 C 0.2 .. .. C 0.1 C 0.1 .. .. C 0.2 .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. H C H 20.0 10.0 30.0 C C 2.0 3.0 C C H 1.5 2.0 3.0 C C H 1.5 2.0 8.0 .. C .. 2.0 F C 3.0 2.0 C O 2.0 1.0 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.2 C 0.1 C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 .. .. .. .. .. .. C 0.2 .. .. .. .. .. .. C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. H 10.0 O 6.0 C 0.3 C 0.5 H 10.0 O 6.0 C 0.3 C 0.5 C 4.0 C 8.0 C 0.5 C 0.5 C 4.0 C 8.0 C 0.5 C 0.5 .. .. .. .. .. .. H 0.2 C 0.2 C 0.2 C 0.1 C 0.5 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. H 4.0 H 4.0 H 4.0 .. .. C 1.0 C 1.0 C 1.0 0 3.0 C-9 (5) Remarks H 30.0 .. S-I H 16.0 .. S-I .. .. T-C H 16.0 H 16.0 U-D Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A N U M B E R 1101 11 GROUP-FOOD PREPARATION SYSTEM Coffee Urn Immersion Heater 1102 Galley Range Burner Assembly Motor 1103 Refrigerator 1104 Freezer 1201 12 GROUP--MAIN ELECTRICAL SYSTEM Electrical Control Panel Control Resistance 1202 Signaling Devices (Warning System) Buzzer-Navigation Light Panel Alarm, General Alarm, Control Panel 1203 Instruments Voltmeters Ammeters 1204 Switches Auxiliary Switch Disconnect Switch 1205 (3) Maintenance functions Panels: Battery Charging Navigation Lighting General Lighting 13 GROUP- STEERING SYSTEM (marine Steering) 1301 Motor Assembly Armature B C D I N S P E C T T E S T S E R V I C E A D J U S T C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 .. .. .. .. .. 0.1 .. .. .. .. .. .. .. .. C 0.1 C 0.1 C .. C 0.1 C 0.1 C 0.1 C 0.1 C 0.3 C 0.1 .. .. .. .. C 0.1 E (4) Tools and equipment G H A L I G N F C A L I B R A T E I N S T A L L R E P L A C E .. .. .. .. .. .. C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. O 2.0 C 1.0 .. .. C 1.0 .. .. .. .. .. .. C 1.0 C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.0 C 0.5 C 0.1 C 0.1 .. .. .. .. .. .. .. .. C 0.3 C 0.1 C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 .. .. C 0.1 C 0.1 C 0.2 C 0.1 C 0.1 .. .. .. .. .. .. .. .. C 0.1 C 0.1 .. .. .. .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. D 0.3 D 0.2 D 0.2 .. .. .. .. .. .. C 1.0 C 1.0 C 0.5 .. .. .. .. .. .. C 0.3 C 0.3 C 0.3 C 0.3 C 0.3 C 0.3 .. .. .. .. .. .. C 0.3 C 0.3 C 0.3 C 0.1 C 0.1 C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.3 C 0.3 C 0.3 C 0.2 C 0.1 .. .. .. .. C 0.2 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 0 8.0 0 8.0 C-10 I J K R E P A I R O V E R H A U L R E B U I L D H 6.0 H 4.0 H 4.0 H 8.0 H 6.0 H 6.0 C 1.0 C 2.0 C 1.0 C 0.5 C 2.0 C 2.0 .. .. .. .. .. .. C J 16.C 30.0 F 20.0 (5) Remarks Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A N U M B E R 1301 (3) Maintenance functions Motor Assembly (Cont'd) Brake Assembly 1302 Control Assembly 1303 Steering Console (stand) 1304 Gear Boxes 1305 Hydraulic Ram 1306 Rudder Assembly 1307 Hydraulic Pump 1308 Steering Valves 1309 Aft Steering (Remote Control) 1401 14 GROUP-NAVIGATION EQUIPMENT Gyro Compass 1402 Magnetic Compass 1403 Radar System Transmitter and Receiver Antenna Motor Generator B C D I N S P E C T T E S T S E R V I C E A D J U S T C 0.1 C 0.1 C 0.1 C 02 C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 .. .. .. .. .. .. .. .. .. .. C 0.2 .. .. .. .. C 0.1 C 0.2 C 0.1 C 0.1 C 0.5 C 0.3 .. .. C 0.2 C 0.1 C 0.1 C 0.2 .. .. .. .. C 0.3 C .. C 0.2 C 0.1 C 0.1 C 0.1 C 0.1 C 0.1 C 0.3 C 0.1 C 0.1 C 0.1 0 0.1 .. .. 0 0.2 .. .. .. .. .. .. C 0.2 C 0.1 C 0.3 C 0.1 C 0.1 C 0.1 C 0.1 H 2.0 C 0.1 .. .. .. .. .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.1 C 0.1 C 0.3 O 0.3 E (4) Tools and equipment G H A L I G N F C A L I B R A T E I N S T A L L R E P L A C E .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. I J K R E P A I R O V E R H A U L R E B U I L D .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. O C H 2.0 2.0 3.0 .. C .. 0.5 .. C .. .. 4.0 O O 2.0 2.0 .. F .. 0.4 H H D 40.0 20.0 40.0 O C H 8.0 8.0 20.0 .. C .. 1.0 .. C .. 2.0 .. .. D 4.0 .. .. H 4.0 O 1.0 .. .. .. .. .. .. D 10.0 .. .. .. .. .. .. .. .. .. .. H C 16.0 16.0 H 16.0 O C H 4.0 4.0 12.0 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. O 2.0 C 1.0 C 1.0 C 1.0 C 0.2 C 0.1 .. .. .. .. .. .. .. .. C 0.2 C 0.3 .. .. .. .. .. .. .. .. C 0.3 O H 4.0 200.0 H 20.0 (5) Remarks .. V-H .. W-B .. X-I .. Y-C 15 GROUP-SEARCHLIGHT AND IL,LUMINATING EQUIPMENT 1501 Searchlight and Running Lights Lamps, Lense and Gaskets wiring Reflector Lamps 16 GROUP --RADIO INTERFERENCE SUPPRESSION 17 1701 GROUP-FIRE FIGHTING EQUIPMENT Portable Fire Fighting Equipment C 0.2 C 0.5 C 0.2 C 0.2 Change 1 C-11 C 1.0 O 0.3 .. Section II. MAINTENANCE ALLOCATION CHART (1) G R O U P (2) Functional group A N U M B E R 1702 (3) Maintenance functions Fixed Fire Fighting Equipment Remote Control Piping Control Valve (Head) Siren (Warning) 1701 17 GROUP- FIRE FIGHTING EQUIPMENT Portable Fire Fighting Equipment 1702 Fixed Fire Fighting Equipment Remote Control Piping Control Valve (Head) Siren (Warning) 1801 18 GROUP--RADIO TELEPHONE SYSTEM Transmitter and Receiver 1802 Converter 1803 Power Panel 1901 19 GROUP-WHISTLE/HORN Whistle, Air 1902 Horn Electric 2001 20 GROUP- LIFE BOAT DAVIT Davit B C D I N S P E C T T E S T S E R V I C E A D J U S T C 0.3 C 0.1 C 0.1 C 0.5 C 0.1 D 0.5 .. .. .. .. .. .. D 0.2 C 0.3 C 0.1 .. .. C 0.5 C 0.1 C 0.3 C 0.3 C 0.1 C 0.1 C 0.5 C 0.1 O 0.3 D 0.5 C .. .. .. .. .. D 0.2 C 0.1 C 0.1 C 0.1 E (4) Tools and equipment G H A L I G N F C A L I B R A T E I N S T A L L .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.3 C 0.3 .. 0.1 .. .. C 0.5 C 0.1 .. .. .. .. C 0.1 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.2 C 0.1 C 0.1 .. .. .. .. .. .. C 0.1 C 0.1 .. .. .. .. C 0.1 C 0.1 C 0.1 .. .. C 0.2 (5) Remarks I J K R E P L A C E R E P A I R O V E R H A U L R E B U I L D .. .. .. .. .. .. .. .. .. .. O 20.0 .. .. O 2.0 O 0.8 O 0.5 C 1.0 C 0.5 C 0.5 C 0.3 C 0.3 .. .. Z-C .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 0.3 O 20.0 .. .. O 2.0 O 0.8 O 0.5 O 0.3 C 1.0 C 0.5 C 0.5 C 0.3 C 0.3 .. .. Y-C .. .. Z-C .. .. .. .. .. .. D 4.0 .. .. .. .. .. .. .. .. .. .. H 1.0 O 0.5 O 0.5 C 2.0 C 2.0 C 2.0 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. C 1.0 C 1.0 C 0.5 C 0.5 .. .. .. .. .. .. .. .. H 8.0 H 1.0 C-12 Change 1 H 8.0 Section III. SPECIAL TOOLS AND TEST EQUIPMENT Reference code 1-H 2-H 3-H 4-H 5-H 6-H 7-I 8-I 9-I 10-I 11-I 12-I 13-I 14-I 15-H 16-H 17-H 18-H 19-H 20-H 21-H 22-H 23-H 24-H 25-H 2G-H 27-H 28-H 29-H 30-I 31-I 32-I 33-I 34-I 35-I 36-I 37-I 38-I 39-I Maintenance category C C C O O O C C C C C C C C H C C C C C C C C C C C C C C C C C C C C C C C C Tool number Nomenclature Wrench, piston pin bracket nut Guide, connecting rod Guide, piston ring Wrench, upper base to cylinder nut Plate, sleeve lifting Puller, discharge valve seat Gage, injection setting Drill, injector valve tip Lever, priming pump Tester, diesel fuel injector nozzle Wrench Wrench Clamp, scavenging pump piston Wrench, scavenging pump piston and flywheel hub bolt Puller, main bearing half Wrench, main bearing nut Wrench, box Reamer, fixture, set Reamer set Driver, bearing and bushing Remove, cylinder liner Driver, valve seat insert Installer, valve guide Remover, pushrod Remover, valve guide Remover, valve seat insert Cleaner, valve guide Test set, diesel engine Remover, injector valve spring Tool set, fuel pump Wrench, fuel pump Drift, forged steel point Wrench, bowl coupling Wrench, spanner Stand, bowl Scoop, bowl shell Clamp, bowl top lifting Wrench, nut, combination Wrench 5120-362-6626 5120-362-6621 5120-362-6620 5120-362-6627 5120-522-2885 5120-522-2880 2815-363-2284 5120-362-6619 2910-362-6270 4910-255-8641 5120-363-0956 5120-415-2378 2815-363-2282 5120-363-0960 5120-362-6624 5120-363-0957 5120-494-1915 4910-219-8392 4910-789-2104 5120-363-7572 (33287) J1918-02 5120-423-6723 5120-706-5588 5120-724-8447 5120-473-7392 5120-706-5586 5120-766-2141 4910-690-8452 5120-219-8400 5180-219-8407 5120-494-1928 5120-213-0460 5120-152-2420 5120-317-2518 4330-774-6438 4330-213-0425 4330-163-0159 5120-213-0352 4320-073-2138 Section IV. REMARKS Reference Reference code Remarks, code A-E/A-J Engine Assembly- Alignment and Overhaul is F-B usually performed during the 24 month period dry docking required by AR 750-29. B-H Cylinder head: When cylinder head is replaced, the piston-cylinder head clearance should be G-D from 0.062 inch to 0.094 inch with the engine cold. C-H Piston Rings: Clean all carbon from ring grooves, to be effective, rings must move freely in H-C grooves. D-H Connecting Rod: When a new connecting rod has been fitted, inspect it at intervals after the engine has been started and apply load gradually. E-D Injection Pump: Each cylinder has its own inI-A jection pump. Each pump is to deliver the same amount of fuel. C-13 Remarks Fuel Injector: The fuelinjector nozzle should open at 2,500 PSI. Remove shims to increase opening pressure and add shims to decrease opening pressure. Overspeed Governor: Overspeed governor is to be adjusted to trip the cut out mechanism when the engine attains a speed of from 350 to 370 rpm. Air Start System: When engine has been shut for a considerable period, blow out all air lines to free them of dirt, scale, etc. Lubricate the air start check valves in the cylinder heads by disconnecting the pivot air tube from the check valve and pouring in a teaspoonful of oil. Cooling System: The recommended engine operating temperature is 130-140 °F. Reference code Remarks J-D Force Feed Lubricator: The force feed lubricator supplys positive lubrication to cylinders and scavenge pump sleeves. Adjustment can be made at a lower engine speed by reducing the number of drops per minute proportionate with the speed. K-D Timing System: Do not change the injection timing by more than (1 ) at a time. Check engine operation and firing pressures after each change is made. L-A/L-D Main bearings: Adjustment of main bearings is necessary when there is excessive clearance between crankshaft and bearing cap. Proper clearance is from 0.004 to 0.006 inch. Excessive clearance may be indicated by loss of pressure in the lubricating system. M-D Packing: Packing gland is to be tightened evenly and only enough to properly seat the packing, allowing a small water drip. Do not overtighten. N-H Cylinder Head: Care should be taken to prevent damage to cylinder head and injector spray tips. O-D Valves: Valves may be adjusted while engine is hot or cold. P-H Fuel Injector: When the fuel injector is replaced, do not run engine until injector racks have been properly positioned. Reference code Q-D H-I S-I T-C U-D V-H W-B X-l Y-C Z-C C-14 Remarks Governor: Fuel injectors must be properly timed before engine is started to adjust governor. Air Compressor: System should be bled of air pressure, or shutoff valves closed before performing repairs. Windlass and Capstan: Care should be taken to protect equipment and parts from the weather while disassembled for repair. Controls: Condensation and moisture must not be allowed to accumulate inside controls. Equipment must be thoroughly dry before operation. Burner Assembly: Burner requires adjustment when rumbling, pulsating, or smokey stack gases occur. Worm Wheel: The worm wheel shell and worm wheel ring should be replaced as a set. Steering System: Rudder should travel 90 °; (45 o right rudder and 45°left rudder). Time of travel for the 90 °should not exceed 12 seconds. Gyrocompass Repair. See TM 55-6605-261-15 and TM 55-6605-261-25P. Fire Extinguishers: (portable) Recharging of the portable CO 2 fire extinguishers will be accomplished at organizational level. Fire Extinguishers: (Fixed) Recharging of the fixed 50 lb CO 2 cylinders will be accomplished at depot level. By Order of the Secretary of the Army: Official: VERNE L. BOWERS Major General, United States Army, The Adjutant General. FRED C. WEYAND General, United States Army, Chief of Staff. Distribution: To be distributed in accordance with DA Form 12-25D, (qty rqr block no. maintenance requirements for Marine Equipment: ALL. 8131 Operator U.S. GOVERNMENET PRINTING OFFICE 1990 - 0-261-872-(20407) PIN : 012459-000 This fine document... Was brought to you by me: Liberated Manuals -- free army and government manuals Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly available information, slap “watermarks” and other junk on it, and sell it. Those masters of search engine manipulation make sure that their sites that sell free information, come up first in search engines. They did not create it... They did not even scan it... Why should they get your money? Why are not letting you give those free manuals to your friends? I am setting this document FREE. This document was made by the US Government and is NOT protected by Copyright. Feel free to share, republish, sell and so on. I am not asking you for donations, fees or handouts. If you can, please provide a link to liberatedmanuals.com, so that free manuals come up first in search engines: Free Military and Government Manuals – Sincerely Igor Chudov http://igor.chudov.com/ – Chicago Machinery Movers

Tm-55-1925-204-12

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