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Pages B-l through B-10, Appendix B, Section I through IM is superseded by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
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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