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Full text of "Technical_manual_boat_bridge_erection_inboard_diesel_engine,Aluminium_hull"

TECHNICAL MANUAL 



OPERATOR AND ORGANIZATIONAL 

MAINTENANCE MANUAL 

BOAT, BRIDGE ERECTION; 

INBOARD DIESEL ENGINE; 

ALUMINUM HULL; 27 FT LG 

(ALUMINUM COMPANY OF AMERICA 

MODEL HICE-27D) 

FSN 1940-182-3097 



This copy is a reprint which includes current 
pages from Changes l through 4. 



HEADQUARTERS, DEPARTMENT OF THE ARMY 



JUNE 1974 



WARMING 

DANGEROUS GASES 
are generated as a result of operating this equipment. 

DEATH 

or severe injury in personnel may result if personnel 
fail to observe safety precautions. 

Do not operate the engines in an enclosed area unless 
it is adequately ventilated. 

Carbon monoxide is a colorless, odorless, deadly poisonous gas 
which when breathed, deprives the body of oxygen and causes suffocation. 

Be alert to symptoms of exposure to carbon monoxide, 

which are headache, dizziness, drousiness, 

loss of muscular control and coma. 

WARNING 

FIRE AND EXPLOSION HAZARD 

Do not smoke or use open flame when servicing the batteries. 

Batteries generate hydrogen, which is a highly explosive gas. 

Also, be extremely careful to avoid grounding the positive 

terminal to the boat structure. 

WARNING 

CLEANING SOLVENT PD-680 is a potentially DANGEROUS CHEMICAL. 
Do not use near an open flame. 

WARNING 

NOISE HAZARD 

Operation of this equipment presents a noise hazard. 
Wear ear muffs or ear plugs to avoid ear injury 

when noise level is excessive. 

There is a potential noise hazard when 

engine speed exceeds 1200 RPMs. 

Wear a life preserver aboard the boat at all times. 




Changes in force: 1, 2 and 3 

TM 5-1 940-221-1: 
C4 

v HEADQUARTERS 

CHANGE I DEPARTMENT OF THE ARMY 

> Washington, D.C., 20 June 1988 
No. 4 \ 

' Operator and Organizational Maintenance Manual 

BOAT, BRIDGE ERECTION, SNBOARD DIESEL ENGINE, 

ALUMINUM HULL, 27 FT LG 

(ALUMINUM COMPANY OF AMERICA MODEL HICE-27D) 

(HIGHWAY PRODUCTS MODEL HPI-27C MODDED) 

(HIGHWAY PRODUCTS MODEL HPI-27B MODDED) 

(MARINETTE MARINE CORP. MODEL A27 MODDED) 

NSN 1940-00-417-0526 



TM 5-1940-221-12, 17 June 1974, is changed as follows: 

Pages B-l through B-10, Appendix B, Section I through IM is superseded by 
new appendix B, Section I through IV. 





5-1940-221-12 




a - General This MAC 

. T ta i ,, 



Section I. INTRODUCTION 



. . 






. 



^ 

J 






Float (OR Pi ,- , 
(ORF) stocks 



,n support of the theater. 



i 



TM 5-1940-221-12 

d. Depot Maintenance. Depot level functions are authorized as indicated by entries in the Depot (D) 
Maintenance level column (4) in the MAC. 

B-2. USE OF THE MAINTENANCE ALLOCATION CHART, SECTION II 

a. The MAC assigns maintenance functions based on the following considerations: 

(1) Skills available. 

(2) Work time required. 

(3) Tools and test equipment required and/or available. 

b. If a lower level of maintenance identified in column (4) of the MAC cannot perform all tasks of a 
single maintenance function (e.g., test, repair), then the higher level that can perform other tasks of that 
function is also indicated. 

c. Higher maintenance levels are automatically authorized to perform maintenance functions assigned 
to a lower maintenance level. 

d. Higher maintenance levels will perform the maintenance functions of lower maintenance levels when 
required or directed by the Commander who has authority to direct such tasking. 

e. Assignment of a maintenance function in the MAC does not carry automatic authorization to carry 
the related spare or repair parts in stock. Information to requisition or secure parts will be as specified in 
the associated RPSTL. 

f . Normally, there will be no deviation from the assigned level of maintenance. However, in cases of 
operational necessity, maintenance functions assigned a higher level may, at the request of the lower level, 
be assigned to the lower level on a one-time basis, if specifically authorized by the maintenance officer ~of 
the higher level to which the function is assigned. In such a case, the special tools, equipment, etc., required 
by the lower level to perform this function will be furnished by the higher level assigned the function. Also, 
transfer of a function to a lower level does not relieve the higher level of responsibility for the function, so 
the higher level will provide technical supervision and inspection of the function being performed at the 
lower level. 

B-3. MAINTENANCE FUNCTIONS 
Maintenance functions will be limited to and defined as follows: 

a. Inspect. Two levels of inspect are covered in the MAC. 

(1) When prescribed at the C or O element of Unit Maintenance level, inspect means to determine 
serviceability by comparing an item's physical, mechanical, and/or electrical characteristics with estab- 
lished standards through examination (i.e., by sight, sound, or feel). These inspections are included in 
preventive maintenance (PM) checks and services, such as PMCS, PMD. 

(2) When prescribed at the Intermediate (F) or Depot (D) maintenance level, inspect refers to an initial 
inspection which is conducted prior to scheduling any repair on repairable items evacuated to this level. 
This inspection is made to determine whether an item qualifies for repair or discard. 

b. Test. To verify serviceability and detect incipient failure by measuring the mechanical or electrical 
characteristics of an item and comparing those characteristics with prescribed standards. 



TM 5-19.40-221-12 

c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean 
(includes decontaminate), to preserve, to drain, or to replenish fuel, lubricants, hydraulic fluids, or com- 
pressed air supplies. 

d. Adjust. To maintain within prescribed limits, by bringing into proper or exact position, or by setting 
the operating characteristics to the 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 equipment used in precision measurement. Consists of comparison of two instru- 
ments, 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, a 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 in appropriate technical publica- 
tions (i.e., DMWR). Overhaul is normally the highest degree of maintenance performed by the Army. 
Overhaul does not normally return an item to a like new condition. 

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 material maintenance applied to Army equipment. The rebuild operation includes the act of returning to 
zero those age measurements (hours/miles, etc.) considered in classifying Army equipment/components. 

B4. EXPLANATION OF COLUMNS IN THE MAC, SECTION II 

a. Column (1), Group Number. Column 1 lists functional group code numbers which are assigned to 
identify maintenance significant components, assemblies, subassemblies, and modules to their next higher 
assembly. 

b. Column (2), Component/Assembly. Column 2 contains the item names of components, assemblies, 
subassemblies, and modules for which group numbers (column 1) are assigned and for which maintenance is 
authorized. 

c. Column (3), Maintenance Function. Column 3 lists the functions to be performed on items listed in 
column 2. (Function definitions are contained in paragraph B-3). 

d. Column (4), Maintenance Level The maintenance levels, Unit, intermediate, and Depot, are allotted 
separate subcolumns within column 4. Entry of a work time figure (such as 1.0, 0.2) in a subcolumn 
indicates that that level is authorized to perform the function listed in column 3, and the average time re- 
quired to do the function is the work time figure. If the number or complexity of tasks within a main- 
tenance function varies from one maintenance level to another, the applicable work time figure for each 
level will be entered for that function. The work time figure represents the average time it takes to restore a 
component/assembly to a serviceable condition under a typical field operating environment. 



TM 5-1940-221-1 

e Column (5), Tools and Equipment. Column 5 specifies, by code, common tool sets (not individual tools 
from those sets), common TMDE, and special tools, TMDE, and support equipment required to perform a 
designated function. The code in Column 5 keys to the listing in Section III of the MAC. 

f. Column (6), Remarks. This column, when applicable, contains a letter code which is keyed to an 
explanation of the code contained in Section IV of the MAC. 

B-5. EXPLANATION OF COLUMNS IN THE MAC, SECTION III 

a. Column (1), Tool or Test Equipment Reference Code. The tool or test equipment reference code cor- 
relates with a code used in the MAC, Section II, Column 5. 

b. Column (2), Maintenance Category. The lowest category of maintenance authorized to use the tool or 
test equipment. 

c. Column (3), Nomenclature. Name or identification of the tool or test equipment. 

d. Column (4), National/NATO Stock Number. The national stock number of the tool or test equipment. 

e. Column (5), Tool Number. The rr inuf acturer 's part number. 

B-6. EXPLANATION OF COLUMNS IN THE MAC, SECTION IV 

a. Column (1), Reference Code. The code recorded in Column 6, Section II. 

b. Column (2), Remarks. This column lists information pertinent to the maintenance function being per- 
formed as indicated in the MAC, Section II. 



i 



TM 5-1940-221-1 2 



(2) 



" Boat, Bridge 



NUMBER-. ASSEMBLY 



(4) 



Running Lights 
Port and Std. 



Spot Light 



'nspect 



Lights 
Wiring 



02 



Repair 

Inspect 

Replace 

Repair 

Inspect 

Replace 

Repair 

Inspect 

Replace 

Repair 




Bitts, Shocks, 
and Clents 

Sheans 
Pushknees 

Couplings, Arms, 
Yoke Hook 



Inspect 
Service 
Replace 
Repair 

Inspect 
Replace 

Inspect 

Replace 

Repair 

Inspect 

Replace 

Repair 



Cable Assemblies, Inspect 
Lashing Tiedown Replace 
and Lifting Slings 

Stern and Bow I Inspect 
Cradles I Replace 

Repair 



01 
' 



0.1 









0.2 



0.5 



1.0 



1 



0.2 



Q 2 



0.1 



01 



1 
' 



OP 



0.1 
0.5 



O.i 



0.5 



1.0 



1.0 



Hull 

(5)~ 

TOOLS AND 



(6) 



REMARKS 



A-l 



A-l 



A- 



TM 5-1940-221-12 



Section IS. MAINTENANCE ALLOCATION CHART 


NOMENCLATURE OF END ITEMS: Boat B , dge Erec , on 2? FJ A|uminum Hu|l 


(1) 

GROUP 
NUMBER 


(2) 

COMPONENT/ 
ASSEMBLY 


(3) 

MAINTENANCE 
FUNCTION 


(4) 
MAINTENANCE LEVEL 


(5) 

TOOLS AND 
EQUIPMENT 


(6) 
REMARKS 


UNIT 


NTERMEDIATE 


EPOT 


c 





F 


H 


D 


02 
(Cont.) 


Boat Hook, 
Anchor and 
Ring 
Buoy 


nspect 
Replace 


0.1 
0.2 
















Lines, Morring, 
Towing and Anchor 


Inspect 
Replace 


0.1 


0.2 














Canvas Cover 


Inspect 
Replace 


0.1 


0.1 












03 


ACCESS HATCH 




















Stern Hatch 


Inspect 
Replace 
Repair 




0.1 
0.5 
1.0 


1.0 








A-l 




Engine Hatch 


Inspect 
Replace 
Repair 




0.1 
0.8 
2.0 


1.0 








A-l 




Bow Hatch 


Inspect 
Replace 
Repair 




0.1 
0.4 
1.5 


1.0 








A-l 




Grating, Bow and 
Cockpit 


Inspect 
Replace 
Repair 




0.1 
0.1 


0.5 








A-l 




Hull Drain Plugs 


Inspect 
Replace 


0.1 


0.1 












04 


CONTROLS 




















Throttle and 
Transmission 
Control Cables 
and Brackets 


Inspect 
Align 
Replace 
Repair 




0.1 
0.2 
1.0 
0.5 














Transmission 
and Throttle 
Control 
Head Assembly 


Inspect 

Aline 
Replace 
Repair 




0.1 

0.2 
1.2 
2.0 














Emergency Stop 
Cable 


Inspect 
Replace 

, it... .-. 




0.1 
1.0 















section ii. iviMin i cmMmisc; ML.I_\J^MI I^/IM <wnn i 


NOMENCLATURE OF END STEMS: Boafj BHdge Erectjon 2? FT Aluminum Hu|| 


0) 

GROUP 
NUMBER 


(2) 

COMPONENT/ 
ASSEMBLY 


(3) 

MAINTENANCE 
FUNCTION 


(4) 
MAINTENANCE LEVEL 


(5) 

TOOLS AND 
EQUIPMENT 


(6) 
REMARKS 


UNIT 


INTERMEDIATE 


DEPOT 


c 


o 


F 


H 


D 


04 
(Cont.) 


Engine Shutoff 
Cable 


Inspect 




0.1 
1.0 












05 


NSTRUMENT 
PANEL 




















Gauges 


Inspect 
Replace 


0.1 


0.2 














Fuses 


Inspect 
Replace 


0.1 


0.1 














Switches 


Inspect 
Replace 


0.1 


0.2 














Instrument and 
Hull Wiring 


Inspect 
Replace 
Repair 


0.1 




16.0 
2.00 












Gauge Lights 


Inspect 
Replace 


0.1 


0.5 














Radio 
Interference 
Suppression 
Components 


Inspect 

Test 
Replace 




0.1 

0.1 
0.3 














Tachometer 
Cable 


Inspect 
Replace 


0.1 


0.5 












06 


FUEL SYSTEM 




















Hoses, Lines, 
Fittings, Shutoff 
Valves and 
Solenoid 
Valves 


Inspect 
Replace 


0.1 


0.5 














Fuel Tank 


Inspect 
Service 
Replace 
Repair 


0.1 


0.3 
1.5 


2.0 








A-l 



TM 5-1940-221-1 2 



Section IS. MAINTENANCE ALLOCATION CHART 


NOMENCLATURE OF END ITEMS: Boat B , dge ^^ ^ fj Alum|num ^ 


(1) 

GROUP 
NUMBER 


(2) 

COMPONENT/ 
ASSEMBLY 


(3) 

MAINTENANCE 
FUNCTION 


(4) 
MAINTENANCE LEVEL 


(5) 

TOOLS AND 
EQUIPMENT 


(6) 
REMARKS 


UNIT 


NTERMEDIATE 


EPOT 


c 





F 


H 


D 


06 
(Cont.) 


Fuel Strainer 


Inspect 
Service 
Replace 


0.1 
0.5 


0.5 












07 


ENGINE 
EXHAUST 
SYSTEM 




















Exhaust Pipes, 
Flanges and 
Gaskets 


Inspect 
Replace 
Repair 




0.1 
2.0 
1.0 














Muffler 


Inspect 
Replace 




0.1 
0.5 












08 


ENGINE 
COOLING 
SYSTEM 




















Heat Exchanger 
(Keel) 


Inspect 
Test 
Replace 
Repair 




0.1 
0.5 


2.0 
. 2.5 












Hoses and 
Fittings 


Inspect 
Replace 


0.1 


2.0 














Anodes 


Inspect 
Replace 




0.1 
0.5 












09 


ENGINE 
STARTING 
SYSTEM 




















Battery Box 


Inspect 
Service 
Replace 


0.1 
0.2 


0.5 














Battery and 
Cables 


Inspect 
Test 
Service 
Replace 


0.1 
0.1 


0.1 
0.5 














Magnetic Cranking 
Switch 


Inspect 
Test 
Replace 


0.1 


0.2 
0.5 

j 








' ~ " 





Section II. MAINTENANCE ALLOCATION CHART 


NOMENCLATURE OF END ITEMS: Boat Brjdge Erection 2 7 FT. Aluminum Hull 




d) 

GROUP 
NUMBER 


(2) 

COMPONENT/ 
ASSEMBLY 


(3) 

MAINTENANCE 
FUNCTION 


(4) 
MAINTENANCE LEVEL 


(5) 

TOOLS AND 
EQUIPMENT 


(6) 
REMARKS 


UNIT 


INTERMEDIATE 


DEPOT 


c 





F 


H 


D 


09 
(Cont.) 


Voltage Regulator 


Inspect 
Test 
Adjust 
Replace 




0.1 
0.4 
0.5 
0.5 












10 


ENGINE 




















Mounts and 
Brackets 


Inspect 
Adjust 
Replace 




0.1 
0.2 
0.3 














Engine Assembly 


Inspect 
Test 
Service 
Replace 


0.6 


0.2 


1.0 
4.0 














Repair 
Overhaul 











10.00 


l-l 


B-l 




Shield Y-Belt 


Inspect 
Replace 


0.1 


0.2 














Y-Belt 


Inspect 
Adjust 
Replace 




0.1 
0.1 
0.2 














Generator 


Inspect 
Test 
Service 
Replace 
Repair 


0.1 


0.1 
0.2 

0.2 


1.5 












Starter and 
Solenoid 


Inspect 
Test 
Service 
Replace 
Repair 


0.1 


0.1 
0.2 

0.3 


1.5 












Expansion Tank 


Inspect 
Service 
Replace 


0.1 


0.1 
0.4 














Water Pump 


Inspect 
Replace 
Repair 


0.1 


0.5 


1.0 








1- . - 





JM 5-1940-221 -12 



Section II. MAINTENANCE ALLOCATION CHART 


NOMENCLATURE OF END STEMS: Boat Bridge ^.^ ^ ^ ^^ H|||| 


(1) 

GROUP 
NUMBER 


(2) 

COMPONENT/ 
ASSEMBLY 


(3) 

MAINTENANCE 
FUNCTJON 


(4) 
MAINTENANCE LEVEL 


(5) 

TOOLS AND 
EQUIPMENT 


(6) 
REMARKS 


UNIT 


INTERMEDIATE 


DEPOT 


c 


o 


F 


H 


D 


10 
(Cont.) 


Thermostat and 
Housing 


Inspect 
Test 
Replace 




0.1 
0.1 
0.3 














Exhaust Manifold 


Inspect 
Replace 




0.1 
0.4 














Air Silencer and 
Blower Screen 


Inspect 
Service 
Replace 




0.1 
0.1 
0.1 














Blower Assembly 


Inspect 
Replace 
Repair 


0.1 




0.5 


4.0 




2-J 






Governor 


Inspect 
Test 
Adjust 
Repair 
Replace 




0.1 


0.1 
0.5 
1.0 
2.0 












Fuel Filter 


Inspect 
Service 
Replace 


0.1 


0.5 
0.5 














Fuel Pump 


Inspect 
Replace 




0.1 
0.3 














Oil Filter 


Inspect 
Service 
Replace 


0.1 
0.5 


0.5 














Oil Cooler, 
Transmission 


Inspect 
Test 
Replace 
Repair 




0.1 


0.5 

1.0 
1.5 












Oil Cooler 
Enginer 


Inspect 
Test 
Replace 
Repair 




0.1 


0.5 
1.0 
1.5 












Cover Rocker 
Arm 


Inspect 
Replace 




0.1 
0.3 













11 





Section II. MAINTENANCE ALLOCATION CHART 




NOMENCLATURE OF END ITEMS: Boatj Bridge Erection 2? FJ A|uminum H|||| 


I 


(1) I (2) 

GROUP COMPONENT/ 
DUMBER I ASSEMBLY 


(3) 

MAINTENANCE 
FUNCTION 


(4) 
MAINTENANCE LEVEL 


(5) 

TOOLS AND 
EQUIPMENT 


(6) 
REMARKS 


UNIT 


INTERMEDIATE 


DEPOT 


c 


o 


F 


H 


D 




10 Tachometer 
(Cont.) Drive 


nspect 
Replace 
Repair 




0.1 
0.5 
0.5 














Tube, Injector 
Control 


Service 
Replace 
Repair 






0.2 
0.5 
0.5 












Crankshaft 
Pulley 


Replace 






0.4 






9-I, 10-1 






Front Cover and 
Oil Pump 


Replace 
Repair 






1.0 
1.0 












Oil Pan 


Replace 






0.5 












Dipstick Gauge 


Replace 




0.1 














Flywheel and 
Housing 


Replace 






1.0 












Connecting 
Rods 


Replace 
Repair 








0.4 
1.0 




11-H, 12-H 






Piston and 
Sleeves 


Replace 
Repair 








0.7 
1.0 




12-A 






Main Benting 


Replace 








1.5 










Injector Lines 
and Fittings 


Replace 




0.1 














Rocker Arms, Shaft, 
Push Rods and Cam. 
Follower 


Replace 
Repair 






0.7 
0.9 












Injectors 


Test 
Adjust 
Replace 
Repair 






0.2 
0.5 
0.2 


1.0 




3-D, 4-B, 5-I 






Cylinder Head 
Assembly 


Inspect 
Test 
Replace 
Repair 






0.1 
0.4 
0.5 
2.2 











TM 5-1940-221 -12 



Section II. MAINTENANCE ALLOCATION CHART 


NOMENCLATURE OF END ITEMS: Boa| Br|jge Erection 2? FJ Mumlnum Hu|| 


0) 

GROUP 
NUMBER 


(2) 

COMPONENT/ 
ASSEMBLY 


(3) 

MAINTENANCE 
FUNCTION 


(4) 
MAINTENANCE LEVEL 


(5) 

TOOLS AND 
EQUIPMENT 


(6) 
REMARKS 


UNIT 


INTERMEDIATE 


DEPOT 


c 


o 


F 


H 


D 


10 

(Cont.) 


Valve and Spring 


Adjust 
Replace 
Repair 






0.1 
0.3 
0.5 












Guides and 
Inserts 


Replace 
Repair 






0.5 
1.0 






6-H, 7-H, 8-H 






Crankshaft 


Replace 
Rebuild 








0.5 


4.0 








Camshaft, Balance 
Shaft and Gears 


Replace 








1.0 










Engine Block 










0.5 


0.5 






11 


TRANSMISSION 




















Oil Strainer 


Inspect 
Replace 




0.1 
0.2 














Shaft Control 


Inspect 
Service 
Replace 
Repair 




0.1 
0.1 
0.5 
0.2 














Lines and 
Fittings 


Replace 






0.2 












Transmission 
Assembly 


Inspect 
Service 
Replace 
Repair 
Overhaul 




0.1 
0.1 


1.0 


4.0 


6.0 








Reduction Gear 
Assembly 


Inspect 
Replace 
Repair 
Overhaul 




0.1 


1.0 


3.0 


4.0 






12 


STEERING 
SYSTEM 




















Rudder Shaft, 
Strut and Bushings 


Inspect 
Service 
Replace 
Repair 




0.1 

0.1 


2.0 

1.5 











13 



TM 5-1940-221 -12 



Section II. MAINTENANCE ALLOCATION CHART 


1 NOMENCLATURE OF END ITEMS: Boat Brjdge Erectjon 2? FT Aluminum Hull 


(1) 

GROUP 
I NUMBER 


(2) 

COMPONENT/ 
ASSEMBLY 


(3) 

MAINTENANCE 
FUNCTION 


(4) 
MAINTENANCE LEVEL 


(5) 

TOOLS AND 
EQUIPMENT 


(6) 
REMARKS 


UNIT 


INTERMEDIATE 


DEPOT 


c 





F 


H 


D 


12 
(Cont.) 


Rudder 


nspect 
Replace 




0.1 
0.8 














Steering 
Linkage 


Inspect 
Service 
Adjust 
Replace 


0.3 


0.2 
1.0 
4.0 














Quadrant 


Service 
Replace 
Repair 




0.1 


0.5 
0.5 












Steering Wheel 


Inspect 
Replace 




0.1 
0.5 














Box, Steering, 
Upper and Lower 


Replace 
Repair 




0.3 
0.3 














Universal Joints 
and Shaft 


Inspect 
Replace 




0.1 
0.5 












13 


PROPELLER AND 
PROPELLER SHAFT 




















Propeller 


Inspect 
Replace 
Repair 




0.1 


0.5 


3.5 










Shaft Coupling 


Inspect 
Replace 




0.3 
0.5 














Propeller Shaft 


Inspect 
Replace 




0.1 


0.4 












Seal, Hose 
and Clamps 


Inspect 
Replace 




0.1 


0.2 












Propeller Strut 
Brace 


Inspect 
Replace 




0.1 


0.5 












Propeller Strut 


Inspect 
Replace 




0.1 


1.5 












Bearing 


Inspect 
Replace 




0.1 


0.7 











TM 5-1940-221-12 



Section II. MAINTENANCE ALLOCATION CHART 


NOMENCLATURE OF END ITEMS: Boaf m ^ & Ef ^. Qn ^ fj A|umSnum ^ 


(1) 


(2) 


(3) 


(4) 


(5) 


(6) 








MAINTENANCE LEVEL 






GROUP 


COMPONENT/ 


MAINTENANCE 


UNIT 


INTERMEDIATE 


DEPOT 


TOOLS AND 




NUMBER 


ASSEMBLY 


FUNCTION 


c 


o 


F 


H 


D 


EQUIPMENT 


REMARKS 


14 


BILGE PUMP 




















Bilge Pump 


Inspect 


0.1 
















Electric 


Service 




0.1 
















Replace 




0.3 














Bilge Pump 


Inspect 


0.1 
















Hand 


Replace 




0.2 












15 


FIRE 




















EXTINGUISHER 




















SYSTEM 




















Lines and Fitting 


Inspect 




0.1 
















Replace 




1.0 














Cylinders 


Inspect 


0.1 


















Replace 




0.2 












16 


DATA PLATES 




















Data Plates, 


Inspect 


0.1 
















Instruction and 


Replace 




0.7 














Identification 


















17 


HULL 




















Hull 


Inspect 


0.1 


















Repair 




4.0 


5.0 








A-l, C-l 



15 



Section III. SPECIAL TOOL AND SPECIAL TEST EQUIPMENT REQUIREMENTS 



Reference 
code 


Maintenance 
category 


Nomenclature 


Tool 
number 


1-1 
?-J 


H 
H 


Plate, Engine Stand Adapter 
Feeler Set 


4910-408-5576 
5210-363-7573 


cs\* 

3-D 
4-B 


F 
F 


Gauge, Injector Timing 
Gauge, Fuel Pressure Checking 


5220-387-9581 
6620-671-4509 


5-1 


H 


Service Set, Injector 


J23435 (33287) 


6-H 


F 


Remover, Valve Seat Insert 


5180-591-6631 


7-H 


F 


Installer, Valve Seat Insert 


4910-603-8925 


8-H 


F 


Installer Set, Crankshaft Pulley 


4910-779-6392 


9-1 


H 


Reamer Set, Connecting Rod 


5180-907-8988 


10-1 


H 


Reamer Set, Piston Pin Bushing 


5120-254-5023 


11-1 


H 


Installer and Remover, Piston and 


5120-254-5022 






Connecting Rod Bushings 




12-1 


H 


Gauge, Cylinder Liner Depth 


5310-023-4798 



Section IV. REMARKS 



Reference 
code 



Remarks 



A-l 
B-l 
C-l 



Direct Support Repair by straightening and welding 

See individual component repair time to perform maintenance function 

Organizational repair by straightening, patching with rivets. 



By Order of the Secretary of the Army: 



Official: 

R. L. OIL WORTH 

Brigadier General, United States Army 
The Adjutant General 



CARL E. VUONO 

General, United States Army 
Chief of Staff 



DISTRIBUTION: 

To be distributed in accordance with DA Form 12-25A, Operator and Unit 
Maintenance requirements for Boat, Bridge Erection, Inboard Diesel Engine, 
27 Ft, (HP1-27A, 27B, 27C, 27D) ' 




^ 
I 



TM 5-1940-221-12 
C 3 

HEADQUARTERS 
DEPARTMENT OF THE ARMY 
WASHINGTON, D.C., 21 July 1987 

Operator and Organizational Maintenance Manual 

BOAT, BRIDGE ERECTION, INBOARD DIESEL ENGINE, 

ALUMINUM HULL, 27 FT LG 

(ALUMINUM COMPANY OF AMERICA MODEL HICE-27D) 

(HIGHWAY PRODUCTS MODEL HPI-27C MODDED) 

(HIGHWAY PRODUCTS MODEL HPI-27B MODDED) 

(MARINETTE MARINE CORP. MODEL A27 MODDED) 

NSN 1940-00-417-0526 

TM 5-1940-221-12, 17 June 1974, is changed as follows: 

Page i, Table of Contents, Appendix C. Change "Basic Issue Items List and Items 
Troop Installed or Authorized" to "Components of End Item and Basic Issue Items 
Lists." 

Page C-l. Delete entire Appendix C, "Basic Issue Items List and Items Troop Instal- 
led or Authorized" and add new Appendix C, "Components of End Item and Basic Issue 
Item Lists" as follows: 



APPENDIX C 
COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS 

SECTION I. INTRODUCTION 
C-l. SCOPE 

This appendix lists components of and basic issue items for the Boat, Bridge 
Erection to help you inventory items required for safe and efficient operation. 

C-2. GENERAL 

The Components of End Item List is divided into the following sections: 

a. Section II. Components of the End Item. Not Used. 

b. Section III. Basic Issue Items. These are minimum essential items re- 
quired to place the Boat, Bridge Erection in operation, to operate it, and to per- 
form emergency repairs. Although shipped separately packed they must accompany 
the unit during operation and whenever it is transferred between accountable offi- 
cers. The illustrations will assist you with hard-to-identify items. This man- _ 
ual is your authority to requisition replacement BII, based on Table (s) of Organ i- 
zational and Equipment (TOE)/Modification Table of Organization and Equipment 
(MTOE) authorization of the end item. 



C 3 
C-3. EXPLANATION OF COLUMNS. 

a. Illustration. This column is divided as follows: 

(1) Figure Number. Indicates the figure number of the illustration on 
which the item is shown (if applicable). 

(2) Item Number. The number used to identify item called out in the il- 
lustration. 

b. National Stock Number (NSN). Indicates the National Stock Number assignee 
to the item and which will be used for requisitioning. 

c. Part Number (P/N). Indicates the primary number used by the manufacturer, 
which controls the design and characteristics of the item by means of its engineei 
ing drawings, specifications, standards, and inspection requirements to identify 
an item or range of items. 

d. Description. Indicates the Federal item name and, if required, a minimum 
description to identify the item. 

e. Location. The physical location of each item listed is given in this col 
umn. The lists are designed to inventory all items in one area of the major item 
before moving on to an adjacent area. 

f. Usable on Code. "USABLE ON" codes are included to help you identify whic 
component items are used on the different models. Identification of the codes 
used in these lists are: 



CODE 

ccc 

CUA 

CUB 

cuc 



USED ON 

Highway Product, Model HP1-27C 
Highway Product, Model HP1-27B 
Marinette Marine, Model A-27 
Aluminum of America, Model HICE-27D 

g. Quantity Required (Qty Reqd). This column lists the quantity of each ite 
ire 



required for a complete major item. 



a ^t^L^suc/as ?c 



Section II. COMPONENTS OF END ITEM 



NOT APPLICABLE 



TM 5-1940-221-12 
C 3 





10 







Figure C-l. Basic Issue Items 



TM 5-1940-221-12 
C 3 



APPENDIX C 
Action in. BASIC ISSUE ITEMS 



ILLUS. 
NUMBER 



(2) 



NATIONAL STOCK 
NUMBER 



4220-00-275-3156 
2040-00-007-1136 
2090-00-368-8194 




Ring, Buoy 
13213E5156-12 (97403) 




4 

, 


2040-00-997-6047 


5 


1 
4020-00-033-4735 


6 


2930-00-997-6041 


1 7 


5110-00-555-8868 


I 8 


2090-00-997-6049 


9 


2040-00-997-6048 


10 


4210-00-270-4512 



Cover, Pole 
13213E5376 (97403) 

Anchor and Anchor Line 
13213E5513 (97403) 

Line, Mooring 
13213E5511 (97403) 

Line, Steering 
13213E5510 (97403) 

Hatchet, Board 
GGG-H-131 (81348) 

Cover, Cargo Well 
132135374 (97403) 

Cover, Cockpit 
13213E5375 (97403) 

Fire Extinguisher 
.02910 (81349) 



(4) 

U/M 

-~ 


(5) 
QTY 
1 rqr 
1 


EA 


1 


EA 


1 


EA 1 


1 


EA 


1 


EA 


4 


EA 


2 


EA 1 


1 


EA 1 


1 



Order of the Secretary of the Army: 



OFFICI ^: 

Dy ,. ,. R - L. DILWORTH 
Bng. dl er General, United States Army 
"ne Adjutant General 

DISTRIBUTION: 



General , C 5nit e E d sffis Army 
Chief of Staff 



TM 5-1940-221-12 
Cl 



CHANGE 
NO. 1 



HEADQUARTERS 
DEPARTMENT OF THE ARMY, 

WASHINGTON. D C, 10 May 2978 



Operator and Organizational Maintenance Manual 



BOAT, BRIDGE ERECTION, INBOARD DIESEL ENGINE, 

ALUMINUM HULL, 27 FT LG 

(ALUMINUM COMPANY OF AMERICA MODEL HICE-27D) 

(HIGHWAY PRODUCTS MODEL HPI-27C MODDED) 

(HIGHWAY PRODUCTS MODEL HPI-27B MODDED) 

(MARINETTE MARINE CORP. MODEL A27 MODDED) 

NSN 1940-00-417-0526 



TM 5-1940-221-12, 17 June 1974, is changed as follows: 



Front Cover. Change "FSN 1940-183-3097" to 
read "NSN 1940-00-417-0526". 

Front Cover. Add: 
(HIGHWAY PRODUCTS MODEL HPI-27C 

MODDED) 
(HIGHWAY PRODUCTS MODEL HPI-27B 

MODDED) 

(MARINETTE MARINE CORP. MODEL A27 
MODDED) 

Page i. Change "FSN 1940-183-3097" to read 
"NSN 1940-00-417-0526". 

Page L Add: 
(HIGHWAY PRODUCTS MODEL HPI-27C 

MODDED) 
(HIGHWAY PRODUCTS MODEL HPI-27B 

MODDED) 

(MARINETTE MARINE CORP. MODEL A27 
MODDED) 

Page Hi. Figure Number 4-60. Change title to 
read: "Transmission oil strainer removal". Figure 
Number 4-61. Change title to read: "Draining the 
transmission oil." 

Page 1-1, Section I, Paragraph 1-3 is superseded 
as follows: 

1-3. Reporting of Errors. 

You can improve this manual by calling atten- 
tion to errors and by recommending improvements 
using DA Form 2028 (Recommended Changes to 
Publications and Blank Forms) or DA Form 2028-2 
and mailing the form direct to Commander, Head- 



quarters, U. S. Army Troop Support and Aviation 
Materiel Readiness Command, ATTN: DRSTS- 
MTPS, 4300 Goodfellow Blvd., St. Louis, MO 63120. 
A reply will be furnished directly to you. 

Page 1-1, Paragraph 1-7, b line 4. Change 
"1593 cubic inches" to read "159.3 cubic inches". 

Page 1-8, Paragraph 1-7, g (3) line 8. Change 
"at 183-21 psi" to read "at approximately 12 psi". 

Page 1-9, Paragraph 1-7, g (5) (a) line 6. 
Change to read "the dipstick with the engine 
stopped". 

Page 1-9, Paragraph 1-7, g (5) (b) line 6. 
Change to read "(full) mark on the dipstick with the 
engine stopped". 

Page 1-9, Paragraph 1-7, h Second and third 
sentences. Delete and add the following: "The sys- 
tem is powered by the engine driven generator, sup- 
plying power for lighting, instruments, alarm sys- 
tem, the stern bilge pump, and power for charging 
the batteries. The batteries supply power for start- 
ing and are a standby source of power when the gen- 
erator is not operating." 

Page 1-10, Paragraph 1-7, h (2) line 6. Delete 
"and current". 

Page 1-10, Paragraph 1-7, ft (3) Third sentence 
is superseded as follows: 

"Each pair of batteries is connected in series provid- 
ing a 24 volt supply. The two pairs are then con- 
nected in parallel to provide a greater ampere (cur- 
rent) capacity." 

Page 1-11, Paragraph 1-7, h (6) (b) 4 line 3. 
Change to read "not sound, first check the ALARM 
fuse on fuse panel." 

1 



Page 1-13, Paragraph 1-8, b (1) is superseded 
as follows: 

(1) General 

(a) Manufacturer -- Aluminum Company of 
America. 

National Stock Number -- 1940-00-417-0526. 

Serial Number Range - Hulls; 71-1 thru 71-46, 73- 

47 thru 73-139. 

Hull Material -- Aluminum. 

Operating Range (maximum load) -- 36 nautical 

miles. 

(b) Manufacturer -- Highway Products 
National Stock Number -- 1940-00-417-0526. 
Serial Number Range - Hulls; 66-1, 66-2, 66-3, 67-4 
thru 67-140, 68-141 thru 68-297, 69-208 thru 69- 
308. 

Hull Material - Aluminum. 

Operating Range (maximum load) - 36 nautical 

miles. 

(c) Manufacturer - Highway Products 
National Stock Number - 1940-00-417-0526. 
Serial Number Range - Hulls; 60-500 thru 60-630, 
61-361 thru 61-706, 62-707 thru 62-767. 

Hull Material -- Aluminum. 

Operating Range (maximum load) -- 36 nautical 

miles. 

(d) Manufacturer -- Marinette Marine 
Corp. 

National Stock Number -- 1940-00-417-0526. 

Serial Number Range - Hulls; 60-1 thru 60-107. 

Hull Material -- Aluminum. 

Operating Range (maximum load) - 36 nautical 

miles. 

Page 1-14, Paragraph 1-8, b (2). Change "Cool- 
ing system" from "4.75 gallons" to "6.5 gallons each 
engine system". After "Engine lubricating system, 
9.5 quarts" add "each engine". After "Transmission 
lubricating system, 3 quarts" add "each trans- 
mission". 

Page 1-14, Paragraph 1-8, 6 (6). Change "Cool- 
ing system capacity" from "4.75 gallons" to "6.5 
gallons (each engine system)". 

Page 1-14, Paragraph 1-8, b (9). Change "Con- 
nection" data to read "2 batteries connected in se- 
ries to provide 24 volt. Two pairs connected in paral- 
lel". 

Page 1-14, Paragraph 1-8, b (11). Change under 
Voltage regulator range limits. "Voltage setting" to 
read "28.5 volts d.c.". 

Page 1-15, Paragraph 1-8, b (12). Change "Volt- 
age draw" to read "Voltage". 

Page 1-15, Paragraph 1-8, b. (13). Change 
"Type" to read "Heavy duty water resistance unit 
with spring loaded disc type contactor assembly". 



Page 1-15, Paragraph 1-8, 6 (14) (a). Change 
"Voltage draw" to read "Voltage 24.0 volts d.c.". 

Page 1-15, Paragraph 1-9 is superseded as 
follows: 

"This manual covers Aluminum Company of Amer- 
ica Model HICE-27D, Highway Products Models 
HPI-27C MODDED and HPI-27B MODDED and 
Marinette Marine Corp Model A27 MODDED 
Bridge Erection Boats. No differences exist for the 
four models covered in this manual" 

Page 2-7, Table 2-2 Third column, line 9. Change 
"sy" to read "at". 

Page 2-7, WARNING, change "1200 RPMs." to 
read "1200 RPM. " 

Page 2-11, Paragraph 2-8, e (1) (a). Delete the 
note. 

Page 3-1, Section II, line 16. Change "2024" to 
read "2404". 

Page 3-2, Table 3-1, 9. Change "Can security" to 
read "and security". Add "(fig. 3-4)" after second 
sentence. 

Page 3-5, Figure 3-4. Change caption third sen- 
tence to read "If necessary, add distilled or clear 
drinking water to 3/8 inch above plates". 

Page 3-7, Table 3-2. Change malfunction 7 to 
read "AMMETER OPERATING ABNORMALLY ". 

Page 3-7, Section IV Second sentence. Change 
"Section II" to read "Section I" and "Section III" to 
read "Section II". 

Page 4-2, Sequence Number 15, Second column. 
Add "(Fig. 3-2)" after first sentence. Sequence 
Number 16, Second column. Add "(Fig. 3-3)" after 
second sentence. 

Page 4-4, Table 4-2, Malfunction 5, Corrective 
Action. Change to read "Refer to Malfunction 2, 
step 4 above." 

Page 4-15, Figure 4-8, Legend item 1. Change to 
read "Lacing wire". 

Page 4-35, Paragraph 4-41. Change "paragraph 
1-5." to read "paragraph 1-7.". 

Page 4-43, Paragraph 4-48. Change "paragraph 
1-5." to read "paragraph 1-7.". 

Page 4-44, Paragraph 4-50, g (1). Change first 
line to read "(1) Polarizing the generator. Before 
starting the engine disconnect". 

Page 4-45, Paragraph 4-50, g (2) (c) . Change- 
second sentence to read "The closing voltage is 25 to 
27 volts.". 

Page 4-60, Figure 4-60. Change the figure title 
to read "Transmission oil strainer removal." 

Page 4-60, Paragraph 4-62, Second sentence. 
Change "paragraph 1-5." to read "paragraph 1-7.". 

Page 4-60, Paragraph 4-63, b (2). Change "'fig. 
4-60^" to read "(fig. 4-61)". 



ft 



Page 4-60, Paragraph 4-63, b (2) (b). Change 

"(fig. 4-60)" to read "(fig. 4-61)". 

Page 4-60, Paragraph 4-63, b (3). Change 
"paragraph 4-68" to read "paragraph 4-64". 

Page 4-60, Paragraph 4-64, b (2). Change "fig- 
ure 4-61" to read "figure 4-60.". 



TM 5- 1940-22 1-12 
Cl 



Page 4-60, Paragraph 4-64, d (2). Change 
"paragraph 4-70 c" to read "paragraph 4-63 c". 

Page: 4-61, Figure 4-61. Change the figure title 
to read "Draining the transmission oil.". 

Page 4-62, Paragraph 4-66. Change "paragraph 
1-5." to read "paragraph 1-7." 



By Order of the Secretary of the Army: 



Official: 

J. C. PENNINGTON 

Brigadier General, United States Army 
The Adjutant General 



BERNARD W. ROGERS 

General, United States Army 
Chief of Staff 



I 



Distribution: 

To be distributed in accordance with DA Form 12-25D, Operator maintenance 
requirments for Boat Bridge Erection. 



ft 



TM 5-1940-221-12 
C2 



CHANGE] 
No. 2 ) 



HEADQUARTERS 
DEPARTMENT OF THE ARMY 
WASHINGTON, D.C. 21 September 1981 



Operator and Organizational Maintenance Manual 



BOAT, BRIDGE ERECTION, INBOARD DIESEL ENGINE, 

ALUMINUM HULL, 27 FT LG 

(ALUMINUM COMPANY OF AMERICA MODEL HICE-27D) 

(HIGHWAY PRODUCTS MODEL HPI-27C MODDED) 

(HIGHWAY PRODUCTS MODEL HPI-27B MODDED) 

(MARINETTE MARINE CORP. MODEL A27 MODDED) 

NSN 1940-00-417-0526 



TM 5-1940-221-12, 17 June 1974, is changed as follows: 



ft 



Page 1-1. 

follows: 



Paragraph 1-3 is superseded as 



1-3. Reporting of Errors. 

You can improve this manual be calling atten- 
tion to errors and by recommending improvements 
using DA Form 2028 (Recommended Changes to 
Publications and Blank Forms) or DA Form 2028-2 
and mailing the form direct to Commander, Head- 
quarters, U.S. Army Troop Support and Aviation 
Materiel Readiness Command, ATTN: DRSTS- 
MTT, 4300 Goodfellow Blvd., St. Louis, MO 63120. 
A reply will be furnished directly to you. 



Page 1-1. Paragraph 
paragraph 1-6. 



1-6.1 is added after 



1-6.1. Navigation Rules and Safety. 

For navigation rules and safety, refer to TM 
5-210, Chapter 2 and FM 5-12C1-2. In addition, 



when personnel operate the bridge erection boat in 
foreign waters, they will become familiar with safe- 
ty and navigation rules of the country. 



Page 2-2. Paragraph 2-2c.l is added after 
paragraph 2-2c. 



c.l. Discharge of Oil Prohibited. The Federal 
Water Pollution Control Act prohibits the 
discharge of oil or oily waste into the water. Oil 
leaks or fuel leaks should be corrected while the 
boat is ashore. Oil or fuel spilled into the hull 
should be cleaned up prior to launching the boat. 
Use a cup, rags or absorbent pads/strips to 
remove oil slops. Bilge pumps should not be used 
to empty out any accumulation of oily slops except 
in an emergency. 



TM 5-1940-22 1-12 
C2 

Page 3-1. Table 3-1 is superseded as follows: 



Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE ( 



INTERVAL 



B-BEFORE OPERATION 
D-DURING OPERATION 



A-AFTER OPER/ 



ITEM 
NO. 



A 



TEM TO BE 
NSPECTED 



PROCEDURES 
CHECK FOR AND HAVE REPA: 
OR ADJUSTED AS NECESSAR' 



OW AND STERN 
ASSEMBLIES 

Hulls, 

Propellers, 

Shafts, 

Rudders, 

Struts, 

Interior 

Hulls, and 

Couplings 



ENGINE 
COMPARTMENT 

Filters, 
Lines, 

Connections, 
Engines, and 
Transmissions 



Before launching, visua 
for structural damage, 
welds, and loose, missi 
cracked, or damaged par 
ware. After launching, 
inspect for water leakii 
the hulls. Check that 
board equipment is in f 
and in good condition (- 
and 1-2). Check that c< 
arms, yokes and hooks ai 
tight, and pinned or lo< 
place (fig. 2-3). 



Visually inspect fuel s^ 
(fig. 1-6 and 4-26), of 
(fig. 1-9), and coolant 
(fig. 1-8 and 4-39) for 
Check for loose holts, i 
mountings. Check for lc 
missing propeller shaft 
bolts (fia. 1-5). 



Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE 



ITEM 
NO. 


B 


D 


A 


ITEM TO BE 
INSPECTED 


PROCEDURES 
CHECK FOR AND HAVE REP 
OR ADJUSTED AS NECESSA 


4 









Fire 


Inspect and replace a 










Extinguisher 


tinguisher if the seal 












sing or broken, or if 












tinguisher system is d 












(fig. 1-3). 












WARNING 


Do not energize electr 












cuits or start engines 












fire extinguishers hav 












checked* 


5 









Steering 


Check that transverse 










System and 


nuts are tight (fig* 4 










Propeller 


Turn steering wheel th 










Shaft Logs 


full range and check f 












smooth and easy operat 












and that rudders respo 












unison. Bleed propel 1 












shaft logs (open vent 












until water appears an 












close fig. 2-4). 


6 









Fuel Level 


Check for a full tank 












fuel. Fill fuel tank 












completion of operatic 












NOTE 



Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont) 



ITEM 
NO. 


B 


D 


A 


ITEM TO BE 
INSPECTED 


PROCEDURES 
CHECK FOR AND HAVE REPAIRED 
OR ADJUSTED AS NECESSARY 


EQUIPMENT IS 
NOT READY/ 
AVAILABLE IF: 


8 










Controls and 
Instruments 


Check for proper operation and 
for the specified limits: 












a. Transmission 
oil pressure 
gage 


Normal : 110 to 150 psi 


Pressure is 
below 110 
psi. 










b. Coolant tem- 
perature gage 


Normal : 160 to 185 F 


Temperature 
is above 
200F. 










c. Tachometer 


Normal : 500 to 3040 rpm 












d. Engine oil 
pressure gage 


Normal : 30 to 40 psi 
Min. at 2500 RPM: 32 psi 
Min. at 2200 RPM: 30 psi 


Oil pressure 
is below 13 

psi . 










e. Battery 
ammeter 


Normal: 1 to 20 amps on pos- 
itive side of ammeter. 


Reading on 
negative side 
of ammeter. 



TM 5-1940-22 1-12 
C2 



Page 4-1. Table 4-1 is superseded as follows: 



Table 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES 



INTERVAL 



W-WEEKLY (40 HOURS) 
M-MONTHLY (100 HOURS) 



H-HOURS (AS INDICATED) 
Q-QUARTERLY (500 HOURS) 
S-SEMIANNUAL (500 HOURS) 



ITEM 



ITEM TO BE 
INSPECTED 



PROCEDURES 

CHECK FOR AND HAVE REPAIRED 
OR ADJUSTED AS NECESSARY 



EQUIPMENT IS 
NOT READY/ 
AVALIABLE IF; 



Fuel Filters 
and Strainers 



Coolant Levels 



Batteries 



V-Belts 



Engine and 

Transmission 

Mounts 



Drain water and sediment into a 
container. Stop as soon as 
clean, water free fuel runs out 
(fig. 3-1 and 3-3). 

Proper level is 2 inches below 
the filler neck. In cold, weath- 
er, check that antifreeze has 
been added (fig. 3-1). 

Check electrolyte levels. Prior 
to adding distilled water, per- 
form a hydrometer check. Remove 
corrosion and check for loose 
terminals (fig. 3-4). 

CAUTION 

In freezing weather, charge bat- 
teries for a minimum of 30 min- 
utes after adding water. 

Check for a cracked or worn 
belt. Adjust belt tension, pro- 
per adjustment is when the belt 
can he depressed to not more 
than 1/2 to 3/4 of an inch. 
Check shield for damage and inse- 
cure mounting (fig. 4-4 and 
4-5). 

Check that mount bolts and nuts 
are tight. Check that mount 
stud nuts are torqued to 100 to 
120 ft Ib (fig. 3-2) 



Table 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont) 



ITEM 
NO. 



W 



ITEM TO BE 
INSPECTED 



PROCEDURES 
CHECK FOR AND HAVE REPAIRED 
OR ADJUSTED AS NECESSARY 



EQUIPMENT IS 
NOT READY/ 
AVALIABLE IF: 



Propeller 
Strut and 
Rudder Plate 
Bolts 



Fire 
Extinguishers 



Bow and Stern 
Assembl ies 



Engine 
Compartment 



Check that propeller strut moun- 
ting bolts are torqued to 51 to 
54 ft Ib. Check that rudder 
plate bolts are torqued to 17 to 
20 ft Ib. 

Weigh cylinders. If the weight 
loss exceeds 10 percent of the 
net weight, recharge or replace 
cylinders. Refer to TM 5-687. 

Inspect the hulls, hatches, 
gratings, cleats, towing bits, 
pushing knees (fig. 1-1 thru 
1-3), heat exchanger (fig. 
4-33), propellers, shafts, cou- 
plings (fig. 1-5), rudders, 
struts, and steering system 
(fig. 1-11) for structural dam- 
age, wear, deterioration, 
cracks, broken welds, looseness, 
or other damage. Make sure all 
bolts, nuts, screws, clamps, and 
mountings are tight. Clean and 
touch-up paint. 

Inspect the exhaust systems 
(fig. 1-7 and 4-32), coolant 
systems (fig. 1-8 and 4-39), 
fuel systems (fig. 1-6 and 
4-26), oil systems (fig. 1-9), 
electrical system (fig. 1-10), 
air intake system (fig 4-18 thru 
4-20), accessories (fig. 1-4), 
control cables (fig. 4-9 and 4- 
12 thru 4-14), engines (fig. 
1-4 and 1-5), and transmissions 
(fig. 1-4 and 1-5) for leaks, 
wear, deterioration, cracks, 
broken welds, looseness, or 
other damage. Make sure all 
bolts, nuts, screws, clamps, and 
mountings are tight. Clean and 
touch-up paint. 



TM 5-1940-221-12 
C2 



Table 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES Ccont) 



ITEM 
NO. 


W 


M 


Q 


S 


H 


ITEM TO BE 
INSPECTED 


PROCEDURES 
CHECK FOR AND HAVE REPAIRED 
OR ADJUSTED AS NECESSARY 


EQUIPMENT IS 
NOT READY/ 
AVALIABLE IF: 


10 










300 


Fuel Filters 
and Strainers 


Replace fuel filter and strainer 
elements (fig. 4-27 and 4-28). 




11 










300 


Engine oil 
and Filters 


Drain oil, replace oil filter 
elements, and refill with new 
oil (fig. 4-27 and 4-28). 





Page 4-23. Paragraph 4-23 is superseded as 
follows: 

4-23. General 

a. This section contains the maintenance pro- 
cedures for the fuel system. A description of the 
fuel system is given in paragraph 1-5. 

WARNING 

Maintenance procedures for the fuel 
system must be performed in a well ven- 
tilated area. Do not allow any sparks or 
flames in the vicinity. 



Page 4-29. Paragraph 
paragraph 4-33d. 



4-33c is added after 



c. Discharge of Oil Prohibited. The Federal 
Water Pollution Control Act prohibits the 
discharge of oil or oily waste into the water. Oil 
leaks from the engine or filters should be corrected 
while the boat is ashore. Oil spilled into the hull 
should be cleaned up prior to launching the boat. 
Use a cup, rags or absorbent pads/strips to 
remove bilge oil slops. Bilge pumps should not be 
used to empty out an accumulation of oily slops ex- 
cept in an emergency. 



b. Discharge of Oil Prohibited. The Federal 
Water Pollution Control Act prohibits the 
discharge of oil or oily waste into the water. Fuel 
leaks from the engine, filters, lines or tank should 
be corrected while the boat is ashore. Fuel spilled 
into the hull should be cleaned up prior to laun- 
ching the boat. Use a cup, rags or absorbent 
pads/strips to remove oily bilge slops. Bilge 
pumps should not be used to empty out an ac- 
cumulation of oily slops except in an emergency. 



Page A-l. Paragraph A-8 is added after 
paragraph A-7. 



A-8. Navigation Rules and Safety. 

TM 5-210 Military floating Bridge Equip- 

ment 
FM 5-12C1-2 Soldiers Manual 



ft 



By Order of the Secretary of the Army: 



Official: 



E.C.MEYER 

General, United States Army 
Chief of Staff 



ROBERT M.JOYCE 

Brigadier General, United States Army 

The Adjutant General 



DISTRIBUTION: 

To be distributed in accordance with DA Form 12-25D, Organizational Maintenance 
requirements for Boat Bridge Erection. 



*TM 5-1 940-321-1 2 



TECHNICAL MANUAL 
NO. 5-1940-221-12 



HEADQUARTERS, 
DEPARTMENT OF THE ARMY 
WASHINGTON, D. C., 17 June 197k 



BOAT, BRIDGE ERECTION; INBOARD DIESEL ENGINE; 

ALUMINUM HULL; 27 FT LG 

[ALUMINUM COMPANY OF AMERICA MODEL H1CE-27D) 
FSN1940 182-3097 



Paragraph 



Page 



I. INTRODUCTION 



CHAPTER 

Section I. General 1-11-5 1-1 

II. Description and data 1-6 1-8 1-1 1-13 

CHAPTER 2. OPERATING INSTRUCTIONS 

Section I. Service upon receipt of equipment 2-1 2-8 2-1 2-7 

II. Operation of auxiliary equipment 2-9 2-13 2-13, 2-14 

III. Operation under unusual conditions 2-14 2-16 2-14, 2-15 

CHAPTER 3. OPERATOR'S MAINTENANCE INSTRUCTIONS 

Section I. Lubrication instructions 3-1 

II. Preventive maintenance checks and services 3-3. 

III. Troubleshooting 3-6 

IV. Operator's maintenance 3-7 

CHAPTER 4. ORGANIZATIONAL MAINTENANCE INSTRUCTIONS 

Section I. Service upon receipt of equipment 4-1, 4-2 4-4 

II. Repair parts, special tools, and equipment 4-3, 4-4 4-1 

III. Preventive maintenance checks and services 4-5, 4-6 4-1 

IV. Troubleshooting 4-7 4-3 

V. Radio interference suppression 4-8 4-11 4-15, 4-16 

VI. Maintenance of engines 4-12 4-2i2 4-16 4^22 

VII. Maintenance of fuel system 4-234-31 4-234-26 

VIII. Maintenance of lubrication system 4-324-37 4-294-32 

IX. Maintenance of exhaust system 4-38 4-40 4-32, 4-33 

X. Maintenance of cooling system 4-41 4-47 4-35 4-40 

XI. Maintenance of electrical system 4-48 4-61 4-43 4-55 

XII. Maintenance of transmission 4-^62 4-65 4-60 

XIII. Maintenance of steering system 4-66 4-71 4-62, 4-63 

XIV. Maintenance of propeller and shaft 4-72, 4-73 4-64 

XV. Maintenance of boat frame assembly 4-74 4-85 4-64 4-68 

CHAPTER 5. MAINTENANCE OF MATERIAL USED IN CONJUNCTION WITH 

MAJOR ITEM 

Section I. Maintenance of fire extinguisher 5-1 5-3 5-4 

II. Electric bilge pump 5-4 5-7 5-3 

III. Manual, bilge pump 5-8 '5-43 5-3 

APPENDIX A. REFERENCES A-l 

B. MAINTENANCE ALLOCATION CHART B4 

C. BASIC ISSUE ITEMS LIST AND ITEMS TROOP INSTALLED OR 

AUTHORIZED C-l 

INDEX 1-1 



This manual supersedes TM 5-1940-221-12, 5 October 1972, including all changes. 



LIST OF ILLUSTRATIONS 



Figure Number 

1-1 

1-2 

1-3 

1-4 

1-5 

1-6 

1-7 

1-8 

1-9 

1-10 

1-11 

1-12 

1-13 

1-13 

2-1 

2-2 

2-2 

2-3 

2-3 

2-4 

2-5 

2-5 

2-6 

2-7 

2-8 

2-9 

2-10 

3-1 

3-2 

3-3 

3-i 

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 

4-24 
4-25 
4-26 
4-27 
4-28 
4-29 



Title 



Page 



. 1-5 

.1-6 

. 1-7 

.1-8 

. 1-9 

1-10 

1-11 

1-12 

1-13 

1-16 

1-17 



27-Foot bridge erection boat, right front view. 1-2 

27-Foot bridge erection boat, left rear view 1-3 

Bridge erection boat orientation 

Engine and transmission 

Power arrangement 

Fuel systems 

Air induction and exhaust systems 

Cooling system 

Engine lubricating oil system 

Electrical system 

Steering system 

Pire extinguisher system 

Wiring diagram (sheet 1 of 2) 

Wiring diagram (sheet 2 of 2) 

Removing the bridge erection boat from the transport vehicle 2-2 

Preparation for launching (sheet 1 of 2) __ 2-3 

Preparation for launching (sheet 2 of 2) 2-4 

Coupling bow and stern assemblies (sheet 1 of 2) . 2-5 

Coupling bow and stern assemblies (sheet 2 of 2) 2-6 

Shaft log bleeding _ 2-6 

Controls and instruments (sheet 1 of 2) , '2-8 

Controls and instruments (.sheet 2 of 2) '2-9 

Engine starting procedures 2-10 1 

Engine stopping procedure < 2-11 

Control lever operation 2-K1 

Line arrangement for maneuvering 60 class rafts 2-12 

Line arrangement for maneuvering M-4 type rafts 12-13 

Engine and transmission servicing 3-3 

Engine and transmission mounts servicing 3-4 

Fuel strainer servicing 3-5 

Battery servicing ^ 3-5 

Fuel lines and fittings, exploded view 4-8 

Engine lubricating oil filter and element, exploded view 4-40 

Fuel pump removal 4-41 

V-belt shield removal . 4-11 

V-belt removal -.. 4-41 

Thermostat housing removal 4-12 

Instrument panel components, exploded view 4-13 

Mufflers and exhaust piping, exploded view 4-44 

Transmission control cable removal 4-15 

Radio interference suppression capacitor removal 4-16 

Tachometer drive removal and installation 4-17 

Speed control (throttle) and shutoff cable removal 4-48 

Emergency stop cable removal 4-19 

Control head removal 4-49 

Control head assembly, exploded view 4-20 

V-belt shield removal 4-21 

V-belts removal 4-21 

Air silencer removal 4-22 

Air shutdown housing removal . 4-22 

Air box drain removal 4_23 

Valve rocker cover removal 4-23 

Fuel strainer and element, exploded view 4-24 

Fuel filter and element, exploded view 4-25 

Fuel pump removal ~__~ 4,35 

Fuel shutoff valve rem>val " ~ 4^26 

Fuel lines and fittings, exploded view I_IIII 4-28 

Engine lubricating oil drain pump 4_3<0 

Engine lubricating oil filter and element, exploded view I_II_I. II__II__I_II 4-31 

Transmission oil cooler removal 4_S2 



TM 5-1940-221-12 

Figure Number Title Page 

4-30 Engine lubricating oil cooler, removal 4-32 

4-31 Exhaust manifold, removal 4-53 

4-32 Mufflers and exhaust piping, exploded view 4-34 

4-33 Heat exchanger drain plug 4-35 

4-34 Water pump removal : - 436 

4-35 Expansion tank removal 4-37 

4-36 Thermostat housing, exploded view 438 

4-37 Thermostat housing removal 4-39 

4-38 Anode removal 4-40 

4-39 Cooling system hoses and fittings, exploded view 4-42 

440 Generator removal __.. 443 

4-41 Generator regulator removal 444 

4-42 Cutout relay air gap and contact point adjustment 4-45 

4-43 Voltage and current regulator air gap adjustment 4-46 

4-44 Testing cutout relay closing voltage 4-47 

4-45 Testing voltage regulator setting 4-48 

4-46 Testing current regulator current setting 4-49 

4-47 Cranking motor (starter) on board testing 4-50 

4-48 Cranking motor (starter) removal 4-51 

4-49 Magnetic cranking switch, removal 4-51 

4--50 Batteries, removal 4-&1 

4-51 Instrument panel components, exploded -view 4^52 

4-52 Fuse removal 4-'53 

4-53 Swatches, exploded view 4-54 

4-54 Running light removal 455 

4-55 Bow light, removal and installation 455 

4-56 Bow light, exploded view 4-56 

4-57 Range light removal and installation 4-57 

4-58 Range light, exploded view 4-458 

4-59 Spotlight, exploded view 4-59 

4-60 -Draining the transmission oil 4-60 

4-61 Transmission oil strainer removal 4-61 

4-62 Transmission control cable removal 4-6B 

4-63 Steering wheel removal 4-62 

4-64 Universal joint removal 4-63 

4-65 Upper gear box removal 4-63 

4-66 Lower gear box removal 4-64 

4-67 Steering gear transverse rod removal 4-64 

4-68 Engine hatch covers removal 4-65 

4-69 Stern hatch cover removal 4-66 

4-70 Bow hatch cover removal 4-66 

4-71 Access panel removal 4-66 

4-72 Push knee removal 4-67 

4-r73 Bow towing bitt .removal . 4-67 

4-74 Stern towing bitt removal 4-67 

475 Haul chock removal ; - - 468 

4-76 Coupling arm removal 4-68 

4-77 Coupling yoke, exploded view 4-68 

4-78 Coupling hook, exploded view 4-69 

5-1 Fire extinguisher removal 5-1 

5-2 Fire extinguisher lines and fittings 5-2 

53 Electric bilge pump removal 53 

5 4 Manual bilge pump removal 5-4 

5-5 Manual bilge pump, exploded view 5-5 



iti 



CHAPTER 1 
INTRODUCTION 



Section I. GENERAL 



1-1. Scope 

This manual is for your use in maintaining the 
bridge erection boat. It provides information for 
the operation and maintenance of the equipment 
and its accessories as directed by the maintenance 
allocation chart. 

1-2. Maintenance Forms and Records 

Maintenance forms and records that you ara re- 
quired to use are explained in TM 38-750. 

13. Reporting of Errors 

You can improve this manual by calling' attention 
to errors and by recommending 1 improvements, 
using- DA Form 2028 (Recommended Changes to 
Publications) or by letter, and mail direct to the 



Commander, U. S. Army Troop Support Com- 
mand, ATTN: AMSTS-MPP, 4300 Goodfellow 
Boulevard, St. Louis, MO. 63120. A reply will 
be furnished direct to you. 

1-4. Equipment Serviceability Criteria (ESC) 

This equipment is not covered by an ESC. 

1-5. Destruction of Army Material to Prevent 
'Enemy Use 

Procedures to be used for destruction of the 
bridge erection boat to prevent enemy use are in 
TM 750-244-3. 

16. Administrative Storage 

For administrative storage instructions, refer to 
TM 740-90-1. 



Section II. DESCRIPTION AND DATA 



1-7. Description 



a. General The Bridge Erection Boat (fig. 1- 
1 and 1-2) is a 27-foot, diesel -powered, alumi- 
num craft that is used to tow and maneuver com- 
ponents of floating bridges. The boat consists of 
two assemblies; the bow and the stern. Each as- 
sembly is transported on its own cradle. Upon 
arrival at the launching site, each assembly is 
lowered into the water independently and the two 
are then coupled together. The bow assembly 
contains a cargo well to carry gear and personnel. 
The bow assembly (fig. 1-3 A) has a bow light 
and a manually-operated bilge pump. The stern 
assembly contains two three-cylinder diesel en- 
gines and the operator's cockpit (fig. 1-3B). 
The stern assembly has an electric bilge pump, 
running and stern lights, a portable spotlight, 
and fire extinguishers. The propellers are driven 
by the engines through transmissions with a 
2.91:1 reduction ratio. 



b. Engine. The two engines are vertical, three- 
cylinder, liquid-cooled, in-line, two-cycle diesels 
(fig. 1-4). They have four exhaust valves per 
cylinder, a displacement of 1593 cubic inches, a 
nominal compression ratio of 21 to 1, and a me- 
chanical governor which limits engine rpm. Each 
engine is equipped with a gear-driven air blower, 
air silencer, emergency shutdown valve, belt- 
driven generator and water pump, gear-driven 
fuel pump, fuel filter, electric starting motor, oil 
cooler, oil filter, and gear-driven oil pump. 

c. Transmission. The two transmissions are 
hydraulic-marine types. A gear is mounted on the 
aft end of the engine and its output shaft is con- 
nected by a flange-type coupling to the propel- 
ler shaft (fig. 1-5). Each gear consists of a 
hydraulically-operated multiple disc forward and 
reverse clutch, 2.91:1 ratio reduction gear, oil 
pump, oil screen, and oil pressure regulator 
valve. The oil is cooled by an engine-mounted 
oil cooler. The transmission oil system is inde- 



1-1 



STARBOARD 

RUNNING 

LIGHT 



ENGINE HATCH 
COVERS 



BOW LIGHT 



CARGO 
WELL 




MANUAL BILGE 
PUMP 



BOW TOWING 
BITT 



BOW ASSEMBLY 



PUSH KNEES 



TS002951 



Figure 1-1. 27-Foot bridge erection boat, right front view. 



pendent of the engine oil system. Transmission 
control is effected by control levers mounted in 
the operator's cockpit. 

d. Fuel System. The fuel system (fig. 1-6) 
consists of a tank, filters, strainers, pump and 
injectors. 

(1) Fuel tank. The 90-gallon capacity fuel 
tank (fig. 1-6) is located behind the operator's 
cockpit. The tank is equipped with baffles to sta- 
bilize fuel movement within the tank. A vent line 
passes from the tank through the hull on the 
port side. Fuel is supplied to each engine through 
two lines independently connected to the center 
forward portion of the tank. The fuel tank filler 
is located on the deck above the aft end of the 
tank. The cap is a non-vented type to avoid water 
entering the tank. A fuel quantity gage (dipstick) 
is on the forward bulkhead of the operator's cock- 
pit (fig. 1-3). 

(2) Fuel filters, strainers, valves, and 
pumps. One primary fuel strainer is located on 



each side of the engine compartment and one 
shutoff valve on each side of the operator's cock- 
pit. Fuel drawn from the tank passes through, 
the manually-operated shutoff valve and primary 
strainer to the inlet side of the fuel pump 
mounted on the engine. Leaving the pump under 
pressure, the fuel is forced through a secondary 
filter into the fuel manifold which is an integral 
part of the cylinder head. The fuel is then trans- 
mitted through pipes to the inlet side of the fuel 
injectors. 

(3) Fuel injectors. A fuel injector is in- 
stalled in each engine cylinder. Each injector is 
actuated by a rocker arm to create the high fuel 
pressure needed to obtain atomizing. The injec- 
tors meter and inject the exact amount, of fuel 
required for the desired engine speed. The in- 
jectors are automatically controlled by a limit- 
ing speed mechanical governor. Excess fuel is 
routed through outlet pipes into the return mani- 
fold and back to the tank. 



1-2 



BOW HATCH 



RANGE LIGHT 



STERN TOWING 
BITT 



PORT RUNNING 
LIGHT 




FUEL FILL 
CAP 



OPERATOR'S 
COCKPIT 



HAUL CHOCK 
ASSEMBLY 



STERN 
HATCH 



RUDDER 
PLATF 



STERN 
ASSEMBLY 



TS002952 



Figure 1-2. 27-Foot bridge erection boat, left rewr view. 



(4) Limiting speed mechanical governor. A 
limiting speed mechanical governor is mounted 
on the left side of each engine. The governor is a 
double-weight limiting-speed type and is gear 
driven by the engine. The governor serves to con- 
trol the engine idle speed and to limit the maxi- 
mum operating speed. The governor is connected 
to the injector control levers to regulate the 
amount of fuel delivered to the cylinders, 

(5) Control levers. The control levers are 
mounted in a quadrant located to the right and 
forward of the steering wheel. The levers serve 
two purposes; they control the speed of the 'an- 
gines and also control the transmission. Each 
lever controls engine speed through a cable and 
linkage to a speed control lever on the governor, 
and controls the transmission gear engagement 
by a cable and linkage to a lever on the trans- 
mission. Initial movement of the control lever en- 
gages the transmission, further movement of the 



lever increase,? engine speed. Forward movement 
of the lever engages the transmission in forward 
drive. Aft movement of the lever engages the 
transmission in reverse drive. The mid position 
of the lever diseng'ag-es the transmission and the 
engine will idle. If engine speed variation is de- 
sired while the transmission is in neutral, the 
lever must be pulled out to the side (away from 
the control quadrant). This permits engine accel- 
eration and deceleration while the transmission 
remains disengaged. 

e. Air Induction and Exhaust Systems. The air 
induction and exhaust systems (fig. 1-7) provide 
the fresh air for engine combustion and the means 
for eliminating the products of combustion. The 
system for each engine consists of an air silencer, 
shutdown housing- and control, blower, exhaust 
manifold, muffler, and connecting- lines. 

(1) Blower. An adr blower is mounted on 
the right side of each engine and provides the air 



1-3 



BOW TOWING 
BiTT 



BOW LIGHT 
RECEPTACLE 



BOAT 
HOOK 



BOW COMPARTMENT (STOWAGE 
FOR): 

ANCHOR AND LINE 

LIFTING SLING 

COCKPIT COVERS 

COVER POLE 

STEERING LINES 

MOORING LINES 



LIFE RING 



CLEAT 



LIFTING 
U-BOLT 



BOW LIGHT 
RECEPTACLE 



A. BOW ASSEMBLY 



STEERING 
VHEEL 



CONTROL LEVERS 
THROTTLE & SHIFT) 



SPOTLIGHT 
STOWAGE 



PORTABLE FIRE 
EXTINGUISHER 



ENGINE COMPARTMENT 
FIRE EXTINGUISHER 



FUEL QUANTITY 
GAGE 




TS002953 



Figure 1-3. Bridge erection boat orientation. 



ENGINE SPEED 
/THROTTLE) CABLE 



SHUT-OFF 
CABLE 



EXPANSION 
TANK 



FUEL STRAINER 



EXHAUST 
MANIFOLD 



THERMOSTAT 
HOUSING 



NOTE 

CRANKING MOTOR (STARTER) 
LOCATED BELOW AIR BLOWER 



A. RIGHT SIDE 



FRONT 

LIFT BRACKET 



VALVE ROCKER 
COVER 



RFAR 

LIFT BRACKET 



TRANSMISSION 
OIL COOLER 



ENGINE LUBRICATING 
OIL COOLER 



TRANSMISSION 
CONTROL CABLE 



AIR BOX 
DRAIN 



TACHOMETER 
ENGINE OIL A DRIVE CABLE 
DRAIN HOSE 




Figure 1-4. Engine and transmission. 



1-5 




ENGINE 



TS002955 



Figure 1-5. Power arrangement. 



for combustion and scavenging. The blower is 
bolted to the engine and is gear driven. During 
the scavenging process, fresh air is forced 
through the intake ports into the cylinder and 
thoroughly eliminates all of the burned gases out 
through the exhaust valve ports. Fresh air then 
remains in the cylinder for combustion. 

(2) Air shut-down housing. The adr shut- 
down housing is mounted on the side, of the 
blower. The air shutdown housing contains a 
valve that, in an emergency, cuts off the air sup- 
ply and stops the -engine. The air shutoff valve is 
manually operated. The EMERGENCY STOP 
control handles are located in front and to the 
left of the steering wheel. The manual controls 
are connected to the air shutoff valve by a cable 
and linkage. Pulling out a handle will close the 
valve and stop engine operation. 

CAUTION 

If the EMERGENCY STOP handle has 
inadvertently been pulled while the en- 
gine is stopped or idling, the air shut- 



down valve must be manually reset. If 
the handle was pulled because of a run- 
away engine, do not attempt to restart 
the engine until it has been inspected by 
direct support personnel. 

(3) Air silencer. An air silencer is mounted 
on each air shutdown housing. The silencer 
serves two purposes; it contains sound absorbent 
material to quiet the rush of air into the system; 
aand it contains a screen so that foreign objects 
cannot be drawn into the blower. 

(4) Exhaust system. The burned gases from 
the engine pass through a water-cooled exhaust 
manifold, which is connected by piping to a muf- 
fler in the stern. The muffler is joined to a tail 
pipe which exhausts above the water line. The 
muffler and piping are wrapped with asbestos 
blanketing for personnel protection, 

/. Cooling System. The cooling system (fig. 1- 
8), for each engine consists of a water pump, 
heat exchanger, thermostat, expansion tank, and 
associated lines and fittings. 



VENT 



FILLER CAP 




FUEL FILTER 



SHUT OFF VALVE 



SUPPLY LINE 



RETURN LINE 



TS002956 



Figure 1-6. Fuel systems. 



(1) Heat exchangers. Two heat exchangers, 
one for each engine, are mounted outside the 
hull on either side of the keel next to the pro- 
peller shafts. The engine coolant is circulated 
through the exchangers and the heat from the 
coolant is transferred to the water surrounding 
the boat. The exchangers are fitted with zinc 
anodes which prevent corrosion to the heat ex- 
changers and the hull caused by electrolytic action 
of the surrounding water. 

(2) Water pumps. A centrifugal-type water 
pump is mounted on top of the engine oil cooler 
housing at the left front corner of each engine. 
The pump is de'lt driven by a pulley mounted 
on the camshaft. The pump circulates coolant 
drawn from the expansion tank through the oil 
cooler, cylinder block, cylinder heads, thermostat 
housing, and, if too warm, the heat exchangers. 

(3) Thermostat A thermostat housing is at- 
tached to the water outlet (forward) end of each 
exhaust manifold. The housing contains a block- 
ing type thermostat that automatically controls 
the temperature of the coolant. A bypass tube is 



connected between the thermostat housing and 
the water tank. At coolant temperatures below 
approximately 170F, the thermostat valve re- 
mains closed and blocks the flow of coolant to 
the heat exchanger. This causes the coolant to cir- 
culate through the cylinder block and heat back 
to the suction side of the pump. When the coolant 
temperature rises, the thermostat valve opens, the 
bypass section is restricted, and the coolant passes 
to the heat exchanger. 

g. Ltibricating Oil System. The lubricating oil 
system (fig. 1-9), for each engine includes an 
oil intake screen and tube assembly, oil pump, 
oil pressure regulator, oil filter with bypass valve, 
oil cooler, and oil cooler bypass valve. Lubricat- 
ing oil from the pump passes through the engine 
front cover and into passages in the cylinder 
block. From the block, the oil passes through the 
filter to the oil coolers. The oil then flows 
through the cooler and back into the engine 
front cover. 

(1) Oil pump. The oil pump is a rotary 
type and is mounted on the inside of the engine 



1-7 



TM 5-1940-221-12 



MUFFLER 




AIR SHUT DOWN 

MLVE 



AIR BLOWER 



AIR SILENCER 



TS002957 



Figure 1-7. Air induction and exhaust systems. 



lower front cover. The pump is driven directly 
by the crankshaft. As the pump rotor revolves, a 
vacuum is formed on the inlet side of the pump 
and oil is drawn from the crankcase and forced 
out under pressure through the discharge port of 
the pump. 

(2) Oil pressure regulator. The oil pressure 
regulator is installed in the engine 'lower front 
cover. The regulator consists basically of a spring- 
loaded piston-type valve. When the oil pressure 
exceeds 51 psi, the valve is forced from its seat, 
and the oil is bypassed into the engine oil pan. 

(3) Oil filter. The lubricating oil filter is 
the full-flow type and is mounted between the 
oil pump and cooler. Oil is forced by pump 
pressure through a passage in the filter base to 
the space around the filter element. Impurities 
are filtered out as the oil is forced through the 
element and it then passes to the oil cooler. A 
valve, which opens at 183-21 psi, is located in the 
filter base and will bypass the oil directly to the 
cooler if the filter is clogged. 

1-S 



(4) Oil coolers. 

(a) Engine cooler. The engine oil cooler 
is mounted on the left side of the cylinder block 
at the lower front corner. Coolant from the en- 
gine cooling system circulates through the oil 
cooler and completely surrounds the oil cooler 
core. Oil flows from the oil filter through the 
cooler core and then to the cylinder block oil 
galleries. The core is cooled by the circulating 
engine coolant. A bypass valve is located in the 
right side of the lower engine front cover. If the 
oil cooler should become plugged, the valve will 
open at approximately 52 psi and pass the oil di- 
rectly to the galleries in the cylinder block. 

(b) Transmission oil cooler. The trans- 
mission oil cooler is mounted over engine oil 
cooler on the left side of the cylinder block. Oil 
flows from the transmission through the cooler 
core and back to the transmission. The core is 
cooled by the circulating engine coolant. 



FILL CAP 




TRANSMISSION OIL 
COOLER 



ENGINE 
OIL COOLER 



TS002958 



Figure 1-8. Cooling system. 



(5) Oil level dipsticks, 

(a) Engine dipstick. A steel ribbon-type 
dipstick is mounted in a tube on the left side of 
the engine. The dipstick has markings to check 
the amount of oil in the engine oil pan. The oil 
level should always be at the F (full) mark on 
the dipstick. 

CAUTION 

The engine should not be operated if the 
oil is below the L mark on the dipstick. 

(b) Transmission dipstick. A dipstick and 
plug assembly is threaded into the upper left 
side of the transmission housing. The dipstick has 
markings to check the amount of oil in the trans- 
mission. The level should be maintained at the F 
(full) mark on the dipstick. 

(6) Oil filler cap and oil sump drain. The 
engine lubricating oil filler cap is located in the 
valve rocker cover. When adding oil, care should 
always be taken to be sure that no dirt or other 



foreign matter enters the filler. Oil is drained 
from the sump by nieans of a manually-operated 
pump through a tube located at the left side of the 
engine. The tube has a threaded plug which is 
removed and the pump fitting attached. 

h. Electrical System. The electrical system (fig. 
1-10) is a 24-volt direct current with negative-to- 
ground. The system is powered by batteries which 
are charged by the engine-driven generator. The 
batteries supply the power fox lighting, starting, 
instruments, the alarm system, and the stern 
bilge pump. 

(1) Generator. The generator is mounted at 
the left forward portion of the engine. It is a 24- 
volt, hinge-mounted, two-brush shunt unit with 
sealed ball bearings. The generator is belt driven 
by a pulley mounted on the camshaft. The gen- 
erator supplies current to charge the batteries 
through a voltage regulator. 

(2) Generator regulator. The generator reg- 
ulators are mounted on the aft bulkhead of the 
engine compartment. The regulators are 24-volt, 



1-9 



OIL PRESSURE 
REGULATOR 







OIL FILTER 



VO ' ' 

-^w 



TS002959 



Figure 1-9. Engine lubricating oil system. 



18-ampere, heavy-duty, water-tight units. The 
regulators are limiting devices designed to pro- 
tect the system from excessive voltage and cur- 
rent. 

(3) Batteries. The four batteries are 
mounted in pairs in two battery boxes located on 
the deck at the forward position of the operator's 
cockpit. The batteries are lead-acid types. Each 
pair of batteries is connected in series. The two 
pairs are then connected in parallel to provide 
a 24-volt supply. The batteries are charged by the 
engine-driven generators. 

(4) Starting motor. The starting motor is a 
heavy duty type with totally enclosed shift lever 
and solenoid plunger. The starting motor is lo- 
cated on the lower left side of each engine. When 
the STARTER switch, located on the switch 
panel is engaged, the solenoid is energized and 
shifts the starting motor pinion in mesh with the 
engine flywheel gear ring. This also closed the 
main contacts within the solenoid and allows bat- 
tery current to flow to the motor causing the ar- 
mature to turn. As the engine starts, an over- 



running clutch drive turns faster than the arma- 
ture and the pinion disengages to protect the 
armature from excessive speed. 

(5) Magnetic cranking switch. A solenoid- 
operated cranking switch is mounted on the aft 
bulkhead of the engine compartment. The crank- 
ing switch connects the batteries in parallel. 

(6) Alarm system. 

(a) The boat is provided with an alarm 
system to alert the operator when an engine mal- 
function exists. The system consists basically of a 
bell located below the instrument panels in the 
operator's cockpit and three sensors. One sensor 
is mounted in the right forward portion of the 
cylinder block and will close the circuit when 
coolant temperature exceeds 205 5F. and 
sound the alarm. Another sensor, located at the 
lubricating oil filter, will close the circuit when 
oil pressure drops below 10 2 psi and will 
sound the alarm. A third sensor is located at the 
outlet of the fuel pump. This sensor establishes 
the circuit in an operating condition when the 
engine is started. 



MAGNETIC 
CRANKING SWITCH 



STARBOARD RUNNING 
LIGHT (GREEN) 



RANGE LIGHT 



*. v> N *^>NS>>vSS>oji>>x *u 




RANGE LIGHT 
RECEPTACLE 



STARTER 



PORT RUNNING 
LIGHT (RED) 



BATTERIES 



BILGE PUMP 



TS002960 



Figure 1-10. Electrical system. 



NOTE 



Any time the MASTER switch is 
in the ON position the alarm will 
sound if both engines are not run- 
ning. This will occur before engine 
starting and after shut down. When 
either engine is running, the alarm 
system will be deactivated if the oil 
pressure and coolant temperature 
are within limits. 

(6) In the event the alarm bell rings, the 
actions to be performed are as follows: 

1. If both engines are stopped, the 
MASTER switch should be placed in the OFF 
position. 

2. If one engine is running-, the water 
temperature and engine oil pressure gages for that 
engine should be checked to determine which 
gage reflects an abnormal condition. Then the 
engine should be shut down and the MASTER 
switch placed in the OFF position. 

8. It both engines are running, the 
water temperature and engine oil pressure gages 



should be checked to determine which engine is 
operating abnormally and what the abnormal 
condition is. Then the malfunctioning engine 
should be shut down. 

4. With both engines stopped and mas- 
ter switch is in ON position, if the alarm does 
not sound, replace ALARM fuse on fuse panel. 
i. Steering System. The steering system (fig. 
1-11) consists essentially of a steering wheel, 
gear boxes, rods, quadrant, and rudders. Rotary 
motion of the steering wheel turns bevel gears 
in the upper gear box. This box transmits this 
motion through a rod to 'the lower gear box and 
in turn to another rod which engages the teeth 
of the rudder quadrant. A shaft is mounted to 
the quadrant and controls positioning of the port 
rudder plate. A transverse rod is connected be- 
tween the quadrant and the starboard rudder 
shaft. 

j. Fire Extinguisher System. The fire extin- 
guisher system (fig. 1-12) consists basically of a 
fire extinguisher bottle installed at the forward 



TM 5-1940-221-12 



jTEERING WHEEL 
/ 



UNIVERSAL JOINTS 




RUDDER PLATE 



LOWER GEARBOX 



QUADRANT 



TRANSVERSE ROD 



TS002961 



Figure 1-11. Steering system. 



starboard portion of the cockpit and a nozzle lo- 
cated in the engine compartment. The system is a 
carton-dioxide type and is suitable for all fires 
including electrical. The system is actuated man- 
ually by a lever type control on the top of the 
bottle. Once the lever is actuated, it will discharge 
all the carbon dioxide in the cylinder. A small 
portable carbon dioxide extinguisher is located 
next to the installed bottle. 

If. Bilge Pumps and Drain Plugs. 

(1) An electric bilge pump is located in the 
forward center portion of the stern assembly (fig. 
1-10). It is controlled by a toggle switch mounted 
on the switch panel. A manual bilge pump is in- 
stalled in the aft portion of the bow assembly 
(fig. 1-1). 

(2) A drain plug is provided at the forward 
center portion of the stern assembly, and another 
is located at the aft center portion of the box 
assembly. These are screw-type fittings with a T- 

handle. 

1-12 



L On-Board Equipment. The boat is equipped 
with accessory equipment as follows: 

(1) A 22-pound anchor with a 100-foot long 
1/2-inch diameter nylon line is stowed in the bow 
compartment. Two steering lines, four mooring 
lines, and a lifting sling are also stowed in the 
bow compartment. 

(2) A 7-foot boat hook is stowed in clips 
on the port side of the forward cockpit. 

(3) A canvas cover, support pole, and 30- 
feet of manila line are provided to cover the for- 
ward cockpit. A canvas cover and 30-foot line is 
supplied for the operator's cockpit. All the items 
are stowed in the bow compartment. 

(4) A ring buoy with line attached is stowed 
in a bracket on the port side of the forward, cock- 
pit. 

(5) An engine lubricating oil drain pump is 
stowed in a bracket on the forward starboard side 
of the engine compartment. 



BOTTLE 




'53***, 

tT>,, 

j? -s^ 



NOZZLE 




Ns5:- x ! 

W' 



TS002962 



Figure 1-12. Fire extinguisher system. 



18. identification and Tabulated Data 

a. Identification. There are 13 identification 
and 2 instruction plates on the bridge erection 
boat. Two additional instruction plates are lo- 
cated on the cradles. 

(1) The boat identification plate is located 
in the operator's cockpit on the port side skirt- 
ing-. This gives the end item dimensions, weight, 
and Federal Stock Number. 

(2) An engine identification plate appears 
on the left side of the valve rocker cover on each 
engine. This gives the manufacturer's name, 
model, seirial number, component type numbers, 
and engine rating. 

(3) An identification plate is located on the 
left of each transmission. This gives the manu- 
facturer's name, model, serial number, and gear 
ratio. 

(4) An identification plate is located on the 
base of each generator regulator. This gives the 
manufacturer's name, serial number, and rating. 

(5) An identification plate is located on the 
right side of each generator. This gives the man- 



ufacturer's name, model, serial number, and rat- 
ing. 

(6) An identification plate is located on the 
bottom of each starter. This gives the manu- 
facturer's name, model, serial number, and rating. 

(7) An identification plate is located on the 
upper left side of each governor. This gives the 
manufacturer, serial number, and idle range. 

(8) A caution plate is located forward of 
the steering wheel. This gives drain plug instruc- 
tions and battery handling. 

(9) A wiring instruction plate is located on 
the top of each battery box. 

(10) A loading diagram is located on the 
right forward side of the bow cradle. 

(11) A loading diagram is located on the 
right forward side of the stern cradle. 

&. Tabulated Data. 

(1) General. 

Manufacturer Aluminum Company of 

America 

Federal stock number 1940-182-3097 

Serial number range Hulls 71-1, 71-2 thru 71- 

46, 73-47 thru 73-139 

1-13 



TAA 5-1940-221-12 



material Aluminum 



ting range 

.maximum load) 

(2) Capacities. 



36 miles 



*.uel (diesel) 90 gallons 

Cooling system 4.75 gallons 

Engine lubricating system 9.5 quarts 
Transmission lubricating 

system 3 quarts 

Bilge pump: 

Electrical 15 gallons per minute 

Manual 3 gallons -per minute 

(3) Performance data. 

Speed (maximum load) 6 miles per hour 

Turning radius: 

Pull speed ahead 70 feet 

Full speed astern 28 feet 

Fuel consumption 

(2800 rpm) 12.4 gallons per hour 

(4) Dimensions and weights. 

Dimensions : 

Length 27 feet 

Beam 8 feet, 2 inches 

Height 6 feet, 5 inches 

Draft (maximum) 3 feet, 4 inches 

Cargo well capacity 2400 Ib. load 



Weights : 

Bow assembly 

(unloaded) 

Stern assembly 

(unloaded) 
Total (unloaded) 

(5) Engine. 

Manufacturer 



Model 

Type 

Horsepower 

Governed speed (maximum) - 

Idle speed 

Number of cylinders 

Firing order 

Cylinder arrangement 

(front to rear) 

Diesel fuel specification 

Lubrication specification - 

(6) Water pump. 



Manufacturer 



Type 

Coolant 

Pump pressure (max) 
Cooling system capacity 



1150 pounds 

60OO pounds 
7150 pounds 



Detroit Diesel Division 
General Motors Corp. 
5032-4000 

Diesel, 2 cycle, in-line 
92 shp @ 2800 rpm 
3040 rpm 
500-&00 rpm 
3 
1-2-3 

1-2^3 

W-F-800 

MIL-M-2104 



Detroit Diesel Engine Di- 
vision, General Motors 
Corp. 

Belt driven impeller 

Fresh water 

10 pounds per inch 

4.75 gallons (with expan- 
sion tank and heat ex- 
changers) 



(7) Thermostat 

Manufacturer Detroit Diesel Engine Divi- 
sion, General Motors 
Corp. 

Type Bimetallic valve installed 

horizontally in housing 

Temperature range 165-180 Fahrenheit 

(8) Fuel pump. 

Manufacturer Detroit Diesel Engine Divi- 
sion General Motors 
Corp. 

Type Positive displacement gar 

Fuel flow 60 gallons per hour 

Drive Governor, driven via square 

coupling 

(9) Electrical system, 24 volts direct current. 

Batteries : 
Voltage 12 

Numbered required 4 

Connection 2 pairs in series then each 

connected in parrallel tc 
provide 24 volts 
Wiring diagram See figure 1-13 



(10) Generator. 



Manufacturer 



Gen- 



Model 
Type 



Voltage output (unregula- 
ted) 



Voltage output (regulated) - 

Current output (max) 

Field coil draw (max) 

Armature rotation 

Brush spring tension (max) 
Bearing type 



Delco Remy Division, 
eral Motors Corp. 

1105993 

Belt driven internally 
grounded, two brush 
shunt unit 



28.5 volts d.c. @ 1.775 rpon 

engine speed 
24.0 volts d.c. @ 1.77-5 rpm 

engine speed 
18.0 amperes (regulated) 

@ 1.775 engine rpm 
0.91 to 0.98 amperes @ 

24.0 volts d.c. 
Clockwise 
28 ounces 
Sealed ball bearings at 

drive and commutator 

end plates 



(11) Generator regulator. 

Manufacturer Delco Remy Division, Gene- 
ral Motors Corp. 

Model 1118644 

Type Heavy duty, 24 volt d.c., 18 

ampere fungus, water 
and corrosion proofed 

negative-to-ground unit 
Voltage regulator range 

limits 27.5 to 29.5 volts d.c. (test) 

Voltage setting 28.2 volts d.c. 

Air gap setting 0.087 inch 

Current regulator range 

limits 16.0 to 20.0 amperes (test 



1-14 



Cutout relay 'dosing range 25.0 to 27.0 volt d.c. (test) 

Voltage setting 24.0 volts d.c. 

Air gap setting 0.048 inch 

Points Platinum and tungsten 

Point opening 0-.-03-5 inch 

(12) Cranking motor (starter) 

Manufacturer Delco Remy Division, Gene- 
ral Motors Corp. 

Type Heavy duty motor equipped 

with an intermediate duty 
overrunning spray clutch 
drive 

Cranking rotation Counterclockwise (drive end) 

Voltage draw 24 volts d.c. 

Drive linkage Solenoid actuated shift lever 

enclosed 

Drive pinion clearance (max) 0.010 to 0.040 inch 

(13) Magnetic cranking sivitch. 

Manufacturer Leece-Neville Company 

Model S001-4924SC 

Type Heavy duty water resistance 

unit with spring loaded 
disc type contactor assem- 
bly paralleling aeries con- 



Ulosang voltage 13.4 volts d.c. 

Field coil current flow 3.2 amperes 

(14) Accessories. 

(a) Electric bilge pump. 

Manufacturer Gross Mechanical Labora- 
tories, Inc. 

Type Heavy duty enclosed motor 

driven impeller 

Voltage draw 12.0 volts d.c. 

Discharge rate 15.0 gallons per minute 

Discharge venting Hose discharge in vent hole 

on starboard side of hull 

(6) Manual bilge pump. 

'Manufacturer Wilcox-Gritteden Co. 

Model .5392W 

Type .Hand-operated piston pump 

19. Differences in Models 

This manual covers only the Aluminum Company 
of America Model HICE-27D Bridge Erection 
Boat. No differences exist for the model covered 
in this manual. 



1-15 




04 

*Sr 



I 



-16 



s O O < ; 
""! Z Z 2 

m >9zz< 

l^pii^l 

^^< J =x J =S^^ llJ 

5 ?cOoo5o 3s 




CM 
O 
O 



_' - . 10 O IV 03 



I CO-*IX03O-CQ 







1-17 



TM 5-1940-221-12 




Section I. OPERATING PROCEDURES 



WARNING 



If equipment fails to operate refer to 
troubleshooting procedures in Chapter 3. 

21 . Suspecting the Equipment 

a. Inspect the lifting slings for damaged cables 
and tiedowns, for kinks, fraying and loose cable 
ends before installing the sling to the equipment. 
After installation, check to insure that all tie- 
downs are properly attached and tight. 

6. Refer to figure 2-1 and remove the bow 
and stern assemblies with their cradles from the 
transport vehicle. Set the loaded cradles on a 
strong flat surface. 

WARNING 

Before proceeding, check the cradle as- 
semblies for signs of damage, missing 
parts, and security. The cradle assem- 
blies support heavy loads and structur- 
al failure could result in damage to the 
equipment and possible injury to per- 
sonnel. 

c. Remove the bow assembly cover (steps 3, 4, 
and 5, fig. 2-2(1) A) and the stem assembly 
cover (steps 3 and 4, fig. 2-2 (1)B). 

d. Make a thorough inspection of the entire 
boat for loss of parts and components or damage 
that may have occurred during loading or ship- 
ment. 

e. Inspect the hull for dents, distortions, and 
cracks. Check that all hatches open freely and 
close securely. 

/. Inspect the instrument, switch, and fuse 
panels for cracked or broken gages, and condi- 
tion of switches and fuse holders. 

g. Inspect all tubing, pipes, hoses, and elec- 
trical wiring for loose connections, breaks, or 
other damage. 

h. Check propellers, propeller shafts, and rud- 
ders for damage. 



t. Operate the steering wheel and control 
levers, and check that they move smoothly and 
freely. 

j. Refer to the Items Troop Installed or Au- 
thorized List (App C Section III) and make sure 
that all items listed are with the boat and in 
serviceable condition. 

2-2. Launching and Coupling 

a. Launching. Refer to figure 2-2(2) and 
launch the bridge erection boat. Be sure to attach 
a line between the bow and stern assemblies and 
the shore before the assemblies are placed in the 
water. 

b. Coupling Bow and Stern Assemblies. The 
coupling operation must be performed by two 
men. Station one man in the bow assembly, and 
the other man in the forward portion of the en- 
gine compartment. Then proceed as given in 
figure 2-3. 

c. Bleeding Propeller Shaft Logs. Bleed both 
propeller shaft logs as given in figure 2-4. 

CAUTION 

The logs must be bled each time the boat 
is placed in the water; otherwise, the 

water-lubricated shaft bearing will 
bum out when the proepller shaft rotates. 



2-3. 'Servicing 



WARNING 



Do not take fuel, lubricants or other vol- 
atile materials aboard, energize electrical 
circuits, or start engines until the fire 
extinguishers have been inspected and 
are known to be in good working order. 

a. General. Perform the daily preventive main- 
tenance services given in chapter 3, section III, 
that do not require starting the engines. 



A CRANE HAVING AT LEAST 
A 5-TON CAPACITY. 



CAREFULLY RAISE STERN 
ASSEMBLY WITH HOIST 



4. CAREFULLY RAISc 

ASSEMBLY WITH HO 1ST 



1. INSTALL SLING AS 
SHOWN IN 
FIGURE 2- 




6. REMOVE TIE-DOWN CHAINS I4i. 



3. REMOVE BLOCKING (8). 



'2. REMOVE TIE-DOWN CHAINS 14) 

TS002965 



Figure 2-1. Removing the bridge erection boat from the transport vehicle. 



b. Lubrication. Lubricate the equipment in ac- 
cordance with the instructions given in chapter 
3, section II. 

c. Fuel System. Fill the fuel tank with the 
proper grade and amount of fuel. The bridge 
erection boat requires 90 gallons of ddesel fuel oil 
for operation. No. ID (FSN 9140-286-5286) oil 
is used in the winter and No. 2D (FSN 9140-286- 
5294) in the summer. 

d. Cooling System. Remove the cap from the 
expansion tank and check the coolant level. If 
the tank is empty, check that all drains are 
closed, and fill the system with coolant. If freez- 
ing temperatures are expected, be sure that anti- 
freeze is used. 

e. Batteries. Check the level of the electrolyte 
in the batteries, and fill with distilled water if 
necessary. Service the batteries in accordance with 
instructions given in TM 9-6140-200-14. 



WARNING 

Do not smoke or use an open flame in the 
vicinity servicing the batteries. Batteries 
generate hydrogen, a highly explosive 
gas. 

2-4. Movement to a New Worksite 

a. Dismantling for Movement. To dismantle 
and load the boat, reverse the procedures given 
on figure 2-3. 

b. Reinstallation after Movement. Refer to 
paragraphs 2-1, 2-3, and 2-4 and proceed in the 
same manner for reinstallation after movement. 

2-5. Controls and instruments 

a. General This section describes, locates, il- 
lustrates (fig. 2-5) and provides the operator/ 
crew with the necessary information concerning- 
the controls and instruments to properly op'srate 
the boat. 



2-2 



TM 5-1940-221-12 



4. REMOVE COVER AND 

STOW IN BOW COMPARTMENT. 



3. REMOVE 
LASHING. 



2. REMOVE TIE-DOWN (4). 



5. REMOVE POLE AND STOW 
IN BOW COMPARTMENT. 




1. LOOSEN TURNBUCKLE f4). 



A, BOW ASSEMBLY TIE-DOWN AND COVER REMOVAL 



3. REMOVE 
LASHING. 



4 . REMOVE COVER. 



2. REMOVE TIE DOWNS (4 . 




1. LOOSEN TURNBUCKLES (6). 



B. STERN ASSEMBLY TIE-DOWN AND COVER REMOVAL 



TS 002 9 6.6 



Figure 2-2. Preparation for launching (sheet 1 of 2). 



2-3 



TM 5-1940-221-12 



INSTALL AND 
TIGHTEN DRAIN PLUG. 



INSTALL AND 
TIGHTEN DRAIN PLUG 



STERN ASSEMBLY 
FORWARD BULKHEAD 



BOW ASSEMBLY 
AFT BULKHEAD 



D. STERN DRAIN PLUG INSTALLATION 



C. BOW DRAIN PLUG INSTALLATION 





2. POSITION SLING LOOP 
ON TOWING BITT. 



LIFTING SLING 



I. SECURE 

SHACKLE TO 
U-BOLT WITH 
BOLT AND NUT (2) 



E. STERN ASSEMBLY CRADLE PIN REMOVAL. 



F. BOW ASSEMBLY SLING ATTACHMENT 




CAUTION 

DO NOT LIFT SLING 
UNTIL CRADLE PIN (STEP E) 
IS REMOVED. 



LIFTING SLING 



1 . SECURE SHACKLE TO 

U-BOLT WITH BOLT AND NUT (2). 



STERN ASSEMBLY SLING ATTACHMENT 




TS002967 



TM 5-1940-221-12 



fr 



COUPLING 
HANDLE 



I . STAND IN COCKPIT 



4.. ROTATE HANDLE 
UNTIL NUT SEATS 
AGAINST LUG 



COUPLING LUG 



5. SEAT COUPLING HANDLE IN 
COUPLING LUG. 



3. ALIGN SHEAR CUPS (2) 
AND PULL TOGETHER 



2. GRASP LIFTING 
HANDLE 



A. LIFTING HANDLE, SHEAR CUPS, AND COUPLING HANDLE 



COUPLING HANDLE AND LUG 



6. ROTATE HANDLE UNTIL BOW 



AND STERN ASSEMBLIES 
ARE SNUG TOGETHER, 



C. COUPLING HANDLE AND NUT 



7. LIFT COUPLING HOOK 
HANDLE UNTIL IT 
SEATS IN BRACKET. 



INSERT PIN 
THROUGH BRACKE 
AND HANDLE 



D COUPLING HOOK HANDLE AND BRACKET 



E. COUPLING HOOK PIN 




TS002968 



Figure 2-3. Coupling bow and stern assemblies (sheet 1 of 2). 



2-5 



TM 5-1940-221-12 



10. REMOVE CAP 



11. CONNECT PLUG 
TO RECEPTACLE 



9. TURN AD JUSTING NUT 
UNTIL COUPLING 
HOOK IS SNUG 



F. YOKE ADJUSTING NUT 




G. BOW LIGHT ELECTRICAL RECEPTACLE AND PLUG 

m 

TS002969 



Figure 2-3. Coupling bow and stern assemblies (sheet 2 of 8). 



2. OPEN VENT COCK 

UNTIL WATER APPEARS, 
AND CLOSE VENT COCK. 




TS002970 



Figure 2-4. Shaft log bleeding. 



b. Controls and Instruments. 

(1) Controls and switches. All the engine 
controls are located forward of the steering whBel 
(A, fig 1 . 2-5(1). The two fuel shutoff valves 
are located on the port and starboard sides of the 
operator's cockpit (E, fig. 2-5(2)). All .except 
one of the switches are on a panel located to 
the right and forward of the steering wheel (C, 
fig. 2-5(1)). The spotlight pushbutton switch is 
located in the spotlight handle (D, fig. 2-5(2)). 
The controls and switches are Mated and de- 
scribed in table 2-1. 

(2) Instruments. All the instruments are lo- 
cated on two adjacent panels located below and 
forward of the steering wheel (B, fig. 2-5(2)). 
The panel on the left contains the instruments 
for the port engine and the panel on the right, 
the instruments for the starboard engine. The in- 
struments are listed in table 2-2. 



Table 2-1. Controls and Switches 



Nomenclature 



Description 



Purpose 



Steering wheel 

Engine PORT and STBD EMER- 
GENCY STOP controls. 
Engine SHUTOFF controls 
Throttle and transmission controls 

Fuel shutoff valves 
RUNNING LIGHTS switch 

ANCHOR LIGHT switch 
BILGE PUMP switch 
SEARCH LIGHT switch 



Rotary with knob 
Push-pull handle 

Push-pull handle 
Rotary lever 

Manual handle 
DPST toggle 

SPST toggle 
SPST toggle 
SPST toggle 



Controls position of rudders. 
Shut off air sup-ply to engines. 

Cut off fuel supply to engines. 

Control engine power and transmis- 
sion gear selection. 

Control fuel supply to engines. 

Energizes port and starboard run- 
ning lights. 

Energizes bow and range lights. 

Energizes stern bilge pump. 

Energizes spot light. 



2-6 



TM 5-1 940-221-12 



Nomenclature 


Description 


Purpose 


Spotlight handle switch 
BATTERY PARALLEL switch 
PORT AND STBD START swatches 
MASTER switch 


SPST toggle 
SPST toggle 
Momentary SFST toggle 
SPST toggle 


Actuates spotlight lamp. 
Energizes magnetic cranking swatch. 
Energize starter solenoids. 
Energizes electrical system. 



LEGEND: SPST Single pole single throw 
DPST Double pole single throw 
SPDD Single pole double duty 



Table 2-2. Instruments. 



Nomenclature 


Description 


Purpose 


TRANSMISSION OIL 
WATER TEMP 
RPM 

AMPERES 
OIL PRESSURE 


Pressure gage 
Temperature gage 
Tachometer 

Ammeter 
Pressure gage 


Reflect transmission oil pressure. 110 
-115 psd, normal. 
Reflect engine water temperature. 
160-185F. normal. 
Reflect speed of engine crankshaft 
and hours of operation. 
Reflect output current generators. 
Reflect engine oil pressure: 40-60 
psi normal, 32 psi minimum sy 
2500 rpm and 80 psi minimum at 
2200 rpm. 



WARNING 

Wear ear muffs or ear plugs to avoid in- 
jury when noise level is excessive. 
There is a potential noise hazard when 
engine speed exceeds 1200 RPMs. 

2-6. Starting 

a. Preparation for Starting. 

(1) Perform the preventive maintenance 
checks and services as given in paragraph 3-5. 

(2) Inspect the on-board equipment and be 
sure it is aboard and properly stowed. 

( 3 ) Secure all hatches . 

(4) Check that the fire extinguishers have 
not been discharged. 

(5) Place the MASTER switch in the ON 
position and all other switches off, and push 
down the shutoff and emergency stop handles. 

(6) Position the control levers in the verti- 
cal (neutral-idle) position. 

b. Starting. 

(1) Refer to figure 2-5E and open the fuel 
line shutoff valves. 

(2) Refer to figure 2-6 and start the en- 
gines. 

2-7. Stopping 

a. Normal Stopping. 

(1) Secure the boat- to its berth with the 
mooring lines. 

(2) Refer to figure 2-7 and stop the en- 
gines. 

(3) Turn off the fuel line shutoff valves. 



b. Emergency Stopping. In the event of a run- 
away engine that cannot be stopped with the 
black shut off handles, the red emergency handle 
must be pulled. 

CAUTION 

This procedure should not be used under 
any circumstances other than an uncon- 
trollable runaway engine. Lubricating 
oil may be sucked up into the cylinders 
and cause engine damage. Therefore, do 
not attempt to restart the-engine until it 
has been inspected by direct support per- 
sonnel. 

2-8. General Operation 

a. General. This paragraph describes in gen- 
eral how the boat is to be operated. It gives gen- 
eral information on pushing and towing compo- 
nents of floating bridges and rafts, and on 
docking and casting off the tow. Specific instruc- 
tions are published in the applicable floating 
bridge manuals for bridge erection boat's oper- 
ating personnel. 

(1) Control lever operation. The engine 
speed control (throttle) and transmission for- 
ward-reverse control for the bridge erection boat 
are incorporated in the same lever. Refer to fig- 
ure 2-8 for control lever operation. 

(2) Steering gear. Both rudders are oper- 
ated simultaneously by the steering wheel. Turn- 
ing the wheel to port will cause the boat to 
move to port. A knob is installed on the wheel 



2-7 



NOTE 

STEERING WHEEL 
REMOVED FOR 
CLARITY 



THROTTLE AND TRANS- 
MISSION CONTROL 
LEVERS 



EMERGENCY 
STOP HANDLES 



SHUT-OFF 
HANDLES 



INSTRUMENT 
PANELS 



A. PANELS AND CONTROLS 



TRANSMISSION 
OIL PRESSURE 
GAGES 



WATER 

TEMPERATURE 

GAGES 



ENGINE OIL 
PRESSURE GAGE 



ENGINE OIL 
^ESvJ^E GAGE 



PORT ENGINE i PANEL LIGHTS I STARBOARD ENGINE 

INSTRUMENT PANELS gg INSTRUMENT PANEL SWITCHES I INSTRUMENT PANEL 




Figure 2-5. Controls and instruments (sheet 1 of 2). 




TM 5-1940-221-12 



ELECTRICAL SYSTEM 
MASTER 



SHUT-OFF VALVE HANDLE 




TS002972 



Figure 2-5. Controls and instruments (sheet 2 of 2). 



so that while maneuvering, the operator can easily 
steer the boat with his left hand, leaving his 
right free to manipulate the control levers. 

CAUTION 

Keep a firm grip on steering wheel and 
avoid excessive speed when moving as- 
tern. Damage to rudder lever may result 
if steering wheel is allowed to spin. 

b. Getting Under Way Forward From a 
Berth. Assuming that the boat is positioned with 
its port side toward the berth, proceed as fol- 
lows: 

( 1 ) Cast off the mooring lines. 

(2) Rotate the steering wheel to starboard. 

(3) Push the port control lever for- 
ward and leave the starboard control lever in 
neutral. 



(4) When the boat is clear of the berth, ad- 
vance the starboard control lever to the same 
position as the port lever. 

(5) When clear of all obstacles, position the 
steering wheel as required and advance both con- 
trol levers to the desired operating speed. 

(6) If the boat was moored with the star- 
board side toward the berth, proceed in the 
same manner as in steps 1 through 5 above but 
use opposite control lever and steering wheel 
positions. 

c. Getting Under Way Astern From a Berth. 
Assuming that the boat is positioned with its port 
side toward the berth, proceed as follows: 

(1 ) Cast off the mooring lines and rotate the 
steering wheel to starboard. 

(2) Pull the port control lever aft, and 
leave the starboard control lever in neutral. 



TM 5-1940-221-12 



EMERGENCY 
STOP HANDLES 



SHUT-OFF 
HANDLES 



NOTE 

STEERING WHEEL 
REMOVED FOR CLARITY, 



STARBOARD 

STARTER 

SWITCH 




1. 

2. 



CHECK THAT HANDLES ARE ALL THE WAY DOWN 

' 



PLACE MASTER SWITCH IN ON POSITION- 
PLACE STARBOARD ENGINE STARTER SWITCH IN 
ON POSITION UNTIL ENGINE STARTS. IF ENGINE 
FAILS TO START AFTER 30 SECONDS RELEASE 

IJ R 7 ER SWITCH AND LET STARTER' MOTOR COOL 

,QD R C n,n! W M1NUTES - 'F PROLONGED CRANKING 
IS REQUIRED, SWITCH THE BATTERY PARALLELING 

?WF, Jr P RT R LARBOARD AS REQUIRED FOR 
o I AK T I NG 

CAUTION 



5. 



6, REPEAT STEPS 4 AND 5 FOR PORT ENGINE. 



TS002973 



Figure 2-6. Engine starting procedures. 



2-10 



TM 5-1940-221-12 



1 . PLACE BOTH CONTROL LEVERS 
IN NEUTRAL (UP) POSITION. 



2. PULL BOTH 
SHUT-OFF 
KNOBS. 




PLACE MASTER SWITCH IN 
DOWN (OFF) POSITION. 



TS002974 



Figure 2-7. Engine stopping procedures. 

(3) When the boat is clear of the berth, po- 
sition the starboard control lever in the same po- 
sition as the port lever and position the steering 
wheel as required. 

d. Getting Under Way from an Anchorage. 
Assuming 1 the boat has been anchored, proceed 
as follows: 

(1) Position a man in the bow and have him 
haul the anchor aboard. 

(2) If the man is unable to break the 
anchor free from the bottom, move both control 
levers slowly forward just until the marine gears 
engage. 

(3) Move forward slowly until the anchor 
has broken free from the bottom and have the 
anchor hauled in. 

e. Maneuvering Rafts. 

(1) Pushing. The most efficient method of 
maneuvering rafts is pushing. This method pro- 
vides maximum stability and maneuverability. 
Proceed as follows to push a raft: 

(a) Approach the raft to be maneuvered 
as shown in figures 2-9 and 2-10, and secure the 
lines as shown. The spring lines shown in figure 
2-9 are only used in high, winds or strong cur- 
rents. If there is any current, position the boat 
downstream of the raft. 

NOTE 

Always use a pushing balk as shown in figure 
2-10 when pushing between ponton and use a 
pushing bracket when pushing against a !>onton. 
The balk is part of the rafting equipment. 




1 . PUSH LEVER FORWARD TO ENGAGE FORWARD GEAR 
(INITIAL MOVEMENT OF LEVER FROM NEUTRAL ENGAGES 
TRANSMISSION). 

2. CONTINUE TO MOVE LEVER FORWARD TO INCREASE EN- 
GINE SPEED. 

NOTE 

PAUSE MOMENTARILY IN THE iDLE- 
NEUTRAL POSITION WHEN SHIFTING 
FROM FORWARD TO REVERSE OR VICE 
VERSA DURING NORMAL OPERATION. 

3. PULL LEVER BACK TO ENGAGE REVERSE GEAR (INITIAL 
MOVEMENT OF LEVER FROM NEUTRAL ENGAGES TRANS- 
MISSION). 

4. CONTINUE TO MOVE LEVER BACK TO INCREASE ENGINE 
'SPEED. 

5. TO VARY ENGINE SPEED WHILE TRANSMISSION REMAINS 
IN NEUTRAL, PULL LEVER OUT (AV/AY FROM HOUSING) 
AND MOVE LEVER AS DESIRED. 

TS002975 



Figure 2-8. Control lever operation. 

(b) Station one man in the bow to man 
the lines. Tighten the steering lines by swinging 
the stern of the boat with engine power and, at 
the same time, pull on the haul cleats. 

(2) Towing astern. 

(a) Place the center loop of the 60-foot 
towline over the stern towing bitt. 

(b) Secure the two loops at the ends of 
the line fast to the raft being towed. 



TM 5-1940-221-12 



CLEAT ON BRIDGE 
SECTION. 




PUSHING 



CLEAT ON FLOAT 




STEERING LINE. 




BACKING LINE. 



SPRING LINE. 




Figure %-9. Line arrangement for maneuvering 60 class rafts. 



(3) Towing alongside. 

(a) Come alongside the raft to be towed 
and secure a 1-inch diameter line to the forward 
stern cleat. Secure the other end of the line to a 
point amidships of the raft to be towed. 

(6) Secure another 1-inch diameter line to 
the rear bow cleat, and to the same midship 
point on the raft as the first line. 

(c) Secure a third 1-inch diameter line to 
the rear stern cleat, run the line between the 
push knees, and secure it at a point forward on 
the raft. 



TS002976 



(4) terming a raft. 

NOTE 

Whenever possible, maneuver into the current 
or wind. 

(a) Approach the berth at a right angle. 
This will bring the bow of the raft to the berth. 

(&) Have the bow of the raft secured to 
the berth. 

(c) Maneuver the stern of the raft along- 
side the berth and secure the stemi. 



2-12 



TM 5-1 94O-22 1-12 



f ^ 



CLEAT ON 
BRIDGii SECTION. 




PUSHING BALK 



WINCH. 



CLEAT ON FLOAT. 



CHOCK. 




PUSHING BALK 



STEERING LINE. 




BACKING LINE. 




T5002977 



Figure 2-10. Line arrangement for maneuvering M-4 type rafts. 

Section II. OPERATION OF AUXILIARY EQUIPMENT 



2-9. General 

This section contains operating instructions for 
auxiliary equipment furnished with the bridge 
erection boat. The operator should become famil- 
iar with the use of this equipment and its location 
aboard the boat before attempting operation. 

2-10. Portable Fire Extinguisher 

a. General. The portable fire extinguisher is a 
four-pound carbon dioxide bottle. It is mounted 
in brackets on the forward bulkhead of the oper- 
ator's cockpit below and to the right of the steer- 



ing wheel (fig. 1-3(2)). The extinguisher is 
suitable for any fire, including electrical. 

b. Operation. 

(1) Pull the extinguisher from its bracket. 

(2) Pull out the safety pin. 

(3) Aim the discharge nozzle at the fire, 
and depress the trigger. 

(4) Continue to operate the extinguisher 
until the fire is out. 

(5) Upon return, immediately exchange the 
extinguisher for a fully charged one and place 
it in the bracket. 



2-13 



TM 5-1940-221-12 

2-1 1 . Spotlight 

a. General. The spotlight is a portable manual 
lamp that is stowed in a box to the left of the 
steering wheel (fig. 1-3). The light is connected 
to the left of the steering wheel (fig. 1-5). The 
light is connected by a cable to the boat electri- 
cal system. The light is energized through the 
SEARCH LIGHT switch located on the switch 
panel (fig. 2-5(1)). The lamp is actuated by a 
toggle switch in the light handle. 

b. Operation. 

(1) Open the stowage box and remove the 
spotlight. 

(2) Place the SEARCH LIGHT switch on 
the switch panel in the ON position. 

(3) Actuate the toggle switch in the handle. 



2-1 2. Electric Bilge Pump 

a. General The electric bilge pump is located 
in the forward portion of the stern assembly. The 
pump is energized through the BILGE PUMP 
switch on the switch panel (fig. 2-5(1)). 

b. Operation. Place the BILGE PUMP switch 
in the ON position. 

2^1 3. Manual Bilge Pump 

a. General The manual bilge pump is mounted 
in the after portion of the bow assembly (fig. 
1-1). 

b. Operation. Grasp the handle on the pump 
and actuate it up and down. 



Section III. OPERATION UNDER UNUSUAL CONDITIONS 



214. Operation in Extreme Cold 

a. Hull and Decks. Examine the hull for any 
evidence of ice damage. Be careful to check that 
ice has not formed between the bow and stern 
assemblies and damaged the couplings. 

b. Cooling System. Have organizational main- 
tenance drain and flush the cooling system and 
refill it with the approved antifreeze. Inspect all 
hoses, components, and fittings to be sure each 
is tight after filling the cooling system. 

c. Electrical System. 

(1) General Clean the batteries and cables, 
and inspect for cracked or damaged cases. Be sure 
the battery terminals are tight, clean, and lightly 
greased. Check that the battery vent holes are 
open. Keep the batteries fully charged to prevent 
them from freezing. 

(2) Batteries. A battery can deliver only half 
the energy at 15F that it can at 80F. Oil 
thickens and makes cranking difficult in cold 
weather. Only a fully charged battery in good 
condition can operate satisfactorily under these 
conditions. If it becomes necessary to add water 
to the batteries, operate the engines for at least 
one hour to mix the water and electrolyte and 
lessen the chances of freezing the battery. A 
paralleling switch (fig. 2-5 c) is provided that 
permits the use of all batteries for starting each 
engine. When the parallel switch is positioned to 
port or starboard the service of both sets of bat- 
teries is available for starting. This increases the 
amperage but the voltage remains at 24 volts. Us- 
ing the parallel switch during cold weather will 
prolong the life of all batteries and avoid dis- 
charging one set of batteries in attempting to 
start a cold engine. 



CAUTION 

Do not turn engine with starter for long- 
er than 45 seconds at a time. Allow 
starter to cool between attempts to 
start. 

d. Fuel System. Keep the fuel tank full to 
prevent condensation. Accumulated moisture will 
freeze and clog the fuel lines, filters, and strain- 
ers. Service the fuel filters and strainers more 
often than usual. 

CAUTION 

When operating at temperatures below 
32 P, use fuel conforming to Federal 
Specification VV-F-800, Symbol DP-1, 
winter grade. 

e. Lubrication. Lubricate the bridge erection 
boat for cold weather conditions in accordance 
with the current lubrication order. 

/. Bilge Pumps. Check that the pumps and 
their outlets are free of ice and operating. If nec- 
cessary, thaw the pumps with warm water. 

g. Steering System. Operate the steering gear 
to ensure it moves freely. 

2-1 5. Operation in Extreme Heat 

a. Engine. Frequently check the temperature 
gages. 

b. Cooling System. Keep the coolant level at 
maximum. Inspect the level at the -end of each 
operating period. 

c. Lubrication. Lubricate the boat in accord- 
ance with the current lubrication order. 



d. Fuel System. Do not fill the fuel tank to its 
maximum capacity. Allow room for expansion of 
the fuel. 

216. Operation in 'Salt Water 

a. General Operation in salt water requires 
special precautions due to the extremely corrosive 
actions that is encountered. Rust and corrosion 
formation are greatly accelerated in a salt- 
water environment. If possible, the boat 
should be hosed down with fresh water when- 
ever removed from salt water. 

b. Engines. Always keep the engine hatch 
covers closed to keep salt water spray from the 
engines and their accessories. After each opera- 
tion, wipe dry the exteriors of the engine and 
their accessories. Keep the engine compartment 



TM 5-1940-221-12 

as dry as possible at all times. Do not allow any 
water to accumulate in the bilge. 

c. Hull Check the hull frequently for signs of 
corrosion. Corrosion is most likely to occur at the 
exhaust flanges, bilge discharge openings, and 
areas subject to wear, such as the rail and grat- 
ings. Signs of corrosion and bare spots in painted 
surfaces should be corrected as soon as practica- 
ble. 

d. Fittings. Often check th fittings for signs 
of corrosion. Keep all parts clean, painted, 
and, if required, lubricated. 

e. Accessories. Frequently inspect the lights, 
bilge pumps, fire extinguishers, electrical connec- 
tions, manila lines, and canvas covers for signs 
of corrosion and salt accumulation. Wipe metal 
items frequently and repaint or lubricate as re- 
quired. 



ft 



2-15 



TM 5-1940-22T-I2 



CHAPTER 3 
OPERATOR/CREW MAINTENANCE INSTRUCTIONS 



Section I. LUBRICATION INSTRUCTIONS 



This section contains lubrication instructions 
which are supplemental to, and not specifically 
covered in the lubrication order. 

a. Storage. Keep all lubricants in closed con- 
tainers and store in a clean, dry place away from 
heat. Do not allow dust, dirt, or other foreign 
material to mix with the lubricants. Keep all lub- 
rication equipment clean and ready to use. 

WARNING 

Dry cleaning solvent PD-680, used for 
cleaning is a POTENTIALLY DANGE- 
ROUS CHEMICAL. Do not use near 
open flame. Flash point of solvent is 100 
F - 138 F. 



b. Cleaning. Keep all external parts not re- 
quiring lubrication clean of lubricants. Before 
lubricating the equipment, wipe all lubrication 
points free of dirt and grease. Clean all lubrica- 
tion points after lubricating to prevent accumula- 
tion of foreign matter. 

c. Points of Lubrication. Lubricate the bridge 
erection boat at proper intervals as given in lub- 
rication order. 

d. OES Oil 

(1) The crankcase oil level must be checked 
frequently, as oil consumption may increase. 

(2) The oil may require changing more 
frequently than usual because contamination by 
fuel dilution and sludge formation will increase 
under cold weather operation conditions. 



Section II PREVENTIVE MAINTENANCE CHECKS AND SERVICES 



To insure that the bridge erection boat is ready 
for operation at all times, it must be inspected 
systematically so that defects may be discovered 
and corrected before they result in serious dam- 
age or failure. The maintenance checks and serv- 
ices to be performed by the operator are listed 
as described in Table 3-1. The item numbers in- 
dicate the sequence of inspection requirements. 
Defects discovered during operation of the unit 



will be noted for future correction to be made 
as soon as operation has ceased. Stop operation 
immediately if a deficiency is noted during oper- 
ation which would damage the equipment if op- 
eration were continued. All deficiencies and 
shortcomings will be recorded together with the 
corrective action taken on DA Form 2024 at the 
earliest possible opportunity. 



Table 8-1. Operator/Crew Preventive Maintenance Checks and Services. 



D __ Daily 

Time required: 6.7 



W __ Weekly 
Time required: 



Interval 
and 
Sequence No. 


Item to be Inspected 
Procedure 


\ WORK 
', TIME 


D W 


1 
2 
3 
4 


Hull 
Check for structural damage. Check fittings for security and damage. 
Sheaves 
Check for damage and wear. Check for secure mounting and proper operation. 
Lights 
Inspect for dirt, security, or damage. Check operation. 
Steering system 
Check for security of mounting. Turn wheel through its full range and check 
that system operates smoothly and pa^i** 


0-4 
0.1 
0.1 

0.6 
0.3 



3-1 



D _. Dally 

Time required: 5.7 



W _- Weekly 
Time required: 



Interval 

and 
Sequence No. 



W 



tern to be Inspected 
Procedure 



WORK 

TIME 
(M/H) 



10 
11 

12 

13 
14 



15 



16 



?ire extinguishers 

Check for security of mounting and that seals are intact 
Controls and instruments 

Inspect security of mounting and for signs of damage. Check controls for proper 
operation. When engines are running, check gages for proper indication. After 
engines are shut down, check that gages indicate properly. 
Fuel system 

Inspect condition of tank, security of mountings, check lines for leaks and tight 
connections. Examine filters for security and leaks. Drain water from filters 
and strainers. Refill tank after operation to avoid condensation. (Figs 3-1, 3-2 
and 3-3). 

Bilge pumps 

Check bilge and remove any debris. Check pump operation and remove any 
accumulation of water. 
Batteries 

Inspect for leaks, cracks, can security of mounting and connections. Check that 
electrolyte level is 3/8 inch above plates. Fill with distilled water if necessary. 
Coolant system 

Check coolant level, and examine lines and connections for signs of leaks. Add 

coolant if necessary. Check antifreeze in cold weather. (Fig. 8-1). 
Engine lubricating oil system (Fig. 3-1). 

Check crankcase oil level with dipstick. Dipstick should indicate FULL. Fill 

with proper grade of lubricating oil if necessary. Check odl filter, cooler and 

lines for security and leaks. (Fig. 3-1) . 
Transmission 

Check for leaks, damage, and security of mounting. Check odl level with dipstick. 

Fill with proper grade of oil. (Figs. 3-1 and 3-2). 
V-belts 

Check for tension, cracks, or shredding. 
Equipment 

Check that all on-board equipment is in place and in good condition. 



0.1 
0.9 

0.9 



0.2 
0.3 
0.3 
0.6 

0.1 

0.1 
0.7 



TM 5-1 940-221-12 



TRANSMISSION 

DIPSTICK AND 
FILL CAP 




TS002978 



Figure 3-1. Engine and transmission servicing. 



3-3 



TM 5-1940-221-12 



TORQUE ENGINE MOUNT 
NUTS 100 TO 120 FT LBS 



CHECK MOUNT NUTS 
FOR TIGHTNESS 



A. ENGINE MOUNTS 



TORQUE TRANSMISSION 
MOUNT NUTS 100 TO 
120 FT LBS 



CHECK MOUN 
NUTS FOR 
TIGHTNESS 



B. TRANSMISSION MOUNTS 




Figure 3-2. Engine and transmission mounts servicing. 



TM 5-194O-221-12 




T5002980 



Figure 3-8. Fuel strainer servicing. 



*> 1 . LOOSEN WING NUTS (2) 
AND REMOVE BOLTS (2) 





REMOVE CAPS AND CHECK ELECTROLYTIC LEVEL. LEVEL 
MUST BE ABOVE BATTERY PLATES. IF NECESSARY, ADD 
DISTILLED WATER TO 3/8 INCH ABOVE PLATES . 

USE WIRE BRUSH TO REMOVE ANY CORROSION ON CABLE 
OR BATTERY TERMINALS. APPLY LIGHT COAT OF LUBRI- 
CANT TO TERMINALS. 



A. BATTERY COVER 



B. BATTERIES 



TS 2981 



Figure S-4. Battery servicing. 



3-5 



TM 5-1940-221-12 

Section 111. TROUBLESHOOTING 

This section contains troubleshooting information This manual cannot list all malfunctions that 

for locating and correcting most of the operating may occur, nor all tests or inspections and correo- 

troubles which may develop in the bridge erec- tive actions. If a malfunction is not listed or^ is 

tion boat. Each malfunction for an individual not corrected by listed corrective actions, notify 

component, unit, or system is followed by a list organizational maintenance personnel, 
of tests or inspections which will help you to de- 
termine probable causes and corrective action to NOTE 
take. You should perform the tests/inspections Before you use this table, be sure you have per- 
and corrective actions in the order listed. formed all applicable operating checks. 

Table $-2. Operator /Crew Troubleshooting 

Malfunction 

Teat or Inspection 

'Corrective Action _______^_ 

ENGINE 

1. STARTING MOTOR DOES NOT CRANK ENGINE WHEN STARTER SWITCH IS ACTUATED 

heck master switch for ON position. 

Place master switch in the ON position. 

2. ENGINE TURNS OVER BUT FAILS TO START 

Step 1. Check to see if shut down handle is pulled. 

Push in the handle. 
Step 2. Check for empty fuel tank. 

Fill the fuel tank with diesel oil, use No. ID (FSN 9140-286-5286) in the winter and No. 

2D (FSN 9140-286-5294) in the summer. 
Step 3. Check shut-off valve for OPEN position. 

Place fuel line shut-off valve in OPEN position. 

3. ENGINE STARTS BUT MISFIRES OR DOES NOT RUN SMOOTHLY OR DEVELOP FULL POWER 

Check fuel oil for proper grade and type. 

Drain and refill fuel tank with fuel oil No. ID (FSN 9140-286-5286) in the winter and No. 2D 
(FSN 9140-286-5294) in the summer. 

4. LOW ENGINE OIL PRESSURE 

Check for very low engine oil level. 

a. Add oil and fill to proper level. Remove the oil filter cap on the rocker cover and add lubri- 
cation oil per LO 5-1940-221-12. 

6. Start the engine and check for leaks. Stop the engine. Allow 5 minutes for oil to drain to 
the crankcase and check the oil level with the dipstick. 

5. ENGINE OVERHEATS 

Step 1. Check for a low coolant level. 

Remove the cap from the expansion tank and check the coolant level. If the tank is empty, check 
that all the drains are closed, and fill the system with coolant. If freezing temperatures are 
expected, be sure that antifreeze is used. 

Step 2. Check to see if the pressure cap is sealing properly or if it is missing. 
Replace the pressure cap. 

Step 3. Check for low engine oil level, 

Add oil and fill to proper level (see para 4 above) . 

6. EXCESSIVE FUEL CONSUMPTION 

Step 1. Check to see if improper fuel is bedng used. 

Replace fuel (see para 3 above). 
Step 2. Check for loose or ruptured lines, fittings, tank, or accessories. 

Tighten loose lines and fittings. 
Step 5. Check to see if the emergency-stop adr valve is partially closed. 

Make certain the emergency-stop linkage works freely. Check that the stop handle is all the 

way down during engine operation. 



TM 5-1940-221-12 



Malfunction 

Test or Inspection 

Corrective Action 



ELECTRICAL SYSTEM 
7. AMMETER OPERATING ABNORMALLY OR SHOWING NO VOLTAGE INDICATION 

Check for loose or corroded battery cable terminals and clamps. 
Clean or tighten the battery cable terminals. 

8- OIL PRESSURE GAGE OPERATING ABNORMALLY OR SHOWS NO INDICATION 

Check for low engine oil level. 

Add oil and fill to proper level (see para 4 above) . 

9. EXCESSIVE HULL VIBRATION 

Step 1. Check for a fouled propeller. 

Clear the propeller. 
Step 2. Check for a loose defective coupling. 

Tighten a loose coupling. 

HULL 

10. WATER IN THE BILGE 

Check for a loose or defective drain plug. 

Tighten or replace the drain plug. 

11. THE BOW AND STERN ASSEMBLY JOINT LOOSE 

Step 1. Check for a loose coupling handle nut. 

Tighten the coupling handle nut. 
Step 2. Check for a loose coupling hook nut. 

Tighten the coupling hook nut. 

Section IV. OPERATOR'S MAINTENANCE 

The only maintenance functions that the operator nance checks and. services in Section III. Any 
is authorized to perform are those that are pre- corrective maintenance procedures are the in- 
ventive. Lubrication instructions are presented in sponsibility of organizational and higher levels 
Section II in this Chapter, and preventive mainte- of maintenance personnel. 



TM 5-1 940-22 1-12 



CHAPTER 4 
ORGANIZATIONAL MAINTENANCE INSTRUCTIONS 



Section I. SERVICE UPON RECEIPT OF EQUIPMENT 



41 . Inspecting and Servicing the Equipment 

Refer to table 4-1 and perform the preventive 
maintenance checks upon receipt of equipment. 

42. Installation of Separately Packed 
Components 

a. Place two mooring and two steering lines on 
the after deck of the stern assembly. 



6. Place the anchor and line, and two mooring 
lines on the forward deck of the bow assembly. 

c. Place the ring buoy in the bracket on the 
port side of the bow cockpit and the boathook in 
the spring clips. 

d. Stow the bow cover and cover pole, and the 
stern cover in the bow compartment. 

e. Place the engine lubricating oil drain pump 
in the bracket on the starboard side of the engine 
compartment. 



Section II. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT 
43. Special Tools and Equipment 44. Maintenance Repair Parts 

No special tools or equipment are required for Organizational maintenance repair parts are listed 
organizational maintenance. and illustrated in TM 5-1940-22 1-20P. 

Section IIS. PREVENTIVE MAINTENANCE CHECKS AND SERVICES 



4-5. General 

To insure that the boat is ready for operation at 
all times, it must be inspected systematically so 
that defects may be discovered and corrected be- 
fore they result in serious damage or failure. The 
preventive maintenance checks and services to be 
performed by organizational maintenance person- 
nel are listed and described in table 4-1. The item 
numbers indicate the sequence of inspection re- 
quirements. Defects discovered during operation 
of the unit will be noted for future correction, to 
be made as soon as operation has ceased. All de- 
ficiencies and short-comings will be recorded to- 



gether with the corrective. action taken on DA 
Form 2404 (Equipment Inspection and Mainte- 
nance Worksheet) at the earliest possible oppor- 
tunity. 

4-6. Quarterly Preventive Maintenance Checks 
and Services 

a,. Table 4-1 presents a listing of the quarterly 
preventive maintenance checks and services. 

b. A quarterly preventive maintenance check 
and service is equivalent to three calendar months 
or 500 operating hours, whichever comes first. 



Table 4-1. Organizational Preventive Maintenance Checks and Services 



Q Quarterly 

Total man-hours required: 10.4 



Sequence 
Number 



Item to be. Inspected 
Procedure 



WORK 

TIME 
(M/H) 



Lubricate in accordance with Lubrication Order (LO 5-1940-221-12). 

EXTERNAL HULL AREA 

External hull 

Inspect for cracks, loose rivets, and broken welds. Check fittings for security, 
damage and wear. 



0.4 



4-1 



Sequence 
Number 



Item to be Inspected 
Procedure 



WORK 

TIME 
(M/H) 



10 
11 

12 
13 

14 

15 
16 

17 
18 



Hatches and gratings 

Inspect for cracks, loose or damaged hinge pins, broken welds and bent or dam- 
aged hatch covers. 

Propellers shafts, and struts 
Inspect propellers for nicks, dents, breaks, distortion, and security. 

Rudders and struts 

Inspect struts for damage and security. Check drain cocks for proper fit. Inspect 
for damage, cracks, distortion. Check torque of propeller strut mounting bolts to 
51-54 ft Ibs, and rudder plate mounting bolts to 17-20 ft Ibs. Check rudder upper 
bearing capscrews for tightness and lower strut brace spring pins for proper 
.seating. 

Heat exchangers 

Inspect for damage, cracks, distortion, and security of mounting. Check zinc anodes 
for deterioration. 

Running lights, bow and range lights 

Inspect for broken lenses, burned out bulbs, security of mounting, and defective 
wiring and connections. 



Fire extinguishers 

Refer to TM 5-687 and weigh cylinders every 100 hours. 'Check security of moun- 
tings and conditions of nozzles, lines, and fittings. 

Controls and instruments 
Check for proper operation, security of mounting and broken glass lens. 

Lights 

Check lights and switches for proper operation. Inspect spotlight for cracked or 
broken lens, burned out bulb, and condition of wiring. 

Batteries 
Check that cables and mounting are tight. Remove corrosion. Check specific gravity. 

Steering system 

Check that steering wheel turns smoothly and easily and that rudders respond in 
unison. Check gear boxes, quadrant, rods, and fittings, for damage, distortion, and 
security of mounting. Check universal joint spring pins for proper seating. 

Shaft logs 
Check for leaks. 

Fuel tank, lines, and fittings. 

Inspect filler, lines, valves, fittings, and tank for leaks, damage, and security. 

ENGINE COMPARTMENT 
Compartment 

Check for indications of fuel, lubricating oil, and coolant leaks at all lines, connec- 
tions, and engine. Inspect 'all wiring for damage and security of connections. 

Engines 
Inspect engine mounts for torque of 100-to 120-ft Ibs. 

Fuel filters and strainers 

Change elements. Check for leaks. Check for evidence of water. 

Expansion tanks 

Check coolant level. Inspect lines and tanks for leaks and damage. 
V-belts 

for cracks and 3hrcdding - 



0.4 

0.4 
0.4 



0.3 
0.2 

0.2 

0.9 
0.6 

0.3 
0.3 

0.1 
0.2 

0.2 

0.3 
0.7 
0.1 
0.2 



TM 5-1940-221-12 



Q Quarterly 

Total man-hours required: 10.4 



Sequence 
Number 


Item to be Inspected 
Procedure 


WORK 

TIME 
(M/H) 




ENGINE COMPARTMENT CONTINUED 




19 


Water pumps 






Inspect pumps for leaking seals and security of mounting. 


0.1 


20 


Oil coolers. 






Check oil coolers and connections for leaks and security of mounting. 


0.2 


21 


Fuel pumps 






Check pumps and connections for leaks and security of mounting. 


0.1 


22 


Governors 






Inspect condition of cables and linkage. Insure that governor control cable mounting 


0.1 




hardware is secure and that governor throttle shaft and shut down lever is secure 






on shaft. 




23 


Generators 






Check generators for proper output and adjust, if necessary. Inspect condition of 


0.4 




cable and security of mounting. 




24 


Generator regulators 






Check regulators for proper operation and adjust, if necessary. 


1.0 


25 


Starter motors 






Check condition of cables and security of solenoid and motor mounting. 


0.4 


26 


Exhaust system 






Inspect manifolds and pipes for damage and evidence of leakage during operation. 


0.3 


27 


Air intake system 






Inspect silencer, shutoff valve housing, and blower for damage and security of mount- 


0.2 




ing. Check shutoff valve linkage for proper operation. Manually reset the valve at 






the engine. 




28 


Transmissions 






Check for leaks, security and condition of mounts, and air breather spring action. 


0.1 


29 


Power lever cables 






Inspect for kinks, breaks, or ther damage. Check operation of linkages. 


0.1 


30 


Propeller shaft couplings 






Check for loose or missing coupling bolts. 


0.4 


31 


Electric bilge pump 






Check that operation is satisfactory. Check condition of wiring and connections and 


0.1 




security of mounting. Inspect hose and fittings for leaks and damage. 






CAEGO WELL 




32 


Manual bilge pump 






Check for proper operation and security of mounting. Inspect hose and fittings for 


0.1 




leaks and damage. Check that screen is clean. 




33 


On-board equipment 






Check that all equipment is present and stowed in proper place. Inspect all equip- 


0.7 




ment for damage. 





Section IV. TROUBLESHOOTING 



4-7. Genera! 



a. This section contains troubleshooting infor- 
mation for locating and correcting most of the 
operating troubles which may develop in the 



bridge erection boat. Each malfunction for an in- 
dividual component, unit, or system is followed 
by a list of tests or inspections which will help 
you to determine probable causes and corrective 
actions in the order listed. 

4-3 



TM 5-1940-221-12 

b. This manual cannot list all malfunctions NOTE 

that may occur, nor all tests or inspections and Before you use this table, be sure you have per- 

corrective actions. If a malfunction is not listed formed all applicable operating checks. 

or is not corrected by listed corrective actions, 
notify your supervisor. 

Table 4-2. Organizational Troubleshooting 

Malfunction 

Test or Inspection 

Corrective Action __________^____________ 

ENGINE 

1. ENGINE FAILS TO CRANK OR CRANKS SLOWLY 

Step 1. Check for loose wiring or connections, at the battery, the battery to the frame, starter switch, the 
starter terminal sttid or engine to frame cable. 

Tighten any loose connections as required. 
Step 2. Check the battery charge. 

Replace a dead battery. Remove the battery box cover. Loosen the battery cable clamps, remove 

the cables and remove the battery. 
Step 3. Check for a defective starter (-cranking motor) . 

Replace the starter. Turn off the master switch and disconnect the batteries. Remove the 

starter cables. Remove the starter mounting screws and washers and remove the starter. 

2. ENGINE CRANKS BUT FAILS TO START 

Step 1. Check for fuel line leaks. 

Tighten loose fuel connectors or replace a defective line. Remove a defective line as shown 
in figure 41. If lines or fittings located between the fuel tank and the shutoff valve ar<* t" 
be removed, drain the tank using a suitable syphon. If the lines between the shutoff valvo ar.d 
the engine are to be removed, close the shutoff valve. 

Step 2. Check to see if the fuel filter and strainer -are clogged. 

Replace a clogged fuel filter element. Place a suitable 'container under the filter, open the drrur, 
cock (3, fig. 4-2) and drain the fuel. Support the shell (6) with one hand. Unscrew the screw t 1 1 
and remove the shell (6), element (8), and gasket (7). Discard the element and gasket. In.stri"! 
the gasket (7), element (8), shell (6), and secure with screw (4), but do not replace plug (ir'. 
Fill the filter with fuel and install the plug (15). 

Step 3. Check for a defective fuel pump. 

Replace a defective fuel pump. Refer to figure 4-3 and remove the fuel pump. To install the fu^I 
pump, place the pump in position (fig. 4-3) and secure with 3 screws and washers. Conrif-*-; 
inlet and outlet hoses. 

Step 4. Check for a clogged or defective air intake. 

Replace a clogged air silencer screen or a defective air silencer assembly. Remove four mounting 
screws and washers and remove the air silencer. Replace the screen or the complete assembly. 

3. ENGINE STARTS BUT FAILS TO KEEP RUNNING 

Step 1. Che-k the fuel system for fuel line leaks, for a clogged fuel filter or strainer, or for a defective fw-1 
pump. 

Refer to malfunction 2 at>ove. 

4. ENGINE STARTS BUT MISFIRES. RUNS ROUGH 

Check the fuel system for fuel line leaks, for a clogged fuel filter or strainer, or for a defective fuel pump. 
Refer to malfunction 2 above. 

5. ENGINE DOES NOT DEVELOP FULL POWER 

Check for a clogged or defective air intake. 

Refer to malfunction 2, step 5 above. 

6. ENGINE OVERHEATS 

Step 1. Check to see if coolant level is low. 

Replenish the coolant. Fill to a level slightly below the bottom of the tank filler neck. If freezing 

temperatures are expected, be sure that anti-freeze is used. 
Step 2. Check for loose or worn V-belts. 

Adjust belt tension or replace a worn belt. Refer to figure 4-4 and remove the V-belt 

shield and to figure 4-5 and remove the V-belts. Refer to figures 4-4 and 4-5 and install the V- 

belt and shield. 



TM 5-1 940-22 1 -T 



Malfunction 



Test or Inspection 

Corrective Action 



Step 3. Check to see if cooling system is clogged. 
Flush the cooling system. 

Step 4. Check for faulty thermostat. 

Refer to figure 4-6 and remove the thermostat housing. Replace the thermostat if defective. Re 
place the gaskets. Close the engine oil cooler drain cock and fill the cooling system. Refer to fig- 
ure 4-6 and install the thermostat housing. 

Step 5. Check for a leak in the cooling system. 

Repair any leaks in the cooling system. 

Step 6. Check if the temperature gage, sending unit, or the wiring is defective. 

Replace defective wiring. Refer to figure 4-7 .and replace defective temperature gage or se: 
ing unit. 

7. ENGINE OIL PRESSURE LOW 

Step 1. Check for a defective oil pressure gage or for defective wiring. 

Repair or replace the wiring. Replace a defective oil pressure gage (fig. 4-7). 
Step 2. Check for a defective oil filter or dirty filter element. 

Replace a defective oil filter or dirty filter element (fig. 4-2). 

8. EXCESSIVE FUEL CONSUMPTION 

Step 1. Check the tank, lines, and fittings for leaks. 

Refer to malfunction 2. 
Step 2. Check for a defective fuel pump. 

Refer to malfunction 2. 

9. ENGINE MAKES UNUSUAL NOISE 

Step 1. Check the exhaust muffler, manifold or exhaust pipes for breaks or cracks. 
Refer to figure 4-8 and replace a defective muffler, manifold, or pipe. 

Step 2. Check for loose exhaust connections or damaged gaskets. 

Replace any damaged gaskets and tighten any loose connections (fig. 4-8). 



TRANSMISSION 



10. HARD SHIFTING 



Check to see if shifting linkage is out of adjustment. 
Adjust the shifting linkage. 

a. Place the transmission control lever in the neutral position. 

b. Refer to figure 4-9 and remove the cotter pin. 

c. Place the transmission shift lever in the neutral position. 

d. Adjust the control cable terminal, shown in figure 4-9, tu aline with the shift lever. 

11. TRANSMISSION SLIPS OUT OF GEAR 

Check to see if shifting linkage is out of adjustment. 

Adjust the shifting linkage. Refer to malfunction 10 above. 

12. TRANSMISSION OIL LEAKAGE 

Check to see if transmission oil level is too high. 
Drain the oil to the proper level. 
a. Remove the dipstick. 

6. Using the hand pump furnished, insert the drain hose into the dipstick opening and pump the 
oil into suitable receptical. 

ELECTRICAL SYSTEM 
18. ALL ELECTRICAL SYSTEMS INOPERATIVE OR WEAK 

Step 1. Check for a defective battery or battery connections. 

Replace or recharge a defective or weak battery. Tighten or replace loose or defective termi- 
nals. 

Step 2. Check the generator to see if it is charging. 
Replace a defective generator, 



4-5 



TM 5-1940-221-12 



Malfunction 

Test or Inspection 

Corrective Actioft- 



14. INDIVIDUAL LIGHTS INOPERATIVE 

Step 1. Check for burned out bulb. 

Replace a burned out light bulb. 
Step 2. Check for loose or broken wiring. 

Tighten or repair loose or broken wiring. 

15. LIGHTS OPERATE INTERMITTENTLY 

Step 1. Check for loose terminals. 

Tighten loose terminals. 
Step 2. Check for loose or broken wiring. 

Tighten or repair loose or broken wiring. 
Step 3. Check for a defective switch. 

Replace a defective switch. 

16. THE ELECTRIC BILGE PUMP DOES NOT DISCHARGE WATER 

Step 1. Check for a defective pump, switch, or wiring. 

Replace a defective pump or switch. Repair any defective wiring. 
Step 2. Check to see if the inlet is clogged. 

Clean a. clogged inlet. 



4-6 




TS002998 



Figure 4-1. Fuel lines and fittings, exploded view. 



TM 5-1940-221-12 



1. Hose assembly 

2. Elbow 

3. Hose assembly 

4. Adapter 

5. Adapter 

6. Bushing 

7. Elbow 

8. Bushing 

9. Elbow 

10. Alarm switch 

11. Bushing 

12. Pipe tee 

13. Hose assembly 

14. Adapter 

15. Bushing 

16. Elbow 

17. Hose assembly 

18. Adapter 

19. Bushing 

20. Hose 

21. Adapter 



22. Adapter 

23. Bushing 

24. Bushing 

25. Hose 

26. Adapter 

27. Bushing 

28. Screw 

29. Nut 

30. Lockwasher 

31. Spacer 

32. Shutoff valve 

33. Hose assembly 

34. Adapter 

35. Bushing 

36. Cap 

37. Screw 

38. Nut 

39. Flat washer 

40. Shield 

41. Gasket 

42. Nipple 



43. Hose 

44. Clamp 

45. Vent assembly 

46. Nut 

47. Washer 

48. Vent 

49. Bolt 

50. Nut 

51. Flat washer 

52. Hose assembly 

53. Adapter 

54. Suction pipe 

55. Adapter 

56. Suction pipe 

57. Adapter 

58. Elbow 

59. Tank 

60. Screw 

61. Support 



Figure 4-1 Continued. 



4-9 



TM 5-1940-221-12 




14 



IX 



TSO 03000 



1. Bolt 

2. Washer 

3. Shell 

4. Gasket 

5. Element 

6. Nut 

7. Eetainer 



8. Washer 

9. Spring 

10. Plug 

11. Screw 

12. Washer 

13. Washer 

14. Gasket 



15. Screw 

16. Retainer 

17. Spring 

18. Valve 

19. Adapter 



Figure 4-2. Engine lubricating oil filter and element. 



1 . CLOSE 
FUEL 
SHUT- 
OFF 
VALVE. 



5. REMOVE 
FUEL 
PUMP. 



4. REMOVE ** 
SCREWS 
(3) AND 
WAS HERS (3). 



2, REMOVE 

OUTLET 
HOSE, 



3, REMOVE 
INLET 
HOSE. 



Figure 4-3. Fuel pump removal. 



^-REMOVES CREWS -2). 4. REMOVE' V- BELT SHIELD . 




TM 5-1 940-22 1-T 2 



1. REMOVE V-BELT 
SHIELD. (REFER 
TO FIGURE 4-16). 



3. LOOSEN SCREW. 



y 

4. PUSH GENERATOR 
TOWARD ENGINE. 



5. REMOVE V-8ELTS (2>. 



2. LOOSEN SCREWS (2) 




TS002989 



Figure ,4-5. V-belt removal. 



TS002988 



Figure 4-4. V-belt shield removal. 



TM 5-1940-221-12 



DRAIN COOLING 
SYSTEM TO BELOW 
OF HOUSING 



5. REMOVE 5C.PEW? 2 



LOOSIN CLAMP 
SCRLW AN!) 
KtMOVt HOSE, 



AND WAOHtK- ?>. 



2 , REMOVE WATER 
TEMPERATURE 
TRANShAlTTER. 



3 . REMOVE SCRLWS 
i2i AND WASHERS t2) 



6, REMOVE HOUSING. 

MKBE^na^Mfl&ffi9flH&9Sffl8i!H^H8fflffl&f88R8&! 

;: TOP OF THERMOSTAT HOUSING 



A BOTTOM OF THERMOSTAT HOUSING 




TS003009 



Figure 4-6. Thermostat housing removal. 



12 




18 



1. Screw 

2. Nut 

3. Washer 

4. Capacitor 
r>. Nut 

f>. Washer 

7. Clamp 

8. Coolant temperature 

0. \ut 

in. Washer 

11. Clamp 

12. Transmission oil pres- 

sure. 



13. Tachometer cable 

14. Nut 

15. Washer 

16. Bracket 

17. Tachometer 

18. Nut 

19. Washer 

20. Clamp 

21. Engine oil pressure 

gage 

22. Nut 

23. Washer 

24. Nut 

25. Switch 



26. Nut 

27. Washer 

28. Base 

29. Shade 

30. Lamp 

31. Nut 

32. Washer 

33. Clamp 

34. Ammeter 

35. Panel 



TS003023 



Figure 4-7. Instrument panel components, exploded view. 



4-13 



TM 5-1940--221-12 




TS003004 



Figure 4-8. Mufflers and exhaust piping, exploded view. 



TM 5-1940-221-12 



1. Lancing wire 

2. Insulation blanket 

3. Bolt 

4. Nut 

5. Lockwasher 

6. Gasket 

7. Bolt 

8. Nut 

9. Lockwasher 
IX). Port header 

11. Starboard header 

12. Flange 

13. Gasket 

14. Bolt 



15. Nut 

16. Lockwasher 

17. Gasket 

18. Bolt 

19. Nut 

20. Lockwasher 

21. Clamp 

22. Bolt 

23. Nut 

24. Lockwasher 

25. Clamp 

26. Flange 

28. Muffler 

29. Bolt 



30. Nut 

31. Lockwasher 

32. Bracket 

33. Bolt 

34. Nut 

35. Lockwasher 

36. Bracket 

37. Capacrew 

38. Nut 

39. Lockwasher 

40. Ring 

41. Gasket 

42. Port tailpipe 

43. Starboard tailpipe 



Figure 4-8 Continued. 



3. PULL TERMINAL 
FROM LEVER. 




A. REMOVE 
CABLE. AND 
TERMINAL. 




CONTROL CABLE. 
B. POWER Lf':VER END 



Figure 4-9. Transmission control cable removal. 



Section V. RADIO INTERFERENCE SUPPRESSION 



4-8. General 



Essentially, suppression is attained by providing 
a low resistance path to ground for stray currents. 
The methods used on the boat include using 
shielding, capacitors, and ground straps. 

4-9. Definitions 

a. Interference. The term "interference" as 
used herein applies to electrical disturbances in 
the radio frequency range which are generated by 
the boat and which may interfere with the proper 



operation of radio receivers or other electronic 
equipment. 

b. Interference Suppression. The term "inter- 
ference suppression" as used herein applies to the 
method used to eliminate or effectively reduce 
radio interference generated by the boat. 

4-10. Radio Interference Suppression 
Components 

Radio interference suppression consists of a 0.5 
mfd, 100 wvdc capacitor (fig. 4-10) mounted on 
the inside of each instrument panel. 



TM 5-1940-221-12 



1 . REMOVE ACCESS 
PANEL. 



OPEN CLIP AND SLIDE 
OUT CAPACITOR. 




4-11. Testing of Radio Interference Suppression 
Components 

Test the capacitors for leaks or shorts with a ca- 
pacitance tester. If a tester is not available and 
interference is indicated, isolate the cause by re- 
placing each capacitor in turn until the cause of 
interference is eliminated. Replace the capacitors 
with new capacitors that have exactly the same 
rating. It is essential that a good metal-to-metal 
contact with washers and terminals is achieved to 
ensure that proper radio interference suppression 
is maintained. 



TS002982 



Figure 410. Radio interference suppression capacitor 
removal. 



Section VI. MAINTENANCE OF ENGINES 



4-12. General 

The engines are installed side by side in the for- 
ward portion of the stern assembly. All location 
references to the engines are based on viewing 
the engines from the rear (transmission end). 
Those procedures which are authorized for orga- 
nizational personnel are listed in the Maintenance 
Allocation Chart. 

4-13. Tachometer Cable 

a. Inspection. Remove the access panel (fig. 4- 
71). Inspect cable for loose connections, kinks, 
or sharp bends. Inspect for cracks or breaks in 
the cable housing. 

6. Removal. 

(1) Disconnect the cable from the tachom- 
eter. 

(2) Remove all the ties and clamps holding 
the cable in place and remove the cable. 

c. Installation. 

(1) Position the cable and secure with ties 
and clamps. 

(2) Connect the cable to the tachometer. 

(3) Install the access panel. 

4-14. Tachometer Drive 

a. General. The tachometer drive is mounted 
on the rear of the engine. The drive has a shaft 
which engages the engine camshaft. The shaft is 
connected through an adapter to a cable which, 
in turn, drives the tachometer mounted on the 
instrument panel. Tachometer maintenance is 
presented in paragraph 4-61. 



b. Removal. Refer to figure 4-11 and remove 
the tachometer drive. 

c. Cleaning, Inspection, and Repair. 

(1) Clean the tachometer drive in clean 
fuel oil and dry with compressed air. 

(2) Inspect for rust, burs, nicks, or cracks. 
Check for damaged or defective parts. 

d. Repair. 

(1) Rust on polished 'non-mating surfaces 
may be removed with a fine oxide-abrasive paper 
and the surface polished with crocus cloth. 

(2) Nicks and burs may be removed with a 
smooth file or hone. 

(3) Damaged painted surfaces should be re- 
painted as soon as possible to prevent corrosion. 

e. Installation. Install the tachometer drive in 
the reverse order of removal. 

415. Engine Control Cables 

a. Engine Speed (Throttle) Cable. The push- 
pull engine speed (throttle) cable is attached be- 
tween the control lever in the operator's cockpit 
and the speed control levar on the governor. 
(I) Removal. 

(a) Remove access panel (fig. 4-71). 
(6) Refer to A, figure 4-12 and remove 
the end of the cable that attaches to the governor. 

(c) Refer to A, figure 4-62 and remove 
the end of the cable that attaches to the trans- 
mission lever. 

(d) Refer to figure 4-14 and remove the 
applicable control lever housing. 



TACHOMETER DRIVE 
ADAPTER 



2. BACK OFF 

LOCKING NUT 



. J. DISCONNECT CABLE. 



, 3. REMOVE TACHOMETER 
DRIVE ADAPTER. 




CAUTION 

WHEN INSTALLING TACHOMETER 
DRIVE ADAPTER, MAKE SURE 
THAT THE KEY ON THE ADAPTER 
SHAFT IS ALIGNED WITH THE 
KEYWAY IN THE SHAFT IN 
THE ENGINE. 

<MHM, . wumamKmmmms&mmmmKwammM 

TS002983 



Figure J+-11. Tachometer drive removal and installation. 

(e) Refer to B, figure 4-12 and remove 
the end of the cable that attaches to the trans- 
control lever. 

(2) Inspection. 

(a) Check that the cable is free of kinks, 
cracks, or breaks. 

(&) Inspect condition of threads. 

(3) Installation. Install the cable in the re- 
verse order of removal. 

b. Engine Shut-Off Cable. The engineee shutoff 
cable is a push-pull type attached between a T- 
handle in the operator's cockpit and the stop 
lever on the governor. 
(1) Removal 

(a) Refer to A, figure 4-12 and remove 
the end of the cable that is attached to the gover- 
nor. 

(6) Remove access panel (fig. 4-71). 

(c) Refer to C, figure 4-12 and remove 
the handle and cable. 



TM 5-1940-221-12 

(2) Inspection. 

(a) Check that the cable is free of kinks, 
cracks, or breaks. 

(b) Inspect condition of threads. 

(c) Check handle for cracks or breaks. 

(3) Installation. Install the cable hi the re- 
verse order of removal. 

c. Emergency Stop Cable. The engine emergen- 
cy stop cable is a push-pull type attached between 
a T-handle in the operator's cockpit and the valve 
in the air shut-down housing. 

(1) Removal. 

(a) Refer to A, figure 4-13 and remove 
the end of the cable that is attached to the aar 
shut-down housing. 

(b) Remove access panel (fig. 4-71). 

(c) Refer to B, figure 4-13 and remove 
the handle and cable. 

(2) Inspection. 

(a) Check cable for kinks, cracks, or 
breaks. 

(b) Inspect condition of threads. 

(c) Check handle for cracks or breaks. 

(3) Installation. Install the cable in the re- 
verse order of removal. 

4-16. Control Head 

a. General The control head is located in 
front of and to the right of the steering wheel. 
The levei^s and mechanisms are contained in two 
identical housings, mounted together to form a, 
single control quadrant. The levers actuate the 
cables controlling engine speed and transmission, 
gear engagement. 

b. Removal 

(1) Remove the engine speed control cable 
as given in paragraph 4-15<z(l)(c) and the 
transmission control cable as given in paragraph. 
4-68. 

(2) Refer to figure 4-14 and remove the con- 
trol head housing from its mounting. 

c. Disassembly. Disassemble the control heac" 
in the order of the key index numbers in figure 
4-15. 

d. Cleaning, Inspection, and Repair. 

(1) Wash all parts with an approved clean 
ing solvent and dry with a clean lint-free cloth 

(2) Check all parts for breaks, cracks, burs 
distortion, or corrosion. 

(3) Remove any corrosion with crocus cloth 
Replace any damaged part. 

e. Reassembly and, Installation. Reassemble an^ 
install the control head in the reverse order o 
disassembly and removal. 



TM 5-1940-221-12 



2. REMOVE TERMINAL NUT AND 
WASHER, AND REMOVE CABLE. 



REMOVE TERMINAL NUT AND 
WASHER, AND REMOVE CABLE. 



1 . REMOVE SCREWS (2), NUTS (2) 
WASHERS (2). AND BRACKET. 



SHUT-OFF CABLE 



SPEED CONTROL 
(THROTTLE) CABLE 



1. REMOVE SCREWS (2), NUTS (2) 
WASHERS (2). AND BRACKET. 



A. GOVERNOR END 



2. REMOVE 
HANDLE. 



3. REMOVE 
LOCKNUT 



1. PLACE 
LEVER 

IN NEUTRAL 
(VERTICAL) 
POSITION. 



3. REMOVE 
RING. 



4. REMOVE 
CABLE . 



4. REMOVE 
CABLE NUT. 



1. LOOSEN LOCKNUT. 

^^^^^^^B^BBjfflfflj^jl 

; C. SHUT-OFF HANDLE END 



5. REMOVE CABLE 
FROM BELOW. 




2. REMOVE 
SCREWS 
(2) AND 
BRACKET. 



B. CONTROL LEVER END 



TS0029B4 



Figure 4-12. Speed control (throttle) and shut-off cable removal. 



4-17. V-Belt Shield 

a. General The V-belt shield is mounted on 
the left front of the engine and serves as pro- 
tective cover for the V-belts and pulleys. 

6. Removal Refer to figure 4-16 and remove 
the V-belt shield. 

c. Installation. Install the V-belt shield in the 
reverse order of removal. 



4-18. V-Belts 

a. General. The V-belts are mounted at the 
front of the engine around the camshaft, water 
pump, and generator pullies. The V-belts drive 
the battery charging generator and the water 
pump. 

b. Removal 

(1) Refer to figure 4-16 and remove the V- 
belt shield. 



4-18 



TM 5-1940-221-12 



1. LOOSEN SCREW AND 
REMOVE STOP. 



4. REMOVE CABLE NUT 



2. REMOVE SCREWS 
(2), WASHERS (2) 
NUTS (2), AND 
CLAMP. 



3. REMOVE CABLE. 



5. WITHDRAW CABLE 
FROM BELOW, 



f B HANDLE END 



A. SHUT-DOWN VALVE END 




Figure 4-1 S. Emergency atop cable removal. 



3, 



REMOVE LEFT 
HOUSING IN 
SAME MANNER. 



REMOVE RIGHT 
HOUSING. 




1. REMOVE SCREWS 
(2), WASHERS (2), 
AND NUTS (2). 



TS002986 



Figure 4-14. Control head removal. 

(2) Refer to figure 4-17 and remove the V- 

belts. 

c. Inspection. 

(1) Inspect V-belts for cuts and deteriora- 



tion. 



(2) Inspect pulleys for burs and nicks. 



d. Repair. 

(1) Replace both belts if one is worn. Single 
belts of similar size should not be used as a sub- 
stitute for a matched set. Premature wear can re- 
sult because of belt length variation. 

(2) Remove pulley nicks and burs with fine 
emery cloth. 

e. Installation. 

(1) Install the V-belts in the reverse order 
of removal. 

(2) Install the V-belt shield in the reverse 
order of removl. 

/. Adjustment. Position the generator so that 
a firm push with the thumb, at a point midway 
between the generator and water pump pulleys, 
will depress the belt l/2-to-3/4 inch. 

41 9. Air Silencer 

a. General. The air silencer is attached to the 
intake side of the air shutoff valve housing on 
the right side of the engine to reduce the sound 
level of air entering the blower. The silencer has 
a sheet metal partition which divides the silen< 
into two sections. The section on the engine si 
forms an air duct to the blower intake; the otl 
(outer) section is filled with sound absorbe 
flame-proof, felted-cotton waste. 

b. Removal Refer to figure 4-18 and r 
the air silencer. 

c. Installation. Insta 11 *kf 
reverrse order of remo T 



TM 5-1940-221-12 



26 




31 



TSO 02987 



1. Nut 

2. Lockwasher 

3. Screw 

4. Screw 

5. Screw 

6. Nut 

7. Washer 

8. Screw 

9. Clamp 

10. Bracket 

11. Screw 



12. Washer 

13. Plate and link 

14. Terminal 

15. Screw 

16. Clamp 

17. Ring 

18. Terminal 

19. Ball 

20. Setscrew 

21. Lever 

22. Pin 



23. Arm 

24. Spring 

25. Bearing 

26. Screw 

27. Lockwasher 

28. Clip 

29. Spring 

30. Ball 

31. Housing 



Figure 4-15. Control head assembly, exploded view. 



TM 5-1940-221-12 



REMOVE SCREW 
AND NUT. 



2. REMOVE SCREW 
SPACER, AND 
WASHER. 




1. REMOVE V-BELT 
SHIELD. (REFER 
TO FIGURE 4-16). 



3. LOOSEN SCREW. 



4. PUSH GENERATOR 
TOWARD ENGINE. 



5. REMOVE V- BELTS (2). 



2. LOOS EN SCREWS (2) 




TS002989 



Figure 4-16. V-belt shield removal. 

4-20. Air Shutdown Valve Housing and 
Blower Screen 

a. General The air shutdown valve housing is 
located between the air silencer and blower. The 
housing contains a valve, which in the event an 
emergency shutdown is required, blocks the pas- 
sage of air to the blower. The valve is actuated 
by a control handle in the operator's cockpit. 
The screen is located b&tween the housing and the 
blower, and is provided to prevent any objects 
from entering the blower. 

b. Inspection. 

(1) Check that shutoff valve operates 
smoothly and easily and that it seats completely. 

(2) Check all parts for cracks, breaks, dis- 
tortion, or other damage. 

c. Removal. 

(1) Refer to figure 4-18 and remove the air 
silencer. 



Figure 4-17. V-belts removal. 

(2) Refer to A, figure 4-13 and remove the 
control cable. 

(3) Refer to figure 4-19 and remove the air 
shutdown housing and blower screen. 

d. Cleaning. Clean the blower air shutoff 
valve housing screen with fuel oil and dry with 
compressed air. 

e. Installation. Install the air shutoff valve 
housing and blower screen in the reverse order 
of removal. 

4-2 1 . Air 'Box Drain 

a. General. The air box drain is mounted on 
the left side of the cylinder block belov * u ~ 
governor. During normal engine operation 
vapor from the air charge and a slight am 
fuel and. lubricating oil fumes condense a 
tie on the bottom of the air box in the c 



TM 5-1940-221-12 



1 . REMOVE SCREWS (4) 
AND WAS HERS (4). 




TS002990 



Figure 4-18. Air silencer removal. 

block. This condensate is removed by air box 
pressure through the air box drain tube. The 
drain tube should be checked occasionally to en- 
sure that air is flowing from the tube; if it is not, 
the tube must be cleaned out. 

6. Removal. Refer to figure 4-20 and remove 
the drain tube. 

c. Cleaning. Blow out the drain tube with com- 
pressed air and flush it with fuel oil. 

d. Installation. Install the air box drain tube in 
the reverse order of removal. 

4-22. Valve Rocker Cover 

a. General. The valve rocker cover encloses the 
valve and injector rocker arms at the top of the 



REMOVE AIR 
SILENCER. 
(REFER TO 
FIGURE 4-9i. 



2. LOOSEN SCREW 
AND REf-AOVE 
STOP. 



3. REMOVE 
SCREWS 
(5) AND 
WASHERS (5). 



4. REMOVE 
HOUSING 
AND 
SCREEN. 




TS002991 

Figure 4-19. Air shut-down housing removal. 

cylinder head. The cover includes a breather as- 
sembly and an oil filler cap. 

b. Removal. 

(1) Refer to figure 4-21 and remove the 
valve rocker cover. 

(2) Remove all traces of old gasket from 
cover and cylinder head. 

c. Inspection. 

(1) Check that sealing edge of cover is 
free of dents, nicks, and distortion. 

(2) Check that breathing tube is securely 
seated in cover. 

(3) Inspect condition of filler cap and gas- 
ket. 

d. Replacement. 

(1) Replace the cover gasket. 

(2) Replace cover or cap if damaged. 

e. Installation. Install the valve rocker cover in 
the reverse order of removal. 



TM 5-1940-221-12 




NOTE 

CAREFULLY CLEAN COVER 
BEFORE REMOVAL. 



2. REMOVE SCREW 
AND PLATE 
ASSEMBLIES (4). 



LOOSEN CLAMP 
AND REMOVE 
BREATHER HOSE. 




TS002992 



TS002993 



Figure 4~20. Air box drain removal. 



Figure 4-21. Valve rocker cover removal. 



Section VII. MAINTENANCE OF FUEL SYSTEM 



4 r 23. Genera! 

This section contains the maintenance procedures 
for the fuel system. A description of the fuel 
system is given in paragraph 1-5. 

WARNING 

Maintenance procedures for the fuel 
system must be performed in a well 
ventilated area. Do not allow any sparks 
or flames in the vicinity. 

4-24. Fuel Strainer 

a. General. A fuel strainer is located on the 
inside of the hull next to each engine in the line 
between the fuel shutoff valve and the fuel 
pump. The strainer contains a density typa ele- 



ment capable of filtering out particles of 30 
microns. A drain cock is provided at the bottom 
of the strainer shell to permit removal of dirt 
and water accumulations. 

b. Removal. 

(1) Place a container under the strainer as- 
sembly, remove plug (12, fig. 4-22), open drain 
cock (5), and drain fuel. 

(2) Disconnect hose assemblies from strain- 
er and cap hose openings. 

(3) Support the shell (8), remove nuts (4), 
lockwashers (2 and 3), and screws (1) and re- 
move the strainer assembly. 

c. Installation. 

(1) Install the strainer assembly in the re- 
verse order of removal, but do not replace plug 
(12, fig. 4-22)). 





TS00299/1 



1. Screw 

2. Lockwasher 

3. Lockwasher 

4. Nut 

5. Cock 

6. -Screw 
*7. "Washer 



8. Shell 

9. Element 

10. Gasket 

11. Plug 

12. Plug 

13. Cover 



Figure 4-22. Fuel strainer and element, exploded 



view. 



(2) Fill the strainer with fuel and install 
plug (12). 

(3) Start engine and check filter for leaks, 

4-25. Fuel Strainer Element Replacement 

a. Removal. 

(1) Place a suitable container under the 
strainer, remove plug (12, fig. 4-22) and open 
drain cock (5). Allow fuel to drain. 

(2) Support shell (8) with one hand. Un- 
screw screw (6), and remove shell (8), element 
(9), and gasket (10). Discard element and 
gasket. 

b. Installation. 

(1) Install the element in the reverse order 
of removal, but do not replace plug (12, fig. 4~ 
22). 

(2) Fill the strainer with fuel and install 
Plug (12). 

(3) Start engine and check filter for leaks. 

4-26. Fuel Filter 

a. General The fuel filter is mounted on the 
left side of the engine in the line between the 
fuel pump and the fuel inlet manifold. The fil- 
ter contains a paper-type element that can remove 
particles as small as 10 microns. A drain cock is 
installed at the bottom of the filter shell to al- 
low removal of dirt and water accumulations. 

b. Removal 

(1) Place a suitable container under the fuel 
filter. Remove plug (15, fig. 4-23) open drain 
cock (3), and drain fuel. 

(2) Disconnect hose assemblies. 

(3) Support the shell (6); remove bolts 
'!), lockwashers (2), and remove the filter. 

c. Installation. 

(1) Install the filter in the reverse order of 
removal, but do not replace plug (15, fig-. 4-23). 

(2) Fill the filter with fuel and replace 
plug (15). 

4-27. Fuel Filter Element Replacement 

a. Removal 

(1) Place a suitable container under the fil- 
ter, remove plug (15, fig. 4-23) and open drain 
cock (3). Allow fuel to drain. 

(2) Support shell (6) with one hand. Un- 
screw screw (4), and remove shell (6), element 
(8), and gasket (7). Discard element and Bas- 
ket. 




1. Screw 

2. Lockwasher 

3. Cock 

4. Screw 

5. Washer 

6. Shell 

7. Gasket 

8. Element 



TS002995 



9. Retainer 

10. Seat 

11. Seal 

12. Seat 

13. Spring 

14. Plug 

15. Plug 

16. Cover 



TM 5-1940-221-12 

6. Installation. 

(1) Install the element in the reverse order 
of removal, but do not replace plug (15, fig. 4- 
23). 

(2) Fill the filter with fuel and install plug 
(15). 

428. Fuel Pump 

a. General. The positive displacement gear- 
type pump is mounted on the governor weight 
housing on the left side of the engine. It is 
driven by the governor shaft. The pump transfers 
fuel from the tank to the fuel injectors. The 
pump supplies fuel to the injectors under pres- 
sure. 

6. Removal. Refer to figure 4-24 and remove 
the fuel pump. 

c. Installation. Install the fuel pump in the re- 
verse order of removal. 

4-29. Fuel Shut Off Valve 

a. General. A manually-operated shutoff valve 
is located in each fuel line on each side of the 
operator's cockpit. The- valves control the flow of 
fuel from the tank to the strainers in the engine 
compartment. 

b. Removal. 

(1) Use a suitable syphon and drain the 
fuel tank. 

(2) Eefer to figure 4-25 and remove the 
valve. 

c. Inspection. 

(1) Check that the valve handle operates 
smoothly. 

(2) Check condition of threads. 



1 . CLOSE 
FUEL 
SHUT- 
OFF 
VALVE . 




5. REMOVE 
FUEL 
PUMP. * 



4. REMOVE " 
SCREWS 
(3) AND 
.WASHERS (3). ,, 



TS002996 



Figure 4-23. Fuel filter and element, exploded view. 



Figure 4-24. Fuel pump removal. 



4-2i 



2. REMOVE SCREWS 
(2), NUTS (2), 
AND WASHERS (2) 




TS002997 



Figure 4-%5. Fuel shut-off valve removal. 

(L Installation. Install the valve in the reverse 
order of removal. 

-430. Fuel Lines and Fittings 

a. General. Fuel is provided to each engine by 
a. separate supply system. Fuel is drawn from the 
tank by the engine fuel pump. The fuel is routed 
through hoses from the tank to a fuel shutoff 
valve, then to a strainer, and on to the engine. 
Excess fuel is returned to the fuel tank by way 
of a separate return hose from each engine. 

b. Removal. 

(1) If any of the lines or fittings located 
between the, fuel tank and shutoff valve are to 
be removed, drain the tank using a suitable 
syphon. If the lines between the shutoff valve 
i,nd the engine are to be removed, close the shut- 
Kf f valve. 

(2) Refer to figure 4-26 and remove the 
ines and fittings. 

c. Inspection. 

^(1) Check hoses for cracks, breaks, deteri- 
ra.tion and loose connections. 

C2) Check condition of fittings and all 
i reads. 

d. Installation. Install the lines and fittings in 
i-e reverse order of removal. 

-31. Fuel Tank 

a~ General The fuel tank is located behind the 
orator's cockpit The tank has a capacity of 90 
lions and is provided with a vent tube, a filler 

26 



port, two fuel suction outlets and two 
inlets. 

b. Removal. 

(1) Refer to figure 4-74 and remove the 
stern towing bit. . ^ 

(2) Turn both fuel shutoff valves (fig. 4- 
26, item 32) to OFF position. _ 

(3) Remove a fuel cap and dram fuel from 
tank, using a suitable syphon. 

(4) Remove screws (37), nuts (38), washers 
(39), shield (40), gasket (41), and nipple (42). 

(5) Remove mounting bolts (49), nuts (50), 
and washers (51), from both securing: pouite. 

(6) Loosen clamp (44), and remove vent 
hose (43), from adapter (57). 

(7) Remove the suction hose (25) from the 
adapter (55) and return hose (52) from adapter 
(53). Repeat this step for the other suction and 
return hoses. 

(8) Slide fuel tank into operators cockpit 
and remove from boat. 

c. Inspection. 

(1) Check tank for leaks, cracks, and corro- 
sion. 

(2) Check the inside of the tank through 
the filler nipple opening for signs of contami- 
nation and corrosion. 

d. Cleaning and Repair 

(1) Cleaning exterior. Wash all exterior 
metal surfaces with a solution of trisodium- 
phosphate, Federal Specification O-T-671, and 
water; rinse thoroughly and dry. 

(2) Cleaning interior. 

(a) Drain all liquid from the tank. 

(b) Fill the tank with cold water and 
overflow for five minutes. Drain completely. 

(c) Purge the tank with a mixture of 
water and purging chemical. 

(d) Repeat step (b) above. 

(3) Repairs. 

(a) Repair leaks, breaks, and other dam- 
age. 

(b) Damaged painted exterior surfaces 
should be repainted as soon as possible to pre- 
vent corrosion. 

e. Installation. Install the fuel tank in reverse 
order of removal. 




TS002998 



lines and fittings, exploded view. 



4-28 



2. Elbow 

3. Hose assembly 

4. Adapter 
5 Adapter 

6. Bushing 

7. Elbow 

8. Bushing 

9. Elbow 

10. Alarm switch 

11. Bushing 

12. Pipe tee 

13. Hose assembly 

14. Adapter 

15. Bushing 

16. Elbow 

17. Hose assembly 

18. Adapter 

19. Bushing 

20. Hose 

21. Adapter 



23. Bushing 

24. Bushing 

25. Hose 

26. Adapter 

27. Bushing 

28. Screw 

29. Nut 

3*0. Lockwasher 

31. Spacer 

32. Shut-off valve 

33. Hose assembly 

34. Adapter 

35. Bushing 

36. Cap 

37. Screw 

38. Nut 

39. Flat washer 

40. Shield 

41. Gasket 

42. Nipple 



44. Clamp 

45. Vent assembly 

46. Nut 

47. Washer 

48. Vent 

49. Bolt 

50. Nut 

51. Flat washer 

52. Hose assembly 

53. Adapter 

54. Suction pipe 

55. Adapter 

56. Suction pdpe 
'57. Adapter 

58. Elbow 

59. Tank 

60. Screw 

61. Support 



Figure 4-26. Continued. 



Section VIII. MAINTENANCE OF ENGINE LUBRICATION SYSTEM 



4-32. General 

This section contains the maintenance procedures 
for the engine lubricating oil system. The lubri- 
cating system for the transmission is presented 
in Section XIV. The transmission oil system is 
independent of the engine system. A description 
of the engine lubrication oil system is given in 
paragraph 1-5. 

4-33. Oil Change 

a. Oil Draining. Due to the lack of room be- 
tween the oil pan and the hull, the oil must be 
pumped out of the crankcase. A manual pump 
(fig. 4-27) has been provided for this purpose. 
The pump is stowed on a bracket forward on 
the starboard side of the engine compartment. 
The oil capacity of the engine is 9.5 quarts. 

(1) Remove plug from drain tube and attach 
pump intake hose to drain tube (fig. 4-27). 

(2) Place a suitable container (at least 10 
quart capacity) in the bilge, position the pump 
outlet hose over the container and pump the 
pump until oil ceases to discharge from the out- 
let hose. 

(3) Remove the pump intake hose from the 
drain tube and replace the plug. 

b. Oil Filling. 

(1) Replace oil filter element (para 4-35). 

(2) Remove oil filler cap on valve rocker 
cover and add 9.5 quarts of oil. Replace cap. 

(3) Start engine and check for leaks. Stop 
engine. Allow 5 minutes for oil to drain to 
crankcase and check oil level with dipstick. 



CAUTION 

Do not operate the engine if the oil 
level is below the "L" mark or above the 
"F" mark on the dipstick. 

4-34. Lubricating Oil Filter 

a. General. The engine lubricating full-flow 
oil filter is mounted on the left side of the engine 
and collects impurities in the oil. A valve, 
which opens at approximately 18-to-20 psi, is lo- 
cated in the filter base to bypass the oil directly 
to the oil cooler should the filter become 
clogged. 

b. Removal. 

(1) Place a suitable container beneath the 
filter, remove plug (10, fig. 4-28), and drain the 
oil. 

(2) Support the shell (3), remove screws 
(11), lockwashers (12), and washer (13); and re- 
move filter and gasket (14). 

c. Installation. 

(1) Place the oil filter in position using a 
new gasket (14) and secure with screws (11), 
lockwashers (12), and washers (13). 

(2) Add one quart of lubricating qdl 
through the valve rocker cover fillcap hole. 

(3) Start the engine and check the ail filter 
for leaks. Stop the engine. Allow five minutes 
for the oil to drain into the crankcase and check 
the oil level. 

4-29 



]. ATTACH ADAPTER 
FITTING & INTAKE 
HOSE TO DRAIN TUBE 





2. PLACE SUITABLE 
CONTAINER UNDER 
DISCHARGE HOSE 



3. PUMP HANDLE 
UNTIL OIL PAN S J 
IS EMPTY 





TS002999 



Figure 427. Engine lubricating oil drain pump. 



435. Lubricating Oil Filter Element 

a. Removal. 

(1) Place a suitable container under the fil- 
ter, remove plug (10, fig. 4-28) and drain the 
oil. 

(2) Loosen bolt (1) until shell (3) is free, 
and remove shell. Remove and discard element 
(5) and gasket (4). 

6. Installation. 

(1) Install plug (10, fig. 4-28) and gas- 
ket (4). 

(2) Insert element (5) in shell (3) and at- 
tach shell to adapter (19) by holding gasket (4) 
in position and allow shell to work gasket into 
cover groove while tightening bolt (1) . 

(3) Add one quart of lubricating oil 
through valve rocker cover f illcap hole. 



(4) Start engine and check oil filter for 
leaks. Stop engine. Allow five minutes for oil to 
drain into crankcase and check odl level. 

4-36. Transmission Oil Cooler 

a. General The transmission oil cooler is lo- 
cated on the left forward portion of the cylinder 
block. Return oil from the transmission circulates 
through a core within the cooler. Surrounding 
the core is a housing through which the coolant 
flows. Heat from the oil is transferred to the 
coolant. From the cooler, the oil returns to the 
transmission. The coolant used is from the engine 
cooling system. 

b. Removal. 

(1) Open the engine lubricating oil cooler 
drain cock (fig. 4-29) and drain the cooling sys- 
tem. 



4-30 



TM 5-1940-221- 






14 



ISO 03000 



1. Bolt 

2. Washer 

3. Shell 

4. Gasket 

5. Element 

6. Nut 

7. Retainer 



8. Washer 

9. Spring 

10. Plug 

11. Screw 

12. Lockwasher 

13. Washer 

14. Gasket 



15. Screw 

16. Retainer 

17. Spring 

18. Valve 

19. Adapter 



Figure 4-28. Engine lubricating oil filter and element, exploded view. 



(2) Refer to figure 4-29 and remove the 
transmission oil cooler. 

c. Replacement. Discard and replace the gasket. 

d. Installation. 

(1) Install the oil cooler in the reverse order 
of removal. 

(2) Refill the cooling system and the trans- 
mission. 

4-37. Engine Lubricating Oil Cooler 

a. General The engine lubricating oil cooler 
is mounted on the lower left side of the engine 
at the front of the cylinder block. The cooler con- 
tains a core through which the oil circulates. Sur- 
rounding the core is a housing through which the 



coolant flows. Heat from the oil is transferred to 
the coolant. From the cooler, the oil and the 
coolant pass to the cylinder block. A valve is in- 
corporated in the cooler which opens at 52 psi 
and bypasses the cooler. This allows the oil to 
flow directly from the pump to the cylinder 
block if the cooler should become clogged. 

b. Removal. 

(1) Drain engine coolant and lubricating 
oil. 

(2) Remove the water pump (fig. 4-34). 

(3) Refer to figure 4-30 and remove the oil 
cooler. 

c. Replacement. Discard and replace the gasket. 

d. Installation. Install the oil cooler in the re- 
verse order of removal. 



1. REMOVE CONNECTIONS (2). 



4. REMOVE 
SCREWS (2) 
AND 
WASHERS i2). 




2. 



TS003Q01 



Figure 4-29. Transmission oil cooler removal. 



REMOVE WATER 
PUMP. (REFER TO 
FIGURE 4-34). 



CAUTION 
THE OH. COOLER 
COKE IS LOOSE 
AND HOUSING 
HOULD Ct TIPPcD 
LHJ1W/.' D AT TOP 
1O FI-T 'ENT DAMAGE 



DRAIN LUB 
RICATING 
OIL AND 
COOLANT 



EMOVE 
BOLTS (8) 
AND 
VMS HERS '8>. 




Figure 4-30. Engine lubricating oil cooler, removal. 



Section IX. MAINTENANCE OF EXHAUST SYSTEM 



438. General 

This section contains the maintenance procedures 
J or the engine exhaust system. A description of 
he exhaust system is presented in paragraph 
-5. 

39. Exhaust Manifold 

a. General. The exhaust manifold is mounted 
n the right side of the cylinder head. The mani- 
>ld consists of an iron casting containing an ex- 
aust chamber that is surrounded by a water 



jacket. Coolant flows from the rear of the cylin- 
der head through the water jacket to the ther- 
mostat housing. 

b. Removal. 

(1) Open the oil cooler drain cock and drain 
the cooling system to below the level of the ex- 
haust manifold. 

(2) Refer to figure 4-31 and remove the 
exhaust manifold. 



4. REMOVE BLANKET 
AND PIPE. 



1 . REMOVE SCREWS (6} 
AND WAS HERS (6). 



3. REMOVE 
HOSE. 



5. REMOVE 
SCREWS (4) 
AND WASHERS(4) 



6. REMOVE 
MANIFOLD. 




TS003003 

Figure 4~S1 . Exhaust manifold, removal. 

c, Cleaning. 

(1) 'Remove any loose scale and carbon that 
accumulated on the internal walls of the mani- 
fold. 

(2) Clean all traces of gasket material from 
the cylinder head and manifold. 

d. Inspection. 

(1) Examine the studs for damage and con- 
dition of threads. 

(2) Check all parts for breaks, cracks, dis- 
tortion or other damage. 



TM 5-1940-221-12 

e. Installation. Replace the gasket. Install the 
exhaust manifold in the reverse order of remov- 
al. After the manifold is installed, perform the 
following: 

(1) Close the oil cooler drain cock and fill 
the cooling system. 

(2) Start the engine and check for leaks. 

4-40. Mufflers and Exhaust Piping 

a. General. The mufflers, one for each engine, 
are located on each side of the hull behind the 
operator's cockpit. Piping is connected between 
the rear of each exhaust manifold and its respec- 
tive muffler and between the muffler and the 
tail pipe in the stern which vents overboard. The 
pdpdng and the mufflers are wrapped in asbestos 
blanketing secured with lacing. 

b. Inspection. 

(1) Check the pipes and mufflers for 
cracks, breaks, or other damage. 

(2) Examine the fittings for condition and 
security of mounting. 

(3) Inspect the asbestos blanketing for con- 
dition and security of lacing. 

c. Removal Refer to figure 4-32 and remove 
mufflers and piping. 

d. Replacement. Replace any damaged part. 

e. 'Installation. Install the mufflers and pipes 
in the reverse order of removal. 



TM 5-1940-221-12 




TS003004 



Figure 4-32. Mufflers and exhaust piping, exploded view. 



TM 5-1940-221-12 



1. Lacing wire 


16. Lockwasher 


31. Lockwasher 


2. Insulation blanket 


17. Gasket 


32. Bracket 


3. Bolt 


18. Bolt 


33. Bolt 


4. Nut 


19. Nut 


34. Nut 


5. Lockwasher 


20. Lockwasher 


35. Lockwasher 


6. Gasket 


21. Clamp 


36. Bracket 


7. Bolt 


22. Bolt 


37. Capscrew 


8. Nut 


23. Nut 


38. Nut 


9, Lockwasher 


24. Lockwasher 


39. Lockwasher 


10. Port header 


25. Clamp 


40. Ring 


11. Starboard header 


26. Flange 


41. Gasket 


12. Flange 


27. Flange 


42. Port tailpipe 


13. Gasket 


28. Muffler 


43. Starboard tailpipe 


14. Bolt 


29. Bolt 




16. Nut 


30. Nut 






Figure 4-32 Continued 





Section X. MAINTENANCE OF COOLING SYSTEM 



441. General 

This section contains the maintenance instructions 
for the engine cooling system. A description of 
the cooling system is contained in paragraph 1-5. 



442. Cooling System Maintenance 

a. General The engine coolant absorbs 



the 



heat developed by the combustion in the engine 
cylinders. Most of this heat is absorbed by the 
coolant in water jackets surrounding the exhaust 
valves, cylinder liners, and pistons. In addition, 
heat absorbed by the lubricating oil is transferred 
to the coolant by the engine and transmission oil 
coolers. 

NOTE 

The boat must be removed from the water to 
perform maintenance on the heat exchangers. 

b. Inspection. 

(1) Inspect the heat exchangers for leakage' 
drainage, and condition of connections. Tighten 
hose clamps on fittings. Replace defective hoses. 
Report a defective heat exchanger to direct sup- 
port maintenance. 

(2) Check that the heat exchanger drain 
plug and engine oil cooler drain cock are securely 
closed. 

(3) Check that expansion tank fillcap valve 
smts operate freely and that cap securely mounts 
on expansion tank neck. Replace a defective cap. 

(4) Inspect all hoses and fittings for deter- 
ioration, security, and leakage. Tighten loose 
connections. Replace defective hoses or fittings. 

c. Draining. 

(1) Remove expansion tank fill cap. 

(2) Remove drain plug (fig. 4-33) from 
heat exchanger, and open engine oil cooler 
drain cock (fig. 4-30). 




DRAIN PLUG 
T5003005 

Figure 4-33. Heat exchanger drain pluff- 

(3) After the system has drained, replace 
the heat exchanger drain plug and close the oil 
cooler drain cock. 

CAUTION 

If the engine is not to be used and 
freezing weather is anticipated, the 
system will not be filled with antifreeze; 
leave the drain plug out and the drain 
cock open. Water trapped within the en- 
gine will expand when frozen and possi- 
bly cause damage. 

d. Seasonal Flushing. The cooling system 
should be flushed in the spring and fall. 
Flushing cleans the system of antifreeze in the 
spring and of the summer rust inhibitor in the 
fall. 

(1) Drain the sy&tem as given in paragraph 
c above. 

(2) Fill the system with soft, clean water. 

4-3! 



TM 5-1940-221-12 



CAUTION 

If the engine is hot, fill the system slow- 
ly to prevent rapid cooling and distor- 
tion of parts. 

(3) Start the engine and operate it for 15 
minutes to thoroughly circulate the water. 

(4) Stop the engine and drain the system 
completely. 

(5) Refill the system with the proper cool- 
ant for the season. 

e. Contaminated Engine Flushing. When the 
engine cooling or lubricating- system becomes 
contaminated, it should be flushed thoroughly 
immediately to remove the contaminants before 
serious engine or transmission damage occurs. 
One possible cause of such contamination is a 
cracked oil cooler core. With a cracked core, oil 
will be forced into the cooling system while the 
engine is running and when it is stopped, coolant 
will leak into the lubricating system. If engine 
contamination is suspected, report to direct sup- 
port maintenance immediately. 

/. Filling. 

(1) Install the heat exchanger drain plug, 
and close the oil cooler drain cock. 

(2) Remove the expansion tank fill cap and 
add coolant to within 2 inches of the fill neck 
and replace the cap. 

CAUTION 

If the engine is hot, fill the system slow- 
ly to prevent rapid cooling and distortion 
of the parts. 

(3) Remove the vent plug (B, fig. 4-37) 
from the thermostat housing to vent any air in 
the system. Excessive amounts of air can hinder 
flow due to pump caviation or can cause hot 
spots. 

(4) Replace the thermostat housing vent 
plug. 

(5) Start the engine and after the engine 
has attained its normal operating" temperature, 
again vent the thermostat housing and check the 
coolant level. The coolant level should be within 
2 inches of the filler neck. If necessary, add cool- 
ant. 

4-43. Water Pump 

a. General The water pump is .mounted on 
top of the engine oil cooler housing on the left 
of the engine. The pump is a centrifugal-type 
that circulates the coolant from the expansion 
tank to the oil coolers and the engine. The pump 



is driven by the engine camshaft through pulleys 
and a V-belt. 

b. Removal. 

(1) Open the engine oil cooler drain cock 
(fig. 4-30) and drain the cooling system. 

(2) Refer to figure 4-34 and remove the 
pump. 

c. Installation. 

(1) Remove all traces of gasket material 
from the pump and oil cooler, discard the gas- 
ket, and replace it. 

(2) Install the water pump in the reverse 
order of removal. 

(3) Close the engine oil cooler drain cock 
and fill the cooling system. 



1. REMOVE 
V-BELT 
SHIELD. 
(REFER TO 
FIGURE 4-16) 



2. REMOVE 
V-BELTS 
(REFER TO 
FIGURE 4-1 7) 



4. REMOVE SCREWS (3) 
AND WASHERS (3). 




TS003006 



Figure 4-54. Water pump removal. 



444. Expansion Tank 

a. General. The expansion tank is located at 
the front of the engine. Coolant is drawn from 
the bank by the water pump and is circulated 
through the cooling system. Coolant is returned 
to the tank from the heat exchanger or the ther- 
mostat housing. 

b. Removal. 

(1) Open the engine oil cooler drain cock 
(fig. 4-30) and drain the cooling system. 

(2) Refer to figure 4-35 and remove the ex- 
pansion tank. 

c. Inspection. 

(1) Check the expansion tank valves for 
proper operation. 

(2) Examine the tank for cracks, breaks, and 
other damage. 



d. Installation. 

(1) Refer to figure 4-3? 
pansion tank in reverse orde 
new gaskets. 

(2) Close the engine oi 
and fill the cooling system. 

4-45. Thermostat and Housing 

a. General The thermos^* 
mounted on the water o 
of the exhaust manifoV 
blocking type, and ai 
temperature of the eng. 
temperatures below app 
thermostat valve remain, 
coolant to the expansion \ 
temperature rises, the valve oeg. 
stricting the passage to the expa 
the coolant passes to the heat exch.~ & . 






i. DRAiN COOLANT TO BELOW 
LEVEL OF TANK 

***** 



5. REMOVE TUBE. 



3. REMOVE 
CLAMP. 



6. REMOVE SCREWS (2) 
AND WASHERS (2). 



2. REMOVE SCREWS (2) 
AND WASHERS (2). 



A. REMOVE HEAT 
EXCHANGER 
RETURN HOSE 
(LOCATED ON 
OUTBOARD 
SIDE OF 
EACH ENGINE). 



7. REMOVE SCREWS (2) 
AND WASHERS (2). 



REMOVE SCREWS (2), 
WASHERS (2), AND 
SPACERS (2). 




Figure i-35. Expansion tank removal. 



4-37 



TM 5-1940-221-12 



UNSCREW AND 
REMOVE ANODES (4). 




TS003010 



Figure k-38. Anode removal. 



4-47. Cooling System Hoses and Fittings 

a. Removal. 

(1) Drain the cooling system. 

(2) Refer to figure 4-39 and remove lines, 
hoses, and fittings as required. 

b. Inspection and Replacement. 

(1) Check all hoses for kinks, cracks, 
breaks, and signs of deterioration. 

(2) Check fittings for condition of threads 
and security. 

(3) Replace any defective part. 

c. Installation. 

(1) Install the lines, hoses, and fittings in 
the reverse order of removal. 

(2) Fill the cooling system. 

(3) Start the engine and inspect for leaks. 



TM 5-1940-221-12 



20 



29 




/VSfeV x 
<tltfe 



t 



0~-"" 



X 



V 



TS 003011 



1. Clamp 

2. Hose 

3. Clamp 

4. Clamp 

5. Hose 



6. Clamp 

7. Elbow 

8. Elbow 

9. Clamp 
10. Clamp 



11. Hose 

12. Hose 

13. Clamp 

14. Clamp 

15. Elbow 



Figure 4-S9. Cooling system hoses and fittings, exploded. 



4-42 



TM 5-1940-221-12 



16. Elbow 


23. Hose 


30. Clamp 


17. Clamp 


24. Clamp 


81. Elbow 


18. Clamp 


25. Screw 


32. Washer 


19. Screw 


26. Nut 


33. Seal 


20. Nut 


27. Lockwaaher 


34. Elbow 


21. Lockwasher 


28. Clamp 


35. Washer 


22. Clamp 


29. Hose 


36. Seal 




Figure 4-S9 Continued. 





Section XI. MAINTENANCE OF ELECTRICAL SYSTEM 



4-48, General 

This section contains the maintenance instructions 
for the boat electrical system. A description of 
the electrical system is presented in paragraph 1- 
5. The system wiring diagram is shown in figure 
1-13. 

WARNING 

Before performing any repair on the 
electrical system, place the MASTER 
switch in the OFF ("down) position and 
disconnect the battery negative cables. 

4-49. Generator 

a. General. The 24-volt generator is mounted 
on the upper left side of the engine. The gen- 
erator is driven by the engine crankshaft through 
pulleys and a V-belt. The generator supplies 
charging current to the batteries through a gen- 
erator regulator. Before attempting maintenance 
of the generator, inspect and test it as given in 
the following paragraphs to determine if replace- 
ment is necessary. 

6. Inspection. 

(1) Check the lights. Dim or extremely 
bright lights may indicate a faulty generator. 

(2) Check the ammeter for sudden fluctua- 
tions or indication of extreme discharge or charge. 

(3) Check V-belt for proper tension. The 
tension is correct if a firm push with thumb on 
the V-belt at a point midway between the genera- 
tor and water pump pulleys depresses the bait 
1/2-to 3/4-inches. 

(4) Check generator mounting and cable 
connection for security. 

(5) Check that generator is not excessively 
noisy. 

c. Test. To test the generator while it is in- 
stalled in the boat, disconnect the generator 
cable and perform the following: 

(1) Check field for open circuit by using 
test points and a test lamp. Place the test points 
in each receptacle terminal and operate the en- 
gine at 2800 rpm. If the lamp does not light, the 



circuit is open. If the circuit is open due to a 
broken lead or bad connection, repair the lead 
or connection. If the open is due to a bad field 
coil, replace the generator. 

(2) If the field is not open, check for a 
shorted field by connecting a 24-volt battery and 
an ammeter in series with the field circuit. The 
field draw at 24 volts should be 0.91-to 0.98- 
amperes. Excessive current draw indicates a 
shorted field and the generator should be re- 
placed. 

d. Removal. 

(1) Turn off MASTER switch and discon- 
nect the batteries. 

(2) Refer to figure 4-40 and remove the 
generator. 

e. Installation. 

(1) Install the generator in the reverse 
order of removal. 

(2) Connect the batteries. 



4. REMOVE SCREW 
AND WASHER. 



3. REMOVE CABLE 



5. REMOVE 
SCREW AND 
WASHER. 

1! 



REMOVE 
V-BELT 
SHIELD. 
(REFER TO 
FIGURE 4-16). 



REMOVE 
GENERATOR 



FIGURE 4-1 7). 




Figure 4-40. Generator removal. 



4-43 



5-1940-221-12 



4-50. Generator Regulator 

a. General. The generator regulator is a heavy 
duty 14-volt, 18-ampere unit. The regulator is 
mounted on the rear bulkhead of the engine 
compartment behind its respective engine. The 
regulator incorporates three features; a cutout re- 
lay! a current regulator, and a voltage regulator. 

b. Inspection. A geneator regulator malfunc- 
tion may be indicated by a high charging rate 
with fully charged batteries, or low batteries 
with a low charging rate or no rate. Always check 
the wiring and connections for security before 
replacing a regulator. 

c. On-Equipment Test (Generator and Regula- 
tor). 

(1) Fully charged battery and high charg- 
ing rate. 

(a) Remove shielded cable from genera- 
tor and regulator and insert test harness or 
adapter. 

(6) Open the field circuit and operate the 
generator at medium speed. If the output re- 
mains high, the generator or the wiring harness 
is defective. If no output is obtained, the regu- 
lator is defective or requires adjustment. 

(2) Low batter ey and low or no charging 
rate. 

(a) Remove shielded cable from generator 
and regulator and insert test harness or adapter. 

(6) Operate generator at medium speed 
and momentarily connect a jumper lead between 
the armature and field leads; increase generator 
speed. If the output does not increase, the gen- 
erator is defective. If the output increases, the 
regulator is defective. 

CAUTION 

A burned resistance unit, regulator 
winding, or fused contacts can result 
from open-circuit or extreme resistance 
in the charging circuit. When these con- 
ditions exist, check all wiring before re- 
installing regulator. 

d. Removal. 

(1) Tum off the MASTER switch and dis- 
connect the batteries. 

(2) Refer to figure 4-41 and remove the 
regulator. 

e. Cleaning and Inspection. Clean and inspect. 
Replace a defective generator regulator. 

/. Adjustments, Mechanical 

(1) Cover removal. Remove four screws, 
lockwashers, cover, and gasket from regulator. 



I. REMOVE NUTS (4) AND 



2. REMOVE CONNECTORS (2\. 




TS003013 



Figure 4-41. Generator regulator removal. 

(2) Cutout relay air gap adjustment. Measure 
air gap (fig. 4-42) between armature and core 
(not between the brass pin and core) with con- 
tact points barely touching. Adjust to 0.048 inch 
by raising or lowering the lower contact bracket. 

(3) Cutout relay contact point adjustment 
(a) Adjust contact point opening to 0.035 

inch by bending upper armature atop as required. 
(&) Be certain that both contacts are 
alined and have same point opening. 

(4) Voltage regulator air gap adjustment, 
(a) Loosen locknut on voltage regulator 

unit (fig. 4-43) and insert the 0.087 inch gage 
between the armature and the part of the core 
next to the residual pin. 

(6) Press armature down against gage 
and hold it in place while turning the contact 
screw until the contacts barely touch. 

(c) Turn contact screw clockwise or 
counterclockwise to obtain an air gap setting of 
0.087 inch. 

(5) Current regulator air gap adjustment. 
Adjust current regulator air gap in the same 
manner as the regulator air gap (4) above. The 
correct current regulator air gap adjustment is 
0.087 inch. 

g. Adjustments on Equipment. 

(1) Polarizing the generator. Disconnect 
the lead from the field terminal of the regulator 
and momentarily touch this lead to the regulator 
battery terminal. This allows a momentary surge 
of current to flow through the generator field 
windings which correctly polarize the generator. 
Failure to do this may result in severe damage 



TM 5-1940-221-12 



UPPER 
ARMATURE STOP 



CONTACT POINT 
OPENING: C.035 INCH 




Figure 4-42. Cutout relay air gap and contact point adjustment. 



since reversed generator polarity causes vibration, 
heavy arcing, and burning of relay contact points. 

(2) Cutout relay closing voltage. 

(a) Connect regulator to generator and 
barfctery terminals as shown on figure 4-44. 

(&) Connect a voltmeter between the ar- 
mature terminal of the regulator and the ground 
screw at the end of the regulator. 

(c) Gradually increase generator speed 
and note voltage at which the cutout relay con- 
tact points close. The current closing voltage is 
25-to 27 volts. 

(d) Turn the spring tension adjusting 
screw on the cutout relay unit (fig. 4-43) clock- 
wise to decrease the closing voltage and counter- 
clockwise to increase the closing voltage. 

(3) Regulator voltage setting. 

(a) Connect a voltmeter from the regula- 
tor armature terminal to the regulator ground 
as shown on figure 4-45. 



NOTE 

Make certain that the lead from the regulator 
battery terminal is disconnected. 

(6) With the generator operating at spec- 
ified speed and the regulator at operating tem- 
perature, note the vpltag-6 setting. The correct 
setting is 28.5 volts. 

(c) Turn the spring- tension adjusting 
screw on the voltage regulator (fig. 4-43) 
clockwise to decrease the voltage setting and 
counterclockwise to increase the voltage setting. 

NOTE 

After each change of adjustment momentarily 
open the voltage regulator points by hand before 
taking voltage reading. 

(4) Current regulator current setting. 

(a) Connect an accurate ammeter in series 
Into the charging circuit at the regulator battery 
terminal to measure the current regulator setting 
(fig. 



4-4 1 



TM 5-1 940-22 1-1 2 



LOCKNUT 



AIR GAP 
LOCKNUT ADJUSTING SCREW 



AIR GAP 
ADJUSTING SCREW 



CUTOUT VOLTAGE 
ADJUSTING SCREW 



VOLTAGE REGULATOR 
ADJUSTING SCREW 



CURRENT REGULATOR 
ADJUSTING SCREW 




TS 003015 



Figure 4-43. Voltage and current regulator air gap adjustment. 



(b) Place a jumper wire across the volt- 
age regulator contact points so the voltage regu- 
lator cannot operate. 

(c) Connect a load of approximately 18 
amperes across the battery by using a carbon pile 
rheostat or a bank of lights. 

(d) Turn the spring tension adjusting 
screw on the current regulator (fig. 4-43) clock- 
wise to decrease the current setting or counter- 
clockwise to increase the current setting. 

(e) Adjust the regulator current setting 
to 18 amperes. 

h. Cover Installation. Position the gasket and 
cover on the regulator and install the four lock- 
washers and screws. 

i. Installation. 

(1) Install the regulator in the reverse 
order of removal. 

(2) Connect the batteries. 



4-51 . Cranking Motor (Starter) 

a. General The cranking motor is mounted at 
the right side of the engine on the flywheel 
housing. When the motor is energized, a sole- 
noid mounted on the motor engages a spline 
drive with the engine ring gear. 

b. Testing. Refer to figure 4-47 and test the 
cranking motor. 

c. Removal. 

(1) Turn off the MASTER switch and dis- 
connect the batteries. 

(2) Refer to figure 4-48 and remove the 
cranking motor (starter). 

d. Inspection. 

(1) Check condition of plunger teeth. 

(2) Examine electrical terminals for securi- 
ty and condition. 

(3) Check security of solenoid mounting 
and wiring. 



4-46 



TM 5-1940-221-12 



VOLTMETER-TO-GROUND LEAD 
VOLTMETER 



AMMETER 



REGULATOR 




VOLTMETER-TO- 
ARMATURE LEAD 



AMMETER 
TERMINALS 

FIELD 
TERMINALS 



GENERATOR 



V 

BATTERIES 4?- 



STEP 1. CONNECT THE VOLTMETER TO THE GENERATOR ARMATURE AND GROUND. 

STEP 2. START THE ENGINE. 

STEP 3. THE VOLTMETER SHOULD INDICATE BETWEEN 25 AND 27 VOLTS. 

STEP 4. STOP THE ENGINE AND REMOVE THE VOLTMETER AND LEADS. 



TS 003016 



Figure 4-44. Testing cutout relay closing voltage. 



e. Installation. 

(1) Install the cranking motor in the reverse 
order of removal. 

(2) Connect the batteries. 

4-52. Magnetic Cranking Switch 

a. General. The magnetic cranking switch is 
located on the after bulkhead of the engine 
compartment. The switch is solenoid operated 



and serves to connect the two pairs of batteries 
in parallel. 

b. Removal. 

(1) Turn off the MASTER switch and dis- 
connect the batteries. 

(2) Refer to figure 4-49 and remove the 
switch. 

c. Testing. Refer to figure 4-49 and test the 
magnetic cranking switch. 



TM 5-1940-221-12 



NOTE: VOLTMETER READING 
27-1/2 TO 29-1/2 VOLTS 



VOLTMETER 

J_ 



REGULATOR* 




AMMETER 




LOAD 



AMMETER TERMINALS 



FIELD TERMINALS 



IN/ 



A 



=lfi 




GENERATOR 



BATTERIES ~ 



Figure 4-45. Testing voltage regulator setting. 



TS 003017 



d. Installation. 



(1) Install the switch in the reverse order 
of removal. 

(2) Connect the batteries. 
4-53. Batteries and Cables 

a. General. The 24-volt batteries are in battery 
boxes (2 batteries per box) on either side of the 
forward portion of the operator's cockpit. The 
electrical system wiring diagram is shown in fig- 
ure 1-13. 

NOTE 

This electrical system is negative to ground. 
4-48 



b. Removal. 

(1) Refer to A, figure 3-4 and remove the 
battery box cover. 

WARNING 

Batteries generate hydrogen, a highly 
explosive gas. Do not smoke or allow 
open spark or flame in the vicinity of 
the batteries. 

(2) Refer to figure 4-50 and remove the 
cables and batteries. 

c. Cleaning. 

(1) Mix a solution of bicarbonate of soda 
and water. Make sure that all battery caps are 
securely screwed down as this solution could con- 
taminate the electrolytic. 



TM 5-1940-221-12 



REGULATOR 



UNIT AMMETER 



AMMETER TERMINALS 




LOAD 



V 

BATTERIES ^F 



GENERATOR 



TS 003018 



Figure 4-46. Testing current regulator current setting. 



(2) Brush the solution on the terminals and 
the cable clamps. When the solution has stopped 
foaming, flush the solution off with clean water 
and dry with a clean cloth. 

(3) Clean the battery tray and box in the 
same manner as in step (2) above. 

d. Inspection. 

(1) Inspect the battery cases for cracks and 
leaks, and security of terminals. 

(2) Examine condition of cable insulation 
and clamps. 

e. Installation. Install the batteries in the re- 
verse order of removal. 



4-54. Instrument Panel Components 

a. General. All the engine instruments are 
mounted on two panels located forward of the 
steering wheel. Each panel also includes a switch 
and two lamps for night illumination. The am- 
meters are the only instruments that are depen- 
dent upon the boat electrical system; all the 
others are independently actuated. The gages are 
described in paragraph 2-8. Maintenance proce- 
dures for the tachometer drive are given in para- 
graph 4-14. 

6. Removal. 

(1) Turn the MASTER switch off. 

(2) Remove the access panel to reach the 
rear of the instrument panel components (fig:. 
4-71). 

-4-49 



TM 5-1940-221-12 




MULTIMETER 




BATTERIES 



VOLTMETER 




TO STARTER 
SWITCH 



STARTER 

SOLENOID 

SWITCH 



_i. r\_ 




S IB 


i 






{. F= 




jC 


i 



STARTER 



VOLTMETER 



TO STARTER 
SWITCH 




STARTER 



1 . DETERMINE THAT BATTERIES ARE FULLY CHARGED AND THAT ALL BATTERY AND STARTER CABLES ARE SERVICEABLE AND 
PROPERLY INSTALLED. 

2. CONNECT A MULTIMETER AS SHOWN IN B ABOVE. CHECK THE CONTINUITY OF THE SOLENOID WITH THE MULTIMETER IN 
THE UNIT (R-l) POSITION. A GOOD SOLENOID WILL INDICATE APPROXIMATELY 1 .2 OHM RESISTANCE. 

3. INSTALL THE SOLENOID-TO-STARTER CONNECTOR. 

4. CONNECT VOLTMETER AS SHOWN IN C ABOVE. IF BATTERY VOLTAGE (24 VOLTS) IS NOT INDICATED, THE STARTER IS 
DEFECTIVE AND MUST BE REPLACED. 

5. MOMENTARILY CONNECT A JUMPER AS SHOWN IN D ABOVE. THE VOLTMETER READING SHOULD DROP TO ZERO AND STARTER 
SHOULD CRANK ENGINE. IF VOLTMETER READING DOES NOT DROP TO ZERO, STARTER SOLENOID SWITCH IS DEFECTIVE AND 
MUST BE REPLACED . IF VOLTMETER READING DROPS TO ZERO BUT STARTER FAILS TO CRANK ENGINE, STARTER IS DEFECTIVE 
AND MUST BE REPLACED. 



(3) Refer to figure 4-51 and remove the de- 
fective component. 

c. Inspection. 

(1) Inspect leads for security. 

(2) Inspect component and fittings for dam- 
age. 



Figure 4-47- Cranking motor (starter) on board testing. 

d. Installation. 



(1) Install the components and panel in the 
reverse order of removal. 

(2) Start engine and check operation of com- 
ponent. 



4-50 



TM 5-1940-221-12 



2. REMOVE SCREWS (3) 
AND WASHERS (3). 




Figure 4-48. Cranking motor (starter) removal. 



1. REMOVE 
SCREWS' (4) 



3. REMOVE NUTS 
AND LOCK 
WASHERS (4). 



4. DISCONNECT j 
WIRES (3). 



5. REMOVE CRANKING 
SWITCH. 



2. REMOVE 
BRACKET. 




Figure 4-49. Magnetic cranking switch, removal. 

4-55. Fuse Panel 

a. General. The fuse panel is located in front 
of the steering wheel. All seven of the fuses for 
the boat are mounted on this panel. A spare 
fuse is provided in the lower left fuse holder. 

b. Removal. 

(1) Turn off the MASTER switch. 

(2) Refer to figure 4-52 to remove fuses 
and/or panel. 

c. Installation. 

(1) Install the fuses and/or panel in the re- 
verse order of removal 



I . REMOVE COVER 

(REFER TO FIGURE 3-4 



3 REMOVE 
\ m ^ BATTERIES 

m\ i 

TS003022 



2. LOOSEN CLAMPS 

AND REMOVE CABLES. 




Figure 4-50. Batteries, removal. 

(2) Turn on MASTER switch and applica- 
ble switch for affected circuit and check opera- 
tion. 

456. Switch Panel 

a. General. The switch panel is located in front 
of and to the right of the steering wheel. This 
panel contains all the manually-operated switches 
on the boat except for the spotlight switch in- 
corporated in the handle of 'the light. 

6. Removal. 

(1) Turn off the MASTER switch and dis- 
connect the batteries. 

(2) Remove the screws (1, fig. 4-53) and 
pull the panel out only far enough to gain access 
to the rear of the defective switch. 

(3) Disconnect the electrical lead from the 
switch. 

(4) Refer to figure 4-53 and remove the 
nut, washer, and bezel securing the defective 
switch. 

c. Installation. 

(1) Refer to figure 4-53 and install the 
switch in the panel (11). 

(2) Connect the electrical lead to the switch. 

(3) Position the panel and secure with 
screws (1). 

(4) Connect the batteries. 

(5) Turn on the MASTER switch and check 
the operation of the replacement switch. 



TM 5-1940-221-12 




18 



19 



20 



35 



TS003023 



1. Screw 

2. Nut 

3. Lockwasher 

4. Capacitor 

5. Nut 

6. Lockwasher 

7. Clamp 

8. Coolant temperature 
gage 

9. Nut 

10. Lockwasher 

11. Clamp 

12. Transmission oil pres- 
sure gage 



13. Tachometer cable 

14. Nut 

15. Lockwasher 

16. Bracket 

17. Tachometer 

18. Nut 

19. Lockwasher 

20. Clamp 

21. Engine oil pressure 
gage 

22. Nut 

23. Washer 

24. Nut 

25. Switch 



26. Nut 

27. Washer 

28. Base 

29. Shade 
SO. Lamp 

31. Nut 

32. Lockwasher 

33. Clamp 

34. Ammeter 

35. Panel 



Figure 4-5 1. Instrument panel components, exploded view. 



4-52 



REPLACEMENT 
FUSE 



TURN SCREWS (4) 
COUNTERCLOCKWISE 
TO REMOVE PANEL. 



PUSH FUSEHOLDER IN AND TURN COUNTERCLOCKWISE 
TO REMOVE CAP AND FUSE. 




Figure 4-52. Fuse removal. 

457. Running Lights 

a. General. The running lights are loacted on 
the port and starboard sides of the cockpit. When 
replacing lamps make sure that the green lens 
is on the starboard and the red lens on the port. 

b. Removal. 

(1) Turn off MASTER switch. 

(2) Refer to figure 4-54 and remove the 
running light. 

NOTE 

If only replacement of the lamp or lens is neces- 
sary, proceed as given in B, figure 4-54. 

c. Inspection. 

(1) Examine lens for cracks or breaks. 

(2) Check condition of gasket, hardware, 
and electrical connections. 

d. Installation. 

(1) Install the light in the reverse order of 
removal. 

(2) Turn on the MASTER switch and the 
RUNNING LIGHTS switch and check operation. 

4-58. Bow Light 

a. General. The bow light is on a mast that 
mounts in a bracket at the forward coaming of 
the cargo well. The light connector mates with 
a receptacle in the coaming. Another connector 
joins with one from the stern assembly. 

b. Removal. 

(1) Turn off the ANCHOR LIGHTS 
switch. 



(2) Refer to figure 4-55 and remove bow 
light. 

c. Disassembly. Refer to figure 4-56 and dis- 
assemble the bow light in the order of the index 
numbers. 

d. Inspection. 

(1) Examine lens for cracks or breaks. 

(2) Check condition of gasket, hardware, 
and electrical connections. 

(3) Inspect wiring for kinks, breaks, and 
damaged insulation. 

e. Reassembly. Reassemble the bow light in the 
reverse order of disassembly. 

/. Installation. 

(1) Install the bow light in the reverse 
order of removal. 

(2) Turn on the MASTER switch and the 
ANCHOR LIGHTS switch and check operation. 

4-59. Range Light 

a. General. The range light is on a mast that 
mounts in a bracket on the after coaming of the 
operator's cockpit. The light connector mates 
\vith a receptacle adjacent to the mast bracket 

5. Removal. 

(1) Turn off the ANCHOR LIGHTS 
switch. 

(2) Refer to figure 4-57 and remove the 
range light. 

c. Disassembly. Refer to figure 4-58 and dis- 
assemble the range light in the order of the in- 
dex numbers. 

d. Inspection. 

(1) Examine lens for breaks and cracks. 

(2) Check condition of gasket, hardware, 
and electrical connectors. 

(3) Inspect wiring for kinks, breaks, and 
damaged insulation. 

e. Reassembly. Reassemble the range light in 
the reverse order of disassembly. 

f. Installation. 

(1) Install the range light in the reverse 
order of removal. 

(2) Turn on the MASTER switch and 
ANCHOR LIGHTS switch and check operation. 

4-60. Spotlight 

a. General. The spotlight is located in a stow- 
age box forward on the port side of the opera- 
tor's cockpit. The light is permanently connected 
to the boat electrical system. 

b. Removal. 

(1) Turn off the MASTER switch and spot- 
light switch. 



4-53 



TM 5-1940-221-12 



10 




TS003025 



1. Screw 

2. Nut 

3. Lockwasher 

4. Bushing 



5. Nut 9. Switch 

6. Switch 10. Switch 

7. Switch 11. Panel 

8. Switch 

Figure 4-53. Switches, exploded view. 



(2) Disconnect the cable (7, fig. 4-59) at 
lugs (3), from the terminal block. 

.c. Disassembly. Refer to figure 4-59 and dis- 
assemble the spotlight in the order of the index 
number. 



d. Inspection. 

(1) Examine the lens for cracks or breaks. 

(2) Inspect condition of hardware and elec- 
trical connections. 



4-54 



4. REMOVE LIGHT. 



2. REMOVE NUT AND 
WASHER. 



A. INBOARD PORTION OF RUNNING LIGHT 




3. REMOVE SCREW 
AND RETAINER. 




8. OUTBOARD PORTION OF RUNNING LIGHT 



TS003026 



Figure 4-54.. Running light removal. 



e. Reassembly. Refer to figure 4-59 and re- 
assemble the spotlight in the reverse order of the 
index numbers. 

/. Installation. 

(1) Connect the cable (7) at lug (3) to the 
terminal block. 

(2) Turn on the MASTER switch and spot- 
light switch. Actuate the pushbutton switch in 
the spotlight handle and check the operation. 



BOW LIGHT 



4. REMOVE 
MAST. 



3. REMOVE SCREW AND 
WING NUT 




NOTE 
WHEN INSTALLING 
MAST, POSITION 
SCREW IN BRACKET 
SLOT. 



1 . REMOVE PLUG FROM) 
RECEPTACLE 



2. INSTALL 
COVER. 



TS003027 



Figure 4-55. Bow light, removal and installation. 



4-61 . Storage Box 

a. General. The storage box is located forward 
on the port side of the operators cockpit. The 
storage box provides a watertight housing and 
storage location for the spotlight. The storage 
box contains a molded polystyrene pad which 
protects the spotlight from vibrations and break- 
age. 

b. Disassembly. 

(1) Remove 2 each mounting bolts and re- 
move storage box. 

(2) Remove pad from inside of box. 

(3) Remove 2 flat head machine screws 
from catch and remove upper catch. 

(4) Remove 2 oval head machine screws from 
lid catch and remove catch. 

(5) Remove electrical cable clamp and rub- 
ber grommet. 

c. Inspection. 

(1) Inspect for condition of latch assembly. 

(2) Insure proper fit of spotlight in pad. 

(3) Inspect pad and box for cracks. 

(4) Inspect interior of storage box for 
evidence of water leaks. 

d. Reassembly. Reassemble the storage box in 
the reverse order of disassembly, paragraph b 
above. 



4-55 



TM 5-1940-221-12 




TS003028 



Figure 4-56. Bow light, exploded view. 



4-56 



TM 5-1949-221-12 



1. Wing nut 

2. Screw 

3. Screw 

4. Retainer 

5. Globe 



6. Gasket 11. Nipple 

7. Lamp 12. Plug assembly 

8. Screw 13. Gasket 

9. Base 14. Cap 

10. Socket 15. Grommet 

Figure 4-56 Continued. 



16. Cable 

17. Grommet 

18. Nut 

19. Post 



RANGE LIGHT 



I . REMOVE 
PLUG FROM 
RECEPTACLE. 



lN.S7.-a... -ECEP'ACLE 
CO.==. 




TSQ02029 



Figure 4-57. Range light removal and installation. 



4-57 



TM 5-1940-221-12 




16 



17 




TS003030 



4-58 



Figure 4-58. Range light, exploded view. 



TM 5-194O-221-12 



1. Screw 

2. Retainer 

3. Globe 

4. Gasket 

5. Lamp 

6. Screw 



7. Base 

8. Socket 

9. Nipple 

10. Plug 

11. Gasket 

12. Cap 



13. Grommet 

14. Cable 

15. Grommet 

16. Mast 



Figure 4-58 Continued. 




TS003031 



1. Ring 

2. Screw 

3. Lug 

4. Lamp 



5. Nut 9. Nut 

6. Switch 10- Washer 

7. Cable 11- Handle 

8. Screw 12. Shell 

Figure 4-59. Spotlight, exploded view. 



4-59 



TM 5-1940-221-12 



Section XII. MAINTENANCE OF TRANSMISSION 



4-52. General 

This section contains the maintenance instruc- 
tions for the transmission that are responsibility 
of organizational maintenance. The transmission 
is described in paragraph 1-5. 

4-63. Transmission Maintenance 

a. General. The only servicing that can be per- 
formed on the transmission by organizational 
maintenance is draining and replenishing the oil. 
The transmission oil is the same as that used for 
engine lubrication. Corrective maintenance proce- 
dures are limited to replacing the strainer and 
control cable. 

Two types of dipstick assemblies are used on this 
transmission, one being a dipstick with an at- 
tached pipe plug and the other a dipstick with 
an attached T-handle and rubber expansion plug. 
6. Draining Oil 

( 1 ) R emove the dipstick assembly. 

(2) Using the suction pump (fig. 4-60), 
pump out the oil. 

(a) Remove the fitting from the suction 
hose. 

(&) Insert the short suction hose (fig. 
4-60) into the dipstick opening and the long dis- 
charge hose into a suitable receptacle. 

(c) Pump the oil into the receptacle. 

(3) Refer to paragraph 4-68 and service the 
oil strainer. 

c. Oil Filling. 

(1) Remove the dipstick assembly and add 
the same type and grade of oil as the engine 
lubricating oil. Fill until the level reflects 
"FULL" on the dipstick, approximately 3 quarts. 
The bottom of the dipstick must make contact 
with the transmission housing to get a correct 
reading on the dipstick. 

(2) Make sure the transmission oil cooler 
return line is securely connected. 

(3) Install the dipstick assembly, tightening 
it enough to prevent oil leakage. 

(4) Start the engine and run it at idle speed 
for 5 minutes until the oil cooler and lines are 
filled. Check the oil level. 

4-64. Transmission Oil Strainer 

a. General. The oil strainer is located on the 
lower right side of the transmission housing 
just below and forward of the mounting bracket. 
The strainer cleans any impurities from the oil 
as it enters the return line to the cooler. The 

4-60 



1 . REMOVE HOSE. 

2. REMOVE ELBOW AND BUSHING 
3. REMOVE BUSHING AND PIPE. 




4. DRAW OUT STRAINER. 




TRANSMISSION HOUSING 



TS003033 



Figure 4-60. Draining the transmission oil. 

strainer should be cleaned each time the oil is 
drained. 

b. Removal. 

(1) Drain the transmission as given in para- 
graph 4-63b. 

(2) Refer to figure 4-61 and remove the 
strainer. 

c. Cleaning and Inspection. 

(1 Wash the strainer with fuel oil and 
dry with clean compressed air. 

(2) Examine the strainer for clogged open- 
ings, breaks, cracks, distortion, or other damage. 

d. Installation. 

(1) Install the strainer in the reverse order 
of removal. 

(2) Fill the transmission with oil as given 
in paragraph 4-70c. 

4-65. Transmission Control Cable 

a. General. The transmission is controlled by a 
cable connected between the shift lever on the 
left side of the transmission and the power con- 
trol lever in the operator's cockpit. 

b. Removal. 

(1) Refer to A, figure 4-62 and remove 
the transmission shift lever end of the control 
cable. 

(2) Remove the engine speed control cable 
(para 4-15). 



TM 5-1 940-221-12 




Figure 4-61. Transmission oil strainer removal. 



(3) Refer to figure 4-14 and remove the (1) Check cable for kinks, cracks, or other 

control head. damage. 

(2) Check security of fittings and conddtion 
of threads. 

d. Installation. Install the control cable in the 
c. Inspection. reverse order of removal. 



(4) Refer to B, figure 4-62 and remove the 
control lever end of the cable. 



4-61 



TM 5-1 940-22 J-12 



3. PULL TERMINAL 
FROM LEVER. 



1 . REMOVE SCREWS (2) 
AND BRACKET, 




2. REMOVE SCREWS (2) 
AND LOCKWASHERS (2) 



4. REMOVE 
CABLE AND 
TERMINAL. 



1 . REMOVE SCREWS 
(2) AND BRACKET. 



TRANSMISSION 
CONTROL CABLE. 



B. POWER LEVER END 




3 - ROTATE 

PLATE. 



ENGINE SPEED 
CONTROL CABLE 

TS003034 



Figure 4-62. Transmission control cable removal. 

Section XIII. MAINTENANCE OF STEERING SYSTEM 



4-65. General 

This section contains the maintenance instruc- 
tions for the steering system. A description of 
the steering system and its operation are pre- 
sented in paragraph 1-5. 

4-67. Steering Wheel 

a. Removal. Refer to figure 4-63 and remove 
the steering wheel. 
6. Inspection. 

(1) Check the wheel for cracks, breaks, or 
distortion. 

(2) Check the condition of the threads on 
the shaft of the upper gear box and wheel re- 
taining nut. If the threads in the nut are dam- 
aged, replace the nut. If the threads are dam- 
aged on the shaft, replace the upper gear box as 
given in paragraph 4-76. 

c. Installation. Install the steering wheel in the 
reverse order of removal. 

4-68. Steering Gear Universal Joints 

a. General The steering, gear has four uni- 
versal joints; one is located at the output shaft 
of the upper gear box, two are located at the 
input and output shafts of the lower gear box, 
and one is located at the steering quadrant. The 
following procedure applies to all the. universal 
joints, as they are identical. 



b. Removal. Refer to figure 4-64 and remove 
the universal joint. 

c. Inspection. 

(1) Check the universal joints for breaks, 
cracks, distortion, or other damage. 

(2) Check that pin is firmly in place and 
there is no excessive backlash. 



2. REMOVE STEERING 
WHEEL 




Figure 4-63. Steering wheel removal 



4-62 



3. SLIDE JOINT UP ON 
TUBE UNTIL JOINT 
CLEARS SHAFT. 



. LOOSEN SET 
SCREWS (2). 



2. REMOVE PIN 



!.VING JOINT AWAY 
F2ON\ SHAFT AND 
r :EMOVE JOINT. 




1. REMOVE STEERING t * , 2 - REMOVE ACCESS 
WHEEL. (REFER TO * PLATE. (REFER TO 
FIGURE 4-63). ^ FIGURE 4-71}. 



Figure 464- Universal joint removal. 

d. Installation. Install the universal joint in 
le reverse order of removal. 



t-69. Upper Gear Box 

a. Removal. 

(1) Refer to figure 4-71 and remove the 
iccess panel. 

(2) Refer to figure 4-65 and remove the 
upper gear box. 

b. Inspection. 

(1) Check the gear box for breaks, cracks, 
distortion, or other damage. 

(2) Rotate one of the gear box shafts and 
check that operation is smooth. 



3. LOOSEN 
SET 
SCREWS (2). 




Figure 4-65. Upper gear box removal, 

c. Installation. Install the upper gear box in 
the reverse order of removal. 

4-70. Lower Gectr Box 

a. Removal. Refer to figure 4-66 and remove 
the lower gear box. 

b. Inspection. 

(1) Check the gear box for breaks, cracks, 
distortion, or other damage. 

(2) Rotate one of the gear box shafts and 
check that operation is smooth. 

c. Installation. Install the lower gear box in 
the reverse order of removal. 

4-71 . Steering Gear Transverse Rod 

a. Removal. 

( 1 ) Open the stern hatch. 

(2) Refer to figure 4-67 and remove the 
transverse rod. 

b. Inspection. 

(1) Check rod for cracks, breaks, distor- 
tion, or other damage. 

(2) Examine the hardware for security and 
condition. 

c. Installation. Install the transverse rod ii 
the reverse order of removal. 



4-63 



TM 5-1940-221-12 



2. REMOVE SCREWS (4) 
AND WASHERS (4). 



I. REMOVE 
UNIVERSAL 
JOINTS (2) 
AND KEYS (2). 




REMOVE COTTER 
PINS (2), WASHERS 
(2), AND PINS(2) 



2. REMOVE 

TRANSVERSE ROD 




Figure 4-67. Steering gear transverse rod removal. 



Figure 4-66. Lower gear box removal. 



Section XIV. MAINTENANCE OF PROPELLER AND SHAFT 



4-72. General 

This section contains the maintenance procedures 
for the propeller shaft coupling. All other main- 
tenance procedures for the propellers and shafts 
are the responsibility of direct and general sup- 
port maintenance. 

4-73. Propeller Shaft Coupling 

a. General. The propeller shaft coupling is a 
flanged type with two halves secured to each 
other with nuts and bolts. The after-half is 



keyed to the propeller and shaft and retained by 
a nut on the threaded end of the shaft. 

b. Inspection. 

(1) Check the condition of the shaft, bolt, 
and nut threads. 

(2) Check coupling for breaks, cracks, or 
distortion. 

(3) Attempt to insert an 0.0015-inch feeler 
gage around several points between the cou- 
plings. If the gage can be inserted at any point, 
report to direct support maintenance. 



Section XV. MAINTENANCE OF BOAT FRAME ASSEMBLY 



4-74. General 

This section contains the maintenance instruc- 
tions for the hatch covers, access covers and the 
towing attachments that are the responsibility of 
organizational maintenance. 

4-64 



are 



4-75. Engine Hatch Covers 

a. General. The engine hatch covers 
mounted on the skirt above the engine compart- 
ment. The two covers are hinged with pins and 
secured by toggle bolts. 



b. Removal. Refer to figure 4-68 and remove 
the hatches. 

c. Inspection and Repair. 

(1) Inspection. Inspect the hatch covers for 
corrosion, cracks, bends, breaks, and damaged 
welds. Check for loose or missing rivets, bent or 
missing hinge pin, and other damaged hardware. 

(2) Repair. Repair cracks and straighten 
bends. Replace missing or damaged rivets, hinge 
pins, and other hardware. 

d. Installation. Install the engine hatches in 
the reverse order of removal. 

4-76. Stern Hatch Cover 

a. General. The stern hatch cover is located on 
the after deck of the stern assembly. The cover 
affords access to the steering gear quadrant and 
transverse rod. 

b. Removal. Refer to figure 4-69 and remove 
the stern hatch cover. 

c. Inspection and Repair. 

(1) Inspection. Inspect the hatch cover for 
corrosion, cracks, bends, breaks, and damaged 
weld. Check for loose or missing rivets, bent or 
missing hinge pms and other hardware. 

(2) Repair. Repair cracks and breaks and 
straighten bends. Replace missing or damaged 
rivets, hinge pins and other hardware. 



d. Installation. Install the stern hatch cover in 
the reverse order of removal. 

477. Bow Hatch Cover 

a. General. The bow hatch cover is located on 
the forward bulkhead of the bow cockpit. The 
hatch affords access to the bow compartment. 
The compartment serves as a stowage area for 
the on-board equipment. 

5. Removal. Refer to figure 4-70 and remove 
the bow hatch cover. 

c. Inspection, and Repair. 

(1) Inspection. Inspect the bow hatch cover 
for bends, breaks, cracks, damaged welds and 
other damage. Check for loose, bent, or missing 
rivets, hinge pins and other hardware. 

(2) Repair. Repair cracks and breaks. 
Straighten bends. Replace missing or damaged 
rivets, hinge pins, and other hardware. 

d. Installation. Install the bow hatch cover in 
the reverse order of removal. 

4-78. Access Panel 

a. General. The access panel is located behind 
the port engine hatch. The panel provides access 
to the steering system upper gear box and the 
rear of the instrument panel. 



2. REMOVE COTTER 

PINS i2) AND PiNS (2). 



* 4. REMOVE STARBOARD 
HATCH COVER IN 
SAME WAY AS PORT 
HATCH COVER . 




Figure 4-68. Engine hatch covers removal. 



4-65 



TM 5-1940-221-12 



j 4. REKAOVE NUTS 14), WASHERS > 
(4), AND BOLTS (4). 



1 . RELEASE TOGGLE 
SOL IS i2'). 

Ti.ft 




A. OPENING HATCH 



TS003041 



Figure 4-69. Stern hatch cover removal. 



b. Removal. Refer to figure 4-71 and remove 
the access panel. 

c. Installation. Install the access panel in the 
reverse order of removal. 

4-79. Push Knees 

a. General. The two push knees are located at 
the bow of the boat and serve as fenders or 
bumpers when pushing rafts. 

6. Removal Refer to figure 4-72 and remove 
the push knees. 

c. Inspection. 

(I) Examine parts for cracks, breaks, dis- 
tortion or other damage. 



(2) Check for loose or missing hardware. 
d. Installation. Install the push knees in the 
reverse order of removal. 

4-80. Bow Towing BItfr 

a. Removal. Refer to figure 4-73 and remove 
the bow towing bitt. 

b. Installation. Install the bow towing bitt in 
the reverse order of removal. 

4-81 . 5 fern Towing Bitf 

a. Removal. Refer to figure 4-74 and remove 
the stern towing bitt. 

b. Installation. Install the stern towing bitt in 
the reverse order of removal. 




3. REMOVE PANEL. 



1 . OPEN PORT ENGINE 

HATCH TO GAIN ACCESS 
TO BOTTOM FASTENERS. 



2. TURN FASTENERS ; 14) 
COUNTERCLOCKWISE 
TO RELEASE. 




Figure 4-70. Bow hatch cover removal. 



4-66 



Figure 4-71. Access panel removal 



2. PULL OUT 
PINS (2). 



I . REMOVE 

COTTER PINS (2) 




Figure 4-72. Push knee removal. 



2. REMOVE TOWING 
BITT. 




1 REMOVE SCREWS (4), 
WASHERS (12), AND 
NUTS (4). 



TS003045 



Figure 4-73. Bow towing bitt removal 



3. REMOVE TOWING 
BITT. 



2. REMOVE CO NEK FIN 
AMD LOCK BAR. 




Figure 4-74. Stern towing bitt removal. 

4-82. Base Haul Chock 

a. Removal. Refer to figure 4-75 and remove 
the haul chock. 

b. Inspection. 

(1) Check sheave for freedom of movement. 

(2) Examine parts for breaks, cracks, distor- 
tion or other damage. . . 

(3) Check condition of rope and splicing. 

c. Installation. Install the haul chock in tne 
reverse order of removal. 



4-83. Coupling Arm 

a. Removal. Refer to flg* 4-76 and 
the coupling arm. 

b. Inspection. 

(1) Check parts for 
tion, or other damage. 

(2) Check condition- 
nut turns smoothl 

c. 
reverse order 



TM 5-1940-221-12 



1 . REMOVE SCREWS (3), NUTS (3), 
WASHERS (3), AND SPACERS (3). 




Figure 4-75. Haul chock removal. 

4-84. Coupling Yoke 

a. Removal Refer to figure 4-77 and disassem- 
ble coupling yoke in the order of the index num- 
bers. 

b. Inspection. 

(1) Examine all parts for cracks, breaks, 
distortion, or other damage. 

(2) Check condition of threads and that the 
nut turns .smoothly. 

c. Installation. Install the coupling yoke in 
the reverse order of removal. 



2. REMOVE COUPLING 
ARM. 




iiliiil 



ITS003048 



Figure 4-76. Coupling arm removal. 

4-85. Coupling Hook 

a. Removal. Refer to figure 4-78 and disassem- 
ble the coupling hook in the order of the index 
numbers. 

b. Inspection. 

(1) Check all parts for cracks, breaks, dis- 
tortion, and other damage. 

(2) Check condition of all threads. 

c. Installation. Install the coupling hook in 
the reverse order of removal. 



10 




TS003049 



1. Pin 
2. 'Nut 
3. Nut 



4. Spacer 

5. Screw 

6. Retainer 



7. Gasket 

8. Packing 

9. Pin 



10. Yoke 



Figure 4-77. Coupling yoke, exploded view. 



4-68 



15 



16 



17 




TS003050 



1. Pin 

2. Nut 

3. Washer 

4. Handle 



5. Key 

6. Nut 

7. Packing 

8. Screw 



9. Plug 

10. Shaft 

11. Key 

12. Washer 



13. Hook 

14. Hook 

15. Screw 

16. Chain 



Figure 4-78. Coupling hook, exploded view. 



4-69 



CHAPTER 5 

MAINTENANCE OF MATERIAL USED IN CONJUNCTION 
WITH MAJOR ITEM 



Section I. FIRE EXTINGUISHER SYSTEM 



. General 

fire extinguishers are carbon dioxide types. 
y are located at the forward right portion of 
operator's cockpit (fig. 1-2) and are suitable 
electrical and flammable liquid fires. One ex- 
uisher is fixed in place and is provided for 
section of the engine compartment. The other 
nguisher is a portable bottle-type. 

NOTE 

Fire extinguisher to be weighed every 12 months 
with a maximum allowable loss of 10%. 

1. Removal 

r er to figure 5-1 to remove the fire extinguish- 
cylinders and to figure 5-2 to remove the 



J. Installation 

tall the fire extinguisher and lines in the re- 
se order of removal (para 5-2). 



1. REMOVE 

CONNECTION. 



2. BACK OFF NUTS 2 
1C LOOSEN CLAMP 




V4. REMOVE EXTINGUISHER. 
[TS003051 



Figure 5-1. Fire extinguisher removal. 



5-1 



TM 5-1940-221-12 



17 



16 




TS003052 



1. Screw 

2. Nut 

3. Washer 

4. Bracket 

5. Nozzle 

6. Grommet 



7. Pipe 

8. Elbow 

9. Screw 

10. Nut 

11. Screw 

12. Nut 



13. Washer 

14. Clamp 

15. Pipe 

16. Elbow 

17. Pipe 

18. Tank and valve assembly 



Figure 5-2. Fire extinguisher lines and fittings. 



5-2 



Section 11. ELECTRIC BILGE PUMP 



I. General 

i electric bilge pump is mounted in the bilge 
"he engine compartment just forward of the 
bulkhead. The pump is connected by a hose 

thru-hull fitting on the port side of the hull. 

pump is actuated by the BILGE PUMP 
ch on the switch panel. A description of the 
tp is given in paragraph 1-5. 

I. Removal 

Turn off the MASTER switch. 

Refer to figure 5-3 and remove the pump. 

>. Inspection 

, Check all parts for breaks, cracks, or other 

lage. 

. Check wiring and connections for condition 

security of fittings. 

7 . Installation 

;all the pump in the reverse order of removal. 



2. REMOVE SCREW (4) 
AND WASHERS (4). 



3. REMOVE PUMP 
AND BRACKET. 




Figwe 5-3. Electric bilge pump removal. 



Section ill. MANUAL SILGE PUMP 



I. General 

nanual bilge pump is mounted at the rear of 
cargo well (fig. 1-1). The pump is hand- 
rated piston-type, the outlet of which is con- 
ted by a rubber hose to a thru-hull fitting 
bhe port side. 

9. Removal 

fer to figure 5-4 and remove the pump. 

10. Disassembly 

i. Unscrew strainer (5, fig. 5-5) and nipple 

!. 

!>. Unscrew the piston assembly (7) from the 
)e (21) at the cap (15) and remove the piston 
sembly (7), the gasket (8), and the valve 
(9). 



c. Unscrew the valve washer (8), from the rod 
8) and remove the valve (10), cup (11), 
isher (12), pin (13), and collar (14). 

d. Remove the cap (15) from the rod (18), 
id remove the nut (17), and packing (16), 
om the cap (15). 

e. Remove the plug (19) and connection (20) 
om the tube (21). 



5-1 1 . Inspection and Repair 

a. Check all parts for cracks, breaks, distor- 
tion, and other damage. 

6. Replace any defective part. 

512. Reassembly 

a. Install the connection (20, fig. 5-5) and 
plug (19) on the tube (21). 

6. Install the nut (17), packing (16), cap 
(15), on the rod (18). 

c. Install the nut (17), and packing (16) in 
the cap (15) . Do not tighten nut. 

d. Install the collar (14), pin (13), washer 
(12), and cup (11), on the rod (18) and secure 
them to the rod with the valve seat (10) . 

e. Install the valve washer (9), gasket (8), 
and piston assembly (7), into the tube (21) and 
secure it by screwing it in at the cap (15). In- 
stall nipple (6), and strainer (5), on connection 
(20). 

5-13. Installation 

Refer to figure 5-4 and install the pump in re- 
verse order of removal. 



5-3 



TM 5-1940-221-12 



1. LOOSEN CLAMP AND 
REMOVE HOSE. 




2. REMOVE SCREWS (4), NUTS (4), 
AND WASHERS (4). 



TS003054 



Figure 5-4. Manual bilge pump removal. 



5-4 






L Screw 4. Bracket 

J. Nut 5. Strainer 

3. Washer 6. Nipple 



7. Piston assembly 

8. Gasket 

9. Washer, valve 



10. Valve seat 

11. Cup 

12. Washer 



13. Pin 

14. Collar 

15. Cap 



Figure 5-5. Manual bilge -pump, exploded view. 



TS003055 



16. Packing 19. Plug 

17. Nut 20. Connection 

18. Rod 21. Tube 



5-5 



im 



APPENDIX A 
REFERENCES 



Fire Protection 

B 5-4200-200-10 

Lubrication 

9100-IL 

5-1940-221-12 

Radio Suppression 

'M 11-483 

Maintenance 

M 9-213 
'B 750-651 

W 38-750 

:M 5-1940-221-34 



Hand Portable Fire Extinguishers Approved for Army Users 



Identification List for Fuels, Lubricants, Oils and Waxes End Item LO 

also. 
Lubrication Order 



Radio Interference Suppression 



Painting Instructions for Field Use 

Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling 

System. 

The Army Maintenance Management System 
Direct and General Support Maintenance 



"M 5-1940-221-20P Organizational Repair Parts and Special Tools List for 27-Foot Bridge 

Erection Boat. 

Direct and General Support Repair Parts and Special Tools List for 27- 
Foot Bridge Erection Boat 

Operation and Organizational, Field, and Depot Maintenance: Storage 
Batteries, Lead-Acid Type. 

Equipment Near Electric Power Lines 



?M 5-1940-221-34P 
?M 9-6140-200-14 
PB 385-101 



Shipment and Storage 

FM 740-90-1 Administrative Storage of USAMEC Mechanical Equipment 

CB 740-93-4 Preservation of Vessels for Storage 

Radioactive Material 

IB 750-248 Instructions for Safe Handling, Maintenance, Storage, and Disposal of 

Radioactive Commodities Managed by U. S. Army Mobility Equipment 
Command 

, Destruction to Prevent Enemy Use 

TM 750-244-3 Procedures for Destruction of Equipment to Prevent Enemy Use 



A-l 



APPENDIX C 

BASIC ISSUE ITEM LIST AND ITEMS 
TROOP INSTALLED OR AUTHORIZED 



Section I. INTRODUCTION 



. Scope 

3 appendix lists basic issue items, items troop 
ailed or authorized which accompany the 
Ige erection boat and required by the crew/ 
rator for operation, installation, or operator's 
ntenance. 

L General 

i basic issue items, items troop installed or 

horized list is divided into the following sec- 

is: 

;. Basic Issue Items List Section II. (Not ap- 

jable). 

>. Items Troop Installed or Authorized List 

>,tion III. A list, in alphabetical sequence of 

us which at the descretion of the unit com- 

nder may accompany the end item, but are 

)T subject to be turned in with the end item. 

3. Explanation f Columns 
.e following provides an explanation of col- 
ins in the tabular list of Basic Issue Items 
st, Section II, and Items Troop Installed or 
ithorized, Section III. 

a. Source, Maintenance, and Recoverability 
>de(s) (SMR): 

(1) Source code indicates the source for the 
jted item. Source codes are: 

h Explanation 

Repair parts, special tools and test equipment 
supplied from GSA/DSA or Army supply system 
and authorized for use at indicated maintenance 
levels. 

'2 Repair parts, special tools and test equipment which 
are procured and stocked for insurance purposes 
because the combat or military essentiality of the 
end item dictates that a minimum quantity be 
available in the supply system. 



(2) Maintenance code indicates the lowest 
level of maintenance authorized to install the 
listed item. The maintenance level code is: 

Code Explanation 

C Crew/Operator 

(3) Recoverability code indicates whether 
unserviceable items should be returned for re- 
covery or salvage. Items not coded are nonrecov- 
erable. Recoverability codes are: 

Code Explanation 

R Applied to repair parts (assemblies and compo- 
nents), special tools and test equipment which are 
considered economically reparable at direct and 
general support maintenance levels. 

S Repair parts, special tools, test equipment and as- 
semblies -which are economically reparable at DSU 
and GSU activities and which normally are furn- 
ished by supply on an exchange basis. 

b. Federal Stock Number. This column indi- 
cates the Federal stock number assigned to the 
item and will be used for requisitioning pur- 
poses. 

c. Description. This column indicates the Fed- 
eral item name and any additional description of 
the item required. 

d. Unit of Measure (U/M). A two-character 
alphabetic abbreviation indicating the amount or 
quantity of the item upon which the allowances 
are based, e.g., ft, ea, pr, etc. 

e. Quantity Furnished With Equipment (BIIL 
only). This column indicates the quantity of an 
item furnished with the equipment. 

/. Quantity Authorized (Items Troop InstaUed 
or Authorized Only). This column indicates the 
quantity of the item authorized to be used with 
the equipment. 

C-l 



TM 5-1940-221-12 



Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST 



Federal 
stock 


Description 


U/M 


Qty 

auth 


4320-775-3793 


Pump Reciprocating, Hand Oil 13213E5470 (97403) 


EA 


1 


4210-270-4512 


Extinguisher, Fire 02910 (81349) 


EA 


1 


2090-997-6049 


Cover, Cargo Well 13213E5374 (97403) 


EA 


1 




Pole Cover 13213E5376 (97403) 


EA 


1 


2030-997-6041 


Line, Steering 13213E5510 (97403) 


EA 


2 


2030-033-4735 


Line, Mooring 13213E5511 (9740<3) 


EA 


4 


2040-997-6047 


Anchor and Anchor Line Assembly 13216E9929 


EA 


1 


2040-007-1136 


Hook, Boat 13216E9929 (97403) 


EA 


1 


2040-997-6048 


Cover, Cockpit 13213E5375 (97403) 


EA 


1 


4220-275-3156 


King, Buoy 13213E5468 (97403) 


EA 


a 



C-2 



INDEX 



panel 

IA 

strative storage L ~~* 

c drain , 4-21 

it down valve housing and blower screen 4-20 

incer ^""19 

4-46 

oupling 4-83 

B 

issue items list C-l 

ies and cables 453 

y charging generator 4-49 

pump, electric 54, 55, 

5-6, 5-7 
>ump, manual 5-8, 5-9, 

5-10 

ow towing 4-43 

tern towing- 4-81 

r screen, air shut-down housing and 420 

rame assembly maintenance 4-74 

latch cover . 4-77 

ght 4-58 

>wing bitt _.__ 4-80 

C 

, batteries and 4-53 

,, engine control 4-15 

\, transmission control 4-69 

base haul 4-82 

operation in extreme 214 

>1 cables, engine 4-15 

)1 cables, transmission 4-&5 

jl head 4-16 

>ls and instruments 2-5 

i.t tank (expansion tank) 4-44 

-, engine lubricating oil 437 

, transmission oil 4-36 

ig system maintenance 4-41, 4-42 

ing arm 4-83 

ing hook 4-85 

.ng, launching and 2-2 

jig, propeller shaft 4-73 

ing yoke 4-84 

, bow hatch 4-77 

, engine hatch 4-75 

, stern hatch 4-76 

, valve rocker 4r-22 

ring motor (starter) 4-51 

ring switch, magnetic 4-52 

D 

iption , 1-5 _ 

led lubrication information : Section I. 

antling for movement 2-4 



4-65 
1-1 
4-21 
4-21 
4-19 
4-39 
4-67 



4-67 

C-l 

4-48 

4-43 

5-3 

5-3 

4-36 
4-66 
4-20 
4-64 
4-65 
4-53 
4-66 



4-48 
4-16 
4-63 
4-67 
2-14 
4-16 
4-60 
4-17 
2-2 
4-37 
4-52 
4-30 
4-35 
4-67 
4-68 
2-1 
4-64 
4-68 
4-65 
4-64 
4-65 
4-22 



4-47 



1-1 



1-1 



TM 5-1940-221-12 

^ . . , _ 4-21 

Dram, air box . _ 

Drive, tachometer ~" 4-16 



Electric bilge pump f"*' f"? S-8 

56, 57 

Electrical system maintenance 4 ~ 48 4-43 

Element, lubricating oil filter 4 ~ 35 4-30 

Element replacement, fuel filter 4 ~ 27 4-24 

Element replacement, fuel strainer ^"25 4_24 

Engine control cables ^~~^ 4-16 

Engine hatch covers 4 ~'' r 5 4-64 

Engine lubricating oil change ^-SS 4-29 

Engine lubricating oil cooler 4 ~39 4_32 

Engine lubrication system 4-32 4_29 

Engine maintenance 4-12 4_lg 

Equipment, inspecting the 2-J. 2-1 

Equipment, operation of 2-8 2-7 

Equipment, special tools and 4-3 4_1 

Errors, reporting of '13 1-1 

Exhaust manifold 4-39 4-32 

Exhaust piping, mufflers and 4-40 4-33 

Exhaust system maintenance ; 4-38 4-3-2 

Expansion tank 4-44 4-37 

F 

Filter element, lubricating oil 4-35 4-30 

Filter element replacement, fuel 4-27 4-24 

Filter, fuel 4-26 4-24 

Filter, lubricating oil 4-34 4-29 

Fire extinguisher 5-1, 5-2, 5-1 

5-3 

Forms and records 1-2 1-1 

Fuel filter 4-26 4-24 

Fuel filter element replacement 4-27 4-24 

Fuel lines and fittings 4_,30 4_26 

Fuel pump 4_2g 4-25 

Fuel shut-off valve 4_29 4-25 

Fuel strainer 4_24 4-23 

Fuel strainer element replacement 4-25 4-24 

Fuel system maintenance __ 4-23 4-23 

Fuel tank IIII_I~I"I~III~I_I~II~I 4-31 4-26 

Fuse panel 4_ 55 4_ 5 1 

Fuses 4_ 55 4 _ 51 

G 

Gear box, lower 4_ 70 4_63 

Gear box, upper 

General lubrication information 

Generator 4 _ 49 4.43 

Generator regulator ^gQ 4_44 

H 

Handling tows _ _ 2_e 2-7 

Hatch cover, bow ~_IIII~I~IIII~III 4-77 4-65 

Hatch covers, engine __ ~ _ 4 _ 7g 4_g4 

Hatch cover, stern I-I~~III~_II I 4-76 4-65 

Haul chock, base _ ^_ S2 4_ 67 

Heat, operation in extreme ~~~ ~~ ^_ 15 2-14 

Hook, coupling - _ _ . 

Housing, thermostat ~II~I~~II ~_ 4_45 



I 

Identification and tabulated data - j_l 

Inspecting- the equipment 1 2-1 

Instrument maintenance ~ ' ~ . 4_49 

1-2 



trument panel components 4-54 

truments, controls and 2-5 

J 

nts, steering gear universal 4-68 

K 
ses, push 4-27 

L 

inching and coupling 2-2 

ht, bow 4-58 

ht, range (stern light) 4-59 

ht, spot - 4-60 

hts, running 457 

es and fittings, fuel 4-30 

per gear box 470 

iricating oil filter 4->34 

wieating oil filter element 4-35 

irication information, detailed Section I 

xrication information, general Section I 

irication system, engine 4-32 

M 

gnetic cranking switch 4-52 

intenance (see specific items) 

intenance allocation chart B-l 

intenance checks and services, preventive, operator's Section II 

intenance checks and services, preventive, organizational 4-5 

intenance repair parts 4_4 

nifold, exhaust 4_39 

nual bilge pump 5-8, 5_g } 

5-10 

tor, cranking (-starter) 4-51 

cement, dismantling for 2-4 

cement, reinstallation after 2-4 

fflers and exhaust piping 4_40 

O 

change, engine lubricating 4-33 

change, transmission 4-62 

cooler, engine lubricating 4_37 

cooler, transmission 436 

filter, lubricating 4-34 

strainer, transmission 4-63 

iration of equipment (handling tows) 2-8 

jration of material used in conjunction with the bridge erection boat 2-9 

oration in extreme cold . 2-14 

jration in extreme heat 2-15 

oration in salt water 2-16 

iratdon under usual conditions 26, 2-7 

P 

lei, access . 4-78 

lei, fuse 4-55 

tel, instrument 4-54 

lei, switch 4-56 

table fire extinguisher description 2-10 

sventive maintenance checks and services, operator's 4-4 

iventive maintenance checks and services, organizational 4-5 

>peller and shaft maintenance 4-72 

ipeller shaft coupling 4-73 

np, electric bilge 5-4, 5-5, 

5-6, 5-7 



4-49 
2-2 



4-62 



4-24 



2-1 
4-53 
4-53 
4-53 
4-53 
4-26 
4-63 
4-29 
4-30 
3-1 
3-1 
4-29 



4-47 

B-l 
3-1 
4-1 
4-1 
4-32 
5-3 

4-46 
2-2 
2-2 

4-33 



4-29 
4-60 
4-32 
4-30 
4-29 
4-60 

2-7 
2-13 
2-14 
2-14 
2-15 

2-7 



4-65 

4-51 

4-49 

4-51 

2-13 

4-1 

4-1 

4-64 

4-64 

5-3 



t 



TM 5-1 940-22 1-T 2 

Pump, fuel 4-29 4_ 25 

Pump, manual bilge 5-8, 5-9 g^g 

5-10- 4| 

Pump, water 4-43 4_ S6 

Push knees 4-79 4 _g 6 w 

Q 

Quarterly preventive maintenance checks and services 4-6 4_^ 

R 

Radio interference suppression 48 4_I5 

tadio interference suppression components 410 4-15 

Radio interference suppression definitions 4-9 

Radio interference suppression components, replacement of 411 

Radio interference suppression components, testing of 4-11 

Range light (stern light) 4-60 4_ 53 

Records, forms and . 1-2 i -t 

Regulator, generator 4-50 4.44 

Reinstallation after movement 2-4 2_ 2 

Repair parts, maintenance 4-4 4_^ 

Reporting of errors 1-3 ., _* 

Rocker cover, valve 4-22 4_2o 

Rod, steering gear transverse 4-71 4_ g3 

Running lights 4_57 

S 

Saltwater, operation in '2-16 

Scope of manual ^ 

Screen, blower 4 _ 2 . ~ 

Sen-icing "__ 2 _ 8 ^ 

Shaft coupling, propeller 4 _ 73 . . . 

Shield, V-belt t-17 til 

Shut-down valve housing, air _ _ 4_ 2 r> 

Silencer, air _ 

Solenoid, cranking (magnetic cranking switch) 4 _ 52 ~ - 

Special tools and equipment _ _ . 

Spotlight "" ~_ t~f *- 1 

spotlight iiiiiiinrv/ TTir~rrrri 2 ~i 4 

Starter (cranking motor) _ _~_ ~__ . C1 4 ~ 53 

Starting " 4 ~ 51 4 ~ 46 

Steering gear lower gear box ^ !__!""""" ~ 

Steering gear upper gear box 

Steering gear transverse rod I_II__ LI~__~_m~_ II ~I Jl?? 4 ~ 63 

Steering gear universal joints III I__I_~_~_"I _"~~_~_~~ llll 4 ~ 63 

Steering system maintenance I~I~_~_ A R R ^~^ 

Steering wheel ~~ __ I 4 ~ 66 

Stern hatch cover I "I_I _I_~ ~_ I ~ 4 ~ 67 

Stern towing bitt _ _ "_ 4 ~ 76 4 ~ 65 

Stopping IIIIIIIIIIIIIII I 4 ~ 81 4 ~ 66 

Storage, administrative "_ I 2 ~ 7 2 ~ 7 

Strainer element replacement, fuel ~_~I~I ! ~ 6 1 ~ 1 

Strainer, fuel ~ 4 ~ 25 

Strainer, transmission oil ~~II~I 4 ~ 24 

Switch, magnetic cranking _ _ _ ~_ 4 ~ 63 4 ~ 60 

Switch panel I_"I I 4-52 4-47 

Switches _ _ 4 ~56 4-51 

4-56 4-51 

T 
Tabulated data, identification and 

Tachometer drive ~ i- 8 1~ 13 

Tank, expansion ~_~~_ 4-13 4-16 

Thermostat and housing __IIIIIIII~~I ~~~ 4 ~ 44 4 ~ 37 

Throttle quadrant (control head) __ II_IIIIIIH II I 4 ~ 45 4 ~ 37 

Tools and equipment, special ~ 4 ~ 16 4-17 

1-4 



wing bitt, bow * 4- 80 

wing bitt, stern ~ 4-81 

ansmission maintenance 4-61, 4-62, 

4-66 

'ansmission oil change 4-62 

ansmission oil cooler 4-36 

ansmission oil 'strainer , 463 

ansverse rod, 'steering gear 4-71 

oubleshooting, operator's Section III 

oubleshooting, organizational 4-7 

U 

liversal joints, steering gear 4-68 

jper gear box 469 

V 

belts 4-18 

belt shield 4-17 

live, fuel shut-off 4-30 

live rocker cover , 422 

Dltage regulator (generator regulator) 4-50 

W 

ater pump ____ __ 443 

r ater tank (expansion tank) 444 

'heel, steering 4-66 

Y 

oke coupling 4-84 




4-62 
4-63 



4-18 
4-18 
4-26 
4-22 
4-44 



4-36 

4-37 
4-62 



4-68 



TM 5-1940-221-12 



rder of the Secretary of the Army: 

CREIGHTON W. ABRAMS, 
General, United States Army, 
ial: Chief of Staff. 

NE L. BOWERS 

r General, United States Army, 

Adjutant General. 

ibution: 

Fo be distributed in accordance with DA Form 12-25D (qty rqr block No. 61) operator mainte- 
j requirements for Boat Bridge Erection. 



&U.S. GOVERNMENT PRINTING OFFICE: I9W - 242^51/05004