Rudder Repeatback Rudder Angle Transmitter.
Rudder Repeatback Rudder Angle Transmitter.
Rudder Repeatback Rudder Angle Transmitter.
TECHNICAL MANUAL
OPERATOR'S, ORGANIZATIONAL,
DIRECT SUPPORT AND
GENERAL SUPPORT
MAINTENANCE MANUAL
OPERATOR / CREW
MAST-CENTRALIZED HYDRAULIC SYSTEMSTEERING SYSTEM
ANCHOR HANDLING SYSTEM
MAINTAINANCE INSTRUCTIONS
TM 55-1905-219-14-7
C2
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 17 APRIL 1992
CHANGE
NO. 2
Operator's, Organizational,
Direct Support and General
Support Maintenance Manual
Insert pages
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
01000
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, (qty rqr block No. 1057)
URGENT
CHANGE
NO. 1
TM 55-1905-219-14-7
C1
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 3 August 1984
}
Operator's, Organizational,
Direct Support, and General
Support Maintenance Manual
Insert pages
a and b
--2. Retain this sheet in front of manual for reference purposes.
a and b
c/d
Official:
ROBERT M. JOYCE
Major General, United States Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25D, Operator Maintenance Requirements for Marine
Equipment, All.
URGENT
TM 55-1905-219-14-7
Wear safety glasses, safety shoes, and a hard hat to provide adequate protection.
Personnel should know the location and operation of all equipment for emergency use.
Before attempting to operate any equipment, read the instructions completely. Then return to the appropriate section
and follow the instructions.
If cleaning agents are used, be sure area is adequately ventilated, and use protective gloves and goggles, or face
shield and apron.
When cutting with a torch, or when welding, always station fire watches, ready with fire extinguishers, in the vicinity
on both sides of the plate that is being cut or welded.
Prior to cutting or welding on the ramp, remove drain plugs on both sides of the ramp and check if ramp interior is
primer coated. If primer coated, flush thoroughly with steam, carbon dioxide, or water. Do not reinstall drain plugs
until the cutting and/or welding operation is completed. Failure to take this precaution may result in explosion of
accumulated primer vapors.
When refueling, shut down the electrical system. Observe the no smoking rule. Do not permit anyone to operate
tools or equipment which may produce sparks near the refueling operation. Sparks or fire may ignite the diesel fuel
and produce an explosion.
Fuel oil and other petroleum products are highly volatile in extreme heat. To minimize the possibility of explosion,
wipe up all spills at once, see that fuel lines and valves are not leaking and pump bilges regularly.
Before attempting to remove any compressed air system lines or components, relieve air-pressure from system.
Failure to do so may result in injury or possible death to maintenance personnel.
Before disconnecting a line in the hydraulic system, bleed the pressure from that portion of the line. Failure to do so
may result in injury or possible death to maintenance personnel.
Change 1 a
TM 55-1905-219-14-7
(Cont)
When working inside the hydraulic oil supply tank, a portable-type circulating blower should be used to prevent vapor
accumulation. For extended work periods inside the tank, an air line tube respirator should be worn. Station an
observer outside tank in case worker is overcome by fumes.
Acids can cause serious burns or blindness, Avoid contact with eyes, skin, or clothing. Do not breathe vapors.
Wear rubber gloves, goggles, and a rubber apron when handling them. When diluting acids, do not add water to
acid; the acid must be added to the mixture slowly and with constant mixing. In case of contact with acid, flush the
affected area with plenty of water and obtain medical aid immediately.
Ramp hinge pins must be replaced one at a time, allowing three remaining pins to support ramp. Removal of two or
more hinge pins may result in the weight of the ramp misaligning the remaining hinges, resulting in damage to ramp
and possible injury or death to maintenance personnel.
Use the recommended air pressure when using compressed air to clean components. Too much air pressure can
rupture, or in some way damage a component and create a hazardous situation that can lead to personal injury.
Avoid excessive injection of ether into an engine during starting attempts. Follow the instructions on the container or
by the manufacturer of the starting aid.
When working on an engine that is running, accidental contact with the hot exhaust manifold can cause severe
burns.
Improper functioning of the engine exhaust system can cause injury or death.
Use extreme care when near rotating fans, belt, and pulleys.
Keep clear of the anchor winch or bar ramp winch while it is in operation.
b Change 1
TM 55-1905-219-14-7
(Cont)
During any removal, disassembly, assembly, or installation of an electrical device, make sure all electrical power is
disconnected and tagged (circuit breaker in the OFF position and tagged).
Avoid making contact across the terminals of the batteries, and do not spill the contents of the battery.
If the Halon Fire System is activated (horn sounds), leave the compartment immediately. Check that no one is left,
and then close and dog the hatch.
Use extreme care when handling gasoline for the Salvage Pump.
Death or severe injury may result if personnel fail to use a lifting device that is adequate for the item to be lifted.
TM 55-1905-219-14-7
C2
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 21 MAY 1984
CHANGE
NO. 2
Operator's, Organizational,
Direct Support and General
Support Maintenance Manual
APPENDIX A
REFERENCES
APPENDIX B
Section I
3-2911
A-1
Introduction
B-1
INDEX
Index-1
i/(ii blank)
CHAPTER 3 (CONTINUED)
SECTION V. MAINTENANCE PROCEDURES (Continued).
PARAGRAPH
Piston
Connecting Rods
Connecting Rod Bearings
Cylinder Liner
3-171.1
3-171.2
3-171.3
3-171.4
3-2911
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
c. The piston is cooled by a spray of lubricating oil directed at the underside of the piston head from a nozzle in the
top of the connecting rod, by fresh air from the blower to the top of the piston and indirectly by the water jacket around
the cylinder.
d. Each piston is balanced to close limits by machining a balancing rib, provided on the inside at the bottom of the
piston skirt.
e. Two bushings, with helical grooved oil passages, are pressed into the piston to provide a bearing for the
hardened, floating piston pin. After the piston pin has been installed, the hole in the piston at each end of the pin is
sealed with a steel retainer. Thus, lubricating oil returning from the sprayed underside of the piston head, and working
through the grooves in the piston pin bushings, is prevented from reaching the cylinder walls.
f. Each piston is fitted with compression rings and oil control rings. Eight equally spaced drilled holes just below
each oil control ring groove permit excess oil, scraped from the cylinder walls, to return to the crankcase.
3-2912
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
g. When an engine is hard to start, runs rough or lacks power, worn or sticking compression rings may be the
cause. Replacing the rings will aid in restoring the engine to normal.
h. The compression rings may be inspected through the ports in the cylinder liners after the air box covers have
been removed. If the rings are free and are not worn to the extent that the plating or grooves are gone, compression
should be within operating specifications.
i. Excessively worn or scored pistons, rings or cylinder liners may be an indication of abnormal maintenance or
operating conditions which should be corrected to avoid a recurrence of the failure. The use of the correct types and
proper maintenance of the lubricating oil filters and air cleaners will reduce to a minimum the amount of abrasive dust
and foreign material introduced into the cylinders and will reduce the rate of wear.
j. Long periods of operation at idle speed and the use of improper lubricating oil or fuel must be avoided, otherwise
a heavy formation of carbon may result and cause the rings to stick.
k.
Keep the lubricating oil and engine coolant at the proper levels to prevent overheating of the engine.
3-2913
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
This task covers:
a. Pre-Inspection
b. Removal
c. Disassembly
d. Cleaning
e. Inspection
f. Reassembly
g. Installation
INITIAL SETUP
Test Equipment
References
Feeler gage
None
Equipment
Condition
Paragraph
Special Tools
Assembly tool piston
ring J8128
Pump, hand
NSN 4930-00-263-9886
Installer and remover
piston and connecting
rod bushings-J1513-02
(part J7032 and J7632
Condition Description
3-163
3-164
3-169
3-170
Material/Parts
Cylinder kit
P/N 5149265
Personnel Required
LOCATION
ITEM
ACTION
REMARKS
PRE-INSPECTION
1. Pistoncompression,
rings
a. Air box
covers
b. Cylinder
liners
Discard gaskets.
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
PRE-INSPECTION (Cont)
REMOVAL
2. Piston
and
connecting
rod
a. Cooling
system
Drain.
b. Oil pan
1. Remove oil.
2. Remove pan.
Oil
inlet
pipe
Remove.
d. Lube oil
pump
Remove.
c.
3-2915
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
e. Cylinder
head
f.
Cylinder
liner
Remove.
.
1. Remove the carbon
deposits from the upper
inner surface of the
cylinder liner
2. Use a ridge cutter
to remove any ridges
in the cylinder liner
at the top of the
piston ring travel.
NOTE
Move the piston to the bottom of its travel and
place a cloth over the top of the piston to collect
the cuttings. After the ridge has been removed,
turn the crankshaft to bring the piston to the top
of its stroke and carefully remove the cloth with
the cuttings.
g. Nut
(1),
bearing
cap
(2),
and
lower
bearing
shell
(3)
Remove.
3-2916
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
h. Piston
and
connecting thru
rod
assembly
i.
Lower
bearing
shell
(3),
bearing
cap
(2),
and
nuts
(1)
3-2917
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
DISSASSEMBLY
3. Piston
and
connecting
rod
a. Piston
and
connecting
rod
assembly
b. Rings
(compression
fire)
(4)
c. Rings
(compression)
(5)
d. Oil
rings
(6)
Remove.
Remove.
3-2918
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY (Cont)
e. Piston
pin
retainer
(9)
f.
Remove.
Piston
pin
(10)
g. Connecting rod
(11)
h. Piston
pin
retainer
(9)
Be careful not
to damage the
piston or bushings.
Remove.
3-2919
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
CLEANING
3-2920
REMARKS
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSPECTION
5. Piston
3-2921
REMARKS
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION
6. Cylinder
liner
and block
bore
Inspect.
7. Connecting
rod,
and
piston
pin
8. Piston
pin
bushing
Inspect.
9. Other
REASSEMBLY
Do not remove the bushings from the piston. They are not serviced separately.
10. Piston
a. Piston
and
cylinder
liner
fitting
3-2922
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY (Cont)
Refer to the Table for
piston diameter specifications.
ENGINE PARTS
(Standard Size, New)
Piston:
Height (centerline of
bushing to top) ..........................
Diameter (above compression rings) .................................
Diameter (at skirt)............................
Clearance--piston skirtto-liner.......................................
Out-of- round...................................
Taper...............................................
Compression rings:
Gap (top-fire ring) ............................
Gap (No. 2, 3 and 4)........................
Clearance--ring-to-groove:
No. 1 (top-fire
ring) ..........................................
No. 2. ........................................
No. 3 and 4 ...............................
Oil control rings:
Gap .................................................
Clearance........................................
MINIMUM
(inches)
(cm)
MAXIMUM
(inches)
(cm)
LIMITS
(inches)
(cm)
3.5430
8.9992
3.5480
9.0119
4.2225
4.2428
10.7252
10.7767
4.2255
4.2450
10.7328
10.7823
.0045
.0114
.0083
.0005
.0005
.0211
.0013
.0013
.0120
.0305
.0230
.0180
.0584
.0457
.0380
.0430
.0965
.1092
.0600
.0600
.1524
.1524
.0040
.0100
.0040
.0102
.0254
.0102
.0070
.0130
.0070
.0178
.0330
.0178
.0180
.0220
.0130
.0457
.0559
.0330
.0080
.0015
.0203
.0038
.0230
.0055
.0584
.0140
.0430
.0080
.1092
.0203
3-2923
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
3. With the cylinder liner
instal1ed in the cylinder
block, hold the piston
upside down in the liner
and check the clearance
in four places 90apart.
4. Use a feeler gage set
to check the clearance.
The spring scale
attached to the proper
feeler gage is used to
measure the force in
pounds required to
withdraw the feeler
gage.
5. Select a feeler gage
with a thickness that
will require a pull of
six pounds (26.7 N) to
remove. The clearance
will be.001 inch
(.003 cm) greater
than the thickness
of the gage used,
i.e., a.004 inch
(.010 cm) feeler
gage will indicate
a clearance of. 005
inch (.013 cm)
when it is withdrawn.
The feeler gage must
be perfectly flat
and free of nicks
and bends.
3-2924
REMARKS
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
3-2925
REMARKS
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
b. Piston
ring
fitting
3-2926
REMARKS
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
3-2927
REMARKS
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
6. Insert one ring at a
time inside the cylinder liner and far
enough down to be
within the normal
area of ring travel.
Use a piston to push
the ring down, to be
sure it is parallel
with the top of the
liner. Then measure
the ring gap with a
feeler gage. Refer
to ring gap specifications.
3-2928
REMARKS
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
3-2929
REMARKS
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY (Cont)
c.
Piston
and connecting
rod
Assemble.
d. Piston
and all
piston
rings
e. Compression
rings
(5)
To avoid breaking or overstressing the rings, do not spread them any more than
necessary to slip them over the piston.
f.
Compression
fire
rings
(4)
Install.
When installing the top compression (fire) ring, be sure the black oxide or copper color
side (also identified by an oval mark) is toward the top of the piston.
g. Compression
rings
(4 and
5)
3-2930
Rotate rings
or piston.
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY (Cont)
h. Ring
expander
(7)
h. Ring
expander
(7)
3-2931
Install with
the legs of the
free ends to-.
ward the top of
the piston.
With the free
ends pointing
up, a noticeable resistance
will be encountered during
installation
of the piston
if the ends of
the expander
are overlapped
and corrective
action can be
taken before
ring breakage
occurs.
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY (Cont)
When installing the oil control rings, use care to prevent overlapping the ends of the ring expanders. An overlapped
expander will cause the oil ring to protrude beyond allowable limits and will result in breakage when the piston is inserted
in the ring compressor during installation in the cylinder liner. Do not cut or grind the ends of the expanders to prevent
overlapping. Cutting or grinding the ends will decrease the expanding force on the oil control rings and result in high
lubricating oil consumption.
i.
Oil
control
rings
(8)
3-2932
Install by hand.
Do not use tool.
Install the
upper half with
the gap 180
from the gap in
the expander.
Then instal1
the lower half
with the gap 45
from the gap in
the upper half
of the ring.
Make sure the
scraper edges
are facing down
(toward the
bottom of the
piston).
TM 55-1905-219-14-7
3-171.1. PISTON - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY (Cont)
NOTES
The face of the top half of the upper oil control ring used on V-71N engines is
chrome-plated.
The scraping edges of all oil control rings must face downward (toward the bottom of
the piston) for proper oil control.
INSTALLATION
12. Piston,
connecting
rod, and
cylinder
liner
For installation,
refer to paragraph 3-171.4.
3-2933
TM 55-1905-219-14-7
3-171.2. CONNECTING ROD - MAINTENANCE INSTRUCTIONS.
a. Each connecting rod (trunk-type piston) is forged to an "I" section with a closed hub at the upper end and a bearing
cap at the lower end. The connecting rod is drilled to provide lubrication to the piston pin at the upper end and is
equipped with a nozzle to spray cooling oil to the underside of the piston head. An orifice is pressed into a counterbore at
the lower end of the oil passage to meter the flow of oil.
b. A helically-grooved bushing is pressed into each side of the connecting rod at the upper end. The cavity between the
inner ends of these bushings registers with the drilled oil passage in the connecting rod and forms a duct around the
piston pin. Oil entering this cavity lubricates the piston pin bushings and is forced out the spray nozzle to oil the piston.
The piston pin floats in the bushings of both the piston and connecting rod.
c.
This paragraph also includes assembly of the piston onto a connecting rod.
3-2934
TM 55-1905-219-14-7
3-171.2. CONNECTING ROD - MAINTENANCE INSTRUCTIONS (Continued).
This task covers:
a. Removal
b. Cleaning
c. Inspection
d. Disassembly
e. Reassembly
f. Assembly
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Paragraph
Special Tools
Remover, connecting rod
spray nozzle J8995
Reamer set, connecting
rod bushing J1686-03
Installer and remover set,
piston and connecting,
rod J1513-02 (part J7032)
Pump, hand
NSN 4930-00-263-9886
3-163
3-164
3-169
3-170
3-171.1
Material/Parts
Condition Description
Cylinder kit
P/N 5149265
Personnel Required
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
1. Engine
a. Oil pan
1. Remove oil.
2. Remove pan.
3-2935
ITEM
ACTION
REMARKS
REMOVAL
b. Oil
inlet
pipe
Remove pan.
c.
Remove.
Remove.
Lube
oil
pump
d. Cylinder
head
2. Connecting
rod(s)
NOTE
The connecting rod bearing caps are numbered IL, IR, 2L, 2R, etc., with matching
numbers and letters stamped on the connecting rods. When removed, each bearing cap
and the bearing shells must always be reinstalled on the original connecting rod.
a. Nuts
(1)
Remove.
b. Bearing
cap
(2)
Remove.
c.
Connecting
rod
(3)
d. Bolts
(4)
Remove.
3-2936
TM 55-1905-219-14-7
3-171.2. CONNECTING ROD - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
e. Upper
bearing
shell
(5)
Do not pound
on edge of
bearing shell
with sharp
tool.
f. Lower
bearing
shell
(6)
Remove if necessary.
Do not pound
on edge of
bearing shell
with sharp
tool.
g. Piston
Disassemble.
3-2937
TM 55-1905-219-14-7
3-171.2. CONNECTING ROD - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
CLEANING
Connecting
rod (3),
orifice
(7),
and
spray
nozzle
(8)
Connecting
rod (3)
INSPECTION
4. Connecting
rod
3-2938
TM 55-1905-219-14-7
3-171.2. CONNECTING ROD - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
5. Connecting
rod
bushings
Bushings
(9)
6. Piston
pin
Pin (10)
Bushings that
have overheated
may become
loose and creep
together, thus
blocking off
the supply of
lubricating oil
to the piston
pin and spray
nozzle.
a. Bushings
that have
overheated
may become
loose and
creep
together,
thus blocking off the
supply of
lubricating
oil to the
piston pi n
and spray
nozzle.
b. When reusing
a piston pin,
the highly
polished and
lapped surface must
not be refinished.
Polishing
or refinishing the piston is not
recommended.
It could result in very
rapid bushing wear.
3-2939
TM 55-1905-219-14-7
3-171.2. CONNECTING ROD - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
c.
LONGITUDINAL INDICATIONS
FOLLOWING FORGED FLOW LINES
ARE USUALLY SEAMS AND ARE NOT
CONSIDERED HARMFUL IF LESS
THAN 1132 DEEP. DEPTH CAN BE
DETERMINED BY GRINDING A SMALL
AREA NEAR THE CENTER OF THE
INDICATION.
3-2940
Since it is subjected to
downward loading only,
free movement of the
piston pin is desired
to secure perfect alignment and uniform wear.
Therefore, the piston
pin is assembled with a
full floating fit in
the connecting rod and
piston bushings with
relatively large clearances. Worn piston pin
clearances up to.010
inch (.025 cm) are
satisfactory.
GRINDING NOTES
CARE SHDULD BE TAKEN IN GRINDING OUT
INDICATIONS TO ASSURE PROPER BLENDING
OF GROUND AREA INTO UNGROUND SURFACE
SO AS TO FORM A SMOOTH CONTOUR.
POOR PRACTICE GOOD PRACTICE
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY
7.
Bushings
Connecting
rod (3)
Use tool
J1513-2.
c.
Use tool
J1513-3.
3-2941
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY (Cont)
8.
Spray
nozzle
(8)
a.
Connecting rod
bushings
(9)
Remove.
Refer to step 7.
b.
Spray
nozzle
(8)
3-2942
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
DISASSEMBLY (Cont)
9.`Orifice
a.
Spray
(7)
(8)
Remove.
nozzle
b.
Orifice
(7)
3-2943
REMARKS
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY
10. Orifice
Orifice
(7)
Install orifice
0.3125 inch
(0.7938 cm)
from lower
surface.
11. Spray
nozzle
Spray
nozzle
(8) and
connecting
rod
(3)
a. Insert nozzle
straight into
counterbore of
connecting rod.
Align holes in
spray nozzle as
shown.
3-2944
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY (Cont)
12. Bushings
a.
Connecting
rod
b.
Bushing
(9)
3-2945
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
REMARKS
2.
Insert installer in
bushing, then insert
handle in the installer.
Use installer
tool J1513-6,
and handle
tool J1513-2.
3.
REASSEMBLY (Cont)
c.
Connecting
rod
(3)
a.
Connecting rod
(3),
bolts
(4),
bearing
cap
(2) ,
and
nuts
(1)
Assemble.
3-2946
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
REASSEBMLY (Cont)
b.
3-2947
REMARKS
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY (Cont)
5.
6.
7.
8.
Remove the reamer and the connecting rod from the fixture.
Blow out the chips and measure
the inside diameter of the bushings. The inside diameter of
the bushings must be 1.5015 to
1.5020 inch (3. 8138 to 3.8151
cm). This will provide a piston
pin-to-bushing clearance of
.0015 to .0024 inch (.0038
to .0061 cm) with a new piston
pin. A new piston pin has a
diameter of 1.4996 to 1.5000
inch (3.8090 to 3.8100 cm).
NOTE
Piston bushings are installed into piston.
Refer to paragraph 3-171.1
ASSEMBLY
14. Connecting
rod to
piston
a.
Piston
pin (10),
piston
bushings
(12)
and
connecting
Lubricate.
3-2948
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
REMARKS
ASSEMBLY (Cont)
rod bushings (9)
b.
Piston
(11)
Place in holding
fixture.
c.
Piston
pin
retainer
(13)
3-2949
TM 55-1905-219-14-7
3-171.2. CONNECTING ROD - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
ASSEMBLY (Cont)
d.
Connecting
rod
(3)
e.
Piston
pin
(10)
f.
Piston
pin
retainer
(13)
1. Place on piston;
then place crowned
end of installer
against the retainer.
2. Place handle on
installer.
3. Strike the handle just
hard enough to deflect
the retainer and seat
it evenly in the piston.
Piston
pin
(10),
and
connecting
rod
(3)
assembled
After the piston pin retainers have been installed, check for piston
pin end clearance by
cocking the connecting
rod and shifting the pin
in its bushings.
3-2950
Use tool
J1513-4.
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
ASSEMBLY (Cont)
3-2951
REMARKS
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
ASSEMBLY (Cont)
h.
Piston
and
connecting
rod
assembled
3-2952
REMARKS
TM 55-1905-219-14-7
3-171.2.
LOCATION
ITEM
ACTION
REMARKS
ASSEMBLY (Cont)
Piston
and
connecting
rod
assembly,
and
cylinder
liner
Assemble.
3-2953
TM 55-1905-219-14-7
3-171.3.
a. The connecting rod bearing shells are precision made and are replaceable with shim adjustments. They consist
of an upper bearing shell seated in the connecting rod, and a lower bearing shell seated in the connecting rod case. The
bearing shells are prevented from endwise or radial movement by a tang at the parting line at one end of each bearing
shell.
b. Multiple layer copper-lead co-plated or aluminum triplated bearings are used. These bearings have an inner
surface (matrix) of copper-lead or aluminum. A thin deposit of babbitt is plated onto the matrix. This babbitt overlay has
excellent resistance to friction, corrosion and scoring tendencies which, combined with the material of the matrix,
provides improved load carrying characteristics. These bearings are identified by the satin silver sheen of the babbitt
when new and a dull gray after being in service.
c. The upper and lower connecting rod bearing shells are different and are' not interchangeable. Both shells are
notched midway between the bearing edges approximately 3/4 of an inch in from each parting line. The lower bearing
shell has a circumferential oil groove that terminates at the notched ends. These notches maintain a continuous registry
with the oil hole in the crankshaft connecting rod journal, and provide a constant supply of lubricating oil to the
connecting rod bearings, piston pin bushings and spray nozzle through the oil passage in the connecting rod.
3-2954
TM 55-1905-219-14-7
3-171.3.
b. Inspection
c. Installation
INITIAL SETUP
Test Equipment
References
Micrometer
None
Equipment
Condition
Paragraph
Special Tools
Torque wrench
Pump, hand
Material/Parts
None
Personnel Required
LOCATION
Condition Description
None
ITEM
ACTION
REMARKS
REMOVAL
1.
Engine
a.
Oil pan
1. Remove oil.
2. Remove pan.
3-2955
TM 55-1905-219-14-7
3-171.3.
LOCATION
ITEM
ACTION
REMARKS
ASSEMBLY (Cont)
2.
b.
Oil
inlet
pipe
Remove.
c.
Lube
oil
pump
Remove.
Connecting
rod(s)
NOTE
The connecting rod bearing caps are numbered 1L, 1R,
2L, 2R, etc., with matching numbers and letters stamped
on the connecting rods. When removed, each bearing
cap and the bearing shells must always be reinstalled on
the original connecting rod.
a.
Nuts
(1)
Remove.
b.
Bearing
cap
(2)
Remove.
c.
Connecting
rod
(3)
d.
Upper
bearing
shell
(4)
Do not pound on
edge of bearing
shell with
sharp tool.
e.
Lower
bearing
shell
(5)
Do not pound on
edge of bearing
shell with
sharp tool.
3-2956
TM 55-1905-219-14-7
3-171.3.
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
NOTE
Do not remove another bearing cap or bearing shells.
INSPECTION
3.
Bearing
shells
Upper
and
lower
shells
3-2957
If any of these
defects are
present, the
bearings must
be discarded.
However, babbitt plated
bearings may
develop minute
TM 55-1905-219-14-7
3-171.3.
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
cracks or small
isolated cav
ities on the
bearing surface
during engine
operation.
These are characteristics of,
and are NOT
detrimental to,
this type of
bearing. The
bearings should
not be replaced
for these minor
surface imperfections. The
upper bearing
shells, which
carry the load,
will normally
show signs of
distress before
the lower bearing shells do.
2. Inspect the backs
of the bearing shells
for bright spots
which indicate they
have been shifting
in their supports.
If such spots
are present,
discard the
bearing shells.
The minimum
thickness of a
worn standard
connecting rod
bearing shell
should not be
less than .1230
inch (.3124 cm)
and, if either
3-2958
TM 55-1905-219-14-7
3-171.3.
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
bearing shell
is thinner than
this dimension,
replace both
bearing shells.
A new standard
bearing shell
has a thickness
of .1238 to
. 43 inch
(. 145 to
.3157 cm).
4.
Connecting
rod
Bearing
bore
5.
Crankshaft
journal
Bearing
shells
3-2959
This clearance
may be checked
by means of a
soft, plastic
measuring strip
which is
squeezed between the
journal and
the bearing.
The maximum
connecting rod
bearing-tojournal clearance with used
parts is .006
inch (.015 cm).
TM 55-1905-219-14-7
3-171.3.
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
6
Connecting
rod(s)
NOTE
Do not replace one connecting rod bearing shell alone. If one bearing
shell requires replacement, install both new upper and lower bearing
shells. Bearing shells are available in .010 inch, .020 inch and .030 inch
undersize for service with reground crankshafts. Do not use these
bearing shells.
a.
Upper
bearing
shell
(4)
3-2960
Be sure the
tang on the
bearing shell
fits in the
groove in the
connecting rod.
TM 55-1905-219-14-7
3-171.3.
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
b.
Crankshaft
journal
c.
Connecting
rod
and
piston
assembly
d.
Bearing
cap (2),
and
lower
bearing
shell
(5)
Assemble.
3-2961
TM 55-1905-219-14-7
3-171.3.
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
e.
Bearing
cap
and
lower
bearing
shell
assembly
(2),
and
nuts
(1)
Install.
lb-ft (81-95
Nm) torque
(lubrite nut)
or 65-75 lb-ft
(88-102 Nm)
torque (castellated nut).
Torque to 60-70
f.
Lube
oil
pump
Install.
g.
Oil
inlet
pipe
Install.
h.
Oil
pan
Install.
i.
Engine
oil
Fill.
3-2962
TM 55-1905-219-14-7
3-171.4. CYLINDER LINER-MAINTENANCE INSTRUCTIONS.
a. The replaceable type cylinder liner is machined and heat treated to provide a long wearing, scuff-resistant
surface. The flange at the top fits into a counterbore in the cylinder block and rests on a replaceable cast iron insert
which permits accurate alignment of the cylinder liner. Compression is sealed with an individual laminated compression
gasket for each cylinder.
b. The liner is cooled by a water jacket in the cylinder block and by the scavenging air introduced into the cylinder
through the air inlet ports around the liner. These ports are machined at an angle to create a uniform swirling motion to
the air as it enters the cylinder. This motion persists throughout the compression stroke and facilitates scavenging and
combustion.
c. The wear on a liner and piston is directly related to the amount of abrasive dust and dirt introduced into the
engine combustion chamber through the air intake. This dust, combined with lubricating oil on the cylinder wall, forms a
lapping compound and will result in rapid wear. To avoid pulling contaminated air into the cylinder, the air silencer must
be serviced regularly.
d. This paragraph also includes installation of the piston and connecting rod assembly into the cylinder liner.
These components are then installed in the engine.
3-2963
TM 55-1905-219-14-7
3-171.4.
b. Inspection
c. Installation
INITIAL SETUP
Test Equipment
References
None
Equipment
Condition
Paragraph
Special Tools
-Remover Cylinder Liner
J1918-02
Holddown Clamp Cylinder
Liner J21793-01
Pump, hand
NSN 4930-00-263-9886
3-161
3-163
3-164
3-169
3-171.1
Material/Parts
Personnel Required
LOCATION
Condition Description
ITEM
ACTION
REMARKS
REMOVAL
1.
Engine
a.
Rocker
arm
cover
Remove.
b.
Oil
pan
1. Remove oil.
2. Remove pan.
3-2964
TM 55-1905-219-14-7
3-171.4.
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
2.
c.
Lube
oil
pump
Remove.
d.
Cylinder
head
Remove.
e.
Piston
Remove.
Cylinder
liner
NOTE
It is very important that the proper method is followed when removing a
cylinder liner. Do not attempt to push the liner out by inserting a bar in
the liner ports and rotating the crankshaft. Otherwise, the piston may be
damaged or the upper ring groove may collapse.
Remover
cylinder
liner
3-2965
TM 55-1905-219-14-7
3-171.4.
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
b. Lower the lower shoe
through the cylinder
liner.
c.
3-2966
Place shoe on
bottom edge of
liner with flat
on shoe paralel with the
crankshaft bore.
TM 55-1905-219-14-7
3-171.4.
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
e. Hold the lower shoe
and bolt assembly
in the pulling position.
f.
Pull up until
cylinder liner
is removed from
cylinder.
3-2967
TM 55-1905-219-14-7
3-171.4.
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
3.
Cylinder
liner
insert
Insert
shims
(if used)
Remove from
counterbore of
engine block.
INSPECTION
Cylinder Liner
liner
a. Clean thoroughly.
Discard. A
slightly scored
liner may be
cleaned up and
reused.
c.
Excessive liner
to-block clearance or block
bore distortion
3-2968
TM 55-1905-219-14-7
3-171.4.
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
will reduce
heat transfer
from the liner
to the block
and to the engine coolant.
Poor contact
between the
liner and the
block bore may
be indicated by
stains or low
pressure areas
on the outer
surface of the
liner.
d. Examine the outside
diameter of the liner
for fretting.
3-2969
Fretting is the
result of a
slight movement
of the liner in
the block bore
during engine
operation, causing material
from the block
to adhere to
the liner.
These metal
particles may
be removed from
the surface of
the liner with
a coarse, flat
stone.
TM 55-1905-219-14-7
3-171.4.
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
e. Inspect for cracks
at the flange.
The liner
flange must be
smooth and flat
on both top and
bottom surfaces.
The liner insert must also
be smooth and
flat on top and
bottom surfaces.
Replace insert
if there is
evidence of
brinelling.
f.
If the clearance
exceeds zero to
.002 inch
(.0051 cm), it
will be necessary to bore the
block for an
oversized liner.
Refer to Direct
Support Maintenance.
NOTES
Cylinder liners are available in .001, .005, .010,.020 and .030 inch (.0025, .0127,
.0254, .0508, .0762 cm) oversize on the outside diameter. When an oversize liner is
used, the amount of oversize is stamped on top of the cylinder block adjacent to the
liner counterbore.
New service liners, standard and oversize, have an inside diameter of 4.2495 to
4.2511 inch (10.7937 to 10.7978 cm).
Do not modify the surface finish in a new service liner. Since the liner is properly
finished at the factory, any change will adversely affect the seating of the piston
rings.
3-2970
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION CONTINUED
g. Install the liner in
the proper bore of
the cylinder block
and measure the inside diameter at the
various points shown.
Use cylinder bore
gage J5347-01, which
has a dial indicator
calibrated in .0001
inch increments, as
it is rather difficult to obtain accurate measurements
with a micrometer.
Set the cylinder
bore gage on zero
in master ring gage
J8386-01. Also,
check the liner for
taper and out-ofround.
3-2971
To reuse the
liner, the
taper must not
exceed .002
inch (.005 cm)
and the outof-round must
not exceed
.0025 inch
(.0064 cm).
in addition,
the ridge
formed at the
top of the
ring must be
removed. If
the out-ofround exceeds
.0025 inch
(.0064 cm),
rotate the
liner 9O0
in the block
bore and
recheck.
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
5.
6.
Engine
block
Cylinder a. Liner
liner
a. Engine
block
bore
and
counterbore
Wipe clean.
b. Cylinder
liner
insert
3-2972
Use a standard
size liner insert 0.1795 to
0. 1800 lnch
(0.4559 to
0.4372 cm).
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
If a new liner
cannot be
pushed in place,
light honing of
the block bore
may be necessary to obtain
the desired
fit for best
heat transfer
liner-to-block
clearance.
MINIMUM
.0000 (.0000 cm)
MAXIMUM
.0020 (.0051 cm)
b. Holddown
clamp
LIMIT
.0025 (.0064 cm)
Install.
3-2973
Use tool
J21793-01.
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
INSPECTION (Cont)
c.
Cylinderliner
1.
NOTE
A .002 inch (.0051 cm) thick shim is available for
adjusting the liner height. The shim must be installed
underneath the liner insert. Do not cut the shim for
installation. Liner inserts which are .0015 inch
(.0038 cm) thicker or thinner than standard are also
available for service.
2. Matchmark the liner
and cylinder block
with chalk or paint
so the liner may be
reinstalled in the
same position in the
same block bore. The
matchmarks should be
on the side opposite
the camshaft.
d. Holddown
clamp
and
cylinder
liner
Remove.
3-2974
REMARKS
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
NOTE
Do not remove the liner insert.
7.
Piston
and
connecting
rod
assembly
Assembly
and
piston
ring
assembly
NOTE
Inspect ring compressor for nicks or burrs, especially
at the nontapered inside diameter end. Nicks or burrs
on the inside diameter of the compressor will result
in damage to the piston rings.
b. ComPlace on wood block
pressor
with chamfered end up.
c.
Piston
and
connecting rod
assembly
Position, (stagger)
the piston ring gaps
properly on the piston.
expanders are
not overlapped.
3-2975
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
INSPECTION (Cont)
d. Assembly
and
compressor
e. Cylinder
liner
f.
Compressor
on
piston,
and
connecting
rod
assembly,
and
cylinder
liner
3-2976
REMARKS
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
NOTE
The numbers on the side of the connecting rod and cap identify the rod with the cap and
indicates the particular cylinder in which they are used. If a new service connecting rod is to be
installed, the same identification numbers must be stamped in the same location as on the
connecting rod that was replaced.
2.
Do not force the piston into the liner. The peripheral abutment type expanders apply considerable more force on the oil ring than the standard expander. Therefore, extra care must be
taken during the loading operation to prevent ring breakage.
g Connecting
1. Remove.
rod
cap
2. Push piston down until
and
the compression rings
ring
pass cylinder liner ports.
compressor
3-2977
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
8.
Cylinder
liner,
piston and
connecting
rod assembly
NOTES
1. If any of the pistons and liners are already in the engine, use hold-down
clamps to retain the liners in place when the crankshaft is rotated.
2. Rotate the crankshaft until the connecting rod journal of the particular cylinder being worked on is at the bottom of its travel. Wipe journal clean and lubrcate it with clean engine oil.
a. Upper
bearing
shell
(1)
Install in connecting
rod (2). Lubricate.
clean engine
oil.
NOTE
Each connecting rod and its cap is numbered on one side - 1L, 1R, 2L, 2R, etc.
These numbers and letters identify the caps with the rods and indicate
the particular cylinder in which they are used. Maintain these positions when
assembling the engine.
b. Piston,
1. Position the piston,
rod and
rod and liner assemliner
bly in front of the
assembly
cylinder block bore
(3)
so the identification
number and letter on
the rod face the outer
edge of the cylinder
block, and the matchmarks on the liner and
block are in alignment.
3-2978
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
INSPECTION (Cont)
2.
3.
REMARKS
3-2979
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
c.
Piston
and connecting
rod (2)
The distance from the vertical center line of the connecting rod bolts to the edges of the rod are not
equal. Therefore, when installing the piston and connecting rod assembly, be sure that the narrow
side of the two connecting rods on the crankshaft journal are together to avoid cocking of the rod.
d. Lower
bearing
shell
(4),
and
bearing
cap
(5)
e. Bearing
cap
with
bearing
shell,
connecting
rod
(2),
and
nuts
(6)
Tighten the
connecting
rod bolt nuts
to 60-70 ft-lb
(81-95 Nm)
torque (notch
or imbedded "0"
lubrite nut) or.
65-75 ft-lb
(88-102 Nm)
torque (castel-lated nut).
f.
The clearance
between each
Connecting
rod
(2)
3-2980
TM 55-1905-219-14-7
3-171.4. Cylinder liner - maintenance instructions (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
should be .008
to .016 inch
(0.020 to 0.041
cm) with new
parts.
NOTES
1. Install the remaining liner, piston and rod assemblies in the same manner. Use hold-down clamps to
hold each liner in place.
2. After all of the liners and pistons have been installed, remove the hold-down clamps.
g. Cylinder Install.
head
h. Lube oil
pump
Install.
i.
Oil
pan
Install.
j.
Rocker
arm
cover
Install.
k.
Engine
TM 55-1905-219-14-7
The maintenance instructions for the crankshaft and the main bearings are contained in the following paragraphs:
DESCRIPTION
PARAGRAPH
Crankshaft Bearings
Crankshaft
Crankshaft Seals
3-172.1
3-172.2
3-172.3
a. The crankshaft main bearings shells are precision made and are replaceable without machining. They consist of an
upper bearing shell seated in each cylinder block main bearing support and a lower bearing shell seated in each main
bearing cap. The bearing shells are prevented from endwise or radial movement by a tang at the parting line at one end
of each bearing shell. The tangs on the lower bearing shells are off-center and the tangs on the upper bearing shells are
centered to aid correct installation.
b. The bearing caps are numbered 1,2,3, etc., indicating their respective positions and when removed, must always be
reinstalled in their original position.
c. An oil hole in the groove of each upper bearing shell, midway between the parting lines, registers with a vertical oil,
passage in the cylinder block. Lubricating oil, under pressure, passes from the cylinder block oil gallery by way of the
bearing shells to the drilled passages in the crankshaft, then to the connecting rods and connecting rod bearings.
d. The lower main bearing shells have no oil grooves; therefore, the upper and lower bearing shells must not be
interchanged.
e. Thrust washers on each side of the rear main bearing, absorb the crankshaft thrust. The lower halves of the twopiece washers are doweled to the bearing cap; the upper halves are not doweled.
f. Main bearing trouble is ordinarily indicated by low or no oil pressure. All of the main bearing load is carried on the
lower bearings; therefore, wear will occur on the lower bearing shells first. The condition of the lower bearing shells may
be observed by removing the main bearing caps.
3-2982
TM 55-1905-219-14-7
g. Bearing failures may result from deterioration (acid formation) or contamination of the oil or loss of oil. An analysis of
the lubricating oil may be required to determine if corrosive acid and sulphur are present which causes acid etching,
flaking and pitting. Bearing seizure may be due to low oil or no oil.
h. Check the oil filter elements and replace them if necessary. Also check the oil by-pass valve to make sure it is
operating freely.
This task covers:
a. Removal
b. Inspection
INITIAL SETUP
Test Equipment
Cylinder Diameter Gage
J5347-01
Micrometer (with ball end)
c. Installation
References
None
Equipment
Condition Condition Description
Paragraph
Special Tools
Torque wrench
Pump, hand
NSN 4930-00-263-9886
3-163
3-169
3-170
Material/Parts
International Compound
#2 or equivalent
Personnel Required
2
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
1.
Engine
a. Oil pan
1. Remove oil.
Use a suitable
container.
Refer to paragraph 3-163.
2. Remove pan.
3-2983
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
2.
b. Oil
inlet
pipe
Remove.
c.
Remove.
Lube
oil
pump
Main
bearings
1, 2, 3
NOTES
All crankshaft main bearing journals, except the rear journal, are drilled
for
an oil passage. Therefore, the procedure for removing the upper
bearing shells with the crankshaft in place is somewhat different on the
drilled
journals than on the rear journal.
If shims are used between the oil pump and the main bearing caps, save
the shims so that they may be reinstalled in exactly the same location.
Remove one main bearing cap at a time and inspect the bearing shells as
outlined under inspection. Reinstall each bearing shell and bearing cap
before removing another bearing cap.
a. Bolts
(1),
and
lockwashers
(2)
Remove.
b. Bearing
cap
(3)
3- 2984
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
c.
Upper
main
bearing
shell
(4)
Rotate crankshaft
to the right (clockwise), and roll bearing shell out of piston. diameter of the
3. Remove bolt.
3-2985
The head of
bolt must not
extend beyond
the outside
bearing shell.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3. Main
bearing
number
(4)
d. Lower
housing
shell
(5)
e. Pipe
plug
(6)
Remove if necessary.
a. Bolts
(7),
and
lockwashers
(8)
Remove.
b. Bearing
cap
(9)
1.
2.
c.
Upper
main
bearing
shell
(10)
3-2986
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3-2987
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMOVAL (Cont)
d. Upper
thrust
washers
(11)
e. Lower
bearing
shell
(12),
and
lower
thrust
washers
(13)
f.
Remove if necessary.
Dowel
pins
(14)
3-2988
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION
4. Upper
and lower
bearing
shells
a. Bearing
shells
(4 and
10),
(5,
and
12)
1. Clean.
2.
3-2989
The lower
bearing
shells which
carry the
load, will
normally
show signs
of distress
before
the upper
bearing
shells.
However, babbitt plated
bearings may
develop minute
cracks or small
isolated cavities on the
bearing surface
during engine
operation.
These are characteristics of
and are not
detrimental to
this type of
bearing. They
should not be
replaced for
these minor
surface imperfections since
function of the
bearings is in
no way impaired
and they will
give many additional hours of
trouble-free
operation.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
If such spots
are present,
discard the
bearing shells.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
Bearing
Size
Standard
.002" Undersize
.010o Undersize
.020" Undersize
.030" Undersize
Bearing
Minimum
Minimum
Minimum
.1548"/.1553"
.1558"/.1563"
.1598"/.1603"
.1648"/.1653"
.1698"/.1703"
.1530"
.1540"
.1580"
.1630"
.1680"
A-Free Diameter
B-Installed Diameter
C-Bearing Thickness
3-2991
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
5.
b. The bearing shells do not form a true circle when not installed. When installed, the bearing shells have a squeeze fit
in the main bearing bore and must be tight when the bearing cap is drawn down. The crush assures a tight, uniform
contact between the bearing shell and bearing seat. Bearing shells that do not have sufficient crush will not have uniform
contact, as shown by shiny spots on the back, and must be replaced. If the clearance between any crankshaft journal and
its bearing shells exceeds .0060 inch (.0152 cm), all of the bearing shells must be discarded and replaced. This
clearance is .0016 to .0050 inch (.0041 to .0127 cm) with new
parts.
3-2992
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
journals in line with the journal oil holes. If this ridge is not removed before the new bearings are installed, then, during
engine operation, localized high unit pressures in the center area of the bearing shell will cause pitting of the bearing
surface. Also, damaged bearings may cause bending fatigue and resultant cracks in the crankshaft. Refer to paragraph
3-172.2 under Crankshaft Inspection for removal of ridges and inspection of the crankshaft.
d. Do not replace one main bearing shell alone. If one bearing shell requires replacement, install both new upper and
lower bearing shells. Also, if a new or reground crankshaft is to be used, install all new bearing shells.
5. Upper
and
lower
thrust
washers
Thrust
washers
(11 and
13)
Inspect.
If the washers
are scored or
worn excessivelie or the crankshaft end play
is excessive,
they must be
replaced. IMproper clutch
adjustments can
contribute to
excessive wear
on the thrust
washers. Inspect the crankshaft thrust
surfaces. If
after dressing
or regrinding
the thrust surfaces, new
standard size
thrust washers
do not hold the
crankshaft end
play within the
specified limits, it may be
necessary to
install an oversize thrust
3-2993
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
washer on one
or both sides
of the rear
main bearing.
A new standard
size thrust
washer is . 1190
to .1220 inch
(.3023 to .3099
cm) thick.
Thrustwashers
are available
in .005 and
.010 inch (.0127
and .0254 cm)
oversize.
INSTALLATION
6. Upper
bearing
numbers
1, 2,
and 3)
Upper
bearing
shells
(4)
a. Clean.
b
Lubricate.
NOTE
The upper and lower main bearing shells are not alike: the upper bearing shell
is grooved and drilled for lubrication - the lower bearing shell is not. Be sure
to install the grooved and drilled bearing shells in the cylinder block and the plain
bearing shells in the bearing caps. Otherwise, the oil flow to the bearings
and to the upper end of the connecting rods will be blocked off. Used bearing shells
must be reinstalled on the same journal from which they were removed.
c.
Install
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
Lower
bearing
shell
(5)
8. Upper
bearing
number
4
Upper
bearing
shell
(10),
and
thrust
washers
(11)
a. Clean.
b. Lubricate.
c.
a. Clean.
b. Lubricate.
c.
Remove from
washer seats.
The slightest
particle of
dirt or burr
may decrease
the clearance
between washers
and crankshaft.
3-2995
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
Remove
slightest particle of dirt
or burr from
washer seat.
These may decrease the
clearance between washers
and crankshaft.
9. Lower
bearing
number
4 (12),
and
thrust
washers
(13)
Lower
bearing
shell
oil.
10. Bearing
cap
numbers
1, 2,
and 3
a. Bolts
(1)
a. Clean.
b. Lubricate.
c.
Remove the
slightest part
icle of dirt or
burr from the
washer seat.
These may decrease the
clearance between washers
and crankshaft.
Use International Compound #2
or equivalent.
area.
b. Bearing
caps (3)
Position on crankshaft.
NOTE
The main bearing caps are bored into position and stamped 1, 2, 3, etc. They
must be installed in their original positions in the cylinder block.
c. Bolts
1. Install and draw up
(1),
tight.
and lockwashers
(2)
3-2996
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
11. Bearing
cap
number
4
2.
3.
Tighten bolts
uniformly.
a. Bolts
(7)
b. Bearing
caps (9)
Position on crankshaft.
c.
Install.
Bolts
(7),
and
lockwashers
(8)
1.
2.
Torque to 70-75
ft-lb (94.9-
101.7 Nm).
Install and draw up
tight.
Rap the bearing cap
sharply with a soft
hammer.
NOTE
If the bearings have been installed properly, the
crankshaft will turn freely with all of the main
bearing cap bolts drawn to the specified torque.
3-2997
To seat the
bearing caps.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
12. Engine
a. Lube
oil
pump
Install.
graph 3-169.
Refer to para-
b. Oil
inlet
pump
Install.
graph 3-170.
Refer to para-
NOTE
If shims were used between the lube oil pump and the
bearing caps, install them in their original positions.
c.
Oil pan
graph 3-163.
1.
Install.
Refer to para-
2.
3-2998
TM 55-1905-219-14-7
a. The crankshaft is one-piece steel forging, heat-treated to ensure strength and durability. The main and connecting
rod bearing journal surfaces and fillers on all crankshafts are induction hardened.
b. Complete static and dynamic balance of the crankshaft has been achieved by counterweights incorporated into the
crankshaft.
c. The crankshaft end play is controlled by thrust washers located at the rear main bearing cap of the engine. Full
pressure lubrication to all connecting rod and main bearings is provided by drilled passages within the crankshaft and
cylinder block.
d. Two dowels and six tapped holes are provided in the rear end of the crankshaft for locating and attaching the
flywheel. One hole is unequally spaced so that the flywheel can be attached in only one position.
3-2999
TM 55-1905-219-14-7
b. Inspection
c. Installation
INITIAL SETUP
Test Equipment
None
References
None
Special Tools
Equipment
Condition Condition Description
Paragraph
Chain hoist
Pump, hand
NSN 4930-00-263-9886
Gear puller
3-157
3-163
3-164
3-167
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
REMOVAL
1.
Engine
a. Cooling
system
Drain.
b. Engine
oil
3-3000
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REMOVAL(Cont)
c
.Engine
d. accessories
and
assemblies
Disconnect
mounts
Remove to permit engine
to be laid over on one
side.
e. Oil
pan
Remove.
f.
Lube
oil
pump
Remove.
g. Flywheel
and
housing
Remove.
h. Crankshaft
pulley
Remove.
i.
Front
engine
support
Remove.
j.
Cylinder
head
Remove.
k. Connecting
rod
bearing
caps
Remove.
1. Pistons
and
connecting
rods
Remove.
3-3001
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REMOVAL(Cont)
2. Oil pump
drive
gear
3. Crankshaft
m. Crankshaft,
timing
gear,
and
oil
pump
drive
gear
Remove.
n. Timing
gear
Remove.
a. Gear
(1)
b. Woodruff
key (2)
Remove.
a. Pipe
plugs
(3)
Remove if necessary.
b. Pipe
plugs
(4)
Remove if necessary.
3-3002
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION
4. Engine
Crankshaft
INSTALLATION
5. Oil pump
drive
gear
Woodruff
key (2)
Place in crankshaft.
Slide on crankshaft.
The gear should be tight
against the shoulder on
the crankshaft.
6. Timing
gear
Install.
graph 3-166.4.
7. Crankshaft
Install in engine.
8. Engine
3-3003
Refer to para-
TM 55-1905-219-14-7
a. The crankshaft front cover is mounted against the cylinder block end plate at the lower front end of the engine. The
engine is supported at the front end by engine supports attached to the front cover.
b. It will be necessary to remove the crankshaft front cover to remove and install the crankshaft.
c. An oil seal is used at each end of the crankshaft to retain the lubricating oil in the crankcase. The sealing lips of the oil
seals are held firmly, but not tight against the crankshaft sealing surfaces by a coil spring.
d. The front oil seal is pressed into the crankshaft front cover. The lip of the seal bears against a removable spacer or
vibration damper inner cone on the end of the crankshaft.
e. A double-lip oil seal is used in engines where there is oil on both sides of the oil seal; the lips of the seal face in
opposite directions. The rear oil seal is pressed into the flywheel housing.
f. Oil leaks indicate worn or damaged oil seals. Oil seals may become worn or damaged due to improper installation,
excessive main bearing clearances, excessive flywheel housing bore runout or grooved sealing surfaces on the
crankshaft or oil seal spacers. To prevent a repetition of any oil seal leaks, these conditions must be checked and
corrected.
3-3004
TM 55-1905-219-14-7
b. Removal
c. Installation
INTIAL SETUP
Test Equipment
None
References
None
Special Tools
Equipment
Condition Condition Description
Paragraph
Hammer (soft)
3-157
3-159
Material/Parts
Gasket kit P/N 5193114
Shellac
Oil seal P/N 5115454
Oil seal P/N 5115335
Grease or vegetable
shortening
3-163
3-167
3-169
3-170
3-171.1
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
1. Engine
front
supports.
Lifter
supports
3-3005
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
2. Crankshaft
front
cover
a. Three
screws
(1),
and
lock washers
(2)
Remove.
b. Two
screws
(3),
and
lock washers
(4)
Remove.
c.
Remove.
Two
screws
(5),
and
lock washers
(6)
d. Front
cover
(7)
3. Oil seal
(front)
e. Gasket
(8)
Remove.
f.
Remove if necessary.
Dowels
(9)
a. Oil
seal
(10)
Discard gasket.
Discard oil
seal.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
b. Spacer
(11),
and
woodruff
key
(12)
Remove.
c.
Remove.
Oil
slinger
(13)
NOTE
When necessary, an oil seal may be removed without removing the front
cover or flywheel housing. This may be done by drilling diametrically opposite holes in the seal casing and threading metal screws, backed by flatwashers, into the casing. Remove the seal by prying against the washers with pry bars.
3-3007
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
4. Oil seal
rear
a. Flywheel
and
flywheel
housing
Remove.
graph 3-167.
b. Oil seal
(14)
c.
Spacer
(15)
Remove.
3-3008
Refer to para-
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMOVAL (Cont)
5. Engine
a. Oil
seals
(14)
(rear)
and
spacer
(15)
b. Oil
seals
(10)
(front),
and
spacer
(11)
3-3009
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
NOTE
Oil seals are made of an oil-resistant, synthetic rubber which is pre-lubricated with a special
lubricant. Do not remove this lubricant. Keep the sealing lip clean and free from scratches. In
addition, a plastic coating which acts as a sealant has been applied to the outer surface of the
casing. Do not remove this coating.
6. Front
oil
seal
a. Oil
slinger
(13),
spacer
(11),
and
Woodruff
key
(12)
3-3010
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSTALLATION (CONT)
Oil
seal
(10)
seal
1.
2.
3.
3-3011
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSTALLATION (CONT)
7. Rear
oil
seal
a.
Spacer
(15)
b.
Oil
seal
(14)
Install in spacer
against the shoulder
in the flywheel housing oil seal bore.
1.
3-3012
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION(CONT)
3.
Remove any excess sealant from the flywheel housing and the seal.
3-3013
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (CONT)
8. Front
cover
a.
Gasket
(8)
b.
Oil
seal
(10)
c.
Two
screws
(5),
and
lock washers
(6)
Install.
d.
Two
screws
(3),
and
lock washers
(4)
Install.
e.
Three
screws
(1),
and
lock washers
(2)
Install.
f.
Screws
(1, 3
and 5)
3-3014
TM 55-1905-219-14-7
3-172.3. CRANKSHAFT SEALS - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION(CONT)
(34.1-41.0 Nm) and the
1/2-13 screws to 80-90 ft-lb
(109.2-122.9 Nm) torque.
9. Flywheel
housing
3-3015
Refer to para
graph 3-167.
TM 55-1905-219-14-7
a. The cylinder block serves as the main structural part of the engine. Transverse webs provide rigidity and
strength and ensure alignment of the block bores and bearings under load.
b. The block is bored to receive replaceable cylinder liners. The cylinder block is designed to provide water
cooling below the air inlet port belt. An air box between the cylinder banks and extending around the cylinders at the air
inlet port belt conducts the air from the blower to the cylinders. Air box openings on each side of the block permit
inspection of the pistons and compression rings through the air inlet ports in the cylinder liners. The air box openings in
the cylinder block assembly are about 1 7/8 inch x 3 1/8 inch (4.76 x 7.94 cm) and are covered with cast covers. The
camshaft bores are located on the inner side of each cylinder bank near the top of the block.
c. The upper halves of the main bearing supports are cast integral with the block. The main bearing bores are
line-bored with the bearing caps in place to ensure longitudinal alignment. Drilled passages in the block carry the
lubricating oil to all moving parts of the engine.
d. The top surface of each cylinder bank is grooved to accommodate - a block-to-head oil seal ring. Each water
or oil hole is counterbored to provide for individual seal rings.
e. Each cylinder liner is retained in the block by a flange at its upper end. The liner flange rests on an insert
located in the counter- bore in the block bore. An individual compression gasket is used at each cylinder. When the
cylinder heads are installed, the gaskets and seal rings compress to form a tight metal-to-metal contact between the
heads and the block.
f. Cylinder block assemblies include the main bearing caps and bolts, dowels and the necessary plugs. Since the
cylinder block is the main structural part of the engine, the various subassemblies must be removed from the cylinder
block when an engine is overhauled.
3-3016
TM 55-1905-219-14-7
b. Repair
INITIAL SETUP
Test Equipment
None
References
None
Special Tools
None
Equipment
Condition Condition Description
None
Material/Parts
Gasket kit P/N 5196375
Personnel Required
1
LOCATION
ITEM
ACTION
REMARKS
a. Cylinder
block
Refer to Direct
Support Maintenance.
b. Air box
covers
Replace.
c.
Air box
drains
Replace.
d.
Water
holes
Replace.
e. Pipe
plugs
Replace.
f.
Replace.
INSPECTION
1.
Engine
End
plate
gaskets
3-3017
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
a. Air box
If damaged.
b.
Air box
Remove bolt (3), flatcover washer (4), copper gasket (5), cover (6), and
gasket (7).
If gasket is
leaking.
c.
Water
hole
cover
If gasket is
leaking.
d.
Pipe
plugs
(12
thru
26)
Replace.
If damaged.
e.
Special
plug
(27)
Replace.
If damaged.
f.
Plug
cups
(28
thru
31)
Replace.
If damaged.
g.
Four
plugs
(32)
and
gasket
(33)
Replace.
If gasket is
leaking.
Remove if damaged.
REPAIR
2. Cylinder
Block
h. Dowel
pins
(34
and
35)
3-3018
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR (Cont)
3-3019
REMARKS
TM 55-1905-219-14-7
3-173. CYLINDER BLOCK - MAINTENANCE INSTTUCTIONS (Continued
LOCATION
ITEM
ACTION
Six
screws
(36),
and
lockwashers
(37)
Remove if necessary.
b.
Rear
plate
(38),
and
gasket
(39)
Remove if necessary.
a.
Six
screws
(40),
and
lockwashers
(41)
Remove if necessary.
b.
Two
screws
(42),
and
lock washers
(43)
Remove if necessary.
REPAIR (CONT)
3. Cylinder
Block
and
rear
plate
4. Cylinder
Block
front
end
plate
c.
Front
end
plate
(44),
and
gasket
(45)
Remove if necessary.
3-3020-
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR (CONT)
3-3021
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
The instrument panel consists of an engine oil pressure gage, tachometer, engine ammeter, and water temperature
gage. The engine starting and stopping controls are mounted near the anchor "A" frame.
a.
The oil pressure gage registers the pressure of the lubricating oil in the engine. As soon as the engine is started,
the oil pressure gage should start to register. If not, the engine should be stopped and the cause of the low oil pressure
determined and corrected before the engine is started again.
b.
c.
Tachometer.
Refer to paragraph 3-155.
3-3022
TM 55-1905-219-14-7
3-174. INSTRUMENT PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
Inspection
b.
Repair
INITIAL SETUP
Test Equipment
None
References
None
Special Tools
None
Equipment
Condition
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
Condition Description
ACTION
REMARKS
INSPECTION
1.
Instrument
pane
a.
Oil
pressure
gage
b.
Water
temperature gage
1.
2.
3.
1.
2.
3-3023
Defective gage
or tubing?
TM 55-1905-219-14-7
3-174. INSTRUMENT PANEL - MAINTENANCE INSTRUCTIONS (Continued)
LOCATION
ITEM
ACTION
REMARKS
REPAIR
2.
Oil
pressure
gage
a.
Flexible
hose
(1)
b.
Elbow
(2)
Remove.
c.
Nuts
(3)
and
lock washers
(4)
Remove.
d.
Gage
clamp
(5)
Remove.
e.
Gage (6)
Remove.
f.
Elbow
(7)
Remove.
g.
Connector (8)
Loosen.
h. Tube
Loosen.
cl i p
(9)
i.
Tube
(10)
Remove.
j.
Pipe tee
(11)
Remove.
k.
Restriction
fitting
(12)
Replace if necessary.
1. Pipe tee
(11)
Install.
3-3024
Remove hose.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR (Cont)
3-3025
REMARKS
TM 55-1905-219-14-7
3-174. INSTRUMENT PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
m.
Tube
(10)
Install.
n.
Tube
clip
(9)
Install.
o.
Connector
(8)
Tighten.
Elbow
(7)
Install.
q.
Gage
(6)
Install.
r.
Gage
clamp
(5)
Install.
s.
Nuts
(3),
lock washers
(4)
and
elbow
(2)
Install.
t.
Flexible Install.
hose
(1)
3-3026
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR(Cont)
3 -3027
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPAIR (Cont)
3.
Water
temper
ature
gage
a. Clip
(13)
Remove.
b. Adaptor
(14)
Remove.
c.
Disassemble.
Nuts
(15),
lock washers
(16),
and
gage
clamp
(17)
d. Gage
(18)
Remove.
e. Gage
(18)
Install.
f.
Assemble.
Gage
clamp
(17),
nuts
(15)
and
lockwashers
(16)
is damaged.
g. Clip
(13)
Install.
3-3028
1. To prevent damage
to the gage assembly
from vibration, the
capillary tube must be
securely fastened
to the engine the
full length, with
suitable clips at
intervals of ten
inches (15 cm) or
TM 55-1905-219-14-7
ITEM
ACTION
REMARKS
REPAIR (Cont)
less. Sharp
bends in the tube
must be avoided,
particularly at
the gage or bulb
connection areas.
Where the tube
must be bent
around any object,
the bend must not
be less than one
inch (2.54 cm)
radius.
2.
h.
Adaptor
(14)
Install.
3-3029
TM 55-1905-219-14-7
3-175.
a.
When starting an internal combustion engine in cold weather, a large part of energy is absorbed by the
pistons, cylinder walls, coolant and in overcoming friction.
b.
Under extremely low temperatures the cold oil in the bearings and between pistons and cylinder walls creates
high friction, thus engine starting is harder than when the engine is warm.
c.
The normal diesel starting is to ignite the fuel sprayed into the combustion chamber by the heat of air
compressed in the cylinder. This temperature is high enough for normal operating conditions, but at extremely low
temperatures may not be high enough to ignite the injected fuel.
CAUTION
Do not actuate the starting aid more than once with the engine stopped.
Overloading the engine air box with this highly volatile fluid could result in a
minor explosion.
To assist engine starting in low temperatures use the cold weather starting
device.
NOTE
The starting aid is not intended to correct deficiencies but for use when other
conditions are normal and air temperature is too low for heat of compression
to ignite the fuel-air mixture.
3-3030
TM 55-1905-219-14-7
3-175. STARTING AID - MAINTENANCE INSTRUCTIONS (Continued).
Inspection
Service
c.
d.
Replacement
Disassembly
INITIAL SETUP
Test Equipemnt
None
Reference
None
Special Tools
None
Equipment
Condition Condition Description
None
Material/Parts
Cylinder starting
aid LP-535
Valve repair kit
LP-3250
Personnel Required
1
3-3031
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION
1.
Starting
aid
Cylinder
(1)
2.
Engine
Atomizer
and filing
valve
assembly
(2)
a. Visual.
b. Check fitting valve
for wear, cracks, and
leakage.
c.
3.
Starting
aid
4.
Body
quick
start
(3)
Pin
assembly
(4)
Clamp (5)
SERVICE
5.
Starting
aid
3-3032
c.
Lubricate cylinder
valve (8) and pin
assembly (4).
d.
TM 55-1905-219-14-7
3.175. STARTING AID - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
SERVICE (Cont)
ACEMENT
gine
Atomizer
and fittingvalve
assembly
(2)
a.
b.
c.
d.
3-3033
REMARKS
TM 55-1905-219-14-7
ITEM
ACTION
REMARKS
DISASSEMBLY
7. Starting
aid
(4)
Pin
assembly
8. Starting
aid
Body quick
start (3)
a.
b.
Discard.
a.
Replace with
new parts.
b.
c.
Lubricate pin
assembly (4) and
gasket (20).
3-3034
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
DISASSEMBLY (Cont)
3 -3 03 5
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY (Cont)
9.
10.
Cylinder
(1)
Atomizer
and
fitting
valve
assembly
(2)
a.
b.
Screw cylinder (1
a.
b.
3-3036
Hand tight.
into body quick
start (3).
If fluid occurs:
disassemble and
retighten air
TM 55-1905-219-14-7
3-176.
a.
The hydrostarter (starting) motor is mounted on the flywheel housing. The hydrostarter has a high rate of
acceleration; therefore, the engine is cranked faster than other starting systems.
b.
The control lever can be attached in any one of four positions where it is most accessible.
C
A positive starting motor engages the control lever by pushing the starter pinion into engagement with the
flywheel ring gear before the control valve is opened. When a tooth abutment is encountered, the valve permits a small
flow of oil to turn the pinion slowly until it snaps into full engagement. Spring action disengages the pinion and closes the
control valve when the lever is released. An overrunning clutch protects the starting rotor at all times from being driven
at high speeds by the engine before disengagement of the pinion.
This task covers:
a.
b.
Inspection
Repair
c. Removal
d. Installation
INITIAL SETUP
Test Equipment
None
References
Paragraph
3-105
3-106
Special Tools
None
Material/Parts
None
Personnel Required
2
Equipment
Condition
Condition Description
None
3-3037
TM 55-1905-219-14-7
ITEM
ACTION
INSPECTION
1.
2.
3.
Hydrostarter
Hose
fittings
Control
valve
4.
5.
Hoses
a.
Gaskets
Pipe
plug
c.
Oil
wick
Fittings
Control
valve
a.
b.
a.
Control
valve pin
a.
Pressure
hose
b.
Supply
hose
c.
Return
hose
3-3038
REMARKS
TM 55-1905-219-14-7
ITEM
ACTION
REMOVAL
6.
Hand pump
Relief
valve
WARNING
The oil pressure in the system must be released prior to servicing the
hydro8 arter or any other components of the system to prevent possible
injury to personnel or equipment.
3 -3039
REMARKS
TM 55-1905-219-14-7
3-176. HYDROSTARTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
7.
8.
Hoses
Hydrostarter
a. Pressure
hose
Use masking
tape to prevent
entry of dirt.
b. Supply
hose
Use masking
tape to prevent
entry of dirt.
c.
Use masking
tape to prevent
entry of dirt.
Return
hose
Hydrostarter
a.
b.
c.
Discard.
d.
Kemove hydrostarter
(6) from its mounting.
3-3040
TM 55-1905-219-14-7
ITEM
ACTION
REMARKS
REPAIR
9.
10.
Hydrostarter
Control
valve
Housing
a.
b.
c.
d.
e.
Remove preformed
packing (13), and
gasket (14).
Discard if
damaged.
a.
If necessary.
b.
If necessary.
Dip wick in
3-3041
Discard seal
rings.
TM 55-1905-219-14-7
ITEM
ACTION
REMARKS
INSTALLATION
11.
Control
valve
Install seal
rings in seal
ring grooves in
valve body.
c.
d. Lubricate control
valve start pin (10).
Lubricate with
engine oil.
g. Install preformed
packing (13).
h. Install lockwasher
(8 and capscrew (7)
3-3042
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
12.
HydroStarter
a. Install hydrostarter
(5) and gasket (6)
on flywheel housing.
b. Install lockwasher
(4) and bolt (3).
c. Instal I lockwashers
(2), and capscrews (1).
3 -3043
Tighten all
bolts (5/8 x
11) to 137147 ft-lb.
(185.8-199.3
Nm) or to 8595 ft-lb.
(115.3-128.8
Nm) torque for
an aluminum
housing.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
13.
14.
Hoses
Hydrostarting
system
a. Pressure
hose
Connect.
Remove tape.
b. Supply
hose
Connect.
Remove tape.
c. Return
hose
Connect.
Remove tape.
Hand pump
Recharge system.
3 3044
TM 55-1905-219-14-7
a. The accumulator is a heavy-duty shell assembly and piston designed to-hold nitrogen pressure for an extended
period of time.
b. The accumulator is preloaded with nitrogen through a small valve and sealed at the time of manufacture. A seal
ring, in the groove of the piston between two back-up rings, prevents the nitrogen from entering the hydraulic system.
The nitrogen is stored in the air valve end of the accumulator and the fluid is discharged at the opposite end.
c. A seal ring and back-up ring at each cap prevents escape of fluid and nitrogen from the shell. Nitrogen is an inert
gas. Nitrogen will not rust or corrode the piston or accumulator.
d. Oil enters the accumulator under pressure from either the engine-driven pump, or-hand pump and forces the
piston back, compressing the nitrogen and storing energy to operate the system.
e. Service replacement accumulators are supplied with a precharge of nitrogen [1250 + 50 psi (8619 + 345 kPa)].
This task covers:
a. Inspection
INITIAL SETUP
Test Equipment
None
b. Replacement
Reference
None
Special Tools
None
Equipment
Condition
Condition Description
None
Material/Parts
None
Personnel Required
1
3 3045
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION
1.
Accumulator
Accumulator
a. Visually inspect
(1) accumulator (1)
cylinder for leakage.
b. Apply a light oil
or soapy solution
on the threaded end
of the accumulator.
Bubbling indicates
a leak.
2.
Valve caps
(2)
3.
Accumulator
valve (3)
(air check
valve)
3 3046
Replace if
leaking.
Replace if
leaking.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT
Hand pump
Relief
valve
3 3047
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT (Cont)
5.
Accumulator
a . Accumulator
b. Accumulator
valve
(air
check
valve)
(3)
1. Unscrew accumulator
(1) at nipple (7).
2. Remove accumulator
(1).
3 3048
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT (Cont)
6.
Accumulator
(1)
a. Screw accumulator
(1) into nipple (7).
b. Assemble clamp and
bolts (5) or "U" bolt.
NOTE
3 3049
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT (Cont)
7.
Hand pump
3 3050
REMARKS
TM 55-1905-219-14-7
a. The hydrostarter charging pump maintains a pressure of approximately 2900-3300 psi (19996-22754 kPa) in the
accumulator. Do not drive pump at a speed over 2500 rpms. The pump body has an unloading valve. The unloading
valve by-passes the pump discharge to the reservoir once operating pressure is reached. This allows the pump to work
at a reduced load.
b. The hydrostarter charging pump is a single-piston positive displacement pump. The ball check valves and the
unloading valve are controlled by the accumulator pressure. The pump shaft is supported on ball bearings and a seal.
The pump is pressed into the bearing retainer to prevent leaks. The pump is attached to the flywheel housing and is
driven by a drive plate bolted to the camshaft.
This task covers:
a. Inspection
b. Removal
c. Installation
INITIAL SETUP
Test Equipment
None
Reference
None
Special Tools
None
Equipment
Condition
Condition Description
None
Material/Parts
Sealant (Permatex No. 2)
Personnel Required
1
LOCATION
ITEM
ACTION
INSPECTION
1.
Engine
Charging
pump
assembly
3 3051
REMARKS
TM 55-1905-219-14-7
3-178. HYDROSTARTER PUMP (ENGINE-DRIVEN) - MAINTENANCE INSTRUCTIONS(Continued).
LOCATION
ITEM
ACTION
INSPECTION
1.
Engine
Charging
pump
assembly
2.
Housing
assembly
3.
Supply
hose
a. Check fittings.
Pressure
hose
a. Check fittings.
Return
hose
a. Check fittings.
b. Check for leaks.
c. Check for cracks,
breaks, or wear.
3 3052
REMARKS
TM 55-1905-219-14-7
3-178. HYDROSTARTER PUMP (ENGINE-DRIVEN) - MAINTENANCE INSTRUCTIONS(Continued).
LOCATION
ITEM
ACTION
REMOVAL
Hand
pump
a. Relief
valve
3 3053
REMARKS
TM 55-1905-219-14-7
3-178. HYDROSTARTER PUMP (ENGINE-DRIVEN) - MAINTENANCE INSTRUCTIONS(Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
7.
Supply
hose
8.
Pressure
hose
Use masking
tape.
9.
Return
hose
Use masking
tape.
3 3054
Use masking
tape.
TM 55-1905-219-14-7
3-178. HYDROSTARTER PUMP (ENGINE-DRIVEN) - MAINTENANCE INSTRUCTIONS(Continued).
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3 3055
REMARKS
TM 55-1905-219-14-7
3-178. HYDROSTARTER PUMP (ENGINE-DRIVEN) - MAINTENANCE INSTRUCTIONS(Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
10.
Charging
pump
INSTALLATION
11.
Engine
driven
pump
a. Charging
pump
CAUTION
Do not force the pump into place. Use of force or,
tightening the bolts when the mounting flange is not
against the flywheel housing, will force the drive arm
against the pump body and result in damage to the
pump when the engine is started.
c. Install five lockwashers (8), and
capscrews (7).
3 3056
Use a new
gasket. Use
Permatex #2
sealant on the
flywheel side
only.
TM 55-1905-219-14-7
3-178. HYDROSTARTER PUMP (ENGINE-DRIVEN) - MAINTENANCE INSTRUCTIONS(Continued).
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
33057
REMARKS
TM 55-1905-219-14-7
3-178. HYDROSTARTER PUMP (ENGINE-DRIVEN) - MAINTENANCE INSTRUCTIONS(Continued).
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
12.
Return
hose
Pressure
hose
Supply
hose
15.
Hand
pump
Relief
valve
3 3058
REMARKS
TM 55-1905-219-14-7
3-179. HYDROSTARTER HAND PUMP - MAINTENANCE INSTRUCTIONS-
a. The hand pump is a single piston double-acting positive displacement pump. The pumping action is never in a
vertical direction and the handle clears all obstructions throughout its stroke.
b. Use the hand pump to provide initial hydraulic pressure and to build up pressure if pressure was released from the
hydrostarter.
c. A ball check valve controls the flow through the pump. A relief valve is manually operated to release the pressure
before work can be done on the hydrostarter system at the hand pump.
This task covers:
a. Inspection
b. Replacement
c. Repair
d. Reassembly
INITIAL SETUP
Test Equipment
None
e. Installation
Reference
None
Special Tools
None
Equipment
Condition
Condition Description
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
|INSPECTIONI
1.
2.
Hand
pump
Hand pump
assembly
Pump
handle
3 3059
REMARKS
TM 55-1905-219-14-7
3-179. HYDROSTARTER HAND PUMP - MAINTENANCE INSTRUCTIONS-
LOCATION
ITEM
ACTION
INSPECTION (Cont)
3.
Cam pump
4.
Boot
5.
Elbow
tubes
and
hoses
REPLACEMENT
Hand
pump
Relief
valve
3 3060
REMARKS
TM 55-1905-219-14-7
3-179. HYDROSTARTER HAND PUMP - MAINTENANCE INSTRUCTIONS-
LOCATION
ITEM
ACTION
REPLACEMENT (Cont)
3 3061
REMARKS
TM 55-1905-219-14-7
3-179. HYDROSTARTER HAND PUMP - MAINTENANCE INSTRUCTIONS-
LOCATION
ITEM
ACTION
REMARKS
REPAIR
7.
Hand
pump
Pump
handle
(1)
Pump
body
Discard metal
gasket.
Discard seal
rings.
Discard seal
rings.
TM 55-1905-219-14-7
3-179. HYDROSTARTER HAND PUMP - MAINTENANCE INSTRUCTIONS-
LOCATION
ITEM
ACTION
REPAIR (Cont)
3 3063
REMARKS
TM 55-1905-219-14-7
3-179. HYDROSTARTER HAND PUMP - MAINTENANCE INSTRUCTIONS-
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY
NOTE
After cleaning and inspection of pump parts, stone
check valve ball seats (10) in the pump body (4), if
necessary. Then thoroughly clean the pump-parts
and reseat the balls (10) in the pump body (4) using
a non-hardened steel rod.
9.
Pistons
(15)
Thoroughly
soak new backup rings (14)
in warm oil
prior to installation.
Check
valves
11.
Pump body
Use Permatex
No. 2, or equivalent, on all
the male threads
except the
threads neares
to the open end,-.
12.
Relief
valve
3 3064
TM 55-1905-219-14-7
3-179. HYDROSTARTER HAND PUMP - MAINTENANCE INSTRUCTIONS-
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
c. Install relief valve
(16).
13.
Pump body
3 3065
REMARKS
TM 55-1905-219-14-7
3-179. HYDROSTARTER HAND PUMP - MAINTENANCE INSTRUCTIONS-
LOCATION
ITEM
ACTION
INSTALLATION
14.
Hand pump
assembly
NOTE
Make sure ,the hoses and fittings are clean before
any connections are made*
d. Check the assemblies.
Make sure all fittings
are tight and that
there are no leaks.
3 3066
REMARKS
TM 55-1905-219-14-7
3-180. HYDROSTARTER RESERVOIR AND FILTER - MAINTENANCE INSTRUCTIONS-
a. The reservoir is a cylindrical steel tank, which holds the entire oil supply for the hydrostarter system. A filler cap
with a dry-type filter is at the top of the reservoir. A fine mesh screen inside the reservoir, filters the fluid flowing to the
pump from the supply hose.
b. The supply hose is connected to the fine mesh screen at the bottom of the reservoir. One return hose connects to
the top of the reservoir. The other hydrostarter return hose connects into the side.
c. A filter is installed on the suction hose to provide a finer filtration that protects the pump mechanism. The filter is
a stacked element that can be cleaned and reused.
DESCRIPTION
Hydrostarter Reservoir
Hydrostarter Filter
PARAGRAPH
3-180.1
3-180.2
3 3067
TM 55-1905-219-14-7
3-180. 1. HYDROSTARTER RESERVOIR - MAINTENANCE INSTRUCTIONS
c. Replacement
d. Installation
INITIAL SETUP
Test Equipment
None
Reference
None
Equipment
Condition
Condition Description
None
None
Special Tools
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
INSPECTION
1.
Reservoir
(1)
2.
Filler
cap (2),
and dry
type
filter
(3)
3 3068
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
3.
Shut-off
valve (4)
4.
Return
piping
(5)
5.
Supply
piping
(6)
3-3069
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
SERVICE
Reservoir
valve
3 -3070
Use oil/water
separation and
recovery system.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPLACEMENT
7.
Reservoir
Disconnect reservoir
(1) from filter (7).
Disconnect return.
piping (5) at top
of reservoir at elbows.
Remove nuts (8), bolts
(9), and,clamps (10)
from reservoir.
3-3071
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
8.
Reservoir
3-3072
Use hydraulic
fluid MIL-L-
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSTALLATION (CONT)
3 -3073
REMARKS
TM 55-1905-219-14-7
c. Removal
d. Installation
INITIAL SETUP
Test Equipment
None
Reference
None
Special Tools
None
Equipment
Condition Condition Description
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
INSPECTION
I
1
Filter
assembly
a. Cover
b. Cannister
c.
Adapter
d. Elbow
Check connections at
cover and elbow for
leaks and cracks.
Check connection at
adapter and supply hose
for leaks and cracks.
3-3074
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSPECTION (Cont)
2.
Mounting
bracket
Relief
valve
SERVICE
3.
Hand pump
3-3075
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
SERVICE (Cont)
The oil pressure in the system must be released prior to servicing the filter or
any other components of the system to prevent possible injury to personnel or
equipment.
4.
Filter
assembly
(1)
Canister
3-3076
Discard.
Dispose of
used hydraulic
fluid properly.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
SERVICE (Cont)
5.
6.
Filter
assembl y
Filter
element
Canister
Remove.
a. Replace gasket (6).
(1)
b. Insert filter (7) in
canister (4).
c. Place cannister (4)
under cover (5).
d. Swing bail (3) in
place.
e. Tighten bail nut (2)
to secure canister
(4) to cover (5).
3-3077
Dispose of
properly.
Wipe gasket
with hydraulic
oil before
assembly.
Use new filter.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMOVAL
7.
Filter
assembly
(1)
8. Mounting
bracket
Cover
(5)
Mounting
bracket
(13)
3-3078
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
9.
Mounting
bracket
Mounting
bracket
(13)
10.
Filter
assembly
(1)
a. Cover
(5)
Tighten.
b. Cover
(5)
4. Tighten.
1. Install adapters
(8), elbow (9),
and hoses (10).
3-3079
TM 55-1905-219-14-7
a. The hydrostarter supply lines carry hydraulic fluid from the reservoir to the engine-driven pump or the hand pump.
b. The hydrostarter return lines carry the hydraulic fluid from the engine-driven pump or the engine starter to the
reservoir.
c. The hydrostarter pressure lines carry hydraulic fluid from the accumulator to the engine-driven pump, hand pump
and the starter.
Inspection
b.
Replacement
INITIAL SETUP
Test Equipment
None
Reference
None
Special Tools
None
Equipment
Condition
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
Condition Description
ACTION
REMARKS
NOTE
All maintenance is to be preformed by Direct Support Maintenance unless otherwise noted.
INSPECTION
1.
Hydrostarter
piping
(1)
3-3080
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (CONT)
2.
Reservoir
(2)
3.
Accumulator
(3)
c.
3-3081
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (CONT)
4.
5.
Hydrostarter
(4)
Pressure
gage (5)
6.
Hand pump
(6)
7.
Solenoid
8.
Filter and
9.
Valve ball
3000 lbs
(9)
3-3082
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSPECTION (CONT)
3 -3083
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT
Release the pressure in the hydrostarter system by opening the relief valve on
side of the pump approximately 1/2 turn.
The oil pressure in this system must be released prior to servicing the solenoid
valve or any other components of the system to prevent possible injury to
personnel or equipment.
10.
Solenoid
valve
Solenoid
valve
(7)
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT (CONT)
c.
Disconnect electrical
wiring from solenoid.
d. Remove bolts and lockwashers and lift off
old solenoid valve.
e. Replace solenoid valve
with a new one.
3-3085
REMARKS
TM 55-1905-219-14-7
b. Service
INITIAL SETUP
Test Equipment
None
References
None
Special Tools
None
Equipment
Condition
None
Condition Description
Material/Parts
Grease MIL-G-10924
Type GAA
Personnel Required
1
LOCATION
ITEM
ACTION
INSPECTION
1.
"A"
Frame
a . A"
Frame
b. Welds
c.
Hardware
d. Toggle
pins
2.
Anchor
a. Shackle
b. Welds
3-3086
REMARKS
TM 55-1905-219-14-7
3-182. "A" FRAME, WIRE ROPE AND ANCHOR - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
c.
3.
Wire
rope
Anchor
a. Rope
b. Shackles
c.
4.
Sheaves
Links,
turnbuckles
Sheave
4951-157
Change 2
3-3087
TM 55-1905-219-14-7
3-182. "A" FRAME, WIRE ROPE AND ANCHOR - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
SERVICE
5.
"A
Frame
6.
Wire
rope
Hinge
pins
(1)
a. Anchor
cable
sheave
(2)
b. Anchor
tiedown
(3)
c. Wire
ropes
Grease week1y.
Grease. Wipe on
light coating.
4954-156
3-3088
Change 2
TM 55-1905-219-14-7
Inspection
b. Service
INITIAL SETUP
Test Equipment
None
References
None
Special Tools
None
Equipment
Condition
None
Condition Description
Material/Parts
Grease MIL-G-10924
Type GAA
Personnel Required
1
LOCATION
ITEM
ACTION
INSPECTION
1.
Fairleader
a. Swivel
head
b. Flange
and
hub
(3-3089 blank)/3-3090
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
SERVICE
2.
Grease
fittings
3-3091
REMARKS
TM 55-1905-219-14-7
b. Repair
INITIAL SETUP
1.
Wire
rope
cutter
Test Equipment
None
References
None
Special Tools
None
Equipment
Condition
None
Condition Description
Material/Parts
Grease MIL-G-10924
Type GAA
Personnel Required
1
a. Base
b. Blade
c.
Shear
rod
and
sledge
hammer
3-3092
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR
2
a. Nuts
(1),
screws
(2)
and
lockwashers
(3)
b. Base
(4)
and
gasket
(5)
c. Plunger
assembly
(6)
Remove.
Remove.
Lift out.
3-3093
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPAIR (CONT)
d. Plunger
(7),
pin
(8)
and
blade
(9)
e. Guide
pin
(10)
and
die
set
(11)
f. Three
screws
(12),
cutter
base
(13)
and
base
(4)
g. Die
set
(11),
and
guide
pin
(10)
h. Plunger
(7),
pin
(8)
and
blade
(9)
Disassemble.
Remove.
Install.
Assemble.
3 -3094
If necessary. .
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR (CONT)
3-3095
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR (CONT)
i.
j.
k.
Plunger
assembly
(6)
Gasket
(5),
base (4),
lock washers
(3),
screws
(2) and
nuts
(1)
Cutter
Install.
Reassemble..
Grease.
3-3096
REMARKS
TM 55-1905-219-14-7
b. Service
c.
Repair
INITIAL SETUP
Test Equipment
None
References
None,
Special Tools
None
Equipment
Condition
None
Condition Description
Material/Parts
Grease MIL-G-10924
Type GAA
Personnel Required
2
LOCATION
ITEM
ACTION
REMARKS
To avoid possible shock and death, make sure all switches and transmitters are turned off and tagged.
INSPECTION
1.
Mast
a.
Blinker
Lights
b. Anchor
Light
c. Masthead
Light
(3-3097 Blank)/3-3098
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSPECTION (Cont)
3 -3099
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
SERVICE
2.
Grease
fittings
(1)
a. Light
and
wiring
Disassemble.
b. Nuts
(2),
lockwashers
(3),
and
screws
(4)
Remove.
If necessary.
a. Light
and
wiring
b. Nuts
(5),
lockwashers
(6),
and
screws
(7)
Disassemble.
graph 3-113.9.
Refer to para-
Remove
If necessary.
a. Light
and
wiring
Disassemble.
REPAIR
3.
4.
5.
Manoverboard
and
Breakdown
Lights
Blinker
Anchor
Light
3-3100
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR (CONT)
3-3101
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPAIR (CONT)
6.
7.
8.
Masthead
Light
wiring
Antenna
AN/ 1729/
VRC
Anchor
Light
Foundation
b. Nuts
(8),
Iockwashers
(9),
and
screws
(10)
Remove.
If necessary.
a. Light
and
Disassemble.
graph 3-113.4.
Refer to para-
b. Nuts
(11),
lockwashers
(12),
and
screws
(13)
Remove
If necessary.
a. Wiring
Disconnect.
b. Nuts
(14),
Iockwashers
(15),
and
screws
(16)
Nuts (17),
lockwashers
(18), and
screws (19)
Remove.
Remove.
3-3102
If necessary.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR (Cont)
9. Pivot
a. Nuts
(20),
Lock washers
(21),
and
screws
(22)
Remove
3-3103
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPAIR (Cont)
10. Strut
11. Mast
12. Brace
b. Nut
(23),
lock washers
(24),
and
hex
head
capscrew
with
cotter
pin
(25)
c. Yardarm
(26)
Nuts
(27),
lockwashers
(28),
and
screws
(29)
Nuts
(30),
lock washers
(31),
and
screws
(32).
Nut
(33),
and
screw
(34)
Remove.
Pivot.
Replace.
Replace.
Replace.
3-3104
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPAIR (Cont)
4954-223
Change 2
3-3105
TM 55-1905-219-14-7
a. The centralized hydraulic system is used to raise and lower the stern gate, the mast, and the anchor "A" frame.
Refer to the following figure for an overall view of the system.
b. The maintenance instructions are contained in the following paragraphs.
DESCRIPTION
PARAGRAPH
3-187
3-188
3-189
3-190
3-191
3-192
3-193
3-194
3-195
3-196
Hydraulic Ram
Hydraulic Control Valve
Hoses and Fittings
3-197
3-198
3-199
3-200
3-201
3-202
3-3106
TM 55-1905-219-14-7
Change 2
3-3107
TM 55-1905-219-14-7
3-3108
Change 2
TM 55-1905-219-14-7
b. Replacement
INITIAL SETUP
Test Equipment
None
References
None
Equipment
Condition Condition Description
Special Tools
Paragraph
None
3-190
Reservoir Drained
Material/Parts
Hydraulic Fluid MIL-L17672 Type 2110TH or
2135TH
Personnel Required
1
LOCATION
ITEM
ACTION
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Hydraulic
Power
Unit
a. Piping
b. Filter
(3-3109 blank)/3-3110
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPLACEMENT
2
a. Wiring
all wiring to motor.
b. Piping
(1
and
2)
3-3111
Drain hydraulic
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPLACEMENT (Cont)
c.
d.
e.
f.
g.
h.
Nuts
(3),
Lockwashers
(4),
and
screws
(5)
Hydraulic Remove.
power
unit
(6)
Hydraulic Install.
power
unit
(6),
screws
(5),
Lockwashers
(4)
and
nut s
(3)
Piping
(1 and
2)
Hydraulic
Power
Unit
Wiring
Remove.
Replace.
3-3112
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT(Cont)
3-3113
REMARKS
TM 55-1905-219-14-7
3-188. ELECTRIC MOTOR AND COUPLING = MAINTENANCE INSTRUCTIONS.
INITIAL SETUP
Test Equipment
References
None
None
Special Tools
None
Equipment
Condition
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
Condition Description
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Hydraulic
Power
Unit
a. Electric
motor
wiring.
b. Coupling
guard
c.
Coupling
3-3114
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT
2. Electric
motor
and
coupling
a. Wiring
Screws
(1),
and
Lock washers
(2)
Remove.
Coupling
guard
(3)
d. Screws
(4)
and
Lock washers
(5)
e. Motor
(6)
Remove.
c.
Remove.
Remove.
3-3115
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPLACEMENT (Cont)
f.
Coupling
(7)
halves and spiders.
g.
key
(8)
h. Coupling
(7),
and
Woodruff
key
(8)
i. Motor
(6),
screws
(4),
and
Lock washers
(5)
j. Coupling Install.
guard
(3),
screws
and
Lock washers
(2)
k. Wiring
Remove.
1. Reassemble to pump
and motor.
2. Tighten setscrews.
Install.
3-3116
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT
3 -3 117
REMARKS
TM 55-1905-219-14-7
b. Replacement
c.
Installation
INITIAL SETUP
Test Equipment
None
References
None
Special Tools
Equipment
Condition Condition Description
Paragraph
None
3-192
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Hydraulic
Power
unit
a. Pump
b. Piping
c.
Pump
mounting
bracket
3 - 3118
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSPECTION (Cont)
d. Coupling
guard
e. Hardware
a. Screws
(1),
and
Lock washers
(2)
b. Coupling Remove.
guard
(3)
Remove.
REPLACEMENT
2. Hydraulic
pump
3-3119
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT (Cont)
d. Screws
(6),
and
lock washers
(7)
e. Pump
mounting
bracket
(8),
and
pump
assembly
f. Coupling
(9),
and
key
(10)
Remove.
g. Screws
(11),
lock washers
(12),
and
flatwashers
(13)
h. Pump
(14),
mounting
bracket
(8)
i. Pump
outlet
nipple
(15)
j. Pump
inlet
pipe
and
Remove.
Remove.
Separate.
Remove.
Remove.
3-3120
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPLACEMENT (Cont)
k.
l.
elbow
(16),
and
nipple
(17)
Nipple
(18)
Gage
(19),
nipple
(20),
reducer
(21)
and
tee
(22)
Remove.
Disassemble.
3-3121
If necessary.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSTALLATION
m. Nipple
(18)
n. Pipe
and
elbow
(16),
and
nipple
(17)
o. Nipple
(15),
and
elbow
(22) p. Pump
(14),
mounting
bracket
(8),
screws
(11),
Lockwashers
(12),
and
flatwashers
(13)
q. Coupling
(9),
and
key
(10)
r. Pump
mounting
bracket
(8),
screws
(6)
Install.
Install.
Install.
Assemble.
3-3122
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
s.
t.
Union
(4 and
5)
Coupling
guard
(3),
screws
(1)
and
lockwand
washers
(2)
Install.
3-3123
REMARKS
TM 55-1905-219-14-7
Inspection
b. Service
c.
Repair
INITIAL SETUP
Test Equipment
None
References
None
Special Tools
None
Equipment
Condition Condition Description
3-192
Gage and Isolator
Material/Parts
Hydraulic fluid MIL-L17672 Type 2110TH
or 2135TH
Personnel Required
2
LOCATION
ITEM
ACTION
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Hydraulic
reservoir
a. Reservoir
b. Filler
cap
3-3124
REMARKS
TM 55-1905-219-14-7
3-190. HYDRAULIC RESERVOIR TANK AND SUCTION FILTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION
c.
Sight
gage
and
thermometer
SERVICE
a. Drain
plug(s)
Remove.
b. Cleanout
cover
Remove.
c.
Filter
d. Cleanout
cover,
and
drain
plugs
e. Filter
1. Replace.
2. Fill reservoir with
10 gallons (37.9
liters) of hydraulic
fluid.
3-3125
Drain hydraulic
fluid into a
suitable container. Do not
drain fluid into bilges.
Use the oil separation and recovery system
to collect
drained oil.
Clean inside
of reservoir
with clean,
lint-free rags.
Clean filter
screen and magnet.
TM 55-1905-219-14-7
3-190. HYDRAULIC RESERVOIR TANK AND SUCTION FILTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
SERVICE
3. Operate system - then
re-check fluid level
in reservoir.
REPAIR
3. Pipe
plug
4. Filter
5. Cleanout
cover
6. Sight
gage
and
thermometer
Plug
(1)
a. Bolts
(2)
b. Filter
cap
(3)
c. Screen
and
magnet
Replace if necessary.
d. Filter
cap
(3),
and
bolts
(2)
Reinstall.
Cover
(4)
Sight
gage
(5)
Replace.
If necessary.
Replace
If necessary,
Remove.
Remove.
Clean thoroughly.
3-3126
TM 55-1905-219-14-7
3-190. HYDRAULIC RESERVOIR TANK AND SUCTION FILTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
3-3127
REMARKS
TM 55-1905-219-14-7
3-191. CONTROLLER -'MAINTENANCE INSTRUCTIONS.
b. Replacement
INITIAL SETUP
Test Equipment
None
References
None
Special Tool
None
Equipment
Condition Condition Description
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
REMARKS
To avoid serious injury or death, shut off andt ag circuit breaker on main power panel.
INSPECTION
1. Controller
a. Enclosure
breaks, and loose
hardware.
3-3128
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
b. Wiring
c.
Electrical
components
3-3129
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT
2. Fuse
3. Controller
a. Captive
screws
(1)
b. Door
(2)
c. Fuse
(3)
d. Door
(2),
and
captive
screws
(1)
a. Captive
screws
(1)
b. Door
(2)
c. Wiring
d. Enclosure
(4)
e. Enclosure
(4)
f. Wiring
g. Door
(2),
and
captive
screws
(1)
Loosen.
Swing open.
Extract and replace.
Swing closed and tighten
screws.
Loosen.
Swing open.
Tag and disconnect.
Disconnect from
bulkhead.
Replace on bulkhead.
Reconnect and remove tags.
Swing closed and tighten
screws.
3-3130
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT (Cont)
3-3131
REMARKS
TM 55-1905-219-14-7
3-192. GAGE AND ISOLATOR - MAINTENANCE INSTRUCTIONS.
b. Replacement
INITIAL SETUP
Test Equipment
References
None
None
Special Tools
None
Equipment
Condition
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
Condition Description
ACTION
REMARKS
To avoid serious injury or death, shut off and tag circuit breaker on main power panel.
INSPECTION
1. Hydraulic Gage
pump
unit
3-3132
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT
2. Gage
Gage
(1)
3-3133
REMARKS
TM 55-1905-219-14-7
3-193. PUSHBUTTON SWITCH - MAINTENANCE INSTRUCTIONS.
c. Replacement
d. Reassembly
INITIAL SETUP
Test Equipment
References
None
None
Special Tools
None
Equipment
Condition
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
Condition Description
ACTION
REMARKS
To avoid serious injury or death, shut off and tag centralized hydraulic magnetic
controller.
INSPECTION
1. Pushbutton
Switch
Control
Station
a. Indicator
b. Switches
3-3134
TM 55-1905-219-14-7
3-193. PUSHBUTTON SWITCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
DISASSEMBLY
2.
a. Screws
(1)
Remove.
b. Cover
(2)
and
case
(3)
Separate.
3-3135
REMARKS
TM 55-1905-219-14-7
3-193. PUSHBUTTON SWITCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPLACEMENT
3. Pushbutton
Switch
a. Diaphragm
(4)
Unscrew.
b. Gasket
(5)
Remove.
c.
Remove.
Pushbutton
(6)
d. Wiring
e. Switch (7)
f.
Wiring
g. Pushbutton
(6)
Replace.
h. Gasket
(5),
and
diaphragm
(4)
Replace.
3-3136
REMARKS
TM 55-1905-219-14-7
3-193. PUSHBUTTON SWITCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY
4. PushButton
Switch
Control
Station
Cover
(2),
case
(3)
and
screws
(1)
Reassemble.
3-3137
REMARKS
TM 55-1905-219-14-7
3-194. STERN GATE-HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS.
c. Repair
d. Installation
INITIAL SETUP
Test Equipment
References
Paragraph
None
3-195
Equipment
Condition
Special Tools
None
Condition Description
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Vehicle
Deck
Aft
Stbd
a. Control
valve
3-3138
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
3-194. STERN GATE HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMOVAL
2. Diretional
Control
Valve
a. Elbow
nuts
(1, 2,
and
3
and
tee
nut
(4)
b. Valve
Remove.
Change 2
3-3139
REMARKS
TM 55-1905-219-14-7
3-194. STERN GATE HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REPAIR
3.
a. Screw
and
washer
assembly
(6)
Remove.
b. Handle
(7),
and
plastic
handle
(8)
Remove.
c.
Remove.
Screws
(9)
nameplate
(10),
and
gasket
(11)
d. Retaining
ring
(12),
stopplate
(13),
detent
ball
(14),
detent
spring
(15),
and
stop
pin
(16)
Remove.
e. Stop pin
(16)
Insert.
3-3140
Do not loose
ball and spring.
TM 55-1905-219-14-7
3-194. STERN GATE HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
f.
Detent
spring
(15),
detent
ball
(14),
and
stopplate
(13)
Assemble.
g. Retaining
ring (12)
Install.
h. Gasket
(11)
nameplate
(10),
and
screws
(9)
Install.
i.
Install.
Handle
(7),
plastic
handle
(8),
and
washer
assembly
(7)
3-3141
REMARKS
TM 55-1905-219-14-7
3-194. STERN GATE HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSTALLATION
4.
a. Valve
(5),
elbows
and
tees
Install.
b. Elbow
nuts
1, 2,
and 3,
and
tee
nut
(4}
Install.
Change 2
3-3142
REMARKS
TM 55-1905-219-14-7
3-195. STERN GATE HYDRAULIC HOSES, FITTINGS AND PIPING - MAINTENANCE INSTRUCTIONS.
b. Replacement
INITIAL SETUP
Test Equipment
References
Paragraph
None
3-195
Equipment
Condition
Special Tools
None
Condition Description
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Vehicle
Deck
Aft
a. Hoses
b. Fittings
3-3144
TM 55-1905-219-14-7
3-195. STERN GATE HYDRAULIC HOSES, FITTINGS AND PIPING - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont.)
c.
Tubing
REPLACEMENT
2. Hoses
a. Connectors
(1)
Loosen.
b. Hoses
(2)
Remove.
Change 2
3-3145
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
d. Installation
e. Adjustment
INITIAL SETUP
Test Equipment
References
Paragraph
None
3-195
Equipment
Condition
Special Tools
None
Condition Description
None
Material/Parts
Grease MIL-S-2104
Type GAA
Personnel Required
1
LOCATION
ITEM
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Vehicle
Deck
Aft
a. Hoses
3-3146
TM 55-1905-219-14-7
3-196. STERN GATE HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont.)
b. Clevis
c.
Ram
d. Flow
control
SERVICE
2. Rams
Fittings
(1)
Lubricate as appropriate.
Change 2
3-3147
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
3-1964. STERN GATE HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
3. Rams
4. Clevis
a. Hoses
Remove.
b. Pivot
pins
and
cotter pins
(2)
c.
Remove.
Rams
(3)
Clevis
(4)
Unscrew.
Change 2
3-3148
Use wrench on
flats of piston
rod to prevent
damage to seals.
TM 55-1905-219-14-7
3-196. STERN GATE HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMOVAL (Cont.)
5. Flow
Control
valves
Valves
(5)
and
elbows
(6)
Unscrew.
Valves
(5)
and
elbows
(6)
Replace.
INSTALLATION
6. Flow
Control
valves
Change 2
3-3149
REMARKS
TM 55-1905-219-14-7
3-196. STERN GATE HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont.)
7. Clevis
Clevis
(4)
Install.
8. Rams
a. Rams
(3),
pivot
pins
and
cotter pins
(2)
Install.
b. Hoses
Reconnect.
Change 2
3-3150
Use wrench on
flats of piston
rod to prevent
damage to seals.
TM 55-1905-219-14-7
3-196. STERN GATE HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
ADJUSTMENT
9. Cushion
3-3151
REMARKS
TM 55-1905-219-14-7
c. Removal
d. Installation
e. Adjustment
INITIAL SETUP
Test Equipment
References
Paragraph
None
3-199
Equipment
Condition
Special Tools
None
Condition Description
None
Material/Parts
Grease MIL-S-2104
Type GAA
Personnel Required
1
LOCATION
ITEM
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Vehicle
Deck
Aft
a. Hoses
3-3152
Refer to para-,
graph 3-199.
TM 55-1905-219-14-7
3-197. MAST HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont.)
b. Clevis
c.
Ram
control
valves
d. Flow
SERVICE
2. Rams
Grease
fittings
(1)
Lubricate.
3-3153
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
3-197. MAST HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
3. Rams
4. Clevis
a. Hoses
Remove.
b. Pivot
pins
and,
retainers
(2)
c.
Remove.
Rams
(3)
Clevis
(4)
Unscrew.
3-3154
Use wrench on
flats of piston
rod to prevent
damage to seals.
TM 55-1905-219-14-7
3-197. MAST HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMOVAL (Cont.)
5. Fittings
a. Elbows
(5)
Replace.
b. Flow
control
valve
(6),
and
piping
(7)
Replace.
Change 2
3-3155
REMARKS
TM 55-1905-219-14-7
3-197. MAST HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSTALLATION
6. Fittings
a. Elbows
(5)
Replace.
b. Flow
control
valve
(6)
and
piping
(7)
Replace.
Change 2
3-3156
REMARKS
TM 55-1905-219-14-7
3-197. MAST HYDRAULIC RAM - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont.)
7. Clevis
Clevis
(4)
Install.
8. Rams
a. Rams
(3),
pivot
pins
and
retainers
(2)
Install.
b. Hoses
Reconnect.
ADJUSTMENT
9. Cushion
Use wrench on
flats of piston
rod to prevent
damage to seals.
TM 55-1905-219-14-7
3-198. MAST HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE
INSTRUCTIONS (Continued).
c. Repair
d. Installation
INITIAL SETUP
Test Equipment
References
Paragraph
None
3-199
Equipment
Condition
Special Tools
None
Condition Description
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Vehicle
Deck
Aft
Stbd
2. Insure all hardware
is tight.
a. Control
valve
b. Tubing
3-3158
Refer to Direct
Support Mainte
nance.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
2. Directional
Control
Valve
a. Hoses
(1, 2,
3,) and
(4)
Remove.
b. Elbows
(5, 6,
7 and 8)
Remove.
c.
Remove.
Valve
(9)
4915-065
Change 2
3-3159
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REPAIR
3.
a. Screw/
washer
assembly
(6)
b. Handle
(7),
and
plastic
handle
(8)
c. Screws
(9) ,
nameplate
(10),
and
gasket
(11)
d. Retaining
ring (12),
stop-plate
detent
ball (14),
detent
spring
(15),
and stoppin (16)
e. Stop-pin
(16)
f. Detent
spring
(15),
detent
ball
(14),
and
stop-plate
(13)
Remove.
Remove.
Remove.
Remove.
Insert.
Assemble.
Change 2
3-3160
Do not lose
ball and ring.
TM 55-1905-219-14-7
3-198. MAST HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
g.
Retaining
ring
(12)
Install.
h.
Gasket
(11),
nameplate
(10),
and
screws
(9)
Install.
i.
Plastic
handle
(8),
handle
(7),
and
screw/
washer
assembly
(6)
Install.
3-3161
REMARKS
TM 55-1905-219-14-7
3-198. MAST HYDRAULIC DIRECTIONAL CONTROL VALVE MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
4.
a.
Valve
(9)
Install
b.
Elbows
(5. 6,
7 and 8)
c.
Hoses
(1, 2,
3 and
4)
Install.
4954-061
Change 2
3-3162
TM 55-1905-219-14-7
3-199. MAST HYDRAULIC HOSES, FITTINGS AND PIPING - MAINTENANCE INSTRUCTIONS.
Inspection
b.
Replacement
INITIAL SETUP
Test Equipment
References
Paragraph
None
3-197 Hydraulic Ram
3-198 Directional Control Valve
Equipment
Condition
Condition Description
Special Tools
None
None
Material/Parts
None
None
Personnel Required
Observe WARNING.
LOCATION
ITEM
ACTION
REMARKS
REPAIR (Cont)
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1.
Vehicle
Deck
Stbd
side
a.
Hoses
b.
Fittings-
3-3163
TM 55-1905-219-14-7
3-199. MAST HYDRAULIC HOSES, FITTINGS AND PIPING MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
c.
Tubing
a.
Straight
connectors
(1)
Loosen.
b.
Hoses
(2)
Remove.
Refer to Direct
Support Maintenance.
REPLACEMENT
2.
Hoses
4951-063
Change 2
3-3164
*U.S. GOVERNMENT PRINTING OFFICE: 1992 - 624-028/60082
TM 55-1905-219-14-7
3-200. ANCHOR "A" FRAME HYDRAULIC WINCH - MAINTENANCE INSTRUCTIONS.
Inspection
Repair
b.
d.
Removal
Installation
INITIAL SETUP
Test Equipment
References
Paragraph
None
3-202 Hydraulic Hoses, Fittings
and Piping
Equipment
Condition
Condition Description
Special Tools
None
None
Material/Parts
None
None
Personnel Required
Observe WARNING
LOCATION
ITEM
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1.
Vehicle
Deck
Aft
a.
Cable
fraying, bends,
broken strands and
damaged or missing
parts of socket.
3-3165
TM 55-1905-219-14-7
3-200. ANCHOR "A" FRAME HYDRAULIC WINCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
b.
c.
d.
Winch
motor
Hoses
Winch
assembly
REPAIR
Cable
a.
Cotter
pin
(1),
and
pin
(2)
Remove.
b.
Winch
control
Operate to unspool
wire (3).
c.
Winch
drum
(4)
d.
Wire
(3)
e.
Winch
control
f.
Pin
(2),
and
cotter
pin
(1)
3-3166
TM 55-1905-219-14-7
3-200. ANCHOR "A" FRAME HYDRAULIC WINCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
3-3167
REMARKS
TM 55-1905-219-14-7
3-200. ANCHOR "A" FRAME HYDRAULIC WINCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
Anchor
Hydraulic
Winch
Assembly
pin
(2)
a.
Cotter
pin
(1),
and
Remove.
b.
Wire
(3)
c.
Swivel
connectors
(5, 6
and 7)
Nuts
(8),
lockwashers
(9),
and
screws
(10)
Winch
assembly
(11)
Disassemble.
Elbows
(12)
Remove.
d.
e.
f.
Remove.
Remove.
3-3168
Remove hoses as
per paragraph
3-202.
TM 55-1905-219-14-7
3-200. ANCHOR "A" FRAME HYDRAULIC WINCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3-3169
REMARKS
TM 55-1905-219-14-7
3-200. ANCHOR "A" FRAME HYDRAULIC WINCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSTALLATION
4.
a.
Elbows
(12)
Install.
b.
Winch
assembly
(11)
screws
(10),
Iockwashers
(9),
and
nuts
(8)
Install.
c.
Swivel
connectors
(5, 6,
and 7)
Reconnect.
d.
Wire
(3),
pin
(2),
and
cotter
pin
3-3170
REMARKS
TM 55-1905-219-14-7
3-200. ANCHOR "A" FRAME HYDRAULIC WINCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
3-3171
REMARKS
TM 55-1905-219-14-7
3-201. ANCHOR "A FRAME Hydraulic DIRECTIONAL CONTROL VALVE MAINTENANCE INSTRUCTIONS.
Inspection
Removal
b.
d.
Repair
Installation
INITIAL SETUP
Test Equipment
References
Paragraph
None
3-202 Hydraulic Hoses, Fittings
and Piping
Equipment
Condition
Condition Description
Special Tools
None
None
Material/Parts
None
None
Personnel Required
Observe WARNINGS.
LOCATION
ITEM
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1.
Vehicle
Deck
Aft
Stbd
a.
Control
valve
33172
1.
2.
TM 55-1905-219-14-7
3-201. ANCHOR "-A" FRAME HYDRAULIC DIRECTIONAL CONTROL VALVE MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
b.
Tubing
a.
Elbow
nuts
(1,
2, 3
and
(4)
1.
2.
Valve
(5)
Remove.
REMOVAL
2.
Directional
Control
Valve
b.
3-3173
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
3-201. ANCHOR "A" FRAME HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
REPAIR
3.
a.
Screw
and
washer
assembly
(6)
Remove.
b.
Handle
(7),
and
plastic
handle
(8)
Remove.
c.
Screws
(9),
nameplate
(10),
and
gasket
(11)
Remove.
d.
Retaining Remove.
ring
(12),
stopplate
(13),
detent
ball
(14),
detent
spring
(15),
and
stoppin
(16)
3-3174
Do not lose
the ball and
spring.
TM 55-1905-219-14-7
3-201. ANCHOR "A" FRAME HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
3-3175
REMARKS
TM 55-1905-219-14-7
3-201. ANCHOR "A" FRAME HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
e.
Stoppin
(16)
Insert.
f.
Detent
spring
(15),
detent
ball
(14),
and
stopplate
(13)
Assemble.
g.
Retaining
ring
(12)
Install
h.
Gasket
(1-1),
nameplate
(10),
and
screws
(9)
Install.
i.
Plastic
handle
(7),
handle
(8),
and
screw/
washer
assembly
(6)
Install.
33176
REMARKS
TM 55-1905-219-14-7
3-201. ANCHOR "A" FRAME HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
3-3177
REMARKS
TM 55-1905-219-14-7
3-201. ANCHOR "A" FRAME HYDRAULIC DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
INSTALLATION
4.
a.
Valve
(5),
and
e1bows
Install.
b.
Elbow
(1, 2,
3, and
4)
Install.
3-3178
REMARKS
TM 55-1905-219-14-7
3-202. ANCHOR "A" FRAME HYDRAULIC HOSES, FITTINGS AND PIPING - MAINTENANCE INSTRUCTIONS.
Inspection
b.
Replacement
INITIAL SETUP
Test Equipment
References
Paragraph
None
3-200 Hydraulic Winch
3-201 Direction Control Valve
Equipment
Condition
Condition Description
Special Tools
None
None
Material/Parts
None
None
Personnel Required
Observe WARNINGS.
LOCATION
ITEM
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1.
Vehicle
Deck
Stbd
side
a.
Hoses
b.
Fittings
1.
3-3179
TM 55-1905-219-14-7
3-202. ANCHOR "A" FRAME HYDRAULIC HOSES, FITTINGS AND PIPING - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
c.
Tubing
a.
Straight
connectors
(1)
and
swivel
connectors
(2)
Loosen.
b.
Hoses
(3)
Remove.
REPLACEMENT
2.
Hoses
3-3180
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
3-203. STEERING SYSTEM - MAINTENANCE INSTRUCTIONS.
The steering system consists of a Cub Hydraulic Pump Unit and the following associated components; a Rudder
Angle Indicator, a Flanking Rudder Limit Switch and a Steering Control Panel.
a.
1.
The Cub Hydraulic Pump Unit is a power source for hydraulic steering systems. This pump unit is used in
conjunction with control and follow-up equipment to make up a complete steering system.
2.
Variations of the basic pump unit are available to suit power requirements and needs of each particular
installation.
3.
The following description of the pump unit is taken in the order of flow of hydraulic fluid. Refer to the block
diagram of the system.
4.
the fluid.
5.
b.
This pump unit is mounted on a 10-gallon (37.85 liter) tank. A 100-mesh strainer located in the sump filters
Vane Pump.
1.
This pump is a rotary, single-stage sliding vane unit consisting of a housing and rotor assembly.
2.
The rotor has a series of slots into which are fitted movable vanes. As the rotor turns, the vanes are thrown
outward by centrifugal force to bear against the surface of an oval shaped ring (cam). As the vanes move across the
inlet chamber, the radius of the oval ring increases to create an increasing space between the rotor and the ring.
Atmospheric pressure acting upon the inlet fluid forces it into this space. Fluid is trapped between vanes as they move
past the inlet chamber. At this point, the radius of the contour decreases and the fluid is forced into the outlet chamber.
c.
The pump relief valve is set to operate at a pressure which actsto divert oil back to the tank whenever the
pressure rises above the established point. The valve is set at installation and need not be readjusted.
3-3181
TM 55-1905-219-14-7
3-203. STEERING SYSTEM - MAINTENANCE INSTRUCTIONS. (Continued).
d.
Directional Valve.
The directional valve is a solenoid operated valve which controls the flow to operate the rudder positioning
cylinders. This valve is electrically controlled from the external electronic control amplifier. The solenoids of the valve
are de-energized if the rudder limit switches are activated.
e.
Brake Valves.
Brake valves lock the cylinders into any position when no changes are being ordered. This valve is set at
installation.
f.
1.
The cylinder relief valves are connected across the lines that link the pump unit to the rudder positioning
cylinders. These valves limit pressure build-up as a result of an object striking the rudder by allowing the rudder to move
even though the brake valves are closed. This prevents damaging the steering gear.
3-3182
TM 55-1905-219-14-7
3-203. STEERING SYSTEM - MAINTENANCE INSTRUCTIONS. (Continued).
3-3183
TM 55-1905-219-14-7
3-203. STEERING SYSTEM - MAINTENANCE INSTRUCTIONS. (Continued).
PARAGRAPH
3-204
3-205
3-206
3-207
3-208
3-209
3-210
3-211
3-212
3-213
3-214
3-215
3-216
3-217
3-218
3-219
3-3184
TM 55-1905-219-14-7
3-204. HYDRAULIC CUB PUMP UNIT - MOTOR - MAINTENANCE INSTRUCTIONS.
Inspection
b.
Disassembly
c.
Reassembly
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Condition Description
Special Tools
None
None
Material/Parts
None
None
Personnel Required
Observe WARNINGS.
LOCATION
ITEM
ACTION
REMARKS
To prevent electrical shock, tag the motor controller and place in the OFF position.
INSPECTION
1.
Motor
a.
Wiring
b.
Frame
3-3185
TM 55-1905-219-14-7
3-204. HYDRAULIC CUB PUMP UNIT - MOTOR - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSPECTION (Cont)
c.
2.
Coupling
guard
Coupling
Guard
2.
1.
2.
DISASSEMBLY
3.
a.
Wiring
b.
Hex
head
screws
(1),
Iockwashers
(2),
and
washers
(3)
Remove.
c.
Coupling
guard
(4)
Remove.
d.
Hex
head,
screws
(5),
and
lock washer
(6)
Remove.
3-3186
REMARKS
TM 55-1905-219-14-7
3-204. HYDRAULIC CUB PUMP UNIT - MOTOR - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY (Cont)
e.
Electric
motor
(7)
Slide back.
f.
Setscrew
(8)
Loosen.
g.
Flexible
coupling
(9), and
key (10)
Remove.
h.
Electric Remove.
motor
(7)
3-3187
Return to
Direct Support
Maintenance.
TM 55-1905-219-14-7
3-204. HYDRAULIC CUB PUMP-UNIT - MOTOR - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY
4.
a.
Electric
motor
(7),
key
(10),
and
flexible
coupling
(9)
Reassemble.
b.
Hex
head
screws
(5),
and
lockwashers
(6)
Reassemble.
c.
Flexible
coupling
(9)
Setscrew
(8)
Adjust.
Coupling
guard
(4),
washers
(3),
lockwashers
(2),
and
hex
head
screws
(1)
Reassemble.
d.
e.
Tighten.
3-3188
REMARKS
TM 55-1905-219-14-7
3-204. HYDRAULIC CUB PUMP-UNIT - MOTOR - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
3-3189
REMARKS
TM 55-1905-219-14-7
3-205. HYDRAULIC CUB PUMP UNIT --MOTOR CONTROLLER - MAINTENANCE INSTRUCTIONS.
A.
GENERAL
1.
The motor controller is an A-C across-the-line non-reversing unit that controls the three-phase electric motor
used with the hydraulic pump on the steering system.
2.
The controller contains a LOCAL-OFF-REMOTE switch and a RESET control on the front panel and houses
a line contactor, power transformer, control relay, and fuses. The controller is used with a steering panel which provides
remote control of the motor starter. In such an installation, the control switch is normally in its REMOTE position. For
testing purposes, the switch can be turned to the LOCAL position, thereby energizing the contactor coil. In the OFF
position, the contactor control circuit is de-energized. The controller contains terminals to which the remote pump run
indicator lamp is connected to show when the motor is energized.
B.
DESCRIPTION.
1.
Starter contacts connect the motor directly to the power line upon actuation of the controller. Control circuits
are isolated from the power line by a 500-volt-ampere transformer that steps down the ship's supply to 115 volts. This
low voltage can also be used to energize indicator lamps and to supply 115 volts at 60 cps to the steering panel with
which the started may be used.
2.
A remote start switch (in a steering panel), or the LOCAL-OFF-REMOTE switch on the controller panel
closes a circuit through the coil of the main line contactor. The coil closes the three line contactors and connects the
motor to the power line as long as the switch remains closed. The main line contactor a1so closes the circuit to light a
"run" indicator lamp.
3.
If the motor load becomes excessive, either of three over-current thermal heaters in serieswith the motor
input opens the normally closed contacts in series with the coil of a control relay. This coil then releases its spring-loaded
contacts which close and energizes the overload circuit. The overload relay remains open until it is mechanically closed
by means of the RESET control. The motor remains connected to the power line despite the over-current because
continued operation is usually more important than possible damage to the motor and hydraulic steering equipment. For
this reason, an overload indicated should be investigated immediately and corrective action taken as soon as possible.
3-3190
TM 55-1905-219-14-7
3-205. HYDRAULIC CUB PUMP UNIT --MOTOR CONTROLLER - MAINTENANCE INSTRUCTIONS.
4.
The indicator circuit is fused in both legs. Also, the circuit that supplies 115 volts 60 cps to a steering panel
is fused in both legs. The 115-volt steering panel supply is energized at all times that power is applied to the controller
even though the motor controlled by the starter is not energized.
LEGEND
M-
LINE CONTACTOR
OL -
OVERLOAD RELAY
CR -
CONTROL RELAY
* IL -
F-
FUSE
3-3191
TM 55-1905-219-14-7
3-205. HYDRAULIC CUB PUMP UNIT - MOTOR CONTROLLER - MAINTENANCE INSTRUCTIONS.
Inspection
b.
Repair
c.
Replacement
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Condition Description
Special Tools
None
None
Material/Parts
None
None
Personnel Required
Observe WARNINGS.
LOCATION
ITEM
ACTION
REMARKS
To prevent electrical shock and possible death, tag the motor controller and place all circuit breakers in the OFF position.
INSPECTION
1.
Controller
a.
Housing
3-3192
1.
2.
TM 55-1905-219-14-7
3-205. HYDRAULIC CUB PUMP UNIT - MOTOR CONTROLLER - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION CONTINUED
b. External
wiring
c.
Internal
REPAIR
2.
a. Fuses
b. Contacts
c.
Stationary
contacts
d. Movable
contact
3-3193
Replace as required.
TM 55-1905-219-14-7
3-205. HYDRAULIC CUB PUMP UNIT - MOTOR CONTROLLER - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
1. Remove plunger.
2. Pull down on two
verticale guides;
one in front, and
one in back of coil.
REPLACEMENT
3.
a. Wiring
b. Case
3-3194
REMARKS
TM 55-1905-219-14-7
3-205. HYDRAULIC CUB PUMP UNIT - MOTOR CONTROLLER - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPLACEMENT (Cont)
1.
2.
3.
4.
5.
6.
TERMINAL STRIP
FUSES
MOTOR STARTER
COIL
CONTACT (Replacement Kit)
OVERLOAD HEATER
3-3195
REMARKS
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP - MAINTENANCE
INSTRUCTIONS.
LOCATION
A.
ITEM
ACTION
REMARKS
GENERAL.
1. This pump is used to develop hydraulic fluid flow for the operation of the steering system equipment. The
positive displacement pumping cartridges are the rotary vane type with shaft side loads hydraulically balanced.
2. All units are designed so that the direction of rotation, pumping capacity and port positions can be readily
changed to suit particular applications.
B.
1. The unit consists principally of a ported body, a ported cover and a pumping cartridge. Components of the
pumping cartridge are an elliptical cam ring, a slotted rotor splined to fit the drive shaft and twelve vanes fitted to therotor slots.
2. The pumping cartridge cam ring is sandwiched between the body and cover. A ball bearing and bushing
located in the body and pressure plate respectively support each end of the drive shaft and center the rotor within the
cam ring. As the drive shaft is driven by the prime mover, the rotor and vanes generate flow by carrying fluid around the
elliptical cam ring contour. Fluid enters the cartridge through the inlet port in the body and is discharged through the
pressure plate into the outlet port of the cover.
3. Fluid flow is developed by the pumping cartridge. The action of the cartridge is illustrated below. The rotor
is driven within the cam ring by the driveshaft, which is coupled to a power source. As the rotor turns, centrifugal force
causes the vanes to follow the elliptical inner surface of the cam ring.
4. Radial movement of the vanes and-turning of the rotor cause the chamber volume between the vanes to
increase as the vanes pass the in- let sections of the cam ring. This results in a low pressure condition which allows
atmospheric pressure to force fluid into the chambers. (Fluid outside the inlet is at atmospheric pressure or higher).
5. This fluid is trapped between the vanes and carried past the large diameter or dwell section of the cam ring.
As the outlet section is approached, the cam ring diameter-decreases and the fluid is forced out into the system. System
pressure is fed under the vanes, assuring their sealing contact against the cam ring during normal operation.
3-3196
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP - MAINTENANCE
INSTRUCTIONS (Continued).
6. The pump cam ring is shaped so that the two pumping chambers are formed diametrically opposed. Thus,
hydraulic forces which would impose side loads on the shaft are cancelled.
7. The pressure plate seals the pumping chamber. A light spring holds the plate against the cartridge until
pressure builds up in the system. System pressure is effective against the area at the back of the plate, which is larger
than the area exposed to the pumping cartridge. Thus, an unbalanced force holds the plate against the cartridge, sealing
the cartridge and providing the proper running clearance for the rotor and vanes.
3-3197
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP - MAINTENANCE
INSTRUCTIONS (Continued).
b. Disassembly
c.
Reassembly
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Special Tools
Condition Description
None
None
Material/Parts
None
None
Personnel Required
Observe WARNING.
LOCATION
ITEM
ACTION
INSPECTION
1. Hydraulic
Power
Unit
a. Pump
b. Piping
3-3198
REMARKS
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSPECTION (Cont)
c.
Pump
mounting
bracket
d. Coupling
guard
e. Hardware
a. Hex
head
screw
cap
(1),
lockwasher
(2),
and
flat
washer
(3)
Remove.
DISASSEMBLY
2.
3-3199
REMARKS
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
DISASSEMBLY (Cont)
b. Coupling
guard
(4)
Remove.
c.
Pipe
union
(5)
Loosen.
d. Steel
tubing
(6)
Loosen.
e. Hex
socket
screw
cap
(7),
and
lockwasher
(8)
Remove.
f.
Vane
pump
and
bracket
assembly
(9)
g. Setscrew
(10)
Loosen.
h. Flexible
coupling
(11a )
and
key
(12)
Remove.
3-3200
REMARKS
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
DISASSEMBLY (Cont)
i.
Pipe
nipple
(13),
union
(5),
and
elbow
(14)
Disassemble.
3-3201
REMARKS
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
DISASSEMBLY (Cont)
j.
Elbow
(15)
Remove.
k.
Hex
head
screw
cap
(16),
and
mounting
bracket
(17)
Remove.
l.
Vane
pump
(18)
Remove.
3-3202
REMARKS
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT HYDRAULIC PUMP MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY
3.
a. Elbow (15)
Install.
b. Elbow (14),
and pipe
nipple
(13)
Install.
c.
Reassemble.
Vane pump
(18), hex
head
screw
cap (16)
and
mounting
bracket
(17)
3-3203
REMARKS
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
d. Key
(12),
and
flexible
coupling
(11a)
Reassemble.
e. Vane
pump
and
bracket
assembly
(9)
f. Flexible
coupling
(11)
g. Setscrew
(10)
h. Hex
socket
screw
cap
(7),
and
lockwasher
(8)
i. Steel
tubing
(6)
Push back.
j.
Reassemble.
Pipe
union
(5)
Adjust.
Tighten.
Reassemble.
Install.
3-3204
REMARKS
TM 55-1905-219-14-7
3-206. HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
k.
Coupling
guard
(4),
flatwasher
(3),
lockwasher
(2), and
hex head
screw
cap (1)
Reassemble.
3-3205
REMARKS
TM 55-1905-219-14-7
3-207. HYDRAULIC CUB PUMP UNIT - BRAKE VALVE - MAINTENANCE
INSTRUCTIONS
A
DESCRIPTION.
1. The brake valve is provided with an integral check valve which permits reverse free flow from the secondary
port to the primary port when the valve is closed.
2. The brake valve is internally drained and remotely operated. It is used primarily as an unloading valve where
the secondary port must be connected directly to the tank. Application of external pressure permits the valve to open fully
independent of the primary pressure. Type 4 valves can also be used as remotely operated counterbalance or brake
valves when provided with the integral check valve.
B.
INSTALLATION.
1. These gasket mounted valves are teed into the supply line. The tee connection is piped to the bottom, or
pressure port in the sub- plate, or to the back surface of the mounting area. The top, or secondary port is piped to the
tank or to the secondary circuit with the covers arranged for internal or external draining and direct or remote control
depending on the valve action required.
2. The point at which the valve begins to function is determined by the position of the adjusting screw (which
varies the force exerted by the spring on the spool), referred to as the pressure setting of the valve. Clockwise rotation of
the screw increases pressure. Counterclockwise rotation decreases pressure.
3. The effective areas of the spool exposed to hydraulic pressure in primary chamber A being equal, the spool
is hydraulically balanced and held in a normally closed position by the force of the spring. When pressure in primary
chamber A - which is effective on the piston through passages C - exceeds the adjusted pressure setting, the piston is
forced upward, moving the spool accordingly.
4. The spool moving upward opens secondary chamber B permitting pump delivery to flow into the secondary
circuit, while maintaining a minimum pressure in primary chamber A equal to the pressure setting of the valve.
5. When the primary pressure decreases, compression of the spring overcomes the hydraulic force effective on
the piston and the spool closes blocking flow to chamber B.
3-3206
TM 55-1905-219-14-7
3-207. HYDRAULIC CUB PUMP UNIT - BRAKE VALVE - MAINTENANCE
INSTRUCTIONS (Continued).
6. Fluid leakage trapped between the piston and the spool escapes through the center hole of the spool, into
spring chamber D, through drain passage E to chamber B and tank, or externally to tank depending on the position of the
top cover.
7. Operation of this valve when used with a gravity returned single acting ram is such that pump fluid passes
free flow into secondary chamber B, then through the check valve and chamber A into the ram. Pressure buildup in the
ram closes the spool.
8. When the work stroke is completed, fluid flow is diverted from the secondary port by directing the pump
delivery to tank.
9. On the return stroke, trapped fluid under pressure in the primary port holds the valve spool and check valve
closed until a small amount of fluid bleeding-off through the needle valve or orifice reduces the trapped pressure.
10.
When pressure drops below the valve setting, the spring forces the valve spool to open directing the
discharge flow through the secondary port to tank.
3-3207/(3-3208 blank)
TM 55-1905-219-14-7
3-207. HYDRAULIC CUB PUMP UNIT - BRAKE VALVE - MAINTENANCE
INSTRUCTIONS (Continued).
This task covers:
a. Inspection
b. Disassembly
c.
Reassembly
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Special Tools
Condition Description
None
None
Material/Parts
None
Personnel Required
Observe WARNING.
LOCATION
ITEM
ACTION
INSPECTION
1. Brake
valve
Valve
3-3209
REMARKS
TM 55-1905-219-14-7
3-207. HYDRAULIC CUB PUMP UNIT - BRAKE VALVE - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY
2.
a. Nut
(1),
and
adjusting
screw
(2)
b. Screws
(3)
Remove.
c.
Remove.
Top
cover
(4),
and
gasket
(5)
d. Preformed
packing
(6),
spring
plug
(7),
spring
(8),
and
spool
(9)
Remove.
e. Spool
(9)
3-3210
Do not discard
gasket.
TM 55-1905-219-14-7
3-207. HYDRAULIC CUB PUMP UNIT - BRAKE VALVE - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
DISASSEMBLY (Cont)
3-3211
REMARKS
TM 55-1905-219-14-7
3-207. HYDRAULIC CUB PUMP UNIT - BRAKE VALVE - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
DISASSEMBLY (Cont)
f.
Screws
(10)
Remove.
g. Bottom
cover
(11)
Remove.
h. Bottom
cover
(11)
i.
Gasket
(12)
Remove.
j.
Seals
(13
and
14)
Remove.
k.
Pilot
piston
(15)
Remove.
l.
Pilot
piston
(15)
m. Plugs
(16
and
17)
Remove if necessary.
3-3212
REMARKS
TM 55-1905-219-14-7
3-207. HYDRAULIC CUB PUMP UNIT BRAKE VALVE MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
DISASSEMBLY (Cont)
3-3213
REMARKS
TM 55-1905-219-14-7
3-207. HYDRAULIC CUB PUMP UNIT - BRAKE VALVE - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY
3.
a. Pilot
piston
(15),
seals
(14
and
13),
and
gasket
(12)
b. Bottom
cover
(11),
and
screws
(10)
c. Spool
(9),
spring
(8),
spring
pIug
(7),
and
preformed
packing
(6)
d. Gasket
(5),
top
cover
(4),
screws
(3),
adjusting
screw
(2),
and
bolt
(1)
Reassemble.
Lubricate seals
with hydraulic
fluid.
Reassemble.
Reassemble.
Reassemble.
3-3214
TM 55-1905-219-14-7
3-207. HYDRAULIC CUB PUMP UNIT - BRAKE VALVE - MAINTENANCE
INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY (Cont)
3-3215
REMARKS
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
A.
GENERAL
The directional control valve is comprised of a rectangular valve body containing a precision fitted sliding spool
in a central, longitudinal bore. Spool lands serve to divide the bore into a series of separate chambers, and ports in the
valve body lead into these chambers. The position of the spool determines which ports are open to each other and which
are sealed off from the others. Thus, oil flow is directed from one port to another within the valve body.
B.
PRINCIPLES OF OPERATION
1. Valve Type:
SPRING CENTERED - Spring centered valves are provided with a spring and centering washer at each end of
the spool. The springs and washers center the spool within the valve body, when solenoids are de-energized.
2. Function
Three cross section views of a valve are shown. The cross sections show location of the spoollands and the
basic valve block machining. Each cross section is provided to show porting of the valve as the spool is moved within the
valve block. Assume the spool is moved to the left within the valve body. The "P" pressure port will connect to the "A"
cylinder port and the "B" cylinder port will open to the "T" tank port.
3-3216
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
If the spool is moved to the right as shown, the "P" pressure port will connect to the "B" cylinder port and the "A"
cylinder port will connect to "T" tank.
When the spool returns to center, (solenoids de-energized), flow is blocked in all ports. It can be seen that the
function of a valve is to direct the flow of system fluid within a circuit. The valve is actually used to direct the flow from
the pump to the actuator and from the actuator to the tank or reservoir.
3-3217
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
Valve Spools
Each spool is constructed for a specific valve application and is dynamically and hydrostatically balanced to
prevent pressure forces from moving the spool within the bore. The spool used is a four-way type.
4. Methods of Control
SOLENOID - Push type solenoids are used to control movement of the spool. A manual plunger is available in
each solenoid to check spool movement during test. Push type solenoids move the spool away from the solenoid when
energized.
3-3218
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
c. Disassembly
d. Cleaning
e. Reassembly
f. Installation
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Special Tools
Condition Description
None
None
Material/Parts
None
Personnel Required
LOCATION
Observe WARNING.
ITEM
ACTION
INSPECTION
1. Directional
Valve
a. Tubing
b. Wiring
3-3219
REMARKS
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (Cont)
c.
Valve
REMOVAL
2.
a. Screw
(1),
identification
plate
(2)
Remove.
b. Gasket
and
wire
subassembly
(3)
1. Lift to disconnect
ground screw (4).
2. Tag and disconnect
external wiring.
3. Remove gasket and
wire subassembly (3).
c.
Piping
Disconnect piping at
union.
d. Receptacle
(5)
Remove.
e. Valve,
and
"O "
ring
(6)
3-3220
Discard "O"
ring.
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3-3221
REMARKS
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY
3.
a. Screws
(7),
and
lock washers
(8)
Remove.
b. Solenoid
(9)
1. Remove.
Discard gasket,
2. Disconnect receptacle
(11).
c.
Screws
(12),
and
lockwashers
(13)
Remove.
d. Solenoid
mounting
plate
(14),
and
gasket
(10)
Remove.
e. Screw
(15)
Remove.
f.
Remove.
Discard gasket
Remove.
Discard "O"
rings.
Adapter
plate
(16),
and
gasket
(17)
g. Retaining
ring
(18),
spring
guide
(19),
3-3222
Discard gasket.
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
DISASSEMBLY (Cont)
O
rings
(20
and
21),
washers
(22),
spring
(23),
and
spring
washers
(24)
3-3223
REMARKS
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY (Cont)
NOTE
To help remove retaining ring (18), apply force to
the end of the push pin (25) located in the opposite
end of the valve.
h. Push
pin
(25),
and
spool
(26)
i. Plugs
(27
and
28)
3-3224
If necessary.
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
CLEANING
4.
All parts must be thoroughly cleaned and kept clean during inspection and assembly. Contamination in the unit
will cause excessive wear, leakage and decreased service life. Clean in accordance with standard procedures
for hydraulic parts. Do not use compressed air to dry parts unless the air is completely filtered in order to
remove water and contaminants.
REASSEMBLY
5.
NOTE
Coat all internal parts lightly with lubricating oil.
a. Push
pin
(25),
and
spool
(26)
3-3225
TM 55-1905-219-14-7
3-208. DIRECTIONAL CONTROL VALVE - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY (Cont)
Spring
washer
(24),
spring
(23),
washer
(22 ),
O-rings
(21 and
20,
spring
guide
(19),
and
retaining
ring (18)
c.
Gasket
(17),
adapter
plate
(16),
and
screws
(15)
Reassemble.
Reassemble.
d. Gasket
solenoid
mounting
plate
(14),
screws
(12),
and
lockwashers
(13)
3-3226
TM 55-1905-219-14-7
3 - 208.
LOCATION
ITEM
ACTION
REMARKS
REASSEMBLY (Cont)
e.
Receiptacle
(11)
f.
Gasket
(10),
solenoid
(9),
screws
(7),
and
lockwashers
(8)
Reassemble.
3-3227
TM 55-1905-219-14-7
3 - 208.
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
6.
a.
"0"
rings
(6)
b.
Wiring
and
piping
Install.
c.
Gasket 1.
and
wire
sub assembly 2.
(3),
identification
plate
(2),
and
screw
(1)
3-3228
TM 55-1905-219-14-7
3 - 209.
Inspection
Service
c.
d.
e.
f.
g.
INITIAL SETUP
Test Equipment
References
Paragraph
Special Tools
Equipment
Condition Condition Description
None
Material/Parts
Hydraulic fluid MIL-L17672 Type 2135TH
Personnel Required
Motor
Hydraulic Pump
Brake Valve
Directional Control Valve
None
Special Environmental Conditions
Do not drain oil into bilges. Use
the oil separation and recovery
system to collect used oil.
General Safety Instructions
Observe WARNING.
3-3229
Installation
Repair
Initial Start-up
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
REMARKS
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1.
Hydraulic
Reservoir
Tank
a.
Piping
Refer to Direct
Support Maintenance.
b.
Directional
control
valve
Inspect.
c.
Brake
valves
Inspect.
d.
Hydraulic
pump
Inspect.
e.
Motor
Inspect.
f.
Reservoir
tank
g.
Hardware
a.
System
SERVICE
2.
Hydraulic
System
3-3230
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
REMARKS
SERVICE (Cont)
2.
Stop operation.
3.
b.
Access
plate
(1)
c.
Strainer
(2)
d.
Reservoir
(3)
Clean.
e.
Filter
breather
(4)
3-3231
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
REMARKS
SERVICE (Cont)
f.
Strainer
(2)
Re-install.
g. Access
plate (1)
Re-install.
h. Filter
pipe (5)
Refill.
NOTE
The entire system holds 30 gallons (113.55 liters) of hydraulic fluid.
i.
Initial
start-up
Refer to step 7.
j.
Filter
breather
(4)
Replace.
3-3232
The reservoir
holds 10 gallons
(37.85 liters) of
hydraulic fluid.
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
4.
Hydraulic
Reservoir
tank
a.
Reservoir
3-3233
Refer to step 2.
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
REMOVAL (Cont)
To prevent electrical shock, tag and place controller switch in the OFF position.
b.
Wiring
c.
Eight
screws
(6),
and
lock washers
(7)
Remove.
d.
Two
manifold
fittings
(8)
Lift up to release
piping.
e.
Nuts
(9),
and
screws
(10)
Remove.
f.
Reservoir
assembly
(3)
Remove.
3-3234
REMARKS
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3-3235
REMARKS
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
5.
a.
Reservoir
(3),
screws
(10),
and
nuts
(9)
Install.
b.
Two
manifold
fittings
(8),
eight
screws
(6),
and
lockwashers
(7)
Install.
c.
Wiring
d.
Filter
breather
(4)
Remove.
e.
Reservoir
(3)
Refill.
f.
Initial
start-up
Refer to step 7.
g.
Filter
breather
(4)
Replace.
3-3236
The reservoir
holds 10 gallons
(37.85 liters)
of hydraulic
fluid.
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
3-3237
REMARKS
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
REMARKS
REPAIR
6.
Sight
Gage
Gage
(11)
Replace if damaged.
INITIAL STARTUP
7.
Hydraulic System.
The following procedure should be followed to ensure that the pump unit is not damaged during initial startup:
a. Fill tank to proper level as indicated on the oil level gauge. Disconnect tubing between the pump and
manifold and fill the pump with oil. Reconnect tubing.
b. Remove a plug from the front of a brake valve and install a 0-3000 psi pressure gage.
c. Check direction of motor shaft rotation by starting the motor long enough to determine the direction of
rotation. Ensure that motor rotation is in the same direction as the arrow on the pump. If the motor rotates in the wrong
direction, reverse two of-the motor leads to change the direction of rotation.
3-3238
TM 55-1905-219-14-7
3 - 209.
LOCATION
ITEM
ACTION
REMARKS
Do not allow the pump to run at full speed for more than 30 seconds if it does not pick up
suction. If the pump does not pick up suction, it may be due to oil with too high a
viscosity, low oil level in the tank, a leak in the tank, or a leak in the suction line to-the
tank.
d. Prime the pump by turning the motor on and off several times in rapid succession.
e. Operate the hydraulic system and fill it will oil by moving rudder from hardover to hardover.
Add oil to the tank to maintain the proper oil level as the system fills.
Operation will be smooth when all air is purged from the system by continuing to move the rudder for several
minutes.
f. The pump relief valve is set at the factory; however, if a different pressure setting should be required proceed as
follows. Note the reading of the pressure gauge as the directional valve is manually activated for right or left rudder.
After the rudder reaches the hardover position, adjust the pump relief valve, if necessary, until the indication is 2200 psi
or less, as required.
g. The cylinder relief valves are set at the factory to 200 psi above the pump relief valve setting. If resetting is
required, follow the procedure in Step f. The pump relief setting must be temporarily increased while setting the cylinder
relief valve.
3-3239
TM 55-1905-219-14-7
3 - 210.
d. Removal
e. Installation
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Condition Description
Paragraph
Special Tools
Spanner Wrench - hooked
3-211
Material/Parts
Personnel Required
LOCATION
ITEM
ACTION
REMARKS
INSPECTION
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
1. Hydraulic
cylinders
a. Hoses
3-3240
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
INSPECTION (Cont)
b.
Hydraulic
cylinder
2.
Adjustable
Iinks
Links
Threaded
rods
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMOVAL
4.
Hydraulic
Cylinder
Main
Rudder
Linkage
a.
Screw
(1),
flatwashers
(2),
spherical
bearing
and
threaded
rod (3)
Remove.
b.
Cotter
pins
(4),
and
pivot
pin
(5)
c.
Hydraulic Remove.
cylinder
(7)
3-3242
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMOVAL (Cont)
5.
Hydraulic
Cylinder
Flanking
Rudder
a.
Cotter
pin
(8),
slotted
hex nut
(9),
and
flatwasher
(10)
Remove.
b.
Cotter
pins
(11) ,
and
pivot
pin
(12)
c.
Hydraulic Remove.
cylinder
(14)
3-3243
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMOVAL (Cont)
6.
7.
Clevis
bracket
(13)
Adjustable
links
a.
Nuts
(15),
and
screws
(16)
Remove.
b.
Clevis
bracket
(13)
Remove.
a.
Cotter
pins
(17),
slotted
hex
nuts
(18),
and
flatwashers
(19)
Remove.
b.
Link
(20)
Remove.
3-3244
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3-3245
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMOVAL (Cont)
8.
Threaded
Rods
a.
Screw
(1),
flatwashers
(2),
spherical
bearing
and
threaded
rod
(3)
Remove.
b.
Nut
(21),
screw
(22),
flatwashers
(23),
and
spherical
bearing
(24)
Remove.
c.
Rod
(25)
Remove.
3-3246
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3-3247
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMARKS
REPAIR
9.
Hydraulic
Cylinder
rod seal
a.
Setscrew
Remove.
b.
Rod eye
(27)
Unscrew.
c.
Rod
cartridge
(28)
Unscrew.
Use a hooked
spanner wrench,
and discard.
d.
Rod
scraper
(29),
rod
seal
cup
(30),
back-up
and
seal
ring
(31)
Remove.
Discard.
e.
Back-up
and
Seal
ring
(31),
rod
seal
cup
(30),
and
rod
scraper
(29)
(26)
3-3248
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMARKS
REPAIR (Cont)
f.
Rod
cartridge
(28)
Install.
g.
Rod eye
(27)
h.
Setscrew
(26)
Install.
3-3249
1.
Use a hooked
spanner wrench.
2.
Install until
it is firmly
seated to rod
end head (32).
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMARKS
REPAIR (Cont)
10. Piston
Seal
a.
Setscrew
(26)
Remove.
b.
Rod
eye
(27)
Unscrew.
c.
Rod
cartridge
(28)
Unscrew.
d.
Nuts
(34)
e.
Retainer
plate
(36),
and
rod
end
head
(32)
Remove.
f.
Piston
rod
(33)
g.
Cotter
pin
(38) ,
and
blank
end
cushion
sleeve
(39)
Remove.
h.
Piston
(40)
3-3250
Use a hooked
spanner wrench.
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMARKS
REPAIR (Cont)
i.
Two
piston
seal
cups
(41),
and
piston
ring
seal
(42)
j.
Two
barrel
seal
rings
(43)
3-3251
Discard.
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMARKS
REPAIR (Cont)
NOTE
Lubricate all seal rings and seals with hydraulic fluid before installing.
k.
Barrel
seal
rings
(43)
l.
Piston
ring
seal
(42)
m.
Piston
seal
cups
(41)
Install as follows:
1. Install one seal in the
groove nearest the rod
end with lips of the seal
facing the rod end of piston.
2. Insert piston into cylinder,
and push it through the
barrel just far enough to
expose the groove for the
second seal.
3. Install the second seal with
the lips of the seal facing
the mounting end of cylinder.
4. Push the piston into the
cylinder barrel.
n.
Rod end
head
(32),
andretainer
plate
(36)
Install.
3-3252
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
REMARKS
REPAIR (Cont)
o.
Nuts
(34)
Install.
Tighten each
alternately to
30 ft-lb (40.7
Nm) torque.
p.
Rod
cartridge
(28)
Install.
1. Use hooked
spanner wrench.
2. Install until
it is firmly
seated to rod
end head (32).
11. Grease
fittings
q.
Rod eye
(27)
r.
Setscrew
(26)
Replace.
If necessary.
Replace.
If necessary.
Fittings
(34)
3-3253
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
INSTALLATION
12. Threaded
Rods
13. Adjustable
link
a.
Rod
(25),
spherical
bearing
(24),
flatwashers
(23),
screw
(22),
and
nut
(21)
Install.
b.
Spherical
bearing
and
threaded
rod
(3),
flatwasher
(2),
and
screw
(1)
Install.
Link
(20),
flatwashers
(19) ,
slotted
hex
nuts
(18)
and
cotter
pin
(17)
Install.
3-3254
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
14. Clevis
bracket
Clevis
bracket
(13)
screws
(16),
and
nuts
(15)
Install.
3-3255
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
15. Hydraulic
Cylinder
Flanking
Rudder
Linkage
a.
Hydraulic
cylinder
(14),
pivot
pin
(12),
and
cotter
pins
(11)
Install in clevis
bracket (13).
b.
Flatwasher
(10),
slotted
hex
nut
(9),
and
cotter
pin
(8)
Install.
3-3256
REMARKS
TM 55-1905-219-14-7
3 - 210.
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
16. Hydraulic
Cylinder
Main
Rudder
Linkage
a.
Hydraulic
cylinder
(7),
pivot
pin
(5),
and
cotter
pins
(4)
Install in clevis
bracket (6).
b.
Threaded
rod
with
spherical
bearing
(3),
fl atwashers
(2),
and
screw
(1)
Install.
3-3257
REMARKS
TM 55-1905-21Y-14-7
3 - 210.
LOCATION
ITEM
ACTION
ADJUSTMENT
17. Adjustable
rods,
threaded
rods,
and
hydraulic
cylinders
a.
Hydraulic
cylinders
b.
Adjustable
rod
to
NOTE
Make sure that all rudders are parallel to fore and aft line.
c.
Threaded
rod
3-3258
REMARKS
TM 55-1905-219-14-7
3-210. STEERING SYSTEM - HYDRAULIC CYLINDER AND LINKAGE MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
ADJUSTMENT (Cont)
2. Adjust spherical
bearing rod end
so that either the
flanking rudder
limit switch, or
the rudder repeatback transmitter
indicates and
operates correctly.
3. Reinstall spherical
bearing, flatwashers
and screws.
3-3259
REMARKS
TM 55-1905-219-14-7
3-211. STEERING SYSTEM - HYDRAULIC HOSES, PIPING AND VALVES MAINTENANCE INSTRUCTIONS.
b. Disassembly
c. Reassembly
INITIAL SETUP
Test Equipment
None
References
None
Equipment
Condition
Special Tools
None
Material/Parts
None
Personnel Required
1
Condition Description
None
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Steering
compartment
a. Hoses
b. Piping
c. Valves
3-3260
Refer to Direct
Support Maintenance
Refer to Direct
Support Maintenance.
TM 55-1905-219-14-7
3-211. STEERING SYSTEM - HYDRAULIC HOSES, PIPING AND VALVES MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
DISASSEMBLY
2.
a. Valve
(1)
Turn off.
b. Union
nut
(2)
Remove.
c. Hose
assembly
(3),
and
pipe
elbow
(4)
d. Hose
fitting
(5),
and
union
halve
(6)
Unscrew.
3-3261
REMARKS
TM 55-1905-219-14-7
3-211. STEERING SYSTEM - HYDRAULIC HOSES PIPING AND VALVES MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REASSEMBLY
3.
a. Hose
fitting
(5),
and
union
halve
(6)
Reassemble.
b. Hose
assembly
(3),
and
pipe
elbow
(4)
Reassemble.
c. Union
nut
(2)
Tighten.
d. Valve
(1)
Turn on.
3-3262
REMARKS
TM 55-1905-219-14-7
The Rudder Angle Indicator indicates the angle of the rudder (right or left) in degrees.
A synchro in the rudder angle indicator is excited by 115-volt, 60-hertz, 1-phase ship's power and aligns
with a similar synchro in the rudder transmitter. Two ratios are available between the Rudder Repeatback and
the Rudder Angle Indicator pointer to give +40 degrees or +50 degrees maximum rudder angle indication. Theunit is waterproofed, with stuffing tubes supplied for wiring. Red back panel lighting with a dimmer control is
also provided.
3-3263
TM 55-1905-219-14-7
3-212. RUDDER ANGLE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
This task covers:
a.
b.
Inspection
Repair
c.
d.
Removal
Installation
e. Adjustment
INITIAL SETUP
Test Equipment
None
References
None
Equipment
Condition
Special Tools
None
Condition Description
None
Material/Parts
None
Personnel Required
1
LOCATION
ITEM
ACTION
To avoid electrical shock, tag and place circuit breaker in the OFF position.
INSPECTION
1. Rudder
Angle
Indicator
a. Lamp
dimmer
3-3264
REMARKS
TM 55-1905-219-14-7
3-212. RUDDER ANGLE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
INSPECTION (CONT)
b. Glass
c. Housing
d. Lamps
a. Knob
(1)
b. Wiring
c. Seal
nut
(2)
Remove.
REPAIR
2. Dimmer
d. Rheostat Remove.
(3)
3-3265
Refer to schematic.
TM 55-1905-219-14-7
3-212. RUDDER ANGLE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
REPAIR (CONT)
e. Rheostat Replace.
(3),
and
sea 1
nut (2)
f. Wiring
g. Knob
(1)
3. Window
Four
screws
(4),
cover
(5),
and
window
(6)
4. Pointer,
dial
and
Indicator
Lamps
a. Four
screws
(4),
cover
(5),
and
window
(6)
Remove.
3-3266
Refer to schematic.
TM 55-1905-219-14-7
3-212. RUDDER ANGLE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
b. Three
screws
(7),
lock washers
(8),
clamp
(9),
and
pointer
disc
(10)
Remove.
c. Pointer
hub
(11),
dial
indicator
(12),
dial
spacer
(13),
and
light
defuser
(14)
Remove.
3-3267
REMARKS
TM 55-1905-219-14-7
3-212. RUDDER ANGLE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
REPAIR (Cont)
d. Lamps
(15)
Remove.
e. Lamp
sockets
(16)
f. Lamp
sockets
(16)
g. Lamps
(15)
Install.
h. Light
defuser
(14),
dial
spacer
(13),
dial
indicator
(12),
and
pointer
hub
(11)
Assemble.
i. Pointer
disc
(10),
clamp
(9),
screws
(7),
and
lock
washers
(8)
Install.
3-3268
Refer to schematic.
TM 55-1905-219-14-7
3-212. RUDDER ANGLE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
j. Window
(6) ,
cover
(5),
and
screws
4)
Install.
3-3269
REMARKS
TM 55-1905-219-14-7
3-212. RUDDER ANGLE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
5. Rudder
Angle
Indicator
a. Screws
(4),
cover
(5),
and
window
(6)
Remove.
b. Screws (17)
Remove.
c. Cover (18)
Remove.
d. Screws
(19),
and
flatwashers
(20)
Remove.
e. Back
casting
(21),
and preformed
packing
(22)
Slide wiring
through stuffing
tube (23).
f. Terminal
strip (24)
Refer to schematic.
3-3270
TM 55-1905-219-14-7
3-212. RUDDER ANGLE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
6.
a. Terminal
strip (24)
b. Preformed
packing
(22),
back
casting
(21),
cover (18),
screws
(19), and
flat
washers
(20)
Reassemble.
c. Cover (18),
and screws
(17).
Install in panel.
d. Window (6),
cover (5),
and screws
(4)
Install.
3-3271
Refer to schematic.
TM 55-1905-219-14-7
3-212. RUDDER ANGLE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
ADJUSTMENT
7.
Dial
Zeroing
a. Screws
(4),
cover
(5),
and
window
(6),
Remove.
b. Screws
(7)
Loosen.
c. Pointer
disc
(10)
d. Screws
(7)
e. Window
(6),
cover
(5),
and
screws
(4)
Install.
Tighten.
3-3272
REMARKS
TM 55-1905-219-14-7
The Rudder Repeatback/Rudder Angle Transmitter contains a torque synchro which generates a rudder
position signal for driving rudder y angle indicators and a rudder repeatback potentiometer which is used with
other steering equipment to position the rudder to a predetermined angle. The rudder repeatback signal is
connected to an amplifier in the steering control equipment where it is compared to a rudder order signal; when
the rudder order and repeatback signals are equal, rudder movement stops. Both units include limit switches to
limit rudder travel.
3-3273
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS.
The Rudder Repeatback/Rudder Angle Transmitter contains a torque synchro which generates a
rudder position signal for driving rudder - angle indicators and a rudder repeatback potentiometer which is used
with other steering equipment to position the rudder to a predeter-mined angle. The rudder repeatback signal is
connected to an amplifier in the steering control equipment where it is compared to a rudder order signal; when
the rudder order and repeatback signals are equal, rudder movement stops. Both units include limit switches to
limit rudder travel.
This task covers:
a.
b.
Inspection
Removal
c.
d.
Installation
Repair
e. Adjustment
INITIAL SETUP
Test Equipment
None
References
None
Equipment
Condition
Special Tools
None
Condition Description
None
Material/Parts
None
Personnel Required
1
INSPECTION
1. Rudder
Repeatback
Transmitter
a. Tie
rods
b. Transmitter
Arm
3-3274
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
INSPECTION (CONT)
c. Transmitter
box
d. Wiring
REMOVAL
2.
a. Screws
(1),
lock washers
(2),
and
flat washers
(3)
Remove.
3-3275
REMARKS
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont)
b. Cover
(4),
and
gasket
(5)
Remove.
c. Wiring
d. Nut
(7),
screw
(8),
and
flat washer
(9)
Remove.
e. Spherical
bearing
(10)
and
tie
rod
(11)
Remove.
f. Nuts
(12) ,
lock washers
(13)
and
screws
(14)
Remove.
g. Transmitter
(15)
Remove.
3-3276
Refer to schematic.
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3-3277
REMARKS
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
3.
a. Transmitter
(15),
screws
(14) ,
Iock washers
(13),
and
nuts
(12)
Install.
b. Tie-rod
(11),
and
spherical
bearing
(10)
Install.
c. Screw
(8),
f1at washer
(9),
and
nut
(7)
Install.
d. Wiring
Reconnect to terminal
strip (6).
Refer to schematic.
e. Transmitter
(15)
Adjust.
Refer to step
6.
3-3278
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
INSTALLATION
3-3279
REMARKS
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
REPAIR
4. Terminal
strip
and
Identification
strip
a. Screws
(1),
lock washers
(2),
and
flat washers
(3)
Remove.
b. Cover
(4),
and
gasket
(5)
Remove.
c. Wiring
d. Screws
(16)
and
lock washers
(17)
Remove.
e. Terminal
strip
(6) ,
and
identi fication
strip
(18)
Remove.
f. Identi fication
strip
(18),
terminal
strip
(6),
Install.
3-3280
Refer to schematic.
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
screws
(16),
and
lock washers
(17)
g. Wiring
h. Cover
(4),
gasket
(5),
screws
(1),
lock washers
(2) ,
and
f1at washers
(3)
Install.
3-3281
Refer to schematic.
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
5. Transmitter
arm
a. Nut
(7),
screw
(8) ,
f1at washer
(9),
spherical
bearing
(10),
and
tie -rod
(11)
Remove.
b. Spring
pin
(19),
and
trans mitter
arm
(20)
Remove.
c. Transmitter
arm
(20),
and
spring
pin
(19)
Install.
d. Tie-rod
(11),
spherical
bearing
(10),
flat washer
(9),
screw
(8),
and
nut
(7)
Install.
3- 3282
REMARKS
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR ( Cont)
3-3283
REMARKS
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
ADJUSTMENT
6. Zeroing
Synchro
3-3284
Do not remove.
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER-MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
ADJUSTMENT (Cont)
b. Wiring
c. Power
source
115 VAC
Connect to terminals
9 and 10.
d. Jumper
wire
e. Voltmeter
f. Power
Turn on.
3-3285
Refer to schematic.
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
ADJUSTMENT (Cont)
g. Synchro
h. Power
i. Jumper
wire
j. Voltmeter
1. Disconnect.
2. Reconnect to terminal s
11 and 13.
3. Place on low AC scale.
k. Power
Turn on at source.
1. Synchro
m. Power
n. Screws
(21 ), and
lockwashers
(22)
Tighten.
3- 3286
This is the
approximate
zero setting.
Null should be
less than 0.25
Volt tms.
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
ADJUSTMENT (Cont)
o. Power
1. Turn on
2. Recheck null.
3. Turn off.
4. Remove wires from
terminals 9 and 10.
p. Voltmeter Disconnect.
q. Wiring
3-3287
Null should be
less than 0.25
Volt tms.
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
ADJUSTMENT (Cont)
7. Repeatback
Potenti ometer
Zeroing
a. Rudder
Position to amidships.
b. Ohmmeter
1. Connect to terminal
strip (6), terminals
(14 (P1) and 15 (P2).
Observe reading.
2. Connect to terminals
15 (P2), and 16 (P3).
Observe reading.
3. Compare readings.
Readings should
be equal (within 25 ohms ).
If necessary,
to obtain an
equal reading
on ohmeter.
c. Setscrew
(25),
and
potentiometer
(26)
3-3288
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
ADJUSTMENT (Cont)
d. Setscrew
(25)
Tighten.
e. Ohmmoter
Remove.
3-3289
REMARKS
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
ADJUSTMENT (Cont)
8. Outside
Limit
Switch
Adjustment
9. Inside
Limit
Switch
Adjustment
a. Rudder
b. Setscrews
(27)
c. Cam
(28)
d. Setscrews
(27)
Tighten.
a. Rudder
b. Setscrews
(29)
c. Cam
(30)
d. Setscrews
(29)
Tighten.
3-3290
REMARKS
TM 55-1905-219-14-7
3-213. RUDDER ANGLE TRANSMITTER - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
ADJUSTMENT (Cont)
3-3291/(3-3292 blank)
REMARKS
TM 55-1905-219-14-7
The Flanking Rudder Limit Switch electrically limits the maximum movement of the rudder to hard left - midships or hard right. When the ordained rudder position is achieved, the rudder limit switch assembly activates the rudder
Position lights on the steering panel.
b. Removal
c. Installation
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition Condition Description
Special Tools
None
None
Material/Parts
None
None
Personnel Required
WARNING
To avoid possible injury, turn off all electrical power and relieve hydraulic pressure.
INSPECTION
1. Flanking
Rudder
Limit
Switch
cracks.
a. Wiring
and damage.
b. Linkage
c. Housing
d. Hardware
3-3293
TM 55-1905-219-14-7
3-214. FLANKING RUDDER LIMIT SWITCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSPECTION (Cont )
3-3294
REMARKS
TM 55-1905-219-14-7
3-214. FLANKING RUDDER LIMIT SWITCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSPECTION (Cont )
3-3295
REMARKS
TM 55-1905-219-14-7
3-214. FLANKING RUDDER LIMIT SWITCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMOVAL
2.
a. Nut
(1),
spherical
bearing
(2),
flatwasher
(3),
and
screw
(4)
Remove.
b. Tie-rod
(5)
Disconnect.
3-3296
REMARKS
TM 55-1905-219-14-7
3-214. FLANKING RUDDER LIMIT SWITCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
REMOVAL (Cont )
c. Housing
cover (6)
Remove.
d. Wiring
e. Nuts (7),
lockwasher
(8), and
screw (9)
Remove.
f. Limit
switch
assembly
Remove.
3-3297
Refer to wiring
diagram.
TM 55-1905-219-14-7
3-214. FLANKING RUDDER LIMIT SWITCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION
3.
a. Limit
switch
assembly,
screws
(9),
lock washers
(8),
and
nuts
(7)
Install.
b. Wiring
board (TB1).
Reconnect to terminal
c. Housing
cover
(6)
Install.
3-3298
Refer to wiring
diagram.
TM 55-1905-219-14-7
3-214. FLANKING RUDDER LIMIT SWITCH - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
d. Tie-rod
(5),
screw
(4),
flatwashers
(3),
spherical
bearing
(2), and
nut (1)
Assemble.
3-3299
REMARKS
TM 55-1905-219-14-7
c. Installation
d. Repair
INITIAL SETUP
Test Equipment
None
Special Tools
References
FO-1 - Steering Control Panel
Wiring Diagram
Equipment
Condition
None
Material/Parts
None
Special Environmental Conditions
None
Personnel Required
1
Condition Description
None
General Safety Instructions
Observe WARNING in procedure.
3- 3300
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSPECTION
1. Control
Panel
a. Fuses
b. Indicator
lamps
c. Switch
(Toggle)
d. Switch
(Rotary
e. Potentiometer
f. Steering
lever
3-3301
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REMOVAL
WARNING
In order to prevent shock, tag and place circuit breaker in the OFF position.
2.
a. Twelve
screws
(1),
and
Iock washers
(2)
Remove.
b. Panel
(3)
Lift up.
c. Wiring
at terminal strips.
d. Panel
(3)
Remove.
3 - 3302
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
INSTALLATION
3.
a. Panel
(3)
Reconnect wiring at
terminal strips.
b. Screws
(1),
and
1ock washers
(2)
Install.
3-3303
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR
4.
a. Fuse
caps
(4)
b. Fuses
(5)
Remove.
c. Wiring
d. Nut
(6),
and
fuseholder
(7)
Remove.
e. Fuseholder
(7),
and
nut
(6)
Replace.
f. Wiring
Reconnect.
g. Fuse
(5),
and
fuse
cap
(4)
Replace.
3 - 3304
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
5. Lamp
Holders
a. Lens
caps
(8)
b. Indicator
lamp (9)
Remove.
c. Wiring
d. Nut
(10),
and
lampholder
(11)
Remove.
e. Lampholder
(11) ,
and
nut
(10)
Replace.
f. Wiring
Reconnect.
g. Lamp
(9),
and
Iens
cap
(8)
Replace.
3-3305
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
6. Switch
(Toggle)
a. Wiring
b. Nut
(12),
and
switch
(13)
Remove.
c. Switch
(13),
and
nut
(12)
Install
d. Wiring
Reconnect.
3-3306
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
7. Switch
(Pushbutton)
a. Wiring
b. Button
holder
(14)
Pull off.
c. Buttons
(15 and
16)
Remove.
d. Switch
(17)
Remove.
e. Switch
(17)
Insert in panel.
f. Buttonholder
(14),
and
buttons
(15 and
16)
Replace.
g. Wiring
Reconnect.
3-3307
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
8. Variable
Resistors
a. Knob
(18)
Remove.
b. Wiring
c. Nut
(19),
and
resistor
(20)
d. Resistor
(20),
and
nut
(19)
Install.
e. Wiring
Reconnect.
f. Knob
(18)
Install.
3-3308
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
9. Pistol
grip
handle
a. Screw
(21),
lockwasher
(22)
Remove.
b. Handle
(23 )
Remove.
c. Handle
(23) ,
screw
(21),
and
1ock washer
(22)
Install.
3-3309
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
10. Rudder
control
lever
a. Rubber
handle
(24 )
Unscrew.
b. Shaft
(25) ,
spring
pin
( 26 ),
spring
(27)
and
ball
(28)
Remove.
c. Shaft
hub
(29)
Remove.
d. Shaft
hub
(29)
Install.
e. Ball
(28) ,
spring
(27) ,
spring
pin
(26),
and
shaft
(25)
Install.
f. Rubber
handle
(24)
Install.
3-3310
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
3-3311
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
11. Detail
Stop
a. Screws
(30),
and
seal
washers
(31)
Remove.
b. Resistor
mounting
plate
(32)
c. Screws
(33),
lockwashers
(34),
and
flatwashers
(35)
Remove.
d. Detail
stop
(36)
Remove.
e. Detail
stop
(36),
screws
(33),
lockwashers
(34),
and
flatwashers
(35)
Install.
3-3312
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
3-3313
REMARKS
TM 55-1905-219-14-7
3-215. STEERING CONTROL PANEL - MAINTENANCE INSTRUCTIONS (Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
f. Resistor
mounting
plate
(32) ,
screws
(30),
and
sea a
washers
(31)
Install.
3-3314
REMARKS
TM 55-1905-219-14-7
The Heading Selector is used as an interface between a gyrocompass and steering control panel to select the
desired heading of they vessel. The gyrocompass transmits actual heading data to the Heading Selector for comparing
the actual heading data with the ordered heading data. If the actual heading and the ordered heading are the same,
there is no signal output from the Heading Selector. If the actual heading and the ordered heading differ, the Heading
Selector will produce a signal that will cause the rudder positioning equipment to change the vessel's actual heading to its
ordered heading.
Three-wire synchro data from the gyrocompass provides the heading information, and the same 115-volt, 400hertz supply that powers the gyrocompass is needed for reference and illumination requirements. The gyrocompass card
is connected to a synchro which is excited by a 115-volt, 400-hertz supply.
Three-wire heading data is transmitted by this synchro to synchro B1 of the Heading Selector. The heading
selector card is connected to synchro B1 rotor so that for any reading of the gyrocompass card, the voltage induced in
synchro B1 rotor will be zero when the heading selector card is set to the same heading. When the heading selector card
and the gyrocompass card are on different headings, an error voltage is induced in synchro B2 rotor.
3-3315
TM 55-1905-219-14-7
Any voltage that is induced in synchro B1 rotor is applied to the primary of transformer T1. A demodulator ring is
connected in series with a leg of each secondary winding of transformer T1.
The same 115-volt, 400-hertz supply that excites the gyrocompass synchro must also be used for reference
purposes in the Heading Selector. This reference voltage is applied to the primary of transformer T2. The output from
transformer T2 secondaries is applied across the demodulator rings. This voltage serves as a trigger to turn the
demodulator rings on or off. Ring 1 (resistors R1, R2; diodes CR1-CR4) conducts during the negative portions of each
reference voltage cycle, and ring 2 (resistors R3, R4; diodes CR5-CR8) conducts only when the reference (trigger) signal
is positive.
When there is any induced voltage across synchro B1 rotor, it will appear across both secondaries of transformer
T1. This voltage can be either positive or negative with respect to the reference voltage at any given instant. The
reference voltage is alternating continuously, and the output from the Heading Selector must be a direct current.
The reference voltage, in effect, switches the demodulator rings on and off in step with its cycles. This forces the
proper transformer T2 secondary to be connected to the output at the right time. The net result is a pulsating d-c voltage
that is proportional to the difference between the actual heading and the ordered heading. Resistor R5 and capacitor C1
provide filtering for the output.
3-3316
TM 55-1905-219-14-7
3-216. HEADING SELECTOR - MAINTENANCE INSTRUCTIONS (Continued).
c. Installation
d. Repair
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Special Tools
None
None
Material/Parts
None
None
Personnel Required
LOCATION
ITEM
ACTION
INSPECTION
Condition Description
a. Dial
lamps
3-3317
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
b. Dimmer
INSPECTION (Cont)
Heading
Selector
3-3318
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSPECTION (Contl)
3-3319
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
a. Four
screws
(1),
lockwashers
(2),
and
flatwashers
(3)
Remove.
b. Heading
selector
(4)
Remove.
c. Connectors
(5 and 6)
REMOVAL
2.
3-3320
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
a. Connectors
(5 and 6)
Reconnect to heading
selector (4).
Heading
selector
(4)
Adjust.
c.
Screws
(1)
lockwashers
(2) ,
and
flatwashers
(3)
Install.
REMARKS
INSTALLATION
3.
3-3321
Refer to step
7.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
a. Panel
light
(7)
Unscrew counterclockwise.
b. Lamp
(8)
c.
REMARKS
REPAIR
4. Panel
lights
Wiring
d. Nut (9),
and
lamp holder
(10)
Remove.
e. Lampholder
(10),
and
nut (9)
Install.
f.
Reconnect.
Wiring
g. Lamp
(8)
h. Panel
light
(7)
Install.
3-3322
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
5. Dimmer
Knob (11)
If necessary.
6. Dial
a. Knobs
(11 and,
12)
Remove.
b. Three
nuts
(13),
screws
(14),
spacers
(15),
and
lock washers
(16)
Remove.
c.
Remove.
REPAIR (Cont)
Control
panel
(17)
d. Dial
(18)
Remove.
e. Control
shaft
(19)
3-3323
Before removal,
mark orientation of dial.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
f.
Insert in front
plate (20).
REMARKS
REPAIR (Cont)
Control
shaft
(19)
g. Dial
(18)
Re-orientation
install.
h. Control
panel
(17)
Install.
i.
Screws
(14),
lock washers
(16),
spacers
(15),
and
nuts
(13)
Install.
j.
Knobs
(11
and
12)
Install.
k.
Heading
selector
3-3324
Refer to step 7.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INITIAL CHECK-OUT
7. Heading
Selector
3-3325
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
ALIGNMENT
8. Heading
Selector
3-3326
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
ALIGNMENT (Cont)
3-3327
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
ALIGNMENT (Cont)
Loosen the three screws
(21) that secure the
synchro body (22) to
the mounting surface.
Rotate the synchro body
until the A-C voltage
between circuit card
terminals 6 and 7 is
nailed. Tighten the
synchro clamp screws
while holding the
synchro body in the
null-voltage position.
3-3328
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
ALIGNMENT (Cont)
f.
3-3329
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Special Tools
None
None
Material/Parts
None
None
Personnel Required
LOCATION
Condition Description
None
ITEM
ACTION
REMARKS
INSPECTION
NOTE
All maintenance is to be performed by Direct Support
Maintenance. Overhaul is to be performed by the
designated General Support Organization.
1. RHMS
Transmitter
Transmitter
3-3330
Inspect when
mast is
lowered.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
Indicator
INSPECTION (Cont)
2. RHMS
Indicator
3-3331
REMARKS
TM 55-1905-219-14-7
b. Replacement
c.
Repair
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Special Tools
None
None
Material/Parts
None
None
Personnel Required
LOCATION
Condition Description
None
ITEM
ACTION
a. Pipe
plug
b. Tiller
c.
INSPECTION
1. Emergency
steering
Block
and
tackle
3-3332
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REPLACEMENT
2.
REPAIR
3. Block
and
tackle
3-3333
REMARKS
TM 55-1905-219-14-7
The ship's course indicator is a servo-driven remote repeater that indicates the ship's heading. The indicator
receives heading data from the ship's gyrocompass. The indicator also receives reference power from the ship's supply.
The gyrocompass signals and reference power actuate the indicator to position graduated dials that show the ship's
heading.
The ship's course indicator is designated a Mark 2, Mod 6 and is a 400-cps two-speed single dial type.
This task covers:
a. Inspection
b. Removal
c.
Repair
INITIAL SETUP
Test Equipment
References
None
None
Equipment
Condition
Special Tools
None
Condition Description
None
Material/Parts
None
None
Personnel Required
None
3-3334
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
a. Indicator
INSPECTION
1. Ship's
Course
Indicator
Pedestal
3-3335
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
2. Ship's
Course
Indicator
a. Six screws
(1),
flatwashers
(2),
and
lockwashers
(3)
Remove.
b. Cover
(4)
Remove.
c.
Wiring
d. Knurled
cap (6)
Loosen.
e. Cable
harness
(7)
Remove.
3-3336
Feed through
elongated hole
(8).
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMOVAL (Cont)
3-3337
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMOVAL (Cont)
f.
Cover
(4),
screws
(1),
flatwashers
(2),
and
lock washers
(3)
g. Nut
(9)
Reassemble.
Loosen.
NOTE
Do not remove studs.
h. Studs
(10)
Backout.
3-3338
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
i.
REMOVAL (Cont)
Ship's
course
indicator
(11)
3-3339
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
j.
Bracket
(12),
and
pedestal
(13)
k.
Bolts
(14),
washers
(15)
and
lock washers
(16)
Remove.
REMOVAL (Cont)
1. Bracket
(12)
Remove.
3-3340
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
REMOVAL (Cont)
m. Screws
(17),
and
lockwashers
(18)
n. Terminal
box
(19)
Remove.
o. Nuts
(20),
lockwashers
(21),
bolts
(22),
and
washers
(23)
Remove.
p. Pedestal
(24)
Remove.
3-3341
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSTALLATION
3.
Place on base.
b. Bolts
(22) ,
washers
(23),
lock washers
(21),
and
nuts
(20)
Install.
3-3342
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
c.
Terminal Install.
box
(19),
screws
(17),
and
lockwashers
(18)
3-3343
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
d. Bracket
(12)
e. Bolts
(14),
washers
(15),
and
lockwashers
(16)
Install,
REMARKS
INSTALLATION Cont)
3-3344
Do not tighten.
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
f.
INSTALLATION (Cont)
Bracket
(12),
and
pedestal
(24)
2. Tighten.
NOTE
If scribe marks are missing, continue assembly.
g. Cable
harness
(7)
3-3345
REMARKS
TM 55-1905-219-14-7
LOCATION
ITEM
ACTION
h. Ship's
course
indicator
(11)
i.
Studs
(10)
Tighten sufficiently to
prevent lateral movement,
but not tight enough to
prevent the indicator
from swinging freely.
j.
Nut
(9)
Tighten.
INSTALLATION (Cont)
3-3346
REMARKS
TM 55-1905-219-14-7
3-219. SHIPS COURSE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
k.
Screws
(1),
flatwashers
(2),
lock washers
(3),
and
cover
(4)
l. Knurled
cap
(6)
m. Cable
(7)
Remove.
3-3347
REMARKS
TM 55-1905-219-14-7
3-219. SHIPS COURSE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
INSTALLATION (Cont)
n. Knurled
cap
(20)
o. Cable
(7)
Tighten.
p. Cover
(4),
screws
(1),
flatwashers
(2),
and
lock washers
(3)
Replace.
Attach as shown.
3-3348
REMARKS
TM 55-1905-219-14-7
3-219. SHIPS COURSE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (cont)
NOTE
If the scribe marks on bracket (12) and pedestal (24) are missing, proceed as follows:
q. Screws
(14)
3-3349
TM 55-1905-219-14-7
3-219. SHIPS COURSE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REMARKS
INSTALLATION (Cont)
r.
Bracket
(12)
s.
Screws
(14)
REPAIR
4. Dial
Light
a. Eight
screws
(25)
b. Cover (26),
lens
(27),
and
preformed
packing
(28)
Remove.
Remove.
3-3350
This alignment
must be exact.
TM 55-1905-219-14-7
3-219. SHIPS COURSE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
c.
Screws
(29),
lockwashers
(30),
flatwashers
(31),
retainers
(32 and
33),
and
filter
(34)
d. Dial
light
(35)
3-3351
REMARKS
TM 55-1905-219-14-7
3-219. SHIPS COURSE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
e. Dial
light
(35)
f. Filter
(34),
retainer
(32 or
33),
screws
(29),
lockwasher
(30),
and
flatwasher
(31)
g. Cover
(26),
lens
(27),
and
preformed
packing
(28)
h. Screws
(25)
Assemble.
Install.
3-3352
REMARKS
TM 55-1905-219-14-7
3-219. SHIPS COURSE INDICATOR - MAINTENANCE INSTRUCTIONS
(Continued).
LOCATION
ITEM
ACTION
REPAIR (Cont)
3-3353
REMARKS
TM 55-1905-219-14-7
3-3354
TM 55-1905-219-14-7
3-222.
INTERMEDIATE STORAGE.
To place a component in intermediate storage (46 to 180) days, proceed as follows:
A.
General
1. Perform the next scheduled preventive maintenance checks and services. (PMCS).
2. Correct all known deficiencies.
3. Clean the exterior of all components with fuel oil (except electrical wiring) and dry with compressed air.
4. Seal all openings with barrier material. The material used must be waterproof, vaporproof, and possess
sufficient physical strength to resist puncture and damage from the expansion of entrapped air. Use metal or
wood covers where practical.
5. In freezing weather, drain all water from the components.
6. Cover with a clear plastic cover.
7. Inspect periodically. If there are any indications of rust or corrosion, take corrective action.
8. At the end of one year, perform a complete inspection and apply additional treatment as required.
B. Engines
1. Add a rust inhibitor to the cooling system.
2. Remove, check and recondition injectors.
3. Reinstall injectors in the engine, time them, and adjust exhaust valve clearance.
4. Operate engine until operating temperature is reached (160F to 185F) (71C to 850C).
a. Stop engine.
b. Remove oil from crankcase.
c.
d. Fill crankcase with 30 weight preservative lubricating oil EMIL-L-21260 Grade 2 (P1O)].
e. Drain and change fuel filter and strainer. Refill cavity between element and shell with rust preventive fuel oil.
Reinstall filter and strainer.
3-3355
TM 55-1905-219-14-7
3-222.
C.
Marine Gear.
Operate engine at 600 RPM for 10 minutes. Engage clutches alternately to circulate oil through all moving parts.
D.
Torque Converter.
1. Operate engine until temperature reaches 150F (66C).
a. Remove oil from the converter.
b. Remove the filter.
CAUTION
3-3356
TM 55-1905-219-14-7
3-223. REACTIVATION FROM STORAGE.
To remove a component from storage, perform the following:
A.
Engine.
1. Remove the valve rocker covers and pour one gallon of engine oil over the rocker arms and push rods.
2. Re-install valve rocker covers.
3. Remove all covers from openings. Do not forget the exhaust outlet.
4. Wash the exterior with fuel oil and dry with compressed air.
5. Tighten belts to bilge pump.
6. Check crankcase oil level.
7. Drain all anti-freeze from cooling system. Refill and add a rust inhibitor.
8. Service the air cleaner.
B. Marine Gear.
Check the marine gear and refill if necessary.
C. Torquematic Converter.
1. Remove covers from all openings.
2. Wash the exterior with fuel oil and dry with compressed air.
3. Start the engine and operate the unit until the temperature reaches 150F (66'C).
a. Drain the preservative oil.
b. Change the filter.
c. Start the engine and stall the converter for twenty seconds at 1000 RPM to scavenge the oil from the
converter.
CAUTION
The torquematic converter containing preservative oil should only be operated enough to
bring the oil temperature to 150F (66C).
d. Install a new filter and drain plug.
3-3357
TM 55-1905-219-14-7
3-223. REACTIVATION FROM STORAGE (Cont).
e. Refill the converter.
D.
Hydrostarter System.
1. Open the relief valve on the side of the pump and release the pressure.
2. Drain, refill, and purge the system.
3-3358
TM 55-1905-219-14-7
APPENDIX A
REFERENCES
REFER TO VOLUME 12
A-1/(A-2 blank)
TM 55-1905-219-14-7
APPENDIX B
MAINTENANCE ALLOCATION CHART
SECTION l. INTRODUCTION
B-1.
GENERAL.
a. This section provides a general explanation of all maintenance and repair functions authorized at various
maintenance levels.
b. Section II designates overall responsibility for the performance of maintenance functions on the identified end
item or component and the work measurement time required to perform the functions by the designated maintenance
level. The implementation of the maintenance functions upon the end item or components will be consistent with the
assigned maintenance functions.
c. Section III lists the tools and test, equipment required for each maintenance function as referenced from
Section II.
d.
B-1
TM 55-1905-219-14-7
(3) Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean
(decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, hydraulic fluids, or compressed air
supplies.
(4) Adjust. To maintain within prescribed limits, by grinding into proper or exact position, or by setting the
operating characteristics to specified parameters.
(5) Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
(6) Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test
measuring and diagnostic equipments used in precision measurement. Consist of comparison of two instruments, one of
which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument
being compared.
(7) Install. The act of emplacing, seating, or fixing into position an item, part, or module (component or
assembly) in a manner to allow the proper functioning of an equipment or system.
(8) Replace. The act of substituting a serviceable "like type" part, subassembly or module (component or
assembly) for an unserviceable counterpart.
(9) Repair. The application of maintenance services (inspect, test, service, adjust, align, calibrate, or
replace) or other maintenance actions (welding, grinding, riveting, straightening, facing remachining or resurfacing) to
restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly,
module (component or assembly), end item, or system.
(10) Overhaul. That maintenance effort (service/action) necessary to restore an item to a completely
serviceable/operational condition as prescribed by maintenance standards in appropriate technical manuals. Overhaul is
normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to a likenew condition.
(11) Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a
like-new condition in accordance with organizational manufacturing standards. Rebuild is the highest degree of material
maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age
measurements (hours/miles, etc.) considered in classifying Army equipments/components.
B-2
TM 55-1905-219-14-7
d. Column (4), Maintenance Level. This column is made up of subcolumns for each category of maintenance.
Work time figures are listed in these subcolumns for the lowest level of maintenance authorized to perform the function
listed in Column 3. These figures indicate the average active time required to perform the maintenance function at the
indicated category of maintenance under typical field N_,-operating conditions.
e. Column (5), Tools and Equipment. This column is provided for referencing by code, the common tool sets (not
individual tools) special tools, test and support equipment required to perform the designated functions.
f.
Column (6), Remarks. This column is provided for referencing by code the remarks pertaining to the
designated functions.
B-3.
a. Column (1), Reference Code. The tool and test equipment referenced code correlates with a maintenance
function on the identified end item or component.
b.
Column (2), Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.
c.
d.
Column (4), National/NATO Stock Number. The National or NATO stock number of the tool or test equipment.
e.
B-3
TM 55-1905-219-14-7
SECTION II
MAINTENANCE ALLOCATION CHART
(1)
(2)
(3)
(4)
GROUP
NUMBER
COMPONENT
ASSEMBLY
MAINTENANCE
FUNCTION
MAINTENANCE LEVEL
C
0550
Pistons,
Connecting Rods
and Liners
Inspect
Replace
Repair
1.0
4.5
5.5
0551
Crankshaft
0551A
Bearings, Mains
Replace
Inspect
Replace
Inspect
.5
6.5
.5
6.5
0552
Cylinder Block
Inspect
Replace
Repair
Inspect
Replace
Repair
1.0
.1
1.5
2.0
Instrument Panel
0554
Starting Aid
Inspect
Service
Replace
Repair
.1
.2
1.5
2.0
0560
Hydrostarter
(Hydrotor)
Inspect
Test
Replace
Repair
Overhaul
.2
0562
Accumulator
Hydrostarter Pump
(Engine Driver)
Inspect
Service
Replace
Repair
37,38,39,
40,41,42,
43,44,45,
46
47
47
10.5
4.5
1.5
55
4.5
54
1.0
1.4
3.5
Inspect
Replace
Repair
Overhaul
.2
1.2
2.5
3.0
Hydraulic Pump
(Hand)
Inspect
Replace
Repair
.2
1.0
3.5
0564
Reservoir
Inspect
Replace
Repair
.2
1.9
Inspect
Replace
Repair
.2
2.0
1.0
Hydraulic Filter
and Hoses
1.5
1.2
0563
0565
.5
0553
0561
(5)
TOOLS
AND
EQUIP
1.0
B-4
2.0
(6)
REMARKS
TM 55-1905-219-14-7
SECTION II
MAINTENANCE ALLOCATION CHART (Continued)
(1)
(2)
(3)
(4)
GROUP
NUMBER
COMPONENT
ASSEMBLY
MAINTENANCE
FUNCTION
MAINTENANCE LEVEL
0570
0571
Fairleader
Inspect
Service
Replace
Repair
.5
1.0
Inspect
Service
Replace
Overhaul
.2
.3
6.0
8.0
Inspect
Repair
.5
4.0
0600
Mast
Inspect
Service
Replace
Repair
.5
.5
5.5
Service
.2
Inspect
Replace
Repair
.2
1.5
Inspect
Replace
Repair
Overhaul
.3
3.5
Inspect
Replace
Repair
.3
2.5
1.0
Inspect
Replace
Repair
.3
2.5
Inspect
Replace
.5
1.3
Inspect
Replace
Repair
.2
1.7
1.0
Ships' Hydraulic
System
0710
Hydraulic Power
Unit
0711
Electric Motor
0712
0713
0714
0715
Hydraulic Pump
Hydraulic Reservoir
Controller
Gages
0716
Push Button
Switch
0720
Stern Gate
2.0
1.0
0572
0700
12.0
29.0
1.0
7.5
5.5
7.5
3.0
4.5
B-5
(5)
TOOLS
AND
EQUIP
(6)
REMARKS
TM 55-1905-219-14-7
SECTION II
MAINTENANCE ALLOCATION CHART (Continued)
(1)
(2)
(3)
(4)
GROUP
NUMBER
COMPONENT
ASSEMBLY
MAINTENANCE
FUNCTION
MAINTENANCE LEVEL
0721
0723
0724
Hydraulic Control
Hoses, Fittings
and Pipings
Inspect
Replace
.5
4.2
Hydraulic Ram
Inspect
Replace
Repair
.5
3.5
Inspect
Replace
Repair
.5
3.5
Inspect
Replace
Repair
.4
3.0
Inspect
Replace
.5
4.2
10.5
Inspect
Replace
Repair
.5
3.0
2.0
10.5
Inspect
Replace
Repair
.4
3.0
Inspect
Replace
.5
4.2
Inspect
Replace
Repair
.3
2.0
2.0
Inspect
Replace
Repair
.5
2.5
0731
Hydraulic Ram
Hydraulic Control
0740
Stern Anchor
Hydraulic System
0741
Hydraulic Winch
0742
Hydraulic Control
0743
0800
Steering Systems
0810
0811
.4
3.0
Mast Hydraulic
System
0734
Inspect
Replace
Repair
0730
0732
Motor
Motor Controller
10.5
10.5
10.5
10.5
10.5
10.5
7.0
4.5
B-6
(5)
TOOLS
AND
EQUIP
(6)
REMARKS
TM 55-1905-219-14-7
SECTION II
MAINTENANCE ALLOCATION CHART (Continued)
(1)
(2)
(3)
(4)
GROUP
NUMBER
COMPONENT
ASSEMBLY
MAINTENANCE
FUNCTION
MAINTENANCE LEVEL
0812
Hydraulic Pump
0813
Brake Valve
0814
Directional
Control Valve
0815
Hydraulic Cylinder
and Linkage
0816
Hydraulic Hoses,
Piping and Valves
0817
0820
Rudder Angle
Indicator
0821
Rudder Angle
Transmitter
0830
Flanking Rudder
Limit Switch
0840
Steering Control
Panel and Gyro
Computer
Inspect
Replace
Repair
Inspect
Replace
Repair
Inspect
Replace
Repair
Inspect
Adjust
Replace
Repair
Inspect
Replace
Repair
Inspect
Replace
Repair
.3
2.0
2.0
.3
2.5
Inspect
Replace
Repair
Overhaul
Inspect
Replace
Repair
Overhaul
Inspect
Replace
Repair
Overhaul
Inspect
Replace
Repair
Overhaul
.5
7.0
4.5
.3
2.5
2.5
1.0
1.0
1.8
1.0
2.0
15.0
13.0
15.0
12.0
4.0
20.0
10.0
4.0
1.5
10.5
.5
4.0
1.0
10.5
.2
1.0
.2
10.0
.5
2.5
2.0
40.0 20.0
B-7
(5)
TOOLS
AND
EQUIP
(6)
REMARKS
TM 55-1905-219-14-7
SECTION II
MAINTENANCE ALLOCATION CHART (Continued)
(1)
(2)
(3)
(4)
GROUP
NUMBER
COMPONENT
ASSEMBLY
MAINTENANCE
FUNCTION
MAINTENANCE LEVEL
0850
0860
Heading Selector
Remote Magnetic
Heading Compass
Inspect
Replace
Repair
Overhaul
.5
.5
1.5
Inspect
Adjust
Replace
Calibrate
Overhaul
.5
(5)
TOOLS
AND
EQUIP
(6)
REMARKS
10.0
H
2.5
7.0
3.5
10.0
0870
Emergency Steering
System
Inspect
Replace
Repair
1.0
2.0
2.5
0880
Ships' Course
Indicator
Inspect
Replace
Repair
.7
5.0
12.5
B-8
40.0
TM 55-1905-219-14-7
INDEX
PARAGRAPH
A
"A" FRAME, WIRE ROPE AND ANCHOR...................................................................................
ACCUMULATOR R.......................................... .............................................................................
ADMINISTRATIVE STORAGE ................... ......... . .....................................................................
ANCHOR "A" FRAME HYDRAULIC DIRECTIONAL CONTROLVALVE. ......................................
ANCHOR "A" FRAME HYDRAULIC HOSES, FITTINGS AND PIPING. ........................................
ANCHOR "A" FRAME HYDRUALIC WINCH....................... .........................................................
3-182
3-177
3-221
3-201
3-202
3-200
C
CENTRALIZED HYDRAULIC SYSTEM ........................... ..........................................................
CONNECTING ROD ...................................... ..............................................................................
CONNECTING ROD BEARINGS .............................. ...................................................................
CONTROLLER............................................ .................................................................................
CRANKSHAFT......................................... .....................................................................................
CRANKSHAFT AND MAIN BEARINGS..................... ...................................................................
CRANKSHAFT BEARINGS...........................................................................................................
CRANKSHAFT SEALS ....................................... ........................................................................
CYLINDER BLOCK ............................... .....................................................................................
CYLINDER LINER ..................................... ..................................................................................
3-186
3-171.2
3-171.3
3-191
3-172.2
3-172
3-172.1
3-172.3
3-173
3-171.4
D
DIRECTIONAL CONTROL VALVE ............................ ................................................................
3-208
E
ELECTRIC MOTOR AND COUPLING .......................... ...............................................................
EMERGENCY STEERING SYSTEM................. ...........................................................................
3-188
3-218
F
FAIRLEADER...................................... .........................................................................................
FLANKING RUDDER LIMIT SWITCH............................. ...........................................................
INDEX-1
3-183
3-214
TM 55-1905-219-14-7
INDEX (Continued)
PARAGRAPH
G
GAGE AND ISOLATOR.................... ...........................................................................................
GENERAL.....................................................................................................................................
3-192
3-220
H
HEADING SELECTOR.................................................................................................................
HYDRAULIC CUB PUMP UNIT - BRAKE VALVE ............... .....................................................
HYDRAULIC CUB PUMP UNIT - HYDRAULIC PUMP........... ......................................................
HYDRAULIC CUB PUMP UNIT - HYDRAULIC RESERVOIR TANK
AND STRAINER ....................................................................................................................
HYDRAULIC CUB PUMP UNIT - MOTOR .................................................................................. ..........
HYDRAULIC CUB PUMP UNIT - MOTOR CONTROLLER.......................................................... ............
HYDRAULIC MOTOR.............. . ...................................................................................................
HYDRAULIC POWER UNIT AND RETURN ..................... ...........................................................
HYDRAULIC RESERVOIR TANK AND SUCTION FILTER
......... .......................
HYDROSTARTER ........................................................................................................................
HYDROSTARTER FILTER............... ............................................................................................
HYDROSTARTER HAND PUMP ..................................................................................................
HYDROSTARTER PIPING ...........................................................................................................
HYDROSTARTER PUMP - (ENGINE DRIVEN) .........................................................................
HYDROSTARTER RESERVOIR...................... ....... .....................................................................
HYDROSTARTER RESERVOIR AND FILTER ................... ........................................................
3-216
3-207
3-206
3-209
3-204
3-205
3-189
3-187
3-190
3-176
3-180.2
3-179
3-181
3-178
3-180.1
3-180
I
INSTRUMENT PANEL ........................................ ........................................................................
INTERMEDIATE STORAGE ......................... .............................................................................
3-174
3-222
L
LUBE OIL DISTRIBUTION SYSTEM ........................ ...............................................................
3-170
M
MAST............................................................................................................................................
MAST HYDRAULIC DIRECTIONAL CONTROL VALVE................................................................
INDEX-2
3-185
3-198
TM 55-1905-219-14-7
INDEX (Continued)
PARAGRAPH
M (Continued)
MAST HYDRAULIC HOSES, FITTINGS AND PIPING........... .......................................................
MAST HYDRAULIC RAM .............................................................................................................
3-199
3-197
P
PISTON .......................................................................................................................................
PISTONS, CONNECTING RODS, AND CYLINDER LINERS................. .......................................
PUSHBUTTON SWITCH ..............................................................................................................
3-171.1
3-171
3-193
R
REACTIVATION FROM STORAGE ..............................................................................................
REMOTE MAGNETIC HEADING COMPASS (RHMS).......................... ........................................
RUDDER ANILE INDICATOR ............................... .......................................................................
RUDDER ANGLE TRANSMITTER ............................. ..................................................................
3-223
3-217
3-212
3-213
S
SHIPS' COURSE INDICATOR ............................... ......................................................................
STARTING AID......................................... ....................................................................................
STEERING CONTROL PANEL................................................ .....................................................
STEERING SYSTEM......................................................... ...........................................................
STEERING SYSTEM - HYDRAULIC CYLINDER AND LINKAGE..................................................
STEERING SYSTEM - HYDRAULIC HOSES, PIPING AND VALVES ..........................................
STERN GATE HYDRAULIC DIRECTIONAL CONTROL VALVE ....... ...........................................
STERN GATE HYDRAULIC HOSES, FITTINGS AND PIPING ...... ..............................................
STERN GATE HYDRAULIC RAM ............................. ...................................................................
3-219
3-175
3-215
3-203
3-210
3-211
3-194
3-195
3-196
W
WIRE ROPE CUTTER ................................................. ................................................................
3-184
TM 55-1905-219-14-7
By Order of the Secretary of the Army:
JOHN A. WICKHAM, JR.
General, United States Army
Chief of Staff
Official:
ROBERT M. JOYCE
Major General, United States Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25D, Operator Maintenance requirements for Marine
Equipment, All.
Liquid Measure
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
Weight
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 centigram = 10 milligrams = .15 grain
1 decigram = 10 centigrams = 1.54 grains
1 gram = 10 decigram = .035 ounce
1 dekagram = 10 grams = .35 ounce
1 hectogram = 10 dekagrams = 3.52 ounces
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 1O quintals = 1.1 shorttons
To
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
newton-meters
newton-meters
Multiply by
2.540
.305
.914
1.609
6.451
.093
.836
2.590
.405
.028
.765
29,573
.473
.946
3.785
28.349
.454
.907
1.356
.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
Multiply by
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
temperature
.007062
.394
3.280
1.094
.621
.155
1.'764
1.196
.386
2.471
35.315
1.308
.034
2.113
1.057
.264
.035
2.205
1.102
PIN: 046751-000
Sincerely
Igor Chudov
http://igor.chudov.com/
Chicago Machinery Movers