Army Preventive Watercraft Maintenance
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* TB 55-1900-202-12/1 TECHNICAL BULLETIN
WATERCRAFT PREVENTIVE MAINTENANCE
Approved for public release; distribution is unlimited.
* This TB supersedes TB 55-1900-202-12/1, 28 August 1988, including all changes.
DEPARTMENT OF THE ARMY 9 January 1992
* TB 55-1900-202-12/1
TECHNICAL BULLETIN
HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C., 9 January 1992
No 55-1900-202-12/1
WATERCRAFT PREVENTIVE MAINTENANCE
Approved for public release; distribution is unlimited.
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication If you find any m stakes or if you know of a way to improve the procedures, please let us know Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this publication directly to: US Army Troop Support Command, ATTN AMSTR-MMTS, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798 A reply will be furnished directly to you.
TABLE OF CONTENTS Section
I.
II.
III.
IV.
GENERAL Paragraph Purpose ...................................................................................................... 1 Scope ......................................................................................................... 2 Preventive maintenance ............................................................................ 3 Records and reports ................................................................................... 4 WATERCRAFT PREVENTIVE MAINTENANCE SYSTEM Role of operating personnel ....................................................................... 5 Scheduled preventive maintenance ........................................................... 6 DAILY SERVICE Before operation service ............................................................................ 7 During operation service ............................................................................ 8 After operation service ............................................................................... 9 Servicing procedures ................................................................................. 10 SCHEDULED MAINTENANCE SERVICES General....................................................................................................... 11 Basic instructions ....................................................................................... 12 Specific procedures ................................................................................... 13
* This TB supersedes TB 55-1900-202-12/1, 28 August 1988, including all changes.
i/(ii blank)
Page 1 1 1 1 1 2 2 2 2 2 7 7 7
TB 55-1900-202-12/1 Section I. GENERAL c. Because of the variety of types of propulsion units and auxiliary equipment and sizes and types of watercraft, the procedures outlined are general in nature.
1. Purpose. This bulletin provides minimum preventive maintenance procedures required for Army watercraft and is to be used in conjunction with records and reports required by DA PAM 738750. Preventive maintenance requirements are separated into daily services and scheduled weekly (50 hour), monthly (200 hour), and semiannual (1200 hour) services and technical inspections.
3. Preventive Maintenance. The purpose of preventive maintenance is to detect and correct incipient electrical and mechanical failures before they occur to preclude expensive, time-consuming repairs or replacement and/or deadlining of equipment. The Army system of preventive maintenance is based upon frequent inspections and services performed by the watercraft crew and organizational maintenance personnel.
2. Scope. a. The provisions of this bulletin are applicable to all U.S. Army water craft for which no Department of the Army organizational maintenance manuals have been published. It will be used pending publication of official organizational maintenance manuals for specific watercraft equipment.
4. Records and Reports. The requirements of DA PAM 738-750 for recording and reporting maintenance activities will be followed.
b. Where specific manuals exist and their provisions conflict with instructions herein, the provisions of the technical manuals will take precedence in all cases.
Section II. WATERCRAFT PREVENTIVE MAINTENANCE SYSTEM b. To effect and maintain good preventive maintenance, operating personnel must become thoroughly familiar with the service items for which they are responsible and with procedures for performing established periodic services. 6. Scheduled Preventive Maintenance.
5. Role of Operating Personnel. a. The most important single factor in effective preventive maintenance is the watercraft operating personnel. Crew members are responsible for keeping their craft in first-class operating condition by regularly scheduled inspections and prompt correction or reporting of discrepancies or failures found. Their responsibilities require the following actions:
a. Preventive maintenance can be effective only when it is properly scheduled and rigidly controlled. The principal criterion for frequency of scheduled services is hours of operation of equipment concerned. However, certain periodic maintenance services must be performed on watercraft and on some items of equipment even though they may not be operated for extended periods of time. This is particularly true in the case of large watercraft since much of the equipment aboard is in operation daily even though it does not leave the wharf.
(1) Inspecting and servicing the craft as prescribed in sections III and IV. (2) Making repairs and adjustments within the limits of authorized maintenance allocations. (3) Promptly reporting defects beyond their capabilities to the maintenance officer.
1
TB 55-1900-202-12/1 d. Required painting will follow the provisions of TB 43-0144, painting of watercraft.
b. To insure that periodic maintenance is performed on all watercraft equipment, whether or not it is actually operated, the interval shown in table 1 will be observed in average or normal situations. The services will be conducted as specified in sections III and IV. Operation under adverse conditions may require more frequent preventive maintenance services, and watercraft masters/chief engineer or unit commanders are authorized to reduce these intervals as environmental or operational conditions dictate.
Table 1. Preventive Maintenance Intervals Service Daily......
Weekly......
c. Monthly, semiannual, and annual services will be scheduled for continuous performance throughout the period so that no large number of watercraft in the same unit will be out of use at the same time. Normally, 5 percent of an organization's watercraft should be scheduled to receive the monthly service every day and 5 percent to receive the semiannual every week.
Monthly......
Semiannual
Annual......
Interval Every day, before during, and after operation. Every week or after 50 hours of operation, whichever occurs first Every month or after 200 hours of operation, whichever occurs first. Every 6 months or after 1200 hours of operation, whichever occurs first. Yearly or after 2400 hours of operation, whichever occurs first.
Accomplished by Crew
Crew under supervision of section leader or chief engineer. Crew assisted by unit maintenance personnel.
Unit maintenance per sonnel assisted by the crew. Unit maintenance per sonnel assisted by the crew.
Section III. DAILY SERVICES 7. Before-Operations Service. The beforeoperation service (B, col. 1, table 2) will be performed each day to insure that the watercraft is ready in every respect for operation. Minor deficiencies found during services and inspections prescribed will be corrected on the spot, and results of the services reported immediately upon completion to the chief engineer or other individual responsible for watercraft maintenance. Before-operation service should never be omitted, even in extreme tactical situations.
3, table 2). Any deficiencies noted during operation are 2 corrected, and the watercraft are readied for the next day's operation. This service will be performed after each use of the watercraft, even in extreme tactical situations. Those units requiring inspection or service while at operating temperature will be attended to as soon as possible after operations cease. Upon completion of after-operation services, results will be reported promptly to the chief engineer or the maintenance officer.
8. During-Operation Service. This service is a check of the watercraft's condition and performance while it is underway (D, col. 2, table 2). Every operation of each item of equipment aboard and its control devices will be tested. All crew members will be alert for signs of trouble such as leaks, rattles, knocks, squeals, hums, or unusual noise or odors; they will closely watch all instruments for indication of improper functioning. If serious trouble develops the engine will be stopped immediately, after notification to the bridge or wheelhouse.
10. Servicing Procedures. Specific procedures for servicing are listed and described in table 2. This tabulation is a general guide only and instructions provided are the minimum required. Additional services may be prescribed by the major command concerned. If technical manuals have been published which describe the system, they should be used whenever specific information about the system is required. The results of all inspections, deficiencies, and corrective actions must be entered on DA form 2404 (Equipment Inspection and Maintenance Worksheet). All corrected faults will be recorded on DA form 55-40 (Deck Department Log) and DA form 5544 (Engine Department Log).
9. After-Operation Service. This service is the basic daily preventive service for watercraft (A, col.
2
TB 55-1900-202-12/1 Table 2. Daily Preventive Maintenance Services B-Before
NO.
B
1
·
2
·
D
INSTRUCTIONS A
·
·
·
·
4
·
·
5
·
·
·
6
· · ·
7
·
· ·
8
A-After
INTERVAL
ITEM
3
D-During
· ·
·
·
Tampering and Damage Inspect for injury or damage to craft, special equipment, or armament. Open engine compartments doors and check for signs of tampering, loosened or damaged accessories, and drive belts Inspect bilge for presence of fuel, oil, or excessive water. Inspect exterior hull for damage. Fire Extinguishers Inspect for tight mountings, full charge, corroded nozzles, and closed valves Pay particular attention to extinguisher lines and nozzles m the engine compartment, checking for damage and correct aiming. See that entire system is m good condition and securely mounted If the red blow-off seal on the extinguisher valve head is blown, or if the extinguisher has been used, report it for refill or replacement Be sure the nozzles are cleaned of obstructions, dirt, and corrosion First Aid Kits, Life Preservers and Life Rafts Check the first aid kit for condition, for shortages and damaged items; replace f necessary See that all life preservers are properly stowed, marked, Coast Guard approved, and in good condition Inspect life raft seals, hydrostatic release and canisters for cracks, damage or broken seals also inspect for proper mounting and securing of canisters General Appearance Inspect glass frames, and brackets for damage, clean the conning tower, wheelhouse, and all door glass Check condition of windshield wipers to see that they operate properly Inspect light lenses and reflectors for cleanliness and damage Inspect entire watercraft for cleanliness. Inspect hull and superstructure carefully for leaks, damage, or loose parts Swab decks and clean bulkheads and bilges Clean glass and polish brightwork as necessary Fuel, Oil and Water Check the amount of fuel in the tanks and spare fuel cans, noting any indications of leaks or tampering; add fuel as necessary. Check oil level, and add oil if necessary; check level and condition of coolant Perform hydrometer test and add antifreeze if necessary. Check circulation of fresh and salt water. Check fuel supply at each regular interval. Check crankcase oil level or lube tank while engine is shut down and add oil to proper level if necessary. Remove expansion water tank filler cap. If a pressure cap is used, be careful of escaping steam. Check coolant to see that it is at the proper level and replenish if necessary Fill fuel tanks, observing safety precautions for grounding static electricity, and bring engine oil to proper level. Refill spare fuel, oil and water cans. If an unusual amount of oil is required, check for leaks. On small craft, check coolant level and replenish if necessary If a large amount of coolant is required, check for leaks. After refilling, test quality of antifreeze with a hydrometer. Accessories and Connections Inspect engine generators, superchargers, fuel injection pump, engine fans, and cooling water pump for loose or damaged connections and mountings. See that above accessories are secure, functioning properly, and that drives and drive belts are properly adjusted and not damaged. Inspect all accessories for loose connections, mountings, and lubrication. Inspect adjustment of drive belts and examine for presence of oil, fraying, wear, or cracking. Tighten or adjust any loose connections, linkage, or mountings. Check accessory drive shafts, couplings, or universal joints to see that they are secure and not leaking or damaged. Auxiliary Equipment Inspect all auxiliary equipment, including winches, motors, auxiliary generators, air compressors, refrigeration units, ventilating units, and fresh and salt water pumps for proper condition and safe operation. See that all mountings, drives, locking devices, and accessories are secure and properly lubricated. See that auxiliary equipment is functioning properly. Check especially for excessive vibration, unusual noise or odor, and leaks. At any sign of trouble, shut off equipment and correct or report the problem Recheck auxiliary equipment for lubrication, adjustment, and alignment in accordance with watercraft or equipment manual Investigate and correct any deficiency noted during operation. Clean equipment and lubricate m accordance with pertinent lubrication order. Tighten loose mountings and connections. Open air tank petcocks on air compressor and dram condensation. Leaks Inspect engine compartment and interior of hull for leaks. Check crankcase, oiltanks, oil coolers, filters, and lines for signs of leaks. Check entire cooling system, particularly at hose connections. Trace all leaks to their source and correct, report and enter on DA 2404 and log book. Inspect hydrostarter for leaks at control valve, pipe fittings, and line connections. See that sufficient oil is in reservoir after accumulator is charged and that pump is bypassing oil to reservoir Before starting engine, open ventilators or hatches to be sure that hull compartments (particularly engine compartments) are clear of fuel leaks and fumes. If watercraft is equipped with exhaust blowers operate them for at least 5 minutes before starting engines.
3
TB 55-1900-202-12/1 Table 2. Daily Preventive Maintenance Services B-Before INTERVAL
ITEM NO.
B
9
·
10
·
D
INSTRUCTIONS
·
·
11
·
·
·
·
·
·
· ·
· ·
·
·
·
·
·
13 ·
·
·
·
·
·
·
·
14
15
A-After
A
·
12
D-During
·
·
Air Cleaners Check to see that oil m cleaners is at proper level and is clean. If excessively dirty, clean element and refill with fresh oil To keep dirt out of engine, air cleaners and breather caps must be kept clean and properly serviced at all times. Filters and Strainers Fuel oil strainer. Check for leaks. Turn handle on fuel oil strainer one complete turn. If fuel tank is above the fuel oil strainer, close shutoff valve in fuel line. Remove plug and dram the bowl. Replace drain plug, tighten securely, reopen shutoff valve, and see that no oil is leaking from dram plug. Replace fuel element in accordance with equipment manual. Oil filter. Do not wash oil filter bags for reuse. Replace filter m accordance with appropriate lube order or watercraft manual Water strainer. Inspect and clean strainers, screens, and bypasses. Note condition of mesh and replace if defective. Start Control Start engine and note action of starter mechanism, particularly for adequate cranking speed and whether it engages and disengages properly without unusual noise when control is operated. Set engine throttle to run at normal warmup speed (see engine manual) until prescribed operating temperature is reached. If oil pressure gage does not indicate proper reading (as specified m engine manual) within 30 seconds, stop engine and correct trouble or report it to chief engineer, master, or maintenance officer. During warmup period proceed with remainder of beforeoperation switches Instruments Oil pressure gage or light indicator. Inspect gage to see that It indicates properly or that light indicator goes out as soon as engine reaches idling speed. If these instruments do not indicate properly, notify the bridge or wheelhouse, stop engine Immediately, investigate cause, and report to chief engineer or master. Ammeter or light indicator. The ammeter should show a high charging rate for first few minutes after starting until generator restores current used m starting It should then register zero or slight positive charge with lights off and engine operating at fast idle Investigate any unusual fall or rise in reading A high charge reading for an extended period may indicate a dangerously low battery or a faulty generator regulator. The light indicator should go out when engine runs at fast idle with lights off. Tachometer. See that tachometer Is operating properly and indicating engine revolutions. If a revolution counter has been installed, it should register accumulating revolutions. Fuel gage. See that gage is operating properly Air pressure gage. During warmup period air pressure should build up at a normal rate to specified maximum limit, and the unloader should stop compressing action when this limit is reached. With engine at idling speed, reduce air pressure several times by bleeding the system to see if compressor cuts in within specified limits each time, and if low-pressure indicator signals properly each time pressure is reduced Allow pressure to buildup again and see that indicator stops at correct pressure. Voltmeter. Check for proper operation. Voltmeter should register at least the nominal battery voltage- usually indicated by a red line on face of instrument. Temperature gage. Engine temperature should increase gradually during warmup period In case of extremely high reading, notify the bridge or wheelhouse, bring the engine to idle immediately and investigate the trouble. Immediately report abnormally low temperature readings to the chief engineer, master, or maintenance officer. Be sure that all instruments are securely mounted, properly connected, and undamaged. Investigate and correct deficiencies noted during operation. Steering Gear and linkage Inspect steering gear and linkage to see that it is in proper condition for safe operation Be particularly alert for bent or loose parts m the steering arms and linkage. Examine steering control mechanism, arms, and linkage for damage and looseness; investigate any irregularities Investigate and correct all deficiencies as soon as possible. Cargo and Tarps Check cargo to see that it is evenly distributed, secure, and that it has not shifted while watercraft was underway. Check tarps for rips, holes, and for missing or worn grommets and lines. See that tarps not m use are properly stowed and secured. Lamps and Running Lights See that all lights operate properly while operating the switches m the ON and OFF positions. Inspect all lenses for damage and to see that they are clean and free of water and corrosion. Towing Connections Inspect towing hooks, capstans, safety chains, and cables for looseness and damage. See that mounting and locking devices are secure and report all deficiencies.
16
4
TB 55-1900-202-12/1 Table 2. Daily Preventive Maintenance Services B-Before
INSTRUCTIONS
NO.
B
17
·
·
18
·
·
19
·
·
20
·
·
·
·
D
A
·
21 ·
·
·
·
22
·
· ·
· 24 25
· ·
· ·
· ·
· 26
A-After
INTERVAL
ITEM
23
D-During
Tools, Spare Parts, and Equipment Check against watercraft, stowage plan to see that all tools, spare parts, and equipment belonging to the watercraft are on hand, clean, serviceable, and properly mounted or stowed; clean off rust, mud, or dirt. Report missing or unserviceable items to chief engineer and vessel master. Electrical Wiring Inspect electrical wiring see that it is securely connected, clean, and undamaged. Check all accessible wiring, fuse terminal blocks, and connections to see that they are securely connected and supported, that insulation is not cracked or chafed, and that the conduit and shielding are secure and in good condition Lubrication (General) Lubricate all items requiring daily lubrication prescribed m pertinent lubrication orders. Lubricate shackles, steering linkage, hinges, latches, auxiliary equipment, accessories, and other points if inspection indicates that It is necessary In unusual operating conditions (extreme heat or dampness) most Items will require more frequent lubrication than specified for normal conditions Inspect drives, transfer units, and gearcases for lubricant level and leaks Refer to watercraft lube order manual for correct lubricant level and type Batteries Inspect batteries to see that they are clean, secure, and are not leaking Check electrolyte level and add distilled water If necessary. Clean and properly fasten cables and vent caps If operating test reveals that battery is too low to start engine, charge battery immediately. Take reading of each cell to determine condition of battery Do not continue to run battery down and do not force solenoid contacts closed. Wipe off dirt from top of battery If terminal connections or posts are corroded, clean them thoroughly and apply a thin coating of grease. Tighten loose terminal bolts. Engine Operation and Condition Be alert for deficiencies m engine performance, such as lack of usual power, misfiring, unusual noise, stalling, indications of engine overheating, unusual exhaust smoke or temperatures, and Improper lubricating oil pressure or temperature. See that engine idles satisfactorily Accelerate and decelerate and note any tendency to muss or backfire, or any unusual engine noise or vibration that might indicate worn parts, loose mountings, incorrect fuel mixture, or faulty ignition. Correct and report all unsatisfactory engine operation conditions to chief engineer or vessel master. Clean exterior of engine and dry thoroughly. Do not use waste or linty rags Hot water and soap not harmful to insulation should be used Clean engine room. Engine Controls and Drives Notice whether engine responds to controls satisfactorily and whether controls are in proper adjustment See that clutch does not grab, chatter, or squeal during engagement, or slip when fully engaged. Clutch lever must have satisfactory free travel, as specified m appropriate technical manual, before it begins to disengage clutch. Otherwise, the clutch may slip when under a load. Too much free travel, however, may keep clutch from disengaging fully and cause gear teeth to clash and become damaged On multiple engine installations, all transmissions should be synchronized to operate simultaneously. Inspect drives and gearcases for overheating or excessive oil leaks. Check for worn or disconnected linkage and report any unsatisfactory conditions noted during operation. Propeller and Rudder Listen for unusual noise from shafts, stuffing tubes and supporting bearings. Inspect for looseness, damage, oil and water leaks, and foreign material Check particularly for excessive leakage from stuffing boxes Check level and condition of lubricant and renew if necessary. Inspect propeller shaft and rudder for loose connections and damage, paying particular attention to loose mountings, blocked vents, and lube level. Propeller cannot be inspected m the water unless it is done by a diver Check for vibration that could be caused by bent propellor, shaft or rudders. Bilge Pump Inspect condition, lubrication, and working operation of bilge pump, paying particular attention to screens, strainers, stuffing boxes, and drives. Look for loose pump connections, water leaks, and damage, paying particular attention to mounting and drive. Clean and service pump assembly m accordance with lubrication order. Check valves, drive, strainers, and lubricants for proper operating conditions Ramp Operation See that ramp winch and winch cable are free and sufficiently coated with grease. Check cable for signs of fraying and wear Check sheaves and fair-leads for condition and lubrication Inspect that the ramp hooks and latches hold ramp securely m place, and that ramp hinges are securely fastened to hull and ramp. Operate ramp winch, engine, or motor and check for unusual noises or signs of binding. See that ramp controls operate properly
5
TB 55-1900-202-12/1 Table 2. Daily Preventive Maintenance Services B-Before
D-During
INTERVAL
ITEM
INSTRUCTIONS
NO.
B
26
·
·
27
·
·
D
A-After
A Check operation of ramp-operating mechanism and controls. See that ramp drains are clear and that all water has drained off. Lubricate in accordance with lube order. Deck Machinery See that power units and moving parts of capstans, windlasses, and winches are properly lubricated, securely mounted, properly alined, and in good condition. See that clutches move freely to both engaged and disengaged positions and that they latch securely. Examine drag brake and automatic brake linings. See that cables are in good condition and evenly wound, and that cable chains and hooks are securely attached. Check oil level in gearcases. Consult manufacturer's instructions for all adjustments and settings.
6
TB 55-1900-202-12/1 Section IV. SCHEDULED MAINTENANCE SERVICES Table 3. Scheduled Maintenance Services
11. General. Regularly scheduled maintenance inspections and services are a preventive maintenance function and are the responsibility of commanders of operating organizations. Intervals given in table I for such services are considered to be the minimum required for normal operations of watercraft equipment, under unusual operating conditions it may be necessary to perform them more frequently. 12. Basic Instructions. a. Defects discovered during scheduled inspections will be corrected on the spot. Those that cannot be corrected will be reported immediately to the chief engineer or the maintenance officer and recorded on DA form 2404. b. Particular attention will be directed to installation tolerances, wear limits, and adjustments. Detailed maintenance procedures are specified in applicable manufacturers' manuals and pertinent technical manuals (where available). These instructions should be studied prior to performing necessary maintenance. c. The highest degree of cleanliness must be maintained in handling engine parts to avoid mechanical failures later. Defective parts discovered during routine cleaning will be repaired or replaced immediately. d. All required tools and repair parts should be available before starting the maintenance operation so that nothing will interfere with successful and timely completion of the work. e. Preventive maintenance services will be performed without disassembling units, unless prescribed in procedures or equipment manuals. Disassembly will always follow instructions provided in applicable procedures or manuals. When it becomes necessary to disassemble a unit, any special services indicated for semiannual (1200 hour) maintenance should be performed. f. Every effort must be made to complete entire services scheduled in one operation. However, when conditions make it impossible to do this, the service may be conducted in segments Efforts will be made to complete all operations within the specified week, if possible, and available time must be used to this end. 13. Specific Procedures. a. Specific procedures for scheduled maintenance services are listed in table 3. As in table 2, the procedures given are for the minimum service required for each phase and additional steps may be prescribed by the major command concerned. b. Instructions are given for the 50-, 200-, and 1200hour services only. The 2400-hour or annual service will follow procedures established for the 1200-hour service. Annual technical inspections constitute a check for adequacy of maintenance performed during the shorter interval services.
50
1
200
1
1,200
1
1
2
3
4
4
4 4
4
5
6
6
6
6
7
Instructions Mountings and Vibration Dampers Inspect outside of engine for loose nuts, bolts, and clamps. Inspect rubber mounts for damage, deterioration and free of fuel and lube oil Check general condition of metal spring mounts, especially for damage and rust. Inspect engine mounting for proper seating and adjustment; check alinement of engine and propeller shaft Inspect flexible exhaust joints for cracks, damage, deterioration, leaks and damaged gaskets Compression Test Test compression in each cylinder and record readings in engineer's log book. Cylinder Head and Liners Remove cylinder heads, clean carbon deposits, and recondition valve seats. Check for pits and cracks in accordance with manufacturers instructions. Measure cylinder liners for wear, and inspect for cracks and corrosion. Valves and Tappets Gage valve tappet clearances and check for broken valve springs and stems. Adjust clearances if necessary. With cylinder heads removed, inspect valve stems, valve stem guides, and springs. Inspect intake and exhaust valves for cracks, pitting, and warping. Recondition or replace valves and seats as necessary to obtain a proper seal. Inspect, clean, and set all cylinder relief valves to correct opening pressure. Be sure that cylinder relief valves are not locked. Pistons Inspect pistons for carbon deposits, cracks, pits, and scoring Inspect rings. Fuel Pump, Filters, Strainers, And Lines Inspect fuel pumps, filters, strainers and fuel lines for leaks and damage. Drain condensation from filters, strainers, and sediment bowls. Test fuel pump pressure in accordance with specifications in manufacturer's manual. See that all linkages and connections and secure.
TM 55-1900-202-12/1 50
200
1,200
7
7
7
8
8
8
8
9
9
9
10
11
9
9
10
10
10
10
11
11
Instructions Lubricating Oil Filters and Strainers Service oil filters and strainers in accordance with applicable lube order Cooling Water Pump and Sea Strainers See that pump and drive belts are in good condition and properly adjusted. Check pump for leaks. Examine shaft for end play and loose bearings. See that valve control linkage is properly connected to valves and that It operates them freely. See that pump lines and strainers are m good condition, properly mounted, and secure Clean strainers. Securely tighten all pump mounting and assembly bolts. Tightening packing nuts will not score shafts. If the packing is too tight then it can cause damage to shaft. Inspect pump and packing gland for corrosion and see that pulleys are properly alined. Battery Charging System Inspect ammeter, wiring, and all electrical connections to see that they are properly connected, clean, and secure. See that generator is mounted securely. Lubricate in accordance with pertinent lube order. Inspect brushes and replace if worn one-half or more of their original length. Clean commutator with a piece of canvas. If necessary to smooth rough spots, the commutator should be dressed with a dressing stone If a stone is not available then use strip of very fine sandpaper placed over a wooden block and press against commutator with engine running. Blow out dust with low-pressure dry compressed air. The belt tension should be checked for 1/2 inch or less of deflection. Voltage Regulator See that regulator is operating properly, is securely mounted, and that all electrical connections are secure. Bring regulator unit to operating temperature and check with low voltage circuit tests per instructions in watercraft manual or those which accompany test instrument. Replace regulator unit if test indicates faulty operation. Starting Motor Start engine and see that general action of the starter is satisfactory, that it engages and operates properly without excessive noise, and that it has adequate cranking speed. See that starter is in good condition and securely mounted, and that all connections are tight Lubricate in accordance with lube order instructions.
50
200 11
1,200 11
12
12
12
13
13
13
14
14
14
15
16
16
16
17
17
17
17
17
17
18
18
18
18
18
18
8
Instructions Remove commutator inspection plate and inspect commutator to see that it is clean and in good condition. See that brushes are clean and free in brush holders, that brush connections are secure, and that wires are not broken or chafed. Replace brushes if they have worn to one-half their original length. Clean commutator end of starter with a dressing stone and blow off dust with low-pressure dry compressed air. Tighten starter mounting bolts securely. Bilge Pumps See that all drive belts, pulleys, shafts, and couplings are in good condition, correctly assembled, and secure; that belts are not oil-soaked, frayed, or bottoming in drive pulleys. Adjust belts according to instructions and specifications in the craft manual, locking all adjustment devices securely. See that drive shaft universal joints are not excessively worn or loose. All defective bolts should be replaced. General Lubrication Check to see that all items have been lubricated in accordance with lube orders. Inspect lube oil system for leaks. Fuel System Inspect entire fuel system for leaks and drain condensation from pressure and day tanks. Service as prescribed in applicable technical manual and lubrication orders. Fuel Injectors Test nozzles, valves, and injectors in accordance with manufacturer's instructions. Governor Check lube oil level m governor where applicable, and add oil If necessary. Check operation of overspeed governor Inspect governor linkage for loose or worn parts or binding. Lubricate linkage with light oil and correct any deficiencies in accordance with manufacturer's instructions Lube Oil System. Check entire lube oil system for leaks. Make spot checks of various items lubricated by the system to see that they are receiving sufficient oil in accordance with manufacturer's instructions. Service system as prescribed by engine manual and applicable lube order. Heat Exchanger See that hose and cap are in good condition, correctly assembled, securely mounted, and not leaking. See that pressure relief valve operates freely and is in correct position for prevailing atmospheric pressure. Clean cooling system if it is contaminated with rust or other foreign material in accordance with manufacturer's instructions. Tighten loose mountings, plates, and clamps. Clean heat exchanger with specified cleaner and inspect for leaks. See that core and zinc plates are in good condition
TM 55-1900-202-12/1 50
200
1,200
19
19
19
19
20
20
20
20
20
21
21
21
22
22
22
22
23
22
23
23
23
23
Instructions Fresh Water Expansion Tank Check cooling water level and quality of antifreeze and refill if necessary. Inspect tank and cooling passages for leaks Remove and clean strainer basket on seawater strainer Drain and clean expansion tank with specified cleaner. Flush cleaner from entire cooling system with clean water Refill, adding antifreeze If necessary Tighten loose mountings, plates, and clamps. Air Intake and Exhaust System Check exhaust piping and mufflers for condition and mounting. Check for carbon streaks and other indications of exhaust leaks. Be sure drain holes in mufflers are not clogged Tighten mounting bolts and connections. See that manifolds and gaskets are in good condition, secure, and not leaking. Empty carbon collector on exhaust silencer Remove hand hole cover over inlet pipe and scrape slot m silencer inlet pipe Remove, clean, and oil air intake silencer and allow to dram before replacing Check exhaust temperatures in accordance with manufacturer's instructions. Batteries Inspect and service lead-acid storage batteries regularly as prescribed by TM 96140-200-4 lead acid storage batteries Auxiliary Generators (DC/AC) Start generator to see whether it starts easily and runs at normal speed. Listen for any unusual noise that might indicate worn, loose, or inadequately lubricated parts. Lubricate m accordance with lube order. DC Generators Only Remove brush head cover plate and check commutator to see that It is in good condition, clean, and not excessively worn. Clean commutator with a piece of canvas or, if necessary to remove rough spots, a dressing stone. If a stone is not available then use a strip of very fine sandpaper, and blow off dust with low-pressure dry air. Renew brushes if worn to one-half their original length. Inspect control panel, instruments, gages, and wiring for insecure mounting and damage. Air Compressor See that air compressor Is properly mounted and correctly alined with its drive pulleys. Check pipeline connections for air leakage by soaping the joints. Lubricate in accordance with lube order. Isolate portions of system to see that valves will hold proper pressure. Check valve disks for Improper seating and listen for air leaks. Regrind or replace valves If necessary in accordance with manufacturer's instructions. Renew gaskets, and take up packing glands.
50
200
1,200 23
24
24
24
25
25
25
25 26
27
9
27
27
27
27
28
28
28
29
29
29
Instructions Clean out all ports and passages. Drain crankcase and clean out sludge Renew crankcase oil. Wash out cylinder water jackets with fresh water. Adjust unloader valve clearances to manufacturer's specifications. Air Starting System Check system for leaks, damaged lines, and connections. See that system operates properly to deliver adequate cranking speed. Drain dirt and water from air tanks. Inspect air starting valves and springs, air start check valve for leakage and satisfactory operation. Report deficiencies found to chief engineer and vessel master and enter on daily 2404. Clutches and Couplings Test clutch lever for satisfactory free travel (in accordance with equipment manual) before beginning to engage or disengage clutch. See that It releases clutch completely before lever has completed its stroke. Listen for unusual noises m release mechanism that may indicate defective clutch plate or pilot bearings, or dry or defective release bearings. Check for indications of clutch stoppage and see that all linkage is properly adjusted. Lubricate clutch mechanism and connections m accordance with lube order, paying particular attention to the throwout bearing and pilot bearings. Check all lines and connections on hydraulic, pneumatic, and vacuum clutches for leakage. Clean and inspect hydraulic couplings Reduction Gears Inspect reduction gears for overheating or unusual noises and other signs of wear Service in accordance with lube order instructions Reverse Gears Operate engine in both forward and reverse positions to see that fuel cutoff is automatic when stopping and reversing. Check automatic braking of the engine, valve operation, interlocking reverse-cycle sequence, pneumatic and manual speed regulation, and maneuvering controls for proper functioning. Check reverse gear adjustment according to manufacturer's instructions. Shafting and Stuffing Boxes See that stuffing boxes are not running hot and are not leaking. Check hose connection between propeller shaft tunnel and stuffing box for leakage. Some craft are designed such that snuff boxes have a slow drip. Check in accordance with manufacturer's instructions. Check to see that stuffing box bearings are receiving adequate water or oil lubrication. Instruments and Gages Check ammeter, voltmeter, water pressure gage, oil pressure gage, air pressure gage, oil temperature gage, water temperature gage, tachometer,
TM 55-1900-202-12/1 50
30
200
1,200
30
30
30
30
31
31
31
32
32
32
33
33
33
33
34
35
36
34
34
34
34
35
35
36
36
Instructions revolution counter, hour meter, fuel gage and any other installed gages to see that they are in proper working order and that they indicate within normal ranges specified m pertinent equipment manuals. Investigate all abnormal readings. Steering Gear Test helm for minimum free play specified in manufacturer's manual. Rotate helm fully m both directions and note any indication of binding or bumping. Lubricate steering control linkages according to lube order instructions. Check position of rudder with helm positions and see that rudder and helm movements correspond. Sanitary Water System Check water pump, storage and pressure tanks, piping, and outlets for leaks. See that disposal pipes are not clogged. Examine water pump in accordance with instructions in item 8. Fresh Water System Same as sanitary water system above. Fire and Bilge System Fire and bilge pumps should be operated and tested weekly Check piping for leaks and see that outlets are not clogged See that tanks and valves feeding the system are in good condition and securely mounted See that control cables and handles are in good condition and free to operate on short notice. See that all hues and nozzles are clean and securely connected. Apply a few drops of engine oil to pulleys and guides through which control cables operate, and tighten all assembly mounting bolts and screws. Ventilating System Check all fans, blowers, filters, dampers, ducts, and mechanical exhausts to see that they are in good condition, secure, and m satisfactory working order. Lubricate all parts requiring lubrication m accordance with lube orders or manufacturer's instructions. Determine that the ventilation in messrooms, galleys, living spaces, and cargo compartments is adequate. Remove and clean all filter elements. Tap glass-wool filters lightly to remove dust, and wash in an approved grease- and soot-cutting solution. Blow dry with compressed air. Heating System Make a periodic check of the heating system, and service in accordance with manufacturer's instructions for the particular type of heating system installed. Automatic Alarm System See that panel box, delay and alarm relay, thermostat, terminal block, electric horn, and horn-silencing switches are properly mounted and connected, and in good
50
200
1,200
37
37
37
37
37
37
38
38
38
38
working order. See that green light is lit at all times when engine is running; if it is out, check bulb, fuses, and throttle switch connections. Test operation of the system in Instructions accordance with manufacturer's instructions. See that throttle switch is in STOP position when engine is not running and that it is closed when engine is in operation. See that adjustment screws on oil pressure and water pressure contacts are adjusted to open and close at pressure specified by the manufacturer. Refrigeration Units Check refrigeration temperature gauges. Frozen foods should be stored at temperatures between 0 and -10 degrees F. -5 degrees F is desirable. Vegetable and dairy products should be stored at temperatures between 35-40 degrees F. Inspect drives, controls, and valves to see that they are in good condition and correctly assembled. Check for indications of excessively worn, loose, or improperly lubricated parts. Inspect controls, regulating and expansion valves, diaphragms, and tubes for serviceability. See that supply of refrigerant is adequate. Tighten all mountings, braces, and connections. Examine for oil, water, and refrigerant leakage. Check for refrigerant shortage, add if necessary. Check oil in circulating system and lubricate according to lube order or manufacturer's instructions. See that expansion valves are properly regulated, and replace excessively worn valves Clean water condenser tubes. Deck Machinery See that power units and moving parts of capstans, windlasses, and winches are properly lubricated, securely mounted, properly aimed, and in good condition. See that clutches move freely to both engaged and disengaged positions and that they latch securely. Examine drag brake and automatic brake linings. See that cables are in good condition, evenly wound, and properly lubricated, and that cable chain and hooks are securely attached. Check oil level in gearcases. Start all units to insure that they are m proper operating condition. Consult manufacturer's instructions for all adjustments and settings. Service m accordance with lube order. Unwind cables and inspect for broken or frayed strands and for flat or rust spots. Clean entire length of cables with a cloth saturated with solvent. Change cables end-for-end and rewind on drums evenly, applying a thin film of cable oil in the process
10
TM 55-1900-202-12/1 50
39
200
39
1,200
39
Instructions On some craft cables cannot be changed end-for-end. On these craft, change cables in accordance with manufacturer's instructions. Tools and Spare Parts Check to see that all authorized tools and spare parts are aboard and in serviceable condition. See that all tool mounting brackets and straps are properly mounted
40
40
40
41
41
41
and that tools with cutting edges are sharp. See that all tools and equipment not in use are treated with an approved rust preventive compound. Tools and spare parts shortages or those m an unserviceable condition should be replaced immediately Paint and Markings See that engine is clean externally. Scrape and wire brush rust spots, and touchup with paint; avoid excessive painting. Check all engine room markings and identification plates to see they are legible, correct, and properly mounted Painting of U S Army watercraft is done m accordance with TB-43-0144. Ramp Operation See that ramp winch and winch cable are free and sufficiently coated with grease Check cable for signs of fraying and wear Inspect condition and lubrication of sheaves and fair-leads. See that ramp hooks and latches hold ramp securely in place and that ramp hinges are securely fastened to hull and ramp. Operate ramp winch, engine, or motor, checking of unusual noises or signs of binding. See that ramp controls operate properly and that ramp drains are clear. Lubricate ramp operating mechanism and linkages in accordance with lube order.
11
TM 55-1900-202-12/1 B
D
A
Instructions
1
......
Inspect for injury etc. etc.
2
......
Inspect for tight mountings etc. etc. ......
See that entire system etc. etc.
3
......
......
Check the first ad kit etc. etc.
4
......
.
Inspect glass, frames, etc. etc
...... 5
......
Check the amount of fuel etc. etc.
......
Check circulation of fresh etc. etc. ......
6
Inspect hull and superstructure etc. etc.
Fill fuel tanks, etc. etc.
......
Inspect engine generators etc. etc.
......
See that above accessories etc. etc. ......
Inspect all accessories for loose etc. etc.
12
The Metric System and Equivalents Linear Measure
Liquid Measure
1 centimeter = 10 millimeters = .39 inch 1 decimeter = 10 centimeters = 3.94 inches 1 meter = 10 decimeters = 39.37 inches 1 dekameter = 10 meters = 32.8 feet 1 hectometer = 10 dekameters = 328.08 feet 1 kilometer = 10 hectometers = 3,280.8 feet
1 centiliter = 10 milliters = .34 fl. ounce 1 deciliter = 10 centiliters = 3.38 fl. ounces 1 liter = 10 deciliters = 33.81 fl. ounces 1 dekaliter = 10 liters = 2.64 gallons 1 hectoliter = 10 dekaliters = 26.42 gallons 1 kiloliter = 10 hectoliters = 264.18 gallons Square Measure
Weights 1 sq. centimeter = 100 sq. millimeters = .155 sq. inch 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq.
1 centigram = 10 milligrams = .15 grain 1 decigram = 10 centigrams = 1.54 grains feet 1 gram = 10 decigram = .035 ounce 1 decagram = 10 grams = .35 ounce acres 1 hectogram = 10 decagrams = 3.52 ounces 1 kilogram = 10 hectograms = 2.2 pounds 1 quintal = 100 kilograms = 220.46 pounds 1 metric ton = 10 quintals = 1.1 short tons
1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile Cubic Measure 1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch 1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches 1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate Conversion Factors To change inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons pound-feet pound-inches
To
Multiply by
centimeters 2.540 meters .305 meters .914 kilometers 1.609 square centimeters 6.451 square meters .093 square meters .836 square kilometers 2.590 square hectometers .405 cubic meters .028 cubic meters .765 milliliters 29,573 liters .473 liters .946 liters 3.785 grams 28.349 kilograms .454 metric tons .907 Newton-meters 1.356 Newton-meters .11296
To change ounce-inches centimeters meters meters kilometers square centimeters square meters square meters square kilometers square hectometers cubic meters cubic meters milliliters liters liters liters grams kilograms metric tons
To Newton-meters inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons
Temperature (Exact) °F
Fahrenheit temperature
5/9 (after subtracting 32)
Celsius °C temperature
Multiply by .007062 .394 3.280 1.094 .621 .155 10.764 1.196 .386 2.471 35.315 1.308 .034 2.113 1.057 .264 .035 2.205 1.102
PIN: 013221-000
WATERCRAFT PREVENTIVE MAINTENANCE
Approved for public release; distribution is unlimited.
* This TB supersedes TB 55-1900-202-12/1, 28 August 1988, including all changes.
DEPARTMENT OF THE ARMY 9 January 1992
* TB 55-1900-202-12/1
TECHNICAL BULLETIN
HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C., 9 January 1992
No 55-1900-202-12/1
WATERCRAFT PREVENTIVE MAINTENANCE
Approved for public release; distribution is unlimited.
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication If you find any m stakes or if you know of a way to improve the procedures, please let us know Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this publication directly to: US Army Troop Support Command, ATTN AMSTR-MMTS, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798 A reply will be furnished directly to you.
TABLE OF CONTENTS Section
I.
II.
III.
IV.
GENERAL Paragraph Purpose ...................................................................................................... 1 Scope ......................................................................................................... 2 Preventive maintenance ............................................................................ 3 Records and reports ................................................................................... 4 WATERCRAFT PREVENTIVE MAINTENANCE SYSTEM Role of operating personnel ....................................................................... 5 Scheduled preventive maintenance ........................................................... 6 DAILY SERVICE Before operation service ............................................................................ 7 During operation service ............................................................................ 8 After operation service ............................................................................... 9 Servicing procedures ................................................................................. 10 SCHEDULED MAINTENANCE SERVICES General....................................................................................................... 11 Basic instructions ....................................................................................... 12 Specific procedures ................................................................................... 13
* This TB supersedes TB 55-1900-202-12/1, 28 August 1988, including all changes.
i/(ii blank)
Page 1 1 1 1 1 2 2 2 2 2 7 7 7
TB 55-1900-202-12/1 Section I. GENERAL c. Because of the variety of types of propulsion units and auxiliary equipment and sizes and types of watercraft, the procedures outlined are general in nature.
1. Purpose. This bulletin provides minimum preventive maintenance procedures required for Army watercraft and is to be used in conjunction with records and reports required by DA PAM 738750. Preventive maintenance requirements are separated into daily services and scheduled weekly (50 hour), monthly (200 hour), and semiannual (1200 hour) services and technical inspections.
3. Preventive Maintenance. The purpose of preventive maintenance is to detect and correct incipient electrical and mechanical failures before they occur to preclude expensive, time-consuming repairs or replacement and/or deadlining of equipment. The Army system of preventive maintenance is based upon frequent inspections and services performed by the watercraft crew and organizational maintenance personnel.
2. Scope. a. The provisions of this bulletin are applicable to all U.S. Army water craft for which no Department of the Army organizational maintenance manuals have been published. It will be used pending publication of official organizational maintenance manuals for specific watercraft equipment.
4. Records and Reports. The requirements of DA PAM 738-750 for recording and reporting maintenance activities will be followed.
b. Where specific manuals exist and their provisions conflict with instructions herein, the provisions of the technical manuals will take precedence in all cases.
Section II. WATERCRAFT PREVENTIVE MAINTENANCE SYSTEM b. To effect and maintain good preventive maintenance, operating personnel must become thoroughly familiar with the service items for which they are responsible and with procedures for performing established periodic services. 6. Scheduled Preventive Maintenance.
5. Role of Operating Personnel. a. The most important single factor in effective preventive maintenance is the watercraft operating personnel. Crew members are responsible for keeping their craft in first-class operating condition by regularly scheduled inspections and prompt correction or reporting of discrepancies or failures found. Their responsibilities require the following actions:
a. Preventive maintenance can be effective only when it is properly scheduled and rigidly controlled. The principal criterion for frequency of scheduled services is hours of operation of equipment concerned. However, certain periodic maintenance services must be performed on watercraft and on some items of equipment even though they may not be operated for extended periods of time. This is particularly true in the case of large watercraft since much of the equipment aboard is in operation daily even though it does not leave the wharf.
(1) Inspecting and servicing the craft as prescribed in sections III and IV. (2) Making repairs and adjustments within the limits of authorized maintenance allocations. (3) Promptly reporting defects beyond their capabilities to the maintenance officer.
1
TB 55-1900-202-12/1 d. Required painting will follow the provisions of TB 43-0144, painting of watercraft.
b. To insure that periodic maintenance is performed on all watercraft equipment, whether or not it is actually operated, the interval shown in table 1 will be observed in average or normal situations. The services will be conducted as specified in sections III and IV. Operation under adverse conditions may require more frequent preventive maintenance services, and watercraft masters/chief engineer or unit commanders are authorized to reduce these intervals as environmental or operational conditions dictate.
Table 1. Preventive Maintenance Intervals Service Daily......
Weekly......
c. Monthly, semiannual, and annual services will be scheduled for continuous performance throughout the period so that no large number of watercraft in the same unit will be out of use at the same time. Normally, 5 percent of an organization's watercraft should be scheduled to receive the monthly service every day and 5 percent to receive the semiannual every week.
Monthly......
Semiannual
Annual......
Interval Every day, before during, and after operation. Every week or after 50 hours of operation, whichever occurs first Every month or after 200 hours of operation, whichever occurs first. Every 6 months or after 1200 hours of operation, whichever occurs first. Yearly or after 2400 hours of operation, whichever occurs first.
Accomplished by Crew
Crew under supervision of section leader or chief engineer. Crew assisted by unit maintenance personnel.
Unit maintenance per sonnel assisted by the crew. Unit maintenance per sonnel assisted by the crew.
Section III. DAILY SERVICES 7. Before-Operations Service. The beforeoperation service (B, col. 1, table 2) will be performed each day to insure that the watercraft is ready in every respect for operation. Minor deficiencies found during services and inspections prescribed will be corrected on the spot, and results of the services reported immediately upon completion to the chief engineer or other individual responsible for watercraft maintenance. Before-operation service should never be omitted, even in extreme tactical situations.
3, table 2). Any deficiencies noted during operation are 2 corrected, and the watercraft are readied for the next day's operation. This service will be performed after each use of the watercraft, even in extreme tactical situations. Those units requiring inspection or service while at operating temperature will be attended to as soon as possible after operations cease. Upon completion of after-operation services, results will be reported promptly to the chief engineer or the maintenance officer.
8. During-Operation Service. This service is a check of the watercraft's condition and performance while it is underway (D, col. 2, table 2). Every operation of each item of equipment aboard and its control devices will be tested. All crew members will be alert for signs of trouble such as leaks, rattles, knocks, squeals, hums, or unusual noise or odors; they will closely watch all instruments for indication of improper functioning. If serious trouble develops the engine will be stopped immediately, after notification to the bridge or wheelhouse.
10. Servicing Procedures. Specific procedures for servicing are listed and described in table 2. This tabulation is a general guide only and instructions provided are the minimum required. Additional services may be prescribed by the major command concerned. If technical manuals have been published which describe the system, they should be used whenever specific information about the system is required. The results of all inspections, deficiencies, and corrective actions must be entered on DA form 2404 (Equipment Inspection and Maintenance Worksheet). All corrected faults will be recorded on DA form 55-40 (Deck Department Log) and DA form 5544 (Engine Department Log).
9. After-Operation Service. This service is the basic daily preventive service for watercraft (A, col.
2
TB 55-1900-202-12/1 Table 2. Daily Preventive Maintenance Services B-Before
NO.
B
1
·
2
·
D
INSTRUCTIONS A
·
·
·
·
4
·
·
5
·
·
·
6
· · ·
7
·
· ·
8
A-After
INTERVAL
ITEM
3
D-During
· ·
·
·
Tampering and Damage Inspect for injury or damage to craft, special equipment, or armament. Open engine compartments doors and check for signs of tampering, loosened or damaged accessories, and drive belts Inspect bilge for presence of fuel, oil, or excessive water. Inspect exterior hull for damage. Fire Extinguishers Inspect for tight mountings, full charge, corroded nozzles, and closed valves Pay particular attention to extinguisher lines and nozzles m the engine compartment, checking for damage and correct aiming. See that entire system is m good condition and securely mounted If the red blow-off seal on the extinguisher valve head is blown, or if the extinguisher has been used, report it for refill or replacement Be sure the nozzles are cleaned of obstructions, dirt, and corrosion First Aid Kits, Life Preservers and Life Rafts Check the first aid kit for condition, for shortages and damaged items; replace f necessary See that all life preservers are properly stowed, marked, Coast Guard approved, and in good condition Inspect life raft seals, hydrostatic release and canisters for cracks, damage or broken seals also inspect for proper mounting and securing of canisters General Appearance Inspect glass frames, and brackets for damage, clean the conning tower, wheelhouse, and all door glass Check condition of windshield wipers to see that they operate properly Inspect light lenses and reflectors for cleanliness and damage Inspect entire watercraft for cleanliness. Inspect hull and superstructure carefully for leaks, damage, or loose parts Swab decks and clean bulkheads and bilges Clean glass and polish brightwork as necessary Fuel, Oil and Water Check the amount of fuel in the tanks and spare fuel cans, noting any indications of leaks or tampering; add fuel as necessary. Check oil level, and add oil if necessary; check level and condition of coolant Perform hydrometer test and add antifreeze if necessary. Check circulation of fresh and salt water. Check fuel supply at each regular interval. Check crankcase oil level or lube tank while engine is shut down and add oil to proper level if necessary. Remove expansion water tank filler cap. If a pressure cap is used, be careful of escaping steam. Check coolant to see that it is at the proper level and replenish if necessary Fill fuel tanks, observing safety precautions for grounding static electricity, and bring engine oil to proper level. Refill spare fuel, oil and water cans. If an unusual amount of oil is required, check for leaks. On small craft, check coolant level and replenish if necessary If a large amount of coolant is required, check for leaks. After refilling, test quality of antifreeze with a hydrometer. Accessories and Connections Inspect engine generators, superchargers, fuel injection pump, engine fans, and cooling water pump for loose or damaged connections and mountings. See that above accessories are secure, functioning properly, and that drives and drive belts are properly adjusted and not damaged. Inspect all accessories for loose connections, mountings, and lubrication. Inspect adjustment of drive belts and examine for presence of oil, fraying, wear, or cracking. Tighten or adjust any loose connections, linkage, or mountings. Check accessory drive shafts, couplings, or universal joints to see that they are secure and not leaking or damaged. Auxiliary Equipment Inspect all auxiliary equipment, including winches, motors, auxiliary generators, air compressors, refrigeration units, ventilating units, and fresh and salt water pumps for proper condition and safe operation. See that all mountings, drives, locking devices, and accessories are secure and properly lubricated. See that auxiliary equipment is functioning properly. Check especially for excessive vibration, unusual noise or odor, and leaks. At any sign of trouble, shut off equipment and correct or report the problem Recheck auxiliary equipment for lubrication, adjustment, and alignment in accordance with watercraft or equipment manual Investigate and correct any deficiency noted during operation. Clean equipment and lubricate m accordance with pertinent lubrication order. Tighten loose mountings and connections. Open air tank petcocks on air compressor and dram condensation. Leaks Inspect engine compartment and interior of hull for leaks. Check crankcase, oiltanks, oil coolers, filters, and lines for signs of leaks. Check entire cooling system, particularly at hose connections. Trace all leaks to their source and correct, report and enter on DA 2404 and log book. Inspect hydrostarter for leaks at control valve, pipe fittings, and line connections. See that sufficient oil is in reservoir after accumulator is charged and that pump is bypassing oil to reservoir Before starting engine, open ventilators or hatches to be sure that hull compartments (particularly engine compartments) are clear of fuel leaks and fumes. If watercraft is equipped with exhaust blowers operate them for at least 5 minutes before starting engines.
3
TB 55-1900-202-12/1 Table 2. Daily Preventive Maintenance Services B-Before INTERVAL
ITEM NO.
B
9
·
10
·
D
INSTRUCTIONS
·
·
11
·
·
·
·
·
·
· ·
· ·
·
·
·
·
·
13 ·
·
·
·
·
·
·
·
14
15
A-After
A
·
12
D-During
·
·
Air Cleaners Check to see that oil m cleaners is at proper level and is clean. If excessively dirty, clean element and refill with fresh oil To keep dirt out of engine, air cleaners and breather caps must be kept clean and properly serviced at all times. Filters and Strainers Fuel oil strainer. Check for leaks. Turn handle on fuel oil strainer one complete turn. If fuel tank is above the fuel oil strainer, close shutoff valve in fuel line. Remove plug and dram the bowl. Replace drain plug, tighten securely, reopen shutoff valve, and see that no oil is leaking from dram plug. Replace fuel element in accordance with equipment manual. Oil filter. Do not wash oil filter bags for reuse. Replace filter m accordance with appropriate lube order or watercraft manual Water strainer. Inspect and clean strainers, screens, and bypasses. Note condition of mesh and replace if defective. Start Control Start engine and note action of starter mechanism, particularly for adequate cranking speed and whether it engages and disengages properly without unusual noise when control is operated. Set engine throttle to run at normal warmup speed (see engine manual) until prescribed operating temperature is reached. If oil pressure gage does not indicate proper reading (as specified m engine manual) within 30 seconds, stop engine and correct trouble or report it to chief engineer, master, or maintenance officer. During warmup period proceed with remainder of beforeoperation switches Instruments Oil pressure gage or light indicator. Inspect gage to see that It indicates properly or that light indicator goes out as soon as engine reaches idling speed. If these instruments do not indicate properly, notify the bridge or wheelhouse, stop engine Immediately, investigate cause, and report to chief engineer or master. Ammeter or light indicator. The ammeter should show a high charging rate for first few minutes after starting until generator restores current used m starting It should then register zero or slight positive charge with lights off and engine operating at fast idle Investigate any unusual fall or rise in reading A high charge reading for an extended period may indicate a dangerously low battery or a faulty generator regulator. The light indicator should go out when engine runs at fast idle with lights off. Tachometer. See that tachometer Is operating properly and indicating engine revolutions. If a revolution counter has been installed, it should register accumulating revolutions. Fuel gage. See that gage is operating properly Air pressure gage. During warmup period air pressure should build up at a normal rate to specified maximum limit, and the unloader should stop compressing action when this limit is reached. With engine at idling speed, reduce air pressure several times by bleeding the system to see if compressor cuts in within specified limits each time, and if low-pressure indicator signals properly each time pressure is reduced Allow pressure to buildup again and see that indicator stops at correct pressure. Voltmeter. Check for proper operation. Voltmeter should register at least the nominal battery voltage- usually indicated by a red line on face of instrument. Temperature gage. Engine temperature should increase gradually during warmup period In case of extremely high reading, notify the bridge or wheelhouse, bring the engine to idle immediately and investigate the trouble. Immediately report abnormally low temperature readings to the chief engineer, master, or maintenance officer. Be sure that all instruments are securely mounted, properly connected, and undamaged. Investigate and correct deficiencies noted during operation. Steering Gear and linkage Inspect steering gear and linkage to see that it is in proper condition for safe operation Be particularly alert for bent or loose parts m the steering arms and linkage. Examine steering control mechanism, arms, and linkage for damage and looseness; investigate any irregularities Investigate and correct all deficiencies as soon as possible. Cargo and Tarps Check cargo to see that it is evenly distributed, secure, and that it has not shifted while watercraft was underway. Check tarps for rips, holes, and for missing or worn grommets and lines. See that tarps not m use are properly stowed and secured. Lamps and Running Lights See that all lights operate properly while operating the switches m the ON and OFF positions. Inspect all lenses for damage and to see that they are clean and free of water and corrosion. Towing Connections Inspect towing hooks, capstans, safety chains, and cables for looseness and damage. See that mounting and locking devices are secure and report all deficiencies.
16
4
TB 55-1900-202-12/1 Table 2. Daily Preventive Maintenance Services B-Before
INSTRUCTIONS
NO.
B
17
·
·
18
·
·
19
·
·
20
·
·
·
·
D
A
·
21 ·
·
·
·
22
·
· ·
· 24 25
· ·
· ·
· ·
· 26
A-After
INTERVAL
ITEM
23
D-During
Tools, Spare Parts, and Equipment Check against watercraft, stowage plan to see that all tools, spare parts, and equipment belonging to the watercraft are on hand, clean, serviceable, and properly mounted or stowed; clean off rust, mud, or dirt. Report missing or unserviceable items to chief engineer and vessel master. Electrical Wiring Inspect electrical wiring see that it is securely connected, clean, and undamaged. Check all accessible wiring, fuse terminal blocks, and connections to see that they are securely connected and supported, that insulation is not cracked or chafed, and that the conduit and shielding are secure and in good condition Lubrication (General) Lubricate all items requiring daily lubrication prescribed m pertinent lubrication orders. Lubricate shackles, steering linkage, hinges, latches, auxiliary equipment, accessories, and other points if inspection indicates that It is necessary In unusual operating conditions (extreme heat or dampness) most Items will require more frequent lubrication than specified for normal conditions Inspect drives, transfer units, and gearcases for lubricant level and leaks Refer to watercraft lube order manual for correct lubricant level and type Batteries Inspect batteries to see that they are clean, secure, and are not leaking Check electrolyte level and add distilled water If necessary. Clean and properly fasten cables and vent caps If operating test reveals that battery is too low to start engine, charge battery immediately. Take reading of each cell to determine condition of battery Do not continue to run battery down and do not force solenoid contacts closed. Wipe off dirt from top of battery If terminal connections or posts are corroded, clean them thoroughly and apply a thin coating of grease. Tighten loose terminal bolts. Engine Operation and Condition Be alert for deficiencies m engine performance, such as lack of usual power, misfiring, unusual noise, stalling, indications of engine overheating, unusual exhaust smoke or temperatures, and Improper lubricating oil pressure or temperature. See that engine idles satisfactorily Accelerate and decelerate and note any tendency to muss or backfire, or any unusual engine noise or vibration that might indicate worn parts, loose mountings, incorrect fuel mixture, or faulty ignition. Correct and report all unsatisfactory engine operation conditions to chief engineer or vessel master. Clean exterior of engine and dry thoroughly. Do not use waste or linty rags Hot water and soap not harmful to insulation should be used Clean engine room. Engine Controls and Drives Notice whether engine responds to controls satisfactorily and whether controls are in proper adjustment See that clutch does not grab, chatter, or squeal during engagement, or slip when fully engaged. Clutch lever must have satisfactory free travel, as specified m appropriate technical manual, before it begins to disengage clutch. Otherwise, the clutch may slip when under a load. Too much free travel, however, may keep clutch from disengaging fully and cause gear teeth to clash and become damaged On multiple engine installations, all transmissions should be synchronized to operate simultaneously. Inspect drives and gearcases for overheating or excessive oil leaks. Check for worn or disconnected linkage and report any unsatisfactory conditions noted during operation. Propeller and Rudder Listen for unusual noise from shafts, stuffing tubes and supporting bearings. Inspect for looseness, damage, oil and water leaks, and foreign material Check particularly for excessive leakage from stuffing boxes Check level and condition of lubricant and renew if necessary. Inspect propeller shaft and rudder for loose connections and damage, paying particular attention to loose mountings, blocked vents, and lube level. Propeller cannot be inspected m the water unless it is done by a diver Check for vibration that could be caused by bent propellor, shaft or rudders. Bilge Pump Inspect condition, lubrication, and working operation of bilge pump, paying particular attention to screens, strainers, stuffing boxes, and drives. Look for loose pump connections, water leaks, and damage, paying particular attention to mounting and drive. Clean and service pump assembly m accordance with lubrication order. Check valves, drive, strainers, and lubricants for proper operating conditions Ramp Operation See that ramp winch and winch cable are free and sufficiently coated with grease. Check cable for signs of fraying and wear Check sheaves and fair-leads for condition and lubrication Inspect that the ramp hooks and latches hold ramp securely m place, and that ramp hinges are securely fastened to hull and ramp. Operate ramp winch, engine, or motor and check for unusual noises or signs of binding. See that ramp controls operate properly
5
TB 55-1900-202-12/1 Table 2. Daily Preventive Maintenance Services B-Before
D-During
INTERVAL
ITEM
INSTRUCTIONS
NO.
B
26
·
·
27
·
·
D
A-After
A Check operation of ramp-operating mechanism and controls. See that ramp drains are clear and that all water has drained off. Lubricate in accordance with lube order. Deck Machinery See that power units and moving parts of capstans, windlasses, and winches are properly lubricated, securely mounted, properly alined, and in good condition. See that clutches move freely to both engaged and disengaged positions and that they latch securely. Examine drag brake and automatic brake linings. See that cables are in good condition and evenly wound, and that cable chains and hooks are securely attached. Check oil level in gearcases. Consult manufacturer's instructions for all adjustments and settings.
6
TB 55-1900-202-12/1 Section IV. SCHEDULED MAINTENANCE SERVICES Table 3. Scheduled Maintenance Services
11. General. Regularly scheduled maintenance inspections and services are a preventive maintenance function and are the responsibility of commanders of operating organizations. Intervals given in table I for such services are considered to be the minimum required for normal operations of watercraft equipment, under unusual operating conditions it may be necessary to perform them more frequently. 12. Basic Instructions. a. Defects discovered during scheduled inspections will be corrected on the spot. Those that cannot be corrected will be reported immediately to the chief engineer or the maintenance officer and recorded on DA form 2404. b. Particular attention will be directed to installation tolerances, wear limits, and adjustments. Detailed maintenance procedures are specified in applicable manufacturers' manuals and pertinent technical manuals (where available). These instructions should be studied prior to performing necessary maintenance. c. The highest degree of cleanliness must be maintained in handling engine parts to avoid mechanical failures later. Defective parts discovered during routine cleaning will be repaired or replaced immediately. d. All required tools and repair parts should be available before starting the maintenance operation so that nothing will interfere with successful and timely completion of the work. e. Preventive maintenance services will be performed without disassembling units, unless prescribed in procedures or equipment manuals. Disassembly will always follow instructions provided in applicable procedures or manuals. When it becomes necessary to disassemble a unit, any special services indicated for semiannual (1200 hour) maintenance should be performed. f. Every effort must be made to complete entire services scheduled in one operation. However, when conditions make it impossible to do this, the service may be conducted in segments Efforts will be made to complete all operations within the specified week, if possible, and available time must be used to this end. 13. Specific Procedures. a. Specific procedures for scheduled maintenance services are listed in table 3. As in table 2, the procedures given are for the minimum service required for each phase and additional steps may be prescribed by the major command concerned. b. Instructions are given for the 50-, 200-, and 1200hour services only. The 2400-hour or annual service will follow procedures established for the 1200-hour service. Annual technical inspections constitute a check for adequacy of maintenance performed during the shorter interval services.
50
1
200
1
1,200
1
1
2
3
4
4
4 4
4
5
6
6
6
6
7
Instructions Mountings and Vibration Dampers Inspect outside of engine for loose nuts, bolts, and clamps. Inspect rubber mounts for damage, deterioration and free of fuel and lube oil Check general condition of metal spring mounts, especially for damage and rust. Inspect engine mounting for proper seating and adjustment; check alinement of engine and propeller shaft Inspect flexible exhaust joints for cracks, damage, deterioration, leaks and damaged gaskets Compression Test Test compression in each cylinder and record readings in engineer's log book. Cylinder Head and Liners Remove cylinder heads, clean carbon deposits, and recondition valve seats. Check for pits and cracks in accordance with manufacturers instructions. Measure cylinder liners for wear, and inspect for cracks and corrosion. Valves and Tappets Gage valve tappet clearances and check for broken valve springs and stems. Adjust clearances if necessary. With cylinder heads removed, inspect valve stems, valve stem guides, and springs. Inspect intake and exhaust valves for cracks, pitting, and warping. Recondition or replace valves and seats as necessary to obtain a proper seal. Inspect, clean, and set all cylinder relief valves to correct opening pressure. Be sure that cylinder relief valves are not locked. Pistons Inspect pistons for carbon deposits, cracks, pits, and scoring Inspect rings. Fuel Pump, Filters, Strainers, And Lines Inspect fuel pumps, filters, strainers and fuel lines for leaks and damage. Drain condensation from filters, strainers, and sediment bowls. Test fuel pump pressure in accordance with specifications in manufacturer's manual. See that all linkages and connections and secure.
TM 55-1900-202-12/1 50
200
1,200
7
7
7
8
8
8
8
9
9
9
10
11
9
9
10
10
10
10
11
11
Instructions Lubricating Oil Filters and Strainers Service oil filters and strainers in accordance with applicable lube order Cooling Water Pump and Sea Strainers See that pump and drive belts are in good condition and properly adjusted. Check pump for leaks. Examine shaft for end play and loose bearings. See that valve control linkage is properly connected to valves and that It operates them freely. See that pump lines and strainers are m good condition, properly mounted, and secure Clean strainers. Securely tighten all pump mounting and assembly bolts. Tightening packing nuts will not score shafts. If the packing is too tight then it can cause damage to shaft. Inspect pump and packing gland for corrosion and see that pulleys are properly alined. Battery Charging System Inspect ammeter, wiring, and all electrical connections to see that they are properly connected, clean, and secure. See that generator is mounted securely. Lubricate in accordance with pertinent lube order. Inspect brushes and replace if worn one-half or more of their original length. Clean commutator with a piece of canvas. If necessary to smooth rough spots, the commutator should be dressed with a dressing stone If a stone is not available then use strip of very fine sandpaper placed over a wooden block and press against commutator with engine running. Blow out dust with low-pressure dry compressed air. The belt tension should be checked for 1/2 inch or less of deflection. Voltage Regulator See that regulator is operating properly, is securely mounted, and that all electrical connections are secure. Bring regulator unit to operating temperature and check with low voltage circuit tests per instructions in watercraft manual or those which accompany test instrument. Replace regulator unit if test indicates faulty operation. Starting Motor Start engine and see that general action of the starter is satisfactory, that it engages and operates properly without excessive noise, and that it has adequate cranking speed. See that starter is in good condition and securely mounted, and that all connections are tight Lubricate in accordance with lube order instructions.
50
200 11
1,200 11
12
12
12
13
13
13
14
14
14
15
16
16
16
17
17
17
17
17
17
18
18
18
18
18
18
8
Instructions Remove commutator inspection plate and inspect commutator to see that it is clean and in good condition. See that brushes are clean and free in brush holders, that brush connections are secure, and that wires are not broken or chafed. Replace brushes if they have worn to one-half their original length. Clean commutator end of starter with a dressing stone and blow off dust with low-pressure dry compressed air. Tighten starter mounting bolts securely. Bilge Pumps See that all drive belts, pulleys, shafts, and couplings are in good condition, correctly assembled, and secure; that belts are not oil-soaked, frayed, or bottoming in drive pulleys. Adjust belts according to instructions and specifications in the craft manual, locking all adjustment devices securely. See that drive shaft universal joints are not excessively worn or loose. All defective bolts should be replaced. General Lubrication Check to see that all items have been lubricated in accordance with lube orders. Inspect lube oil system for leaks. Fuel System Inspect entire fuel system for leaks and drain condensation from pressure and day tanks. Service as prescribed in applicable technical manual and lubrication orders. Fuel Injectors Test nozzles, valves, and injectors in accordance with manufacturer's instructions. Governor Check lube oil level m governor where applicable, and add oil If necessary. Check operation of overspeed governor Inspect governor linkage for loose or worn parts or binding. Lubricate linkage with light oil and correct any deficiencies in accordance with manufacturer's instructions Lube Oil System. Check entire lube oil system for leaks. Make spot checks of various items lubricated by the system to see that they are receiving sufficient oil in accordance with manufacturer's instructions. Service system as prescribed by engine manual and applicable lube order. Heat Exchanger See that hose and cap are in good condition, correctly assembled, securely mounted, and not leaking. See that pressure relief valve operates freely and is in correct position for prevailing atmospheric pressure. Clean cooling system if it is contaminated with rust or other foreign material in accordance with manufacturer's instructions. Tighten loose mountings, plates, and clamps. Clean heat exchanger with specified cleaner and inspect for leaks. See that core and zinc plates are in good condition
TM 55-1900-202-12/1 50
200
1,200
19
19
19
19
20
20
20
20
20
21
21
21
22
22
22
22
23
22
23
23
23
23
Instructions Fresh Water Expansion Tank Check cooling water level and quality of antifreeze and refill if necessary. Inspect tank and cooling passages for leaks Remove and clean strainer basket on seawater strainer Drain and clean expansion tank with specified cleaner. Flush cleaner from entire cooling system with clean water Refill, adding antifreeze If necessary Tighten loose mountings, plates, and clamps. Air Intake and Exhaust System Check exhaust piping and mufflers for condition and mounting. Check for carbon streaks and other indications of exhaust leaks. Be sure drain holes in mufflers are not clogged Tighten mounting bolts and connections. See that manifolds and gaskets are in good condition, secure, and not leaking. Empty carbon collector on exhaust silencer Remove hand hole cover over inlet pipe and scrape slot m silencer inlet pipe Remove, clean, and oil air intake silencer and allow to dram before replacing Check exhaust temperatures in accordance with manufacturer's instructions. Batteries Inspect and service lead-acid storage batteries regularly as prescribed by TM 96140-200-4 lead acid storage batteries Auxiliary Generators (DC/AC) Start generator to see whether it starts easily and runs at normal speed. Listen for any unusual noise that might indicate worn, loose, or inadequately lubricated parts. Lubricate m accordance with lube order. DC Generators Only Remove brush head cover plate and check commutator to see that It is in good condition, clean, and not excessively worn. Clean commutator with a piece of canvas or, if necessary to remove rough spots, a dressing stone. If a stone is not available then use a strip of very fine sandpaper, and blow off dust with low-pressure dry air. Renew brushes if worn to one-half their original length. Inspect control panel, instruments, gages, and wiring for insecure mounting and damage. Air Compressor See that air compressor Is properly mounted and correctly alined with its drive pulleys. Check pipeline connections for air leakage by soaping the joints. Lubricate in accordance with lube order. Isolate portions of system to see that valves will hold proper pressure. Check valve disks for Improper seating and listen for air leaks. Regrind or replace valves If necessary in accordance with manufacturer's instructions. Renew gaskets, and take up packing glands.
50
200
1,200 23
24
24
24
25
25
25
25 26
27
9
27
27
27
27
28
28
28
29
29
29
Instructions Clean out all ports and passages. Drain crankcase and clean out sludge Renew crankcase oil. Wash out cylinder water jackets with fresh water. Adjust unloader valve clearances to manufacturer's specifications. Air Starting System Check system for leaks, damaged lines, and connections. See that system operates properly to deliver adequate cranking speed. Drain dirt and water from air tanks. Inspect air starting valves and springs, air start check valve for leakage and satisfactory operation. Report deficiencies found to chief engineer and vessel master and enter on daily 2404. Clutches and Couplings Test clutch lever for satisfactory free travel (in accordance with equipment manual) before beginning to engage or disengage clutch. See that It releases clutch completely before lever has completed its stroke. Listen for unusual noises m release mechanism that may indicate defective clutch plate or pilot bearings, or dry or defective release bearings. Check for indications of clutch stoppage and see that all linkage is properly adjusted. Lubricate clutch mechanism and connections m accordance with lube order, paying particular attention to the throwout bearing and pilot bearings. Check all lines and connections on hydraulic, pneumatic, and vacuum clutches for leakage. Clean and inspect hydraulic couplings Reduction Gears Inspect reduction gears for overheating or unusual noises and other signs of wear Service in accordance with lube order instructions Reverse Gears Operate engine in both forward and reverse positions to see that fuel cutoff is automatic when stopping and reversing. Check automatic braking of the engine, valve operation, interlocking reverse-cycle sequence, pneumatic and manual speed regulation, and maneuvering controls for proper functioning. Check reverse gear adjustment according to manufacturer's instructions. Shafting and Stuffing Boxes See that stuffing boxes are not running hot and are not leaking. Check hose connection between propeller shaft tunnel and stuffing box for leakage. Some craft are designed such that snuff boxes have a slow drip. Check in accordance with manufacturer's instructions. Check to see that stuffing box bearings are receiving adequate water or oil lubrication. Instruments and Gages Check ammeter, voltmeter, water pressure gage, oil pressure gage, air pressure gage, oil temperature gage, water temperature gage, tachometer,
TM 55-1900-202-12/1 50
30
200
1,200
30
30
30
30
31
31
31
32
32
32
33
33
33
33
34
35
36
34
34
34
34
35
35
36
36
Instructions revolution counter, hour meter, fuel gage and any other installed gages to see that they are in proper working order and that they indicate within normal ranges specified m pertinent equipment manuals. Investigate all abnormal readings. Steering Gear Test helm for minimum free play specified in manufacturer's manual. Rotate helm fully m both directions and note any indication of binding or bumping. Lubricate steering control linkages according to lube order instructions. Check position of rudder with helm positions and see that rudder and helm movements correspond. Sanitary Water System Check water pump, storage and pressure tanks, piping, and outlets for leaks. See that disposal pipes are not clogged. Examine water pump in accordance with instructions in item 8. Fresh Water System Same as sanitary water system above. Fire and Bilge System Fire and bilge pumps should be operated and tested weekly Check piping for leaks and see that outlets are not clogged See that tanks and valves feeding the system are in good condition and securely mounted See that control cables and handles are in good condition and free to operate on short notice. See that all hues and nozzles are clean and securely connected. Apply a few drops of engine oil to pulleys and guides through which control cables operate, and tighten all assembly mounting bolts and screws. Ventilating System Check all fans, blowers, filters, dampers, ducts, and mechanical exhausts to see that they are in good condition, secure, and m satisfactory working order. Lubricate all parts requiring lubrication m accordance with lube orders or manufacturer's instructions. Determine that the ventilation in messrooms, galleys, living spaces, and cargo compartments is adequate. Remove and clean all filter elements. Tap glass-wool filters lightly to remove dust, and wash in an approved grease- and soot-cutting solution. Blow dry with compressed air. Heating System Make a periodic check of the heating system, and service in accordance with manufacturer's instructions for the particular type of heating system installed. Automatic Alarm System See that panel box, delay and alarm relay, thermostat, terminal block, electric horn, and horn-silencing switches are properly mounted and connected, and in good
50
200
1,200
37
37
37
37
37
37
38
38
38
38
working order. See that green light is lit at all times when engine is running; if it is out, check bulb, fuses, and throttle switch connections. Test operation of the system in Instructions accordance with manufacturer's instructions. See that throttle switch is in STOP position when engine is not running and that it is closed when engine is in operation. See that adjustment screws on oil pressure and water pressure contacts are adjusted to open and close at pressure specified by the manufacturer. Refrigeration Units Check refrigeration temperature gauges. Frozen foods should be stored at temperatures between 0 and -10 degrees F. -5 degrees F is desirable. Vegetable and dairy products should be stored at temperatures between 35-40 degrees F. Inspect drives, controls, and valves to see that they are in good condition and correctly assembled. Check for indications of excessively worn, loose, or improperly lubricated parts. Inspect controls, regulating and expansion valves, diaphragms, and tubes for serviceability. See that supply of refrigerant is adequate. Tighten all mountings, braces, and connections. Examine for oil, water, and refrigerant leakage. Check for refrigerant shortage, add if necessary. Check oil in circulating system and lubricate according to lube order or manufacturer's instructions. See that expansion valves are properly regulated, and replace excessively worn valves Clean water condenser tubes. Deck Machinery See that power units and moving parts of capstans, windlasses, and winches are properly lubricated, securely mounted, properly aimed, and in good condition. See that clutches move freely to both engaged and disengaged positions and that they latch securely. Examine drag brake and automatic brake linings. See that cables are in good condition, evenly wound, and properly lubricated, and that cable chain and hooks are securely attached. Check oil level in gearcases. Start all units to insure that they are m proper operating condition. Consult manufacturer's instructions for all adjustments and settings. Service m accordance with lube order. Unwind cables and inspect for broken or frayed strands and for flat or rust spots. Clean entire length of cables with a cloth saturated with solvent. Change cables end-for-end and rewind on drums evenly, applying a thin film of cable oil in the process
10
TM 55-1900-202-12/1 50
39
200
39
1,200
39
Instructions On some craft cables cannot be changed end-for-end. On these craft, change cables in accordance with manufacturer's instructions. Tools and Spare Parts Check to see that all authorized tools and spare parts are aboard and in serviceable condition. See that all tool mounting brackets and straps are properly mounted
40
40
40
41
41
41
and that tools with cutting edges are sharp. See that all tools and equipment not in use are treated with an approved rust preventive compound. Tools and spare parts shortages or those m an unserviceable condition should be replaced immediately Paint and Markings See that engine is clean externally. Scrape and wire brush rust spots, and touchup with paint; avoid excessive painting. Check all engine room markings and identification plates to see they are legible, correct, and properly mounted Painting of U S Army watercraft is done m accordance with TB-43-0144. Ramp Operation See that ramp winch and winch cable are free and sufficiently coated with grease Check cable for signs of fraying and wear Inspect condition and lubrication of sheaves and fair-leads. See that ramp hooks and latches hold ramp securely in place and that ramp hinges are securely fastened to hull and ramp. Operate ramp winch, engine, or motor, checking of unusual noises or signs of binding. See that ramp controls operate properly and that ramp drains are clear. Lubricate ramp operating mechanism and linkages in accordance with lube order.
11
TM 55-1900-202-12/1 B
D
A
Instructions
1
......
Inspect for injury etc. etc.
2
......
Inspect for tight mountings etc. etc. ......
See that entire system etc. etc.
3
......
......
Check the first ad kit etc. etc.
4
......
.
Inspect glass, frames, etc. etc
...... 5
......
Check the amount of fuel etc. etc.
......
Check circulation of fresh etc. etc. ......
6
Inspect hull and superstructure etc. etc.
Fill fuel tanks, etc. etc.
......
Inspect engine generators etc. etc.
......
See that above accessories etc. etc. ......
Inspect all accessories for loose etc. etc.
12
The Metric System and Equivalents Linear Measure
Liquid Measure
1 centimeter = 10 millimeters = .39 inch 1 decimeter = 10 centimeters = 3.94 inches 1 meter = 10 decimeters = 39.37 inches 1 dekameter = 10 meters = 32.8 feet 1 hectometer = 10 dekameters = 328.08 feet 1 kilometer = 10 hectometers = 3,280.8 feet
1 centiliter = 10 milliters = .34 fl. ounce 1 deciliter = 10 centiliters = 3.38 fl. ounces 1 liter = 10 deciliters = 33.81 fl. ounces 1 dekaliter = 10 liters = 2.64 gallons 1 hectoliter = 10 dekaliters = 26.42 gallons 1 kiloliter = 10 hectoliters = 264.18 gallons Square Measure
Weights 1 sq. centimeter = 100 sq. millimeters = .155 sq. inch 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq.
1 centigram = 10 milligrams = .15 grain 1 decigram = 10 centigrams = 1.54 grains feet 1 gram = 10 decigram = .035 ounce 1 decagram = 10 grams = .35 ounce acres 1 hectogram = 10 decagrams = 3.52 ounces 1 kilogram = 10 hectograms = 2.2 pounds 1 quintal = 100 kilograms = 220.46 pounds 1 metric ton = 10 quintals = 1.1 short tons
1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile Cubic Measure 1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch 1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches 1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate Conversion Factors To change inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons pound-feet pound-inches
To
Multiply by
centimeters 2.540 meters .305 meters .914 kilometers 1.609 square centimeters 6.451 square meters .093 square meters .836 square kilometers 2.590 square hectometers .405 cubic meters .028 cubic meters .765 milliliters 29,573 liters .473 liters .946 liters 3.785 grams 28.349 kilograms .454 metric tons .907 Newton-meters 1.356 Newton-meters .11296
To change ounce-inches centimeters meters meters kilometers square centimeters square meters square meters square kilometers square hectometers cubic meters cubic meters milliliters liters liters liters grams kilograms metric tons
To Newton-meters inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons
Temperature (Exact) °F
Fahrenheit temperature
5/9 (after subtracting 32)
Celsius °C temperature
Multiply by .007062 .394 3.280 1.094 .621 .155 10.764 1.196 .386 2.471 35.315 1.308 .034 2.113 1.057 .264 .035 2.205 1.102
PIN: 013221-000
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