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TM55-320

WAR DEPARTMENT TECHNICAL MANUAL

NIA LOS
OF CALIFOR ,
SOUTH
REGION
FACILIT
LIBRAR
ERN
UC
ALY

FEB 2 1945
OOO
>>

LIBRARY

SMALL BOAT AND

CO

6
HARBOR CRAFT

PREVENTIVE

MAINTENANCE

WAR DEPARTMENT • NOVEMBER 1944

W A R D E P A R T M E N T TECHNICAL M A N U AL

T M 5 5 - 3 2 0

SMALL BOAT AND

HARBOR CRAFT

PREVENTIVE

MAINTENANCE
ED

OF
UNIT

WA
R FICE
OF

WAR DEPARTMENT N O V E M B E R 1 9 4 4

For sale by the Superintendent of Documents, Washington 25, D. C.

United States Government Printing Office

Washington : 1944
 WAR DEPARTMENT,

Washington 25, D. C., 30 November 1944

TM 55–320, Small Boat and Harbor Craft Preventive Maintenance, is pub

lished for the information and guidance of all concerned .
[ AG 300.7 ( 10 Oct. 44 ) .]

By ORDER OF THE SECRETARY OF War :

G. C. MARSHALL ,

Chief of Staff

OFFICIAL :

J. A. ULIO,

Major General,

The Adjutant General.

DISTRIBUTION :

As prescribed in paragraph 9a FM 21—6, except D ( 0 ) ; C & H 55 ( 3 )

( less railway units ) : PE ( 15 )

For explanation of symbols , see FM 21–6 .

ii
 SRLF
URL

CONTENTS

Paragraph Page
CHAPTER 1. GENERAL.

Purpose and scope of manual. 1 1

Responsibilities for maintenance of marine craft 2 1

Inspections 3 1

Preventive maintenance. 4 1

Records and reports.. 5 2

CHAPTER 2. FIRST ECHELON PREVENTIVE MAINTENANCE

OF MARINE CRAFT.

Section 1. General .. 6-8 5

Role of operating personnel 6 5

Inspection and service. 7 5

Scheduled preventive maintenance 8 5

II. Procedures for scheduled preventive maintenance services 9–12 6

General .. 9 6

Before -operation service. 10 6

During -operation service . 11 9

After-operation service. 12 10

CHAPTER 3. SECOND ECHELON PREVENTIVE MAINTE

NANCE AND TECHNICAL INSPECTION OF
MARINE CRAFT.

General 13 14

Preventive Maintenance services and technical inspection

work sheets .. 14 14

General procedures 15 14

Specific procedures 16 18

APPENDIX 30

iii
 Chapter 1

GENERAL

1. Purpose and Scope of Manual e. FIFTH ECHELON . Maintenance by this echelon

involves the rebuilding of major and accessory
a. PURPOSE. The purpose of this manual is to
assemblies and sub-assemblies . Fifth echelon shops
outline the procedures to be followed by boat
crews and shore personnel when engaged in tech may be established at base depots, or use may be
made of available local facilities , military or
nical inspections and preventive maintenance of
civilian .
Transportation Corps marine craft.
b. SCOPE. The procedures outlined are general,
3. Inspections
and they apply to the structure and equipment of
The primary objective of all inspections of marine
Transportation Corps marine craft of all types
except propulsion units of steam vessels. Detailed equipment and of operating and servicing person
instructions on technical inspections and preven nel is to improve the operating efficiency of mili
tary marine transportation . There are two basic
tive maintenance of specific marine engines, and
types of inspection: command and technical.
equipment are prescribed in specific technical
manuals listed in FM 21-6 . a. COMMAND INSPECTIONS. Command inspec
tions are made by unit commnaders to determine
2. Responsibilties for Maintenance of Marine the condition and adequacy of marine equipment,
Craft tools and supplies, the efficiency of personnel and
their commands, and the economical assignment,
Maintenance of marine craft is performed under
pooling, and use of craft . This type of inspection
the five echelon system, as follows:
may or may not be scheduled, and the exact nature
a . First ECHELON . Maintenance by this echelon
and frequency of the inspection is left to the dis
includes elementary preventive maintenance serv cretion of the commanding officer. Command in
ices accomplished by members of the vessel's crew . spections may be either formal or informal or may
b. SECOND ECHELON. Maintenance by this ech take the nature of spot checks .
elon includes : b. TECHNICAL INSPECTIONS . Technical inspec
( 1 ) Advanced preventive maintenance services tions are made by qualified personnel to deter
and repairs that may be accomplished by techni mine whether or not a vessel should be continued
cally qualified members of the vessel's crew . in service , or withdrawn for overhaul or recla
( 2 ) Advanced preventive maintenance services, mation of component parts. These inspections
inspections, and repairs made by personnel of a are also a check on the condition of vessels when
Harbor Craft Company ( T/ O & E 55–157 ), in they are transferred, or when a report of survey is
cluding replacement of minor assemblies, and required . Technical inspections may take the
emergency repairs and adjustments that do not form of examinations and tests to discover causes
involve the removal of superstructure or deck . of difficulties encountered in operation .
c. THIRD ECHELON . Maintenance by this ech
elon includes the removal and replacement of as 4. Preventive Maintenance
semblies which do not involve the removal of the
a. PURPOSE. The purpose of preventive mainte
deck or superstructure , and repairs that may be nance services performed by the first and second
made by Army marine repair shops or shops echelons is to keep the craft in satisfactorty operat
manned by Ship Repair Companies (T/O & E ing condition and to provide a means for the syste
55–47 ). matic detection and correction of possible or minor
d. FOURTH ECHELON . Maintenance by this eche mechanical failures before they occur or develop
lon includes maintenance and heavy repairs ac into major defects.
complished by shore personnel of Port Marine b. FIRST ECHELON. ( 1 ) Scheduled daily serv
Maintenance Units ( T/O & E 55–500 ). ices. Ordinarily it is the duty of the crew to re

1
plenish fuel, oil , grease, water, and battery liquid , gaged in a non-tactical mission or not in convoy
to clean the craft, to tighten loose bolts, nuts, and is required to carry aboard his vessel a WD AGO
connections, to care for tools, equipment, and bat Form 55–124, Marine Craft Operator's Daily Trip
tery, to make emergency repairs as needed, and to Ticket and P.M. Service Record ( fig. 2 ) . This
check lubricant levels daily. These maintenance form is the commanding officer's official authori
services are performed daily, before, during, and zation for operating the craft . When properly
after operation, and weekly, as described in chap filled out the form contains a record of the route,
ter 2 . destination, load , tachometer and hour readings,
( 2 ) Supervision. The daily and especially the and other information pertinent to the trip . In
addition , this form lists items on the craft to which
weekly maintenance services are performed under
the direction of the section leader or chief engineer attention must be given daily ( before-operation ,
and under the supervision of the company officer during -operation, and after operation ) and week
or craft's captain . ly . While commanding officers operating vessels

( 3 ) Lubrication . On the propulsion engines in convoy are not required to carry a trip ticket,
they may use the form as a reminder or check- list
and auxiliary equipment, oil levels are checked
during training for their daily and weekly main
and lubricant replenished by the crew as a matter
of daily routine. tenance activities . Instructions for performing
the services scheduled for each of these items are
( 4 ) Reports. Maintenance personnel will re
contained in chapter 2, and in the technical man
port the results of servicing operations to the sec
ual on the specific engine or equipment.
tion leader or other designated authority. Services
b. SECOND ECHELON AND TECHNICAL INSPECTION .
or repairs beyond the scope of the personnel's abil
ity, supplies , tools, or time, and those not permitted WD AGO Form 55–125, Preventive Maintenance
by the tactical situation are referred to unit me Service and Technical Inspection Work Sheet for
chanics, who make adjustments, minor repairs, Marine Craft ( figs. 3 and 4 ) , is provided as a re
and unit replacements within their scope. minder and as a record of second echelon preven
tive maintenance services and technical inspec
c. SECOND ECHELON . ( 1 ) Monthly and semi
tions . Instructions for performing these services
annual service. The second echelon performs 200
are contained in chapter 3, and in the technical
hour, or monthly, and 1200 -hour, or semi-annual,
manual on the specific engine or equipment .
maintenance service. These periodic preventive
maintenance services should be performed contin c. DUTY ROSTER . While preventive maintenance
uously throughout the period so that no large services must be performed on a regular time cycle,
number of craft will be tied up at any one time . only a small proportion of the equipment used by
One - twentieth of an organization's craft should an organization can be tied up for these services
receive the 200 - hour monthly service every day at any given time. A control system is prescribed ,
and 1/26 should receive the 1200 - hour service each and a record of it will be kept in WD AGO Form
week . 6, Duty Roster, suitably adapted for this purpose.
( 2 ) Work beyond echelon's scope. The second ( 1 ) Adapting the form . How WD AGO
echelon refers work beyond its scope to the third Form 6 may be adapted for use as a maintenance
of fourth echelon, as required . roster is illustrated in figure 1. On the outside
( 3 ) Special circumstances. Special preventive cover the words “ DUTY ROSTER " will be lined
maintenance services to meet special operating out, and the words “MARINE CRAFT PRE
conditions may be performed by the first or sec VENTIVE MAINTENANCE ROSTER " will be
ond echelon , or both . These include seasonal
entered . The words in parenthesis “ ( SEE AR
services and maintenance of craft operating under 345–25 ) ” will be lined out, as will be “ FOR THE
abnormally high or low temperature or other MONTH OF.” The first 5 columns of all left
unusual conditions.
handed pages throughout the form will not be
used ; they will be left blank. The heading “NA
5. Records and Reports TURE OF DUTY AND WHEN LAST PER

a. FIRST ECHELON. The commanding officer or FORMED ” will be lined out . The heading
other authorized individual operating a vessel en “ KITCHEN POLICE ” at the top of column 6

2
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will be lined out, and the word " NO . ” entered . ly service . If M is used, a small numeral should
The word “MAKE ” will be entered at the top of be written next to it indicating the number of
column 7, " NOMENCLATURE ” at the top of months that have passed since the last semi-annual
column 8, and “ CRAFT NO . ” at the top of col service. Thus, W1 would indicate the first week
umn 9. The words "GUARD ROSTER " at the ly service since the last monthly service took place ;
top of all right-hand pages will be lined out . In M4 would indicate the fourth monthly service
the space will be entered, at the left, “MARINE since the last semi-annual service took place.
CRAFT PREVENTIVE MAINTENANCE
( c) After each inspection and service, the date
ROSTER,” followed by, at the right, the month and nature of the next scheduled inspection and
and year.
service will be indicated, as follows: W1 , W2, W3,
( 2 ) Left -hand pages. The lines on the left -hand MI , W1 , W2, W3, M2, W1 , W2, W3, M3,
pages will be used to list the number of items be Wi , W2, W3, M4, W1 , W2, W3, M5,
ing entered , the make, nomenclature, and craft W1 , W2, W3, S.
designation number of each craft operated by the ( d) Additional symbols to be used where they
organization . One line will be used for each apply follow :
craft if lubrication records on the craft are kept P_Deadlined for lack of parts.
separately. However, if lubrication records are A ~ Deadlined because of accident.
not kept separately, a record of lubrication activi R - Deadlined in repair shop .
ties will be entered in the roster. In such cases
( e ) When conditions make it impossible to per
two lines of the page will be used for each craft. form maintenance operations on schedule, the
( 3 ) Right-hand pages. The right-hand pages entry in the roster will be circled . This circle will
contain 32 columns . The first 31 columns repre indicate that the craft was serviced out of normal
sent the 31 days of the month . The last column is order.
used for a numerical listing of items.
(5 ) Scheduling. Each day, or whenever con
( 4 ) Making entries. ( a ) To start the roster, venient, an officer detailed for the purpose will
enter on the left-hand pages the make, nomencla determine which craft are due for weekly, month
ture, and craft designation number of each craft ly, or semi-annual services.
operated by the organization . On right-hand ( 6 ) Checking. When the weekly service is
pages, and on the line with each craft, leave blank under way, a check should be made to determine
spaces for the number of days remaining until the that the daily services are being performed prop
craft is scheduled to receive its next weekly, erly . When the monthly service is being per
monthly, or semi-annual preventive maintenance formed , an individual representing the operating
service.
personnel should be present to perform weekly
( 6 ) In the column representing the day of the service and to supply necessary information to the
month on which maintenance inspection takes second echelon .
place, enter the letter W, for weekly, M , for ( 7 ) Regularity. Every effort should be made to
monthly or 200 hours, or S, for semi-annually or assure that each craft undergoes preventive main
1200 hours. If W is used, a small numeral should tenance at the scheduled time. Circled entries in
be written next to it to indicate the number of the roster , indicating off- scheduled servicing, will
weeks that have passed since the preceding month be kept to a minimum .
 Chapter 2

FIRST ECHELON PREVENTIVE MAINTENANCE OF

MARINE CRAFT

Section I. General

6. Role of Operating Personnel training will use WD AGO Form 55–124 as a

a. DETECTING TROUBLE EARLY . The operating check list.

personnel of a vessel is the most important single c. RELATED ITEMS. The general inspection and
factor in effective preventive maintenance. Crew service of each piece of equipment or part applies
members are responsible for keeping their craft also to any supporting part or connection . In
in good, sound operating condition by taking pre addition , it usually includes a check to see whether
cautionary measures at regular intervals. Each the part is in good condition, correctly assembled,
crew member is required to perform certain daily secure, or excessively worn .
maintenance duties, and the faithful performance ( 1 ) Inspection for “ good condition ” usually is
of these duties will prolong the life of the craft an external visual inspection to determine if the
and avoid the necessity for major repairs and unit is damaged beyond safe or serviceable limits,
overhaul by higher echelons. or if it is in such a condition that damage will
b. DUTIES AND RESPONSIBILITIES. Preventive result when it is operated. “Good condition ”
maintenance by operating personnel involves the means not rusted, corroded , bent, twisted, chafed,
following duties and responsibilities : burned , broken, cracked , bare, frayed , dented ,
( 1 ) Inspection and servicing of craft in accord collapsed , torn, cut, or inadequately lubricated .
ance with the list of maintenance services pre ( 2 ) Inspection of a unit to see that it is " cor
scribed on WD AGO Form 55–124 . rectly assembled ” is usually an external, visual in
( 2 ) Repair of defects which crew members are spection to determine if it is in its normal position
authorized to repair, capable of repairing, and in relation to other units.
equipped to repair. ( 3 ) Inspection of a unit to determine if it is
( 3 ) Reporting the existence of defects which " secure” is usually an external inspection, a hand
cannot be repaired by operating personnel . feel, or a wrench-check for looseness. The inspec
( 4 ) Avoidance of operating practices which tion should include any brackets, lock washers,
may result in abusive handling of vessel and equip lock nuts, locking wires, or cotter pins used in an
ment. assembly .
( 4 ) “ Excessively worn ” means worn close to or
7. Inspection and Service beyond serviceable limits, and likely to result in a
a. LIST OF ITEMS. The items to be inspected and failure if not replaced before the next scheduled
serviced daily and weekly by operating personnel inspection .
are listed on WD AGO Form No. 55–124 . The
service items apply to all craft operated by the 8. Scheduled Preventive Maintenance
Transportation Corps. Procedures involved in a. BEFORE -OPERATION SERVICES . These services
these service items are described in section II of are performed to determine if conditions have
this chapter.
changed since the last after-operation service .
b. FAMILIARITY WITH ITEMS. Operating person Many things can happen to a vessel between serv
nel of all craft are required to become thoroughly ice inspections. Sabotage may be attempted ,
familiar with the service items listed and with the booby traps may be installed, another vessel may
procedures to be followed in doing the work in run into it, an object may fall on it, moisture may
dicated , so that the services will be performed damage the electrical system, and oil, fuel, or
automatically at the proper times, either before, water may leak out. Therefore, at least a quick
during, or after operation. Personnel undergoing check is necessary before any craft is put into op

5
eration . The before-operation service should never or other authorized individual . This service
be entirely omitted , even in extreme tactical situa should never be entirely omitted even in extreme
tions. tactical situations .

b . DURING -OPERATION SERVICES. The during -op a. ITEM 1 , TAMPERING AND DAMAGE. Inspect for
eration service consists of detecting improper per any injury to craft, special equipment, or arma
formance. It is important to be alert for unusual ment. Inspect for any damage that may have
noises, smoke, steam , or odors, to detect unsatis
resulted from falling debris, shell fire, sabotage,
factory performance of engine or equipment, and collision, or booby traps. Open engine compart
to take corrective steps before the deficiencies de ment doors, and look for signs of tampering or
velop to the point of actual breakdown, fire, or sabotage such as loosened or damaged accessories
accident. or drive belts. Inspect bilge for presence of gaso
C. AFTER -OPERATION SERVICES. After-operation line, oil, or excessive water due to leakage. Dry
services prepare the craft to operate again at a spark plugs, distributor, or magnetos and wiring,
moment's notice . This service is particularly im if they are wet . This will facilitate starting. In
portant, because it is at this time that crew mem spect outside of hull for evidence of damage.
bers inspect the craft thoroughly to detect any
b. ITEM 2, FIRE EXTINGUISHERS. Inspect for tight
deficiencies that may have developed and correct
mountings, full charge, corroded nozzles, and
those coming within their authority. Results of
closed valves . Pay particular attention to extin
this servicing should be reported to the section
guisher lines and nozzles in the engine compart
leader, or other designated authority. If this ment, checking for damage and correct aiming.
service is performed thoroughly, the craft should
C. ITEM 3, FUEL, OIL, WATER. Check the amount
be ready to operate immediately when required .
The after-operation services should never be omit of fuel in the tanks, noting any indications of leaks
ted entirely even in extreme tactical situations . or tampering. Add fuel if necessary, and check
spare fuel cans. Check oil level, and add oil if
d. WEEKLY SERVICE. Weekly service is designed necessary. Check level and condition of coolant.
to re-inforce daily maintenance. It consists of the
During period when antifreeze is used, make hy
after-operation services plus additional attention
drometer test of coolant. Add anti-freeze to water
to certain items, including a general tightening,
if required.
cleaning, and lubrication if required . The section
Note : Any appreciable change in levels since the last after
leader, chief engineer, and the company officer
operation service should be investigated and reported to designated
should carefully supervise and inspect the weekly authority.
maintenance work performed by the crew .
d. ITEM 4, ACCESSORIES AND DRIVES. Inspect all
accessories, such as carburetors, generators, regu
Section 11. Procedures for Scheduled Preven
lators, supercharger, fuel-injection pump, starters,
tive Maintenance Services
fans, shrouds, and water pumps for loose or dam

9. General aged connections or mountings.

e. ITEM 5, START CONTROL. Start the engine and
The before, during, and after -operation preventive
note action of the starter mechanism , particularly
maintenance services to be performed are listed whether the starter has adequate cranking speed
on WD AGO Form 124, illustrated in Figure 2 .
and engages and disengages properly without un
A description of what is involved in each item of
usual noise when starting control is operated.
service is given in the succeeding paragraphs of
Inspect for proper oil circulation. Set throttle so
this section .
that engine will run at normal warm -up speed
( idling ). During the warm -up period, proceed
10. Before -operation Service with the following before-operation services.
Before-operation service consists of inspecting the Caution : If oil pressure gauge does not indicate
items listed below according to the procedures properly within 30 seconds, the engine should be
prescribed , and of correcting any deficiencies or stopped and the trouble corrected or reported to
reporting them to designated authorities. Upon proper authority.
completion of the service, results should be re f. ITEM 6, INSTRUMENTS. ( 1 ) Oil pressure gauge
ported promptly to the organization commander or light indicator. Inspect the gauge to see

6
W.D. , A.G.0 . DESIGNATION NO . OF CRAFT DATE
FORM NO.55– 124
9 August 1944 MARINE CRAFT OPERATOR'S
DAILY TRIP TICKET AND P.M. SERVICE RECORD NAME OF OPERATOR

REPORT TO ORGANIZATION TIME OUT TIME IN

DEPARTMENT OR ADDRESS KIND OF WORK ( or route )

REQUESTED BY ( Organization or Individual ) DISPATCHER'S SIGNATURE

FUEL ADDED ( gals. ) OIL ADDED ( ats . ) ENGINE LOG RECORD

" PORT" " STA ' BOARD"
I have performed the " Preventive Maintenance Services" on TACHOMETER HOUR METER TACHOMETER HOUR METER
this for and recorded all deficiencies and any accident. IN
( Operator's Signature )

OUT
I have noted all entries on this form and taken the ne
cessary action. ( Dispatcher's , etc. , Signature ) TOTAL

TRIP OR LOAD RECORD PASSENGERS OR WE I GHT TACHOMETER HOUR METER

FROM
TO
TO
TO
TO
TO
TO
TO
TO
RELEASED AT ( Tachometer - Hour Meter ) RELEASED AT ( Date ) RELEASED AT ( Hour )

DAILY PREVENTIVE MAINTENANCE SERVICES

Perform these services according to the instructions in TM55-320 or craft manual.
BEFORE OPERATION SERVICES DURING OPERATION SERVICE
1. TAMPERING AND DAMAGE 9. HORN AND WS WIPERS 15. ENGINE OPERATION 22. ACCESSORIES
2. FIRE EXTINGUISHERS 10. GLASS AND TARPS 16. CONTROLS AND DRIVE 23. LEAKS - GENERAL
3. FUEL , DIL , WATER 11. LAMPS 17. PROPELLER AND RUDDER 24 . BILGE PUMP
4. ACCESSORIES AND DRIVES 12. TOWING CONNECTIONS 18. FUEL , OIL AND WATER 25. TOHING CONNECTIONS
5. START CONTROL 13. TOOLS , SPARE PARTS , 19. INSTRUMENTS 26. HULL , LOAD , TARPS
6. INSTRUMENTS AND ECUIPMENT 20. TEMPERATURES AND PRES 27. APPEARANCE AND GLASS
7. STEERING LINKAGE 14. AUXILIARY EQUIPMENT SURES 28. AUXILIARY ECUIPMENT
8 . LEAKS - GENERAL 21. STEERING GEAR , LINKAGE

AFTER OPERATION SERVICE

29. ENGINE- GENERAL * 42 . BILGE PUMP * 48 . AUXILIARY EQUIPMENT
30. FUEL , OIL , WATER 43. FIRE EXTINGUISHERS * 49 . HULL , LOAD , TARPS
31. INSTRUMENTS 44. HORN AND WSWIPERS * 50 . LUBRICATE AS NEEDED
* 32 . BATTERIES 45. GLASS AND LAMPS 51. FIRST AID KIT AND LIFE PRESERVERS
* 33 . ACCESSORIES AND BELTS 46. TOWING CONNECTIONS
* 34 . ELECTRICAL WIRING 47. TOOLS , SPARE PARTS AND EQUIP .
* 35 . AIRCLEANERS, BREATHER CAPS THOSE ITEMS MARKED BY AN ASTERISK ( REQUIRE ADDITIONAL WEEKLY SERVICES
* 36 . FILTERS , STRAINERS ( Oil , Fuel , RECORD ANY ACCIDENT AND ALL DEFICIENCIES , INDICATING IF CORRECTED ; IF NONE ,
Water ) STATE NONE ( For additional space use reverse side )
37. ENGINE CONTROLS
38. PROPELLER AND RUDDER
* 39 . GEAR OIL LEVELS
* 40 . AIR COMPRESSOR ( Tank )
41. LEAKS - GENERAL

Figure 2 . WD AGO Form 55-124, Marine Craft Operator's Daily Trip Ticket and P.M. Service Record .
7
whether it indicates properly, and check the light g. ITEM 7, STEERING LINKAGE . Inspect gear and
indicator to see whether it fails to go out. If linkage to see that they are in condition for safe
these instruments do not indicate properly, stop operation. Pay particular attention to the steer
the engine immediately , investigate the cause , and ing arms and steering linkage, looking for loose
report it to the proper authority. or bent parts.
( 2 ) Ammeter or light indicator. The ammeter h . ITEM 8, LEAKS - GENERAL. Inspect in the en
should show a high charging rate for the first gine compartment and interior of the hull for in
few minutes after starting until the generator re dications of leaks . Observe whether oil is leak
stores to the battery the current used in starting. ing from crankcase, oil tanks, oil coolers, filters,
After this period, the ammeter should register a or lines. Inspect the cooling system for leaks,
zero or slight positive charge with lights and ac paying particular attention to connecting hose.
cessories turned off and the engine operating at
Caution : As a precaution against fire or explo
a fast idle. Any unusual drop or rise in reading sion , before starting the engine, open the ventila
should be investigated. A high charge reading tors or hatches to be sure that the hull compart
for an extended period may indicate a dangerously ments, partitcularly the engine compartment, are
low battery or faulty generator regulator. A light clear of fuel drippings and gas fumes. On craft
indicator should go out when the engine is run equipped with exhaust blowers, operate blowers
ning at fast idle with lights turned off. at least five minutes before staring engines .
( 3) Tachometer. Observe whether tachometer
i. ITEM 9, HORN AND WINDSHIELD WIPERS. Press
is operating properly and indicating the approxi the horn or siren button ( unless tactical situation
mate engine revolutions per minute. If there is
prohibits ) to see that the signal is normal . In
a revolution counter, it should register the accu
spect the windshield wipers for missing or dam
mulating revolutions.
aged blades or arms, and note whether the blades
( 4 ) Fuel gauge. Observe whether gauge is op
contact the glass properly. Start the windshield
erating properly. Normally, fuel tanks should
wipers, and see that they operate normally
have been filled after operation, and the gauge
through their full stroke.
should register “ FULL . "
j. ITEM 10, GLASS AND TARPs. Insect glass,
( 5 ) Air pressure gauge . During the warm -up
frames, and brackets for damage ; also clean the
period , operate the engine at idling speed and ob
windshield and door glass. Inspect tarpaulins for
serve whether the air pressure builds up at a nor
rips or damage and , if not in use, observe whether
mal rate to the specified maximum limits, and
whether the governor then cuts off to stop com they are properly stowed and secured .

pressing action . With the engine at idling speed , k . ITEM 11 , LAMPS. Within the limits permitted
bleed the air pressure down by repeated release by the tactical situation, check operation of all
application, and observe whether the governor switches and see that all lamps ( lights ) operate
cuts in the compressor within the specified limits . properly. See that the lamps are secure, and that
Again bleed down the air pressure and observe lenses are clean and not broken .
whether the low pressure indicator signals prop 1. ITEM 12 , TOWING CONNECTIONS. Be sure
erly at the specified air pressure. Build up the air
mounting and locking devices are secure ; report
pressure again and observe whether the indicator any damage or deficiency that may have occurred .
stops as pressure is built up above the danger Inspect all towing hitches and units to see that
point.
they are in proper condition for safe operation .
( 6 ) Voltmeter. Note whether voltmeter is op
m . ITEM 13, Tools, SPARE PARTS , AND EQUIP
erating properly. It should register at least the
MENT. See that tools, spare parts, and equipment
nominal battery voltage usually indicated by a
red line on the face of the instrument. belonging to the craft are present, clean, servicea
( 7 ) Temperature gauge . Engine temperature ble, and properly mounted or stowed .
should increase gradually during the warm-up n. ITEM 14, AUXILIARY EQUIPMENT. Inspect

period. Extremely low temperature after a reas condition of auxiliary equipment and units, in
onable warm -up period may indicate existing cluding bilge pumps, to see that they are in proper
troubles that should be investigated and corrected . condition for safe operation. Be sure all mount
Extremely high temperatures may indicate defect ings, drives, locking devices, and accessories are
in the cooling system . secure . Report any damage or deficiency.
8
11. During - operation Service check the fuel supply. ( When refueling, use
During -operation service consists of observing the safety precautions for grounding static electricity,
items listed below, and noting minor deficiencies and allow space for expansion in filler neck .
to be corrected and reported at the earliest oppor Filler cap vents must be open , pressure cap valves
tunity, usually the next scheduled halt. The ves must be replaced securely . ) Check the crankcase
sel should be halted if serious trouble develops . oil level or lube tank and , if necessary, add oil to
Operating personnel should listen for signs of proper level . Remove expansion water tank filler
trouble, such as rattles, knocks, squeals, or hums . cap, being careful of steam , especially if a pres
They should watch for steam or smoke coming sure cap is used .Check coolant to see that it is at
from any part of the vessel, and should be on the proper level, and replenish as necessary. Do not
alert to detect unusual odors, such as may come fill to overflowing, but leave sufficient space for
from an overheated generator, overheated clutch , expansion .

boiling coolant, overheated lubricants, fuel vapors e . Item 19, INSTRUMENTS . Observe the readings
from leaks, exhaust gas, or other sources of of all instruments frequently during operation to
trouble . Action of clutch should be observed see whether they are indicating properly .
carefully every time it is operated. Instruments
( 1 ) Temperature gauge. See that the gauge
should be watched carefully for indications of reads in normal range. Excessive engine heat
improper functioning of important parts . may indicate trouble and should be investigated
a. ITEM 15, ENGINE OPERATION . Be on the alert immediately
for deficiencies in engine performance, such as ( 2 ) Oil-pressure gauge. In case of any unusual
lack of usual power, misfiring, unusual noise or drop or no oil pressure, stop the engine imme
stalling, indications of engine overheating, unusual diately, and report trouble to qualified personnel
exhaust smoke or temperatures, and improper aboard, for correction . Lack of oil pressure may
lubricating oil pressure or temperature . indicate insufficient oil , leaks, loose bearings, or a
b . ITEM 16, CONTROLS AND DRIVE . Notice
defective oil pump, and may result in premature
whether engine responds to the controls satisfac wear, or may damage the engine to the extent of
torily, and see that the controls are in proper ad failure. Gauge may be defective.
justment . See that the clutch does not grab, chat ( 3 ) Viscometer. See that indicator remains in
ter , or squeal during engagement, or slip when the normal range section of the dial with engine
fully engaged. Clutch lever must have satisfac at normal operating temperature. Report any ob
tory free travel , as specified in the appropriate tech normal reading
nical manual, before it begins to disengage clutch . ( 4 ) Ammeter. During operation, the ammeter
Otherwise, clutch may slip when under load .
must indicate a zero or a positive reading with all
Too much free travel, however, may keep the
lights and accessories turned off. A discharge
clutch from disengaging fully, thus causing gear
reading may indicate a faulty generator or regu
teeth to clash and be damaged in operation .
lator. When a signal light is used instead of an
Gears and clutch must engage smoothly, operate
ammeter, the light should be off when the engine
quietly, and not disengage during operation. is operated at or above a fast idle.
Jumping out of gear may indicate faulty adjust
ment or worn parts . On multiple engine installa ( 5 ) Tachometer. See that tachometer indicates
the engine speed and accumulating revolutions
tions, all transmissions should be synchronized to
correctly at all times when the engine is running.
operate simultaneously. Inspect all drives and
The engine speed should not be allowed to exceed
gear cases for overheating or excessive oil leaks .
c. ITEM 17,> PROPELLER AND RUDDER . Listen for that specified on the caution plate . On multiple
engine installations, all tachometers must register
any unusual noise from shafts and supporting
bearings . Inspect for looseness, damage, oil and approximately the same revolutions per minute .
This indicates that the engine controls are syn
water leaks and foreign material . Check partic
chronized properly.
ularly for excessive leakage from stuffing boxes .
Also check level and condition of lubricant ; renew ( 6 ) Air -pressure gauge. See that gauge indi
if necessary. cates no more nor less than the specified governed
d . ITEM 18, FUEL , OIL, AND WATER . Check cir air pressure .
culation of fresh and salt water . At each halt , ( 7 ) Fuel gauge . See that the gauge continues

9
to indicate the approximate amount of fuel in the and not damaged, and when not in use, properly
tank . stowed .
( 8 ) Hour-Meter. Hour-meter must indicate m . ITEM 27, APPEARANCE AND GLASS . Inspect
and register the total amount of accumulated en windshield , door and window glasses, light lenses,
gine-running-hours. reflectors and blackout curtains, and inspect en
( 9) Voltmeter. Inspect the voltmeter to see tire craft for cleanliness and damage.
whether it registers at least the nominal battery n . ITEM 28, AUXILIARY EQUIPMENT. Inspect
rating. This is usually indicated by a red line on condition , lubrication and working operation of
the face of the instrument.
auxiliary pumps , generators, winches, motors,
f. ITEM 20, TEMPERATURES AND PRESSURES. Check compressors, refrigerating units, ventilating units
and observe lube oil pressure and temperature,
and accessories. Inspect wiring and controls.
and circulating water temperature for proper heat Notice if any unit indicates that it may be oper
range . Check exhaust temperature and cylinder ating improperly. If there is trouble, detect the
pressure for equalization . Inspect fuel pumps source of it and either correct it or report it to the
and injection system. See that air pressure is proper authority.
maintained throughout the operation . Deficien
cies will be corrected , or reported to proper au
12. After- operation Service
thority. Caution : If low oil pressure is indicated ,
After -operation service consists of inspecting the
stop the engine, correct the situation , or report it
items listed below and correcting any deficiencies
to the proper authority.
or reporting them to designated authorities. This
g. Item 21 , STEERING GEAR, LINKAGE. Examine
will be performed immediately after each use of
the steering control mechanism , arms, and link the craft. Items marked with an asterisk ( * )
age for damage and looseness, and investigate any will receive certain additional attention at the
irregularities noted during operation. See that time weekly service is performed (par. 8d) .
there is no excessive pulling from either side or Upon completion of these services, results will be
excessive wandering of the craft. This may be
reported promptly to the commanding officer or
caused by excessive play in the steering mechan other authorized individual. When performing
ism , excessive wear in the steering linkage, loose
after -operation services, operating personnel will
parts, or maladjustment . take into consideration any irregularities in per
h . ITEM 22, ACCESSORIES. See to it that water formance noticed in the during-operation service.
pumps, generator, supercharger, fuel -injection Units requiring inspection or service while at oper
pump, carburetor, regulator, starter, fans, shrouds, ating temperatures should be inspected as soon
etc., are secure and that all their drives and drive
as possible after operations cease . The after-opera
belts are in correct adjustment and not damaged .
tion service should never be omitted entirely even
See that they are functioning properly . in extreme tactical situations.
i. ITEM 23 , LEAKS - GENERAL. Observe whether
a. ITEM 29, ENGINE - GENERAL. ( 1 ) See that
oil is leaking from crankcase, oil tanks, oil cool
the engine idles satisfactorily. Accelerate and de
ers, filters, or lines. Check the cooling system for
celerate the engine, and note any tendency to miss
leaks. Inspect the fuel system and the air system
or backfire, or any unusual engine noise or vibra
for leaks, paying particular attention to valves,
tion' that might indicate worn parts, loose mount
couplings, fittings and connections.
ings, incorrect , fuel mixture, or faulty ignition .
j. ITEM 24, BILGE PUMP . Inspect condition, lu Correct or report any unsatisfactory engine oper
brication, and working operation of bilge pump, ating characteristics noted during operation.
paying particular attention to screens, strainers,
( 2 ) Clean exterior of the engine and dry thor
stuffing boxes, connections and drives.
oughly, taking care to keep cleaning solvent away
k. ITEM 25, TOWING CONNECTIONS. Inspect all from electrical wiring and equipment. Hot water
towing connections in use to see that they are and soap not harmful to insulation should be used
properly fastened and securely locked . when available. Caution : Do not use waste or

1. ITEM 26, HULL, LOAD, TARPs . Inspect craft hull linty rags when cleaning a diesel engine.
and loads for shifting and condition ; also check ( 3 ) Clean out the engine room .
the tarpaulins to see that they are properly secured b . ITEM 30, FUEL, OIL , WATER . Check coolant

10
 *
level and replenish as necessary, taking care to g. ITEM 35 ,AIR CLEANERS , BREATHER CAPS .
leave sufficient space for expansion . If a large Check to see that the oil in the air cleaner is at the
amount of coolant is required , check the quality of correct level and not excessively dirty. It is not
the antifreeze. Fill fuel tanks, observing safety usually necessary to remove the air cleaner to make
precautions for grounding static electricity, and this inspection . If the oil in the cleaner is ex
bring engine oil to proper level . Refill spare fuel , cessively dirty, clean and refill with fresh oil. In
oil, and water cans . If an unusual amount of oil order to keep the abrasive dirt out of the engine ,
or coolant is required for engine, check for leaks air cleaners and breather caps must be kept clean
and report the condition .. and properly serviced at all times . Weekly : Re
Note: In cold weather have a hydrometer test made of the coolant. move and disassemble the air cleaners . Clean the
C. ITEM 31 , INSTRUMENTS . Be sure all instru bodies and elements in solvent . Fill the reservoirs
ments are securely mounted , properly connected , to the correct level with clean engine oil . Apply
and undamaged . engine oil to the elements and allow the excess to
d. ITEM 32, * BATTERIES. Inspect the battery to drain . When reassembling the cleaners , make
see that it is clean, secure , and not leaking. Cables sure that all gaskets are in good condition and in
and vent caps should be cleaned and fastened . place . Reinstall the air cleaners , giving special at
Weekly: Wipe off dirt from top of battery. If tention to mountings to see that cleaners are
terminal connections or posts are corroded , clean pressed firmly in place against the air -horn seals ,
them thoroughly and apply a thin coating of correctly alined, and secure. Remove all breather
grease. Tighten terminal bolts if they are loose. caps and crank -case filter cleaning elements .
Remove vent caps and check level of electrolyte . Wash them thoroughly in solvent, dip in engine

Add water if required, taking precautions so that oil , drain off the excess, and reinstall. If breathers
battery will not be damaged during freezing tem are of the oil-bath type, clean and service them in
the same manner as for the oil -bath air cleaner
peratures. Battery should be secure , not bulging,
above .
cracked or leaking electrolyte. The battery car
rier should be secure, clean, free of rust, and well h . ITEM 36, * FILTERS, STRAINERS ( OIL , FUEL ,
painted . If mountings are loose, tighten them WATER). ( 1 ) Fuel filter. On Cuno-type filters
cautiously so as not to damage the battery case . turn the handle one complete turn . Check all fuel
Report any defects to designated authority. filters for leaks . Weekly : On craft where the fuel
e. Item 33, * ACCESSORIES AND BELTS. Inspect tank is above the filter, close the shut-off valve in
all accessories, such as pumps, starters, regulators, the fuel line. Remove the drain plug to allow
generators, etc. , for loose connections, mountings, water and sediment to drain out of the filter bowl .
and lubrication . Inspect adjustment of accessory Then replace drain plug, tighten it securely, re
drive belts. Belts should deflect the amount speci open shut-off valve in fuel line, and note whether
fied in craft manual. Weekly: Tighten or adjust fuel is leaking from drain plug. Replace fuel
any loose connections, linkage or mountings on element in accordance with craft manual .
accessories. Examine all belts for fraying, wear , ( 2 ) Oil filter. Do not wash oil filter bags for
cracking or presence of oil. Loose belts may cause re -use. Clean metal type filters with solvent or
improper operation of accessories and may become diesel fuel. Replace oil filters in accordance with
damaged . Tight adjustment may cause damage Lubrication Order or craft manual.
to both accessories and belts. Also check any ac
( 3 ) Water strainer. Inspect and clean circu
cessory drive shafts, couplings, or universal joints lating water strainers, screens and bypasses, noting
to see that they are secure and not leaking or condition of the mesh ; if defective, replace .
damaged .
i. ITEM 37, ENGINE CONTROLS . Check for worn ,
f. ITEM 34, * ELECTRICAL WIRING . Inspect all
disconnected linkage ; report any unsatisfactory
electrical wiring to see that it is securely connected ,
engine control linkage noted during operation .
clean , and not damaged. Weekly: Inspect all ac
cessible wiring, fuse terminal blocks and connec j . ITEM 38 , PROPELLER AND RUDDER. Inspect these
tions to see that they are securely connected and items for loose connections, leaks of lubricant,
supported, that the insulation is not cracked or water or oil, and damage, paying particular atten
chafed , and that its conduits and shielding are in tion to loose mountings, blocked vents, and lube
good condition and secure . level .

11
 k. ITEM 39, * GEAR OIL LEVELS. Inspect drives,, necessary. Be sure that all lamps are off after
transfer units and gear cases for lubricant level and they have been inspected .
leaks. Refer to craft manual for correct lubricant r. ITEM 46 , TOWING CONNECTIONS. Inspect tow
level and type. Weekly : Observe condition of ing hooks, capstans, safety chains, and cables for
lubricant, replace if visual inspection shows need. looseness or damage.
Refer to craft manual for correct lubricant level ,
s. ITEM 47, Tools, SPARE PARTS, AND EQUIPMENT.
type and replacement period . Correct any lube
Check against craft stowage lists to see that all
leaks.
tools, spare parts, and equipment assigned to the
1. ITEM 40, * Air COMPRESSOR ( TANK ) . Ex craft are aboard and properly stowed or mounted .
amine the air compressor to see that it is in good Clean all tools and equipment of rust, mud , or
condition, properly alined with its drive pulleys, dirt, and see that they are in good condition . Re
and secure. Open air tank pet cocks and drain port missing or unserviceable items to proper au
water ( condensation ). Correct any deficiencies thority .
noticed during operation . Weekly : Lubricate in t. Item 48, * AUXILIARY EQUIPMENT . Inspect
accordance with Lubrication Order. Clean gov
auxiliary equipment, including all pumps, for
ernor air strainer, adjust unloader valve clearance ,
lubricant, adjustment, and alinement . Weekly :
tighten or adjust all drives, drive belts, pulleys, Clean and service auxiliary equipment. Refer to
hubs and engine mounts. Tighten loose tank craft manual for correct lubricant levels, adjust
mountings and air line connections. Clean air ment, and servicing instructions.
line of any grease and oil .
u. ITEM 49, * Hull, LOADS, TARPS. Inspect the
m . ITEM 41 , LEAKS - GENERAL. Inspect engine hull and cargo carefully for leaks, damage, or
compartment and engine for indications of fuel, loose parts. The load should be evenly distributed
oil, air, or water leaks. Trace all leaks to their and secure. Tarpaulin should cover the load to
source, and correct or report them . protect it against the elements . All ropes should
n . ITEM 42, * BILGE PUMP . Inspect loose pump be lashed securely to hooks or rings . Check tar
connections , lubricant, water leaks and damage , paulin and curtains for rips or holes, missing or
paying particular attention to mounting and drive . worn grommets, and ropes .
Weekly: Clean and service pump assembly in ac Note: Decks should be swabbed daily and bulkheads and bilges
kept clean at all times. If there are any odors of gas, the source
cordance with Lubrication Order . Check valves, should be located and the trouble corrected.
drive, strainers and lubricant for proper operating
conditions . v. ITEM 50, * LUBRICATE AS NEEDED. Items such
as shackles, steering linkage, hinges, latches, aux
0. ITEM 43, FIRE EXTINGUISHERS. See that the
iliary equipment, accessories and other points that
entire system is in good condition and securely
are lubricated by the operating personnel should
mounted . If the red blow -off seal on the valve
be lubricated if inspection indicates it is necessary.
head of the fire extinguisher is blown, or if the ex
Weekly: Lubricate in accordance with the Lubri
tinguisher has been used, report it for refill or re cation Order for the craft concerned . Lubricate
placement. Be sure the nozzles are cleaned of
all points shown on the Lubrication Order re
any obstructions, dirt or corrosion .
quiring weekly lubrication, also all other points
p. ITEM 44, HORN AND WINDSHIELD WIPERS . See
where experience and inspection indicate a need
that the horn is mounted and properly connected . for lubrication. The need for more frequent lu
See that the arms and blades of windshield wipers brication than is provided by the regular lubrica
are in good condition, and that the wipers operate tion schedule is usually due to abnormally hot or
properly. wet operating conditions.
q . ITEM 45, GLASS AND LAMPS. Clean wind w. ITEM 51 , FIRST -AID KIT AND LIFE PRESERVERS.
shield and other glass to be sure it is securely Check the first -aid kit for condition and supply of
mounted and undamaged . Observe whether the necessary items for replacement. Observe that all
lights operate properly with the switches at all life preservers are properly mounted in position .
“ on ” positions, and go out when switched "off. ' Check for shortage and worn or damaged equip
Inspect all lenses for dirt or damage ; clean if ment, and replace it.

12
 Chapter 3

SECOND ECHELON PREVENTIVE MAINTENANCE AND

TECHNICAL INSPECTION OF MARINE CRAFT

13. General ( 1 ) To determine whether a craft should be

a. PREVENTIVE MAINTENANCE SERVICES. Regular continued in service or withdrawn for overhaul
or reclamation of component parts.
ly scheduled maintenance inspections and services
are a preventive maintenance function, and are ( 2 ) To determine extent of damage and esti
the responsibility of the commanders of operating mated cost of repair in Report of Survey, and
organizations . other similar proceedings.
An efficient control system is an
( 3 ) To discover causes of difficulties encoun
essential aid in determining when vessels are due
for periodic maintenance services, either because tered in operation of craft, so that efficiency may
of time elapsed or of running time accumulated . be improved.
These preventive maintenance services include :
14. Preventive Maintenance Services and
( 1 ) Maintenance services by company, detach
ment, or similar units, for craft and auxiliary Technical Inspection Work Sheets
equipment at monthly ( 200 -hour) intervals . For purposes of establishing uniform procedure
(2) Maintenance services by regiment , battalion, for preventive maintenance services and technical
separate company or detachment, for craft and inspections, a Work Sheet has been devised and
auxiliary equipment at semiannual ( 1200-hour ) adopted as WD AGO Form 55–125, Preventive
intervals .
Maintenance Service and Technical Inspection
b . INTERVALS. The frequencies of preventive Work Sheet for Marine Craft. The front and
maintenance services outlined in this manual are
reverse sides of this form are illustrated in figures
considered to be the minimum requirement for 3 and 4, respectively. The general procedures de
normal operation of craft. Under unusual oper scribed in succeeding paragraphs are to be applied
ating conditions it may be necessary to perform to this form in conducting maintenance services
the maintenance services more frequently. and technical inspections. The specific pro
c. FIRST ECHELON PARTICIPATION . (1) Oper cedures explain in detail the manner in which
ating personnel should accompany their craft each item listed on the form is to be inspected
when possible and assist the mechanics while and serviced . Due to their similarity, the pro
periodic second echelon preventive maintenance cedures for the 1200 -hour ( semiannual) main
services are performed. tenance service and for the technical inspection
( 2 ) Ordinarily the craft should be presented have been listed on the same form . Ordinarily,
for a scheduled preventive maintenance service however, the technical inspection is performed by
in a reasonably clean condition . third or higher echelon , while the 1200 -hour serv
d. TECHNICAL INSPECTIONS. These inspections ice is performed by second echelon. If instruc
tions other than those contained in either the
are performed by technically qualified personnel,
under direct supervision of technically qualified general or the specific procedures are required
officers. Whenever a craft goes to third or higher for the correct performance of a preventive main
echelon maintenance shop for repair, it will re tenance service or for the correction of a deficiency,
the craft engineer or the craft manual should be
ceive a technical inspection to insure that all
defects have been corrected before it is returned consulted .

to the using organization . Except in the theater

15. General Procedures
of operations, technical inspections will be made
whenever accountability is transferred, to de a. BASIC INSTRUCTIONS. These general pro
termine craft condition. Technical inspections cedures are basic instructions which are to be
are made for the following purposes : followed when performing the services on the craft

13
 W.D. , A.G.O. DESIGNATION NUMBER DATE
FORM NO . 55- 125
9 August 1944 PREVENTIVE MAINTENANCE SERVICE
AND TECHNICAL INSPECTION WORK SHEET FOR LENGTH AND TYPE

MARINE CRAFT
ENGINE MFGR .
1200 HOUR ( Semi - annual ) Maintenance or Technical Inspection.
200 HOUR (Monthly ) Maintenance.
TYPE CYCLE MODEL CYLINDERS BORE STROKE H.P. R.P.M. START DRIVE SUPERCHARGER

SEE TM 55- 320 AND CRAFT MAINTENANCE MANUAL FOR DETAILED INSTRUCTIONS .
Legend for Marking :V . Satisfactory , X -Adjustment Required, XX . kepair or Replacement Required, O- De fect Corrected.

4444
Symbols : Inspect and correct; C - Clean ; T- Tighten ; A- Adjust; L -Lubricate; D- Drain; S- Serve.
1200 200 1200 200
HOUR HOUR MOUR HOUR
1. AIR PRESSURE ( Build- Up ) ( Governor Cut . CE 36. COIL AND WIRING (High and Low Voltage )
Orf) (Low Pressure Indicator ) ( Supports )
2 . INSTRUMENTS AND GAGES ( Oil Pressure and A 31. MAGNETOS (Point . )

STOPPED
Temperature and Hour Meter ) (Ammeter and AL AL 38. DISTRIBUTOR ( Cap ) ( Rotor ) ( Points )

ENGINE
Voltmetes ) ( Tachometer and Revolution ( Shaft ) ( Advance Units )
Counter ) ( Engine Temperature ) ( Fuel Oil cs_cs_ 39. BATTERY ( Cable . ) ( Hold - Downs ) ( Gravity
RUNNING
ENGINE

Pressure ) ( Fuel ) and Voltage )

3. WINDSHIELD , WINDSHIELD WIPER , HORN CLA CLA 40. AIR COMPRESSOR ( Unloader Valve )
4. CLUTCH DRIVE ( Free Travel) ( Linkage ) ( Governor ) (Lines ) ( Tank )
5. GEAR DRIVE (Lever Action ) ( Declutching ) 41. GEAR OIL LEVELS
( Vibration ) (Noise ) ( Control Synchroni . CL CL 42. STARTING MOTOR (Air ) (Electric )
sation ) Controls )
6. STEERING ( Gear) ( Control ) ( Linkage ) 43. TIMING ( Diesel ) ( Gasoline )
1. DIRECT DRIVE REVERSE GEAR MECHANISM JA JA 44. BILGE PUMPS ( Drives ) ( Valves )
8. AIR CONTROL ( Controlair ) (Actuator ) ( Control) ( Lines ) ( Strainera )
( Pneu dyne) ( Valves ) I L 45. PROPELLER ( Shafts ) ( Sealo ) (Joints )
9. SUPERCHARGER (Operation ) (Lube ) ( Vibra . ( Boaring . ) ( Stuffing Box )
tion ) II 46. RUDDER ( Shafts ) ( Arms ) ( Cables ) ( Rod)
10. ENGINE ( idle) ( Acceleration ) (Pover ) ( Brackets ) ( Controls )
(Noire ) ( Smoke ) ( Governed Spoed) JA JA 47. PUMPS ( Drives ) ( Valves ) ( Controls )
AUXILIARI

11. SAFETY DEVICES (Overspeed Safety Trip ) ( Lines ) ( Strainers )

Manglend
4551

(Lov Oil Safety Shutdown ) _CS_CS_48. WINCH ( Clutch ) ( Brake ) ( Drive )

12. LEAKS ( Fuel Oil ) ( Engine Oil ) ( Water ) ( Controls ) ( Cable ) ( Guidos )
(Air )
ES

с C_49 . ELECTRIC MOTOR ( Commutator ) (Brushes )

555
100W

( Control Box ) ( Wiring )

HIT

13. CYLINDER HEAD AND GASKETS

4513

14. VALVE MECHANISM (Clearance) ( Lubrication) CE 50. GENERATOR ( Commutator) ( Brusher )

od

( Cover Gaskets ) ( Control Box ) ( Wiring )

sobom
11

TCS ICS 51. REFRIGERATION UNITS ( Drives ) ( Controls)

o4

15. DIESEL FUEL NOZZLES AND LINES

Hf

CA CA 16. SPARK PLUGS ( Gap . ) ( Deposits ) ( Valves ) (Refrigerant )

, UPERSTRUCTURE

17. COMPRESSION TEST 52. VENTILATORS ( Intakes ) ( Blowers )

18. ENGINE (Nounting and Braces ) ( Ground ( Drives ) ( Ducts )
ACCESSORIES

Strap ) ( Side Pano ) DLA OLA 53. AIR COMPRESSOR ( Valves ) ( Governor)
T T 19. MANI FOLOS AND HEAT CONTROL ( Intake ) (Lines ) ( Tank ) ( Drive )
( Exhaust ) 54. SUPERSTRUCTURE ( Doore ) (Hardvare)
I 20 . EXHAUST PIPES AND MUFFLERS ( Glass ) ( Seats ) ( Safety Straps and
HULL
STOPPED

SAND
ENGINE

D 0 21 . FUEL ( Tanks) ( Vento ) (Lines ) Grab Railo ) ( stovage Compartments )

CS с 22. FUEL FILTERS , SCREENS AND LINES ( Tarpaulins ) ( Ventilatora ) ( Black Out
23. FUEL PUMP ( Vacum and Pressure ) Screena )
TAS TA 24. FUEL INJECTOR PUMP ( Primer ) 55. HULL ( Plugo ) ( Decka ) ( Vontilatoro ) .
LA LA 25. THROTTLE ( Linkage ) ( Dual . Throttle ( Plates ) ( Compartments ) ( Bulkheade )
Synchronization ) ( Frame )
_ $ T T 26. ENGINE OIL ( Tanks ) ( Coolers ) ( Lines and ICS ICS 56. RIGGING ( Boom ) ( Blocks ) ( Cable ) (Hoist )
Fittings ) ( Viscosity) 57. WIRING (Junction and Terminal Blocka )
CS . Cs 27. ENGINE OIL FILTERS ( Reclaimers ) ( Fuses and Spares)
28. AIR CLEANERS ( Carburetor ) ( Diesel ) ( Air L 58. HEATERS , FANS , AND DEFROSTERS
Compressor ) 59. PLUMBING , FIXTURES , ETC.
TA TA 29. WATER PUMPS ( Fresh Water ) ( Sea Water ) TL TL 60. FIRE EXTINGUISHER SYSTEM ( Tanks )
A A 30. ACCESSORY DRIVES ( Belt ) (Pulleys ) ( Valves ) (Lines and Nossles )
( Shafts and Couplings ) (Mountings )
CT_CT_31. HEAT EXCHANGER ( Core ) ( Shutters ) (Hose ) 61. PAINT AND MARKINGS
( Cap ) ( Zinc Plate ) ( Scale ) 62. COMPASS ( Fluid) ( Lamp )
CT CT 32. FRESH WATER EXPANSION TANK ( Antifreeze ) 63. TOW ( Chain ) (Cable ) ( Rope ) ( Block )
( Cap ) ( Hose ) 64. ANCHOR , HAND BILGE PUMP AND BOAT HOOK
CT CT 33. GENERATOR ( Commutator ) ( Brushes ) (Wiring ) 65. TOOLS AND EQUIPMENT
34. REGULATOR UNIT ( Connections ) ( Voltage ) 66. FIRST AID KIT AND LIFE PRESERVERS
( Current ) ( Cut - Out )
35. CARBURETOR ( Choke ) ( Throttle ) (Linkage )
( Governor )
NOTE: For craft having only one engine, one copy of this work sheet is sufficient for the entire craft at any one
time. For craft having more than one engine, propulsion or auxiliary, one copy should be used for each engine,
non - applicable parts of the form being disregarded.
REMARKS ( For additional space use reverse side )

Figure 3. Front side of WD, AGO Form 55-125 , Preventive Main tenance Service and Technical Inspection Work Sheet for Marine Craft.

14
 SPECIAL MAINTENANCE
1. Lube oil change engines: Oil is to be changed in accordance with " Lubrication Order " using oil meeting U. S.
Army Specification 2-104B, or latest revision .
2 . Lube oil filters: Do not wash filter bags for reuse. Clean metal type filters.
AFTER 1200 - HOUR OPERATION OR SEMI - ANNUALLY
3 . Fuel injectors: Remove, flean, inspect and check .
4 . Intake and Bxhaust Valves: Remove, inspect, clean and check.
6 , Connecting rods: Check clearances.
AFTER 2400 HOURS OR ANNUALLY
6 . General Overhaul. ( a) Remove engine heads, pistons and connecting rods; clean , check, replace piston rings
and grind valves.
( b ) Clean gear cases and refill.
SPECIAL INSTRUCTIONS
1. Clean out generators, motors , and electrical controls with clean dry air of not more than 70 pound pressure
2 . Caption is to be observed in lubricating the bearings of the generators. Over - lubrication is hamtal to the
bearings as it causes heating.
3 . Bagine is to be cleaned periodically with suitable cleaning material as conditions warrant. Electrical equip
ment is to be kept free of oil. Do not use waste or linty rags when cleaning a diesel engine.
4 . Battery is to be cleaned with bicarbonate of soda solution lone ( 1 ) pound of soda to a gallon of water ) . Apply
a thin coating of vaseline or cup grease to cable terminal.
BATTERY
VOLTAGE ELECTROLYTE TEMP .

SPECIFIC GRAVITY WATER ADDED (pte )

COMPRESSION TEST- P COMPRESSION TEST- S

ANTI - FREEZE PROTECTION

MAN HOURS REQUIRED FOR 1200 - HOUR MAINTENANCE TO (Number of NAME AND BADGE NO . OF MECHANIC OR INSPECTOR
200 - HOUR MAINTENANCE degrees F)

REPAIRS REQUESTED ( Date and Initiala ) REPAIRS INITIATED ( Date and Initial . ) REPAIRS ACCOMPLISHED( Date and Initiale)

200 - Hour : May be retained until the completion of the next 1200 hour , then destroy .
DISPOSITION OF WORK SHEETS : 1200 - Hour : May be retained until the completion of the next 1200 hour , then destroy .
NOTE : A record of all maintenance, including date of oil change and amount of make- up crankcase oil used in engines
and air compressors , is to be kept in the Craft Log Record .
REMARKS

Figure 4. Reverse side of WD AGO Form 55–125, Preventive Maintenance Service and Technical Inspection Work Sheet for Marine Craft.

15
items listed on WD AGO form 55-125 . Second is appropriate, and explain under REMARKS on
echelon personnel must be so thoroughly trained the reverse side of the form . Record the item
in these procedures that they will apply them number for identification . When the defect is
automatically .
corrected , either by organization mechanics or by
b. ONE FOR EACH ENGINE . For craft having only higher echelon mechanics , draw a circle around
one engine, one copy of the form is sufficient for the X or XX , as follows: 0 or 09 .
the entire vessel. For craft having more than one
i. DETERMINING ECHELON . The following con
engine , either propulsion or auxiliary , one form
should be used for each of these engines, non siderations will govern in determining whether a
maintenance operation should be referred to a
applicable parts of the form being disregarded.
higher echelon or be performed by the operating
c. IDENTIFICATION DATA. All of the required
identification data for the craft should be entered organization . Repair to craft will be performed
in the lowest echelon of maintenance consistent
in the spaces provided at the top of each form .
with :
d . INAPPLICABLE HEADINGS . In order to indicate
( 1 ) Availability of suitable tools,
on the work sheet whether one of the periodic
preventive maintenance services or the technical ( 2 ) Availability of necessary parts,
( 3 ) Capabilities of mechanics,
inspection is being performed , line out the main
( 4 ) Time available,
items or sub- items that do not apply to the service
( 5 ) Tactical situation .
or inspection to be performed.
j. RETURN TO OPERATION . After a technical in
e . USE OF BOXES . Boxes are placed opposite each
item on the work sheet. These boxes indicate spection, the craft should be restored to a safe
which of the maintenance or inspection services operating condition , unless it is to be deadlined for
is to be performed for each item . Each box indi repair. Any disassembled parts or assemblies that
cates that the item is to be inspected and corrected are damaged in handling during the inspection
when necessary. Special service symbols like C, should be replaced by serviceable ones .
T , A, L, or S appear in some of the boxes. These preventive
k. MINIMUM DISASSEMBLY . The
symbols indicate that certain additional mandatory
maintenance services should be performed with
services are to be performed , and are explained in
out disassembling units, unless prescribed in the
detail in n , below .
procedures, or unless disassembly should be made
f. PERFORM IN SEQUENCE . Items not lined out
in accordance with instructions in the craft
on the form should usually be performed in the
manual . Ordinarily , new gaskets should be used
order in which they are listed , since they have
when the parts are reassembled .
been arranged for economy of motion .
1. NEW INSTALLATIONS . When new or over
should be
g. ACTION ON DEFECTS . All defects hauled sub - assemblies are installed to correct de
corrected upon discovery or should be reported
ficiencies, care should be taken to see that they are
to higher echelons for correction .
clean , properly lubricated, and adjusted .
h . MARKINGS. The condition in which items
are found and the correction of defects should be m . RELATED ITEMS . The general inspection of
each item applies also to any supporting member
indicated on the form by the following markings:
or connection , and usually includes a check to see
V - Mark the box with a check if found
whether the item is in good condition , correctly
satisfactory assembled , secure, or excessively worn . Mechanics
X - Mark the box X if adjustment is
must understand thoroughly the meaning of these
required
terms . The terms are defined in paragraph 6c .
XX—Mark the box XX if repair or re
n . SPECIAL SYMBOLS . Special service symbols, as
placement is required
applied to the items of the periodic preventive
Ø or 00 – When a defect is found and not cor
maintenance services, indicate that the part is to
rected immediately
receive certain mandatory services. For example:
or if the correction is to be made by higher An inspection box with a T in it indicates that the
echelon, mark the box with X or XX, whichever part not only must be secure, but that the mount

16
ing bolts must be tightened properly with a complete all operations within the week if pos
wrench . These symbols are : sible . All available time must be utilized if neces
( 1 ) A, Adjust. Make all necessary adjustments sary to assure that the maintenance operations are
in accordance with the craft manual, special bul completed . When limited by the tactical situa
letins, or other directives . tion , items marked with special service symbols
( 2 ) C , Clean . Clean units of the craft to re in the boxes should be given first consideration.
move lubricant or dirt, using dry-cleaning solvent. p. DISASSEMBLED UNITS . If it is necessary to dis
After the parts are cleaned , rinse them in clean assemble a unit, any special services indicated on
Auid and dry them well . Be careful to keep the the 1200 -hour maintenance should be performed.
parts clean until reassembled . Keep cleaning q . DISPOSITION OF FORMS. All 200 -hour main
fluid away from rubber or other material which
tenance work sheets may be held in the organiza
it will damage . Clean the protective grease coat tion file until the next 1200 -hour maintenance
ing from new parts. This material usually is work sheet is filed . The old sheet may then be
not a good lụbricant. destroyed . The 1200 -hour maintenance work
( 3 ) L, Special Lubrication. Special lubrication
sheet, or technical inspection report, may be held
applies either to lubrication operations that do not until the next 12000 -hour maintenance form is
usually appear on the craft Lubrication Order, or
filed, and then may be destroyed .
to items that do appear on the Order but should
be performed in connection with the maintenance 16. Specific Procedures
operations if parts have to be disassembled for in
Specific procedures for performing each item in
spection.
the monthly ( 200-hour ) and semiannual ( 1200
( 4 ) S, Serve. This usually consists of perform
hour ) maintenance services, and in the technical
ing special operations, such as replenishing battery
, and inspections are described onthe following pages.
water, draining and refilling unitswithoil
The three columns at the left of each page corre
changing or cleaning the fuel or oil- filter cartridge,
spond to the columns provided in WD AGO Form
strainers, tanks, etc.
55–125 for indicating items to be covered in the
( 5 ) T , Tighten . All tightening operations 200 -hour maintenance, the 1200-hour maintenance,
should be performed with sufficient wrench torque
and the technical inspection. While the 1200
( force on the wrench handle ) to tighten the units hour maintenance and technical inspection are in
according to good mechanical practice, using the
cluded in the same column on the work sheet,
proper tool without additional extension handle .
separate columns for these items are provided in
Use torque- indicating wrench where specified.
the following pages. ' Often it will be found that a
Do not overtighten, since this may strip threads
or cause distortion . Tightening will always be particular procedure does not apply to both the
understood to include the correct installation of 200 -hour maintenance, the 1200-hour maintenance,
lock washers, lock nuts, and cotter pins or locking and the technical inspection . The sample below,
wires provided to secure the tightening. taken from the specific procedures on the follow
0. PARTIAL MAINTENANCE . When conditions ing pages, illustrates the application of these pro
make it difficult to perform the complete preven cedures . The numbers appearing under the
tive maintenance service at one time, it may be columns at the left are the numbers of the items
done in installments . Efforts should be made to listed on the form .
17
 SAMPLE

Tech . 1200 200 Remarks

Insp. Hour Hour

24 24 24 FUEL INJECTOR PUMP (PRIMER ). Note whether the pump ( in Applies to 200-hour mainte
cluding any transfer pump) is in good condition , correctly nance, 1200-hour maintenance
assembled , and securely mounted . See that its connections do and technical inspection .
not leak . Determine the oil level in the pump with the dip
stick. Add oil if needed .

24 24 Tighten . Tighten all assembly and mounting bolts and cap screws. Applies to both 200 -hour and
1200 -hour maintenance.
Adjust. Adjust the fuel injector pump timing according to the Applies to both 200 -hour and
instructions and specifications in the craft manual. Note whether 1200 -hour maintenance.
hand pump primer is in good condition and in operating order.

24 Serve. Drain the oil from the fuel injector pump and refill to Applies to 1200-hour mainte
correct level with specified engine oil. } nance only.

18
 SPECIFIC MAINTENANCE PROCEDURES

Engine
Running
Tech 1200 200
Insp. Hour Hour

1 1 1 AIR PRESSURE ( Build Up ) ( Governor Cut-Off) ( Low Pressure Indicator) .

During the warm -up period operate the engine at idling speed and observe whether the air pressure
builds up at a normal rate to the specified maximum limits, and whether the governor then cuts off
to stop compressing action. Observe whether the pressure indicator registers the approximate pressure
as pressure is built up to the maximum limit.
2 2 2 INSTRUMENTS AND GAUGES (Oil Pressure, Oil Temperature, and Hour Meter ) (Ammeter and
Voltmeter) (Tachometer and Revolution Counter ) ( Engine Temperature ) (Fuel Oil Pressure )
(Fuel ) .
Oil Pressure, Oil Temperature and Hour Meter.
Observe the oil pressure and temperature to determine whether it is sufficient for safe operation of
the engine, and whether the hour meter registers the accumulating engine running hours. Continue
to observe the oil pressure and temperature to see that it is normal throughout the engine speed range.
Also observe whether the hour meter continues to register at all times when the engine is running.
Caution : If the oil pressure gauge indicates excessively low oil pressure, stop the engine immediately
and investigate the cause.
Ammeter and Voltmeter.
See that the ammeter and voltmeter are indicating normally. With the battery fully charged,
charge should be indicated by ammeter for a short time after starting the engine ( to restore the
current used by the starter ); the ammeter should return to slightly above zero, with all lights and
electrical accessories switched off. When the battery is low, charge will be indicated for a longer
period.
Tachometer and Revolution Counter.
Observe the tachometer to see whether it operates normally without excessive fluctuation or unusual
noises that might indicate worn or damaged gears or drive cables. Also observe the revolution
counter to see whether it registers the accumulating revolutions.
Engine Temperature.
Note the engine temperature gauge and exhaust temperature gauge ( pyrometer ) to see that they
indicate in the normal range. The engine temperature should increase gradually during the
warm -up period and normally should not exceed 180 ° F. The temperature at which the gauge
hesitates indicates the opening of the thermostatic control .
Fuel Oil Pressure, Fuel.
Observe whether the fuel gauges indicate the approximate amount of fuel in the tanks and determine
whether the fuel pressure is sufficient for the proper operation of the engine.
3 3 3 WINDSHIELD , WINDSHIELD WIPER, HORN.
See that the windshields are in good condition and secure, that the windshield glass is clean, that the
wipers operate correctly through their full stroke without evidence of looseness in their motor mount
ings, and that the blades contact the glass properly. If the tactical situation permits, sound the horn
to determine whether the signal is normal .
4 4 4 CLUTCH DRIVE ( Free Travel) (Linkage ).
Observe whether the clutch lever has satisfactorily free travel ( in accordance with the craft manual )
before beginning to disengage or engage the clutch ; see that releases the clutch completely before
the lever has completed its stroke and note whether there are any unusual noises in the clutch release
mechanism that would indicate dry or defective release bearings, defective clutch plate or pilot bear
ings. When engaging the clutch, and when the clutch is fully engaged , observe whether there is
any indication of slipping and whether linkage is properly adjusted .
5 5 5 GEAR DRIVE ( Lever Action ) (Declutching) ( Vibration )
( Noise ) (Control Synchronization ).
With the craft in motion, operate levers of the driving units through all positions, noting whether
the levers move easily and snap into each position. Observe whether there are any unusual vibrations
that might indicate loose mountings, and whether the gears jump out of mesh . On multiple-engine
installations equipped with hydraulic or air controls, observe whether they appear to shift properly and
whether the transmissions shift simultaneously. Continue these observations throughout the test.
6 6 STEERING (Gear) (Control) (Linkage).
Steering wheel should have minimum free play in accordance with craft manual . Rotate the steering
wheel fully in both directions and note any indication of binding or bumpy feel. Examine the steer
ing column and steering wheel to see that they are in good condition and secure. On booster control
unit, observe the free play of the steering gear to see whether there is excessive lash in
the steering mechanism , or any indication of binding. Notice whether the steering booster appears to
operate properly to assist the steering mechanism , and notice any abnormal pull to one side.

19
 Engine
Running
Tech . 1200 200
Insp. Hour Hour

7 7 7 DIRECT DRIVE REVERSE GEAR MECHANISM.

Operate the engine in both forward and reverse positions, observing whether fuel cut-off is automatic
when stopping and reversing the engine. Observe the automatic braking of the engine, valve opera
tion, interlocking reverse cycle sequence, pneumatic and manual speed regulation, and maneuvering
controls for proper functioning.
8 8 8 AIR CONTROL (Controlair ) ( Actuator ) ( Pneudyne) ( Valves ) .
Inspect these items for proper operation, and be sure that they are in good condition , correctly as
sembled, secure and adequately lubricated . Observe the action of :
Controlair , for proper control of maneuvering and speed regulation of the engine.
Actuator, for proper regulation of engine speed , as selected from the Controlair.
Pneudyne, for proper positioning of the engine camshaft and camshifting interlock and for shifting
of engine clutch in accordance with the lever position of the Controlair.
Camshifting Interlock Valve, for the proper interlocking of pneumatic control equipment with the
engine camshaft position .
Throttle Latch Pilot Valve, for the proper operation of fuel cutoff valve when changing engine direction.
Fuel Cutof Valve, for the proper shutoff and control of fuel when engine is stopped, started or re
versed.
Relay Air Valve, for the proper control of air as directed by the Controlair lever.
Reducing Valves, for the proper limiting of air pressure to Controlair and Pneudyne in accordance
with craft manual.
9 9 9 SUPERCHARGER (Operation ) ( Lube) ( Vibration ).
Observe operation of the supercharger, paying particular attention to vibration of rotors, indicating
loose or worn parts or marred surfaces. Examine drive and coupling assembly for indications of ex
cessive lash. Inspect unit for loose mounting, oil leaks, proper and adequate lubricant.
10 10 10 ENGINE ( Idle) ( Acceleration ) ( Power) (Noise ) ( Smoke) ( Governed Speed) .
Idle. Observe whether the engine runs smoothly at idling speed and listen for knocks and rattles
as the engine is accelerated and declerated and while it is under light and heavy loads .
Acceleration , Power, and Noise. Observe whether the engine has normal acceleration , pulling power,
and operating characteristics in each speed . Listen for other noises that might indicate damaged ,
excessively worn, inadequately lubricated engine parts or accessories, or loose drive belts.
Smoke. During operation of the engine test, look for any indication of excessive or unusual smoke
from the exhaust.
Governed Speed . Slowly accelerate the engine and observe the tachometer reading. Notice that
engine reaches but does not exceed the governed speed ( rpm ) specified on the caution plate or
recommended by the craft manual. Do not acclerate engine beyond fast idle without load .
11 11 11 SAFETY DEVICES (Overspeed Safety Trip ) ( Low Oil Safety Shutdown ) .
Overspeed Safety Trip. With engine running, trip the overspeed safety trip to make sure that all
parts are in working order. Reset trip lever. Examine linkage and controls for adequate lubri
cation.

Low Oil Safety Shutdown. Test cut-out switch for low oil safety and excessive water temperature,
to insure that all parts and units are in working order . Examine horn or howler if used in con
nection with switch. Any deficiencies in the operation of the safety devices must be corrected
before engine is started again.
12 12 12 LEAKS ( Fuel Oil ) ( Engine Oil ) (Water) ( Air) .
Check the engine compartment thoroughly , including the entire engine, for indications of oil , air,
water, or fuel leaks and determine their source. This should be corrected or reported to the proper
authority.
Engine Stopped
13 13 13 CYLINDER HEAD AND GASKETS.
Look for cracks or indications of oil , water, or compression leaks around studs, cap screws, and gas
ket. Caution : Cylinder heads should not ordinarily be tightened unless there is a definite indication
of looseness or leaks. If tightening is necessary, use a torque-indicating wrench and tighten in the
sequence and to the tension specified in the craft manual . When a new gasket is installed , tighten
three times as follows : First, upon installation ; second , after engine is warmed up, and third , after
completing final test. On valve- in -head engines, adjust the tappet clearances to specifications after the
final tightening of the head nuts.

20
 Engine
Running
Tech . 1200 200
Insp . Hour Hour

14 14 14 VALVE MECHANISM ( Clearances ) (Lubrication ) ( Cover Gaskets).

On valve -in -head engines, examine valve tappet clearances while hot. Valve tappets, rocket arms,
shafts, and springs should appear in good condition, correctly assembled , and secure. Oil should be
delivered properly. Also make sure that the valve cover gaskets are in good condition. On L -Head
engines perform the above service only as the need for such service is indicated by valve noises or
engine performance . Remove valve mechanism covers, observe valve clearances and condition of
valve mechanism .
14 14 Adjust. Adjust the clearances to specifications, taking care that the lock nuts are secure when the
clearances are last noted during the adjustment.
15 15 15 DIESEL FUEL NOZZLES AND LINES.
Observe whether these items are in good condition, secure, and do not leak.
15 Use fuel nozzle test stand , if available, taking every precaution to keep spray away from personnel .
Observe whether there is any “ after-dribble ” from the spray nozzle. If the spray pattern is not
normal or a dribble occurs, the nozzle should be replaced by a new or reconditioned and tested
nozzle. Tighten all fuel nozzle mounting nuts , cap screws, and line connections securely .
16 16 16 SPARK PLUGS ( Gaps ) (Deposits).
Spark Plugs. Examine the installed spark plugs to see that their insulators are in good condition and
clean, and that there is no leakage around the insulators or gaskets . When operating conditions re
quire, the spark plugs may be removed for service.
16 16 16 Remove the spark plugs and examine for poor condition, paying particular attention to broken insula
tors, excessive carbon deposits, and electrodes which are burned thin . Replace unserviceable plugs.
Report excessive deposits or damaged insulators. These conditions may indicate incorrect heat range.
The porcelain insulators inside spark plugs of proper heat-range will be coffee-brown in color.
16 16 Clean . Clean deposits from the electrodes and insulators, and inspect again for cracks. If a plug
cleaner is not available, install new or reconditioned plugs .
16 16 Adjust. Adjust gaps to specifications. After completing Item 17, reinstall the plugs, using new
gaskets and taking care not to overtighten them , as this may cause distortion and damage.
COMPRESSION TEST
17 17 Gasoline. With all spark plugs out and engine warm , insert the compression gauge in a spark plug
hole, and with the throttle wide open, revolve the engine at cranking speed until the maximum
compression is indicated . Record the reading in the space provided on the back of the form. Re
peat this process for each cylinder. Refer to the craft manual for specified compression pressures
and for variations due to condition and weat. If pressure in a cylinder is below normal, squirt
sufficient engine oil on the piston head to temporarily prevent loss of compression, and recheck the
compression of the cylinder. Low compression brought up to normal by oil sealing indicates piston,
ring, or cylinder wear or damage. Low compression not brought up to normal by this method
indicates compression leakage by valve or gasket .
17 17 Diesel. Attach pressure indicator to cylinder, turn scale sleeve to bring red disk in register with
letter " C " for compression readings. (Note : Ser index sleeve to read about 50 to 100 pounds per
square inch in excess of the expected maximum cylinder pressure.) Connect neon flasher to indi
cator valve and obtain reading of cylinder pressure. Repeat this process for each cylinder. Record
the reading in the space provided on the back of the form . Where the pressure indicator cylinder
valve is not on the unit, use compression gauge and proceed as for gasoline engines.
18 18 18 ENGINE (Mounting and Braces) (Ground Strap) (Side Pans). See that engine is properly installed,
taking care that all mountings and ground straps are securely tightened. Be sure engine side pans ,
if present, are in good condition , correctly assembled and do not leak.
19 . 19 19 MANIFOLDS AND HEAT CONTROL (Intake) (Exhaust) .
Note whether the manifolds and their gaskets are in good condition, correctly assembled, secure, and
do not leak . Check for indication of leaks by looking for carbon streaks. Check exhaust tempera
tures and temperature gauges. Equalize cylinder exhaust temperatures to the minimum appreciable
varitaions . On a manually operated heat control determine if it is in good condition, secure, and set
at the correct position . If the control is automatic, note whether the bi -metal control spring is in
good condition and securely connected to the heat-control valve shaft and mountings. See that the
shaft operates freely and that the spring controls the shaft properly.
19 19 Tighten . Tighten all manifold assembly, mounting, exhaust pipe, and carburetor connecting flange
nuts evenly and securely .
20 . 20 20 EXHAUST PIPES AND MUFFLERS.
Note whether they are in good condition, securely assembled , and mounted, and whether there are
indications of exhaust leaks, usually indicated by carbon streaks. Be sure the drain holes in the muf
flers are not clogged , so that all condensate may drain off.
20 20 Tighten. Tighten all mounting bolts and connections securely.

21
 Engine
Running
Tech . 1200 200
Insp . Hour Hour

21 21 21 FUEL ( Tanks) ( Vents) (Lines ).

Inspect fuel tanks to see that they are in good condition and securely mounted . Examine caps for
defective gaskets and note whether the vents are open and whether there are indications of fuel leaks
from the tanks, lines or pumps. See that the filler necks are in good condition and the caps fit
securely. Inspect fuel lines and fittings to see that they are in good condition, securely supported, and
not leaking.
21 21 Drain . Remove the fuel tank drain plugs and drain off the accumulated water and sediment. Drain
only until the fuel starts to run clean.
22 22 22 FUEL FILTERS AND SCREENS.
Note whether the fuel filters and cleaner bowls are in good condition, secure, and not leaking at
gaskets or connections.
22 Clean. Remove fuel screens and cartridge-type elements, clean all screens thoroughly in dry -cleaning
solvent, dry with compressed air, and reinstall . Observe whether the cartridge-type element is in
satisfactory condition for further service. If so, clean and replace it, being sure that all element
and cover gaskets are in good condition and in place. On disk-type filters, turn the handle one
complete turn. Remove the plug, and drain the sediment bowl.
22 Serve and Clean. On a cartridge -type fuel filter, replace the cartridge, and clean all fuel screens.
On a disk-type filter, remove the element from the cleaner bowl, and wash in dry -cleaning solvent
until the disks are clean and free. Clean the bowl thoroughly, and reinstall the element, making
sure all gaskets are in good condition and in place. Do not scrape or damage the disks.
23 23 23 FUEL PUMP ( Vacuum and Pressure) .
See that the fuel pump lines are in good condition, secure , and not leaking. Attach the fuel test
gauge properly and with the engine idling note , whether the pump pressure is within specified limits,
which are listed in the craft manual. Replace any pump that does not produce proper pressure,
being sure to make a similar check of the new pump to see that it is satisfactory.
24 24 24 FUEL INJECTOR PUMP (Primer) .
Note whether the pump ( including any transfer pump) is in good condition , correctly assembled ,
securely mounted , and its connections do not leak . Determine the oil level in the pump with a dip
stick Add oil if needed .
24 24 Tighten. Tighten all assembly and mounting bolts and cap screws.
24 24 Adjust. Adjust the fuel injector pump timing according to the instructions and specifications in the
craft manual. Note whether hand pump primer is in good condition and in operating order.
24 Serve. Drain the oil from the fuel injector pump and refill to correct level with specified engine oil .
25 25 25 THROTTLE ( Linkage) (Dual-Throttle Synchronization) .
See that the throttle and all of its connecting linkage are in good condition and securely connected .
Also, on craft equipped with more than one engine, follow the instructions in the craft manual , and
note whether the linkage is properly synchronized, so that the throttle valves open and close together.
On those craft having automatic transmissions and transfer units, check according to instructions in
the craft manual to see whether the throttle control linkage is properly synchronized with the controls
of these units.
25 25 Adjust. On craft equipped with automatic transmission and transfer units, follow the instructions in
the craft manual , and adjust the relationship between controls of these units and the acceleration
linkage so that they are properly synchronized.
25 25 Lubricate . Lubricate all linkage pins, fulcrums, joints and other connections requiring lubrication .
Refer to craft manual and Lubrication Order.
26 26 26 ENGINE OIL (Tanks ) (Coolers) ( Lines and Fittings) ( Viscosity ) . Observe whether they are in good
condition , correctly assembled , securely mounted , and whether there are indications of oil leaks ,
Measure the level of the oil in the supply tanks with the bayonet gauge . Inspect a sample of oil for
grit, water or fuel dilution, and determine the viscosity with the use of " visgage."
26 26 Tighten . Tighten all oil tank mountings and oil line support clips or brackets securely .
26 Serve. Drain all oil from the supply tanks, close the drain cocks, and fill tank approximaetly one
fourth full with light engine oil. Agitate with a clean stick or rod to loosen the sediment. Con
tinuing to stir the oil , open the drain cock and drain the oil and sediment from the tanks . After
Alushing oil is thoroughly drained , close the drain cocks and fill the tanks to the proper level with
specified engine oil.
Note: If crankcase oil change is due, drain the crankcase and refill to the proper level with specified oil . Do not start
the engine again until Item 27 is completed .
27 27 27 ENGINE OIL FILTERS ( Reclaimers) .
Inspect oil filters, coolers , and all external engine oil lines to see whether they are in good condition ,
secure and do not leak.
27 27 Clean . On disk type filters, turn the handle one complete turn , remove the drain plug, and drain
off the contents.

22
 Engine
Running
Tech . 1200 200
Insp . Hour Hour

27 27 Clean and Serve. When due or when oil filter cartridge condition indicates a filter cartridge change
is necessary, remove the filter cartridge, clean the case with solvent and install a new filter cartridge
of the correct type, installing new gaskets and tightening the cover securely. On disk type filters,
remove the cover and element and without disassembling, clean them in dry-cleaning solvent. Blow
dry with compressed air if available. If the element is serviceable, reinstall it ; if not replace.
28 28 28 AIR CLEANERS ( Carburetor) ( Diesel ) ( Air Compressor ) .
Remove all carburetor, Diesel, or air -compressor air cleaner elements. See that all gaskets, seals,
clamps, and any connecting hose or tubes are present and in good condition. Observe the condition
of the cleaning elements, baffles and body. Note the oil in the reservoir of oil -bath cleaners , paying
particular attention to the amount of dirt present in the oil. Also see that the oil level is satisfactory .
28 28 Clean and Serve. Wash cleaner element in dry- cleaning solvent, dry , apply engine oil to element,
and drain excess oil. On oil -bath air cleaner, refill the reservoir to the correct level with clean
engine oil . Reassmble, making certain all gaskets are in good condition and in place. Install air
cleaner, being careful that it is pressed firmly into place and that the mounting is secure. If the
air cleaner is equipped with an external air baffle, see that it is correctly alined with the air stream .
Also note whether connecting hose is in good condition and properly clamped to the air cleaner
and horn .
29 29 29 WATER PUMPS ( Fresh Water) (Sea Water ) .
Inspect pumps to see that they are in good condition and secure. See that the drive, belt, and chain
are in good condition and properly adjusted and that the pulleys and sprockets are in good condition ,
secure, properly alined and not excessively worn . Examine shaft for end play and loose bearings .
Note whether the valve control linkage is properly connected to the valves and operates them freely.
Also see if the pump lines and strainers are in good condition, properly mounted, and secure. Particu
larly , see whether or not the strainers are clogged .
29 29 Adjust. Adjust pump drive chain or belt according to instructions in craft manual .
29 29 Tighten. Tighten all pump mounting and assembly bolts securely, and pump packing nuts cautiously .
Over-tightening will score shafts and cause leaks.
30 30 30 ACCESSORY DRIVES ( Belt) ( Pulley ) ( Shafts and Couplings ) . See that these items are in good con
dition , correctly assembled , and secure. Pay particular attention to drive belts and pulleys, seeing that
they are well alined and not excessively worn . Also note whether they are frayed, oil soaked , im
properly adjusted, or bottoming in the drive pulleys . See that the universal joints of drive shafts are
not excessively worn or loose.
30 30 Adjust. Adjust all drive belts according to instructions and specifications in the craft manual , locking
all adjustment devices securely .
31 31 31 HEAT EXCHANGER ( Core ) ( Shutters ) ( Hose) ( Cap) ( Zinc Plate ) ( Scale ) . See that these items are
in good condition , correctly assembled , securely mounted and do not leak . If air cooled , note whether
the core air passages are obstructed with dirt or trash . Examine the shutter control linkage to see
that it is in good condition, secure , and operates freely. Note whether the steam relief valve operates
freely and is in correct position for the prevailing atmospheric temperature. Also examine coolant to
see whether it is contaminated with rust, oil , or other foreign matter that would require the cooling
system to be cleaned . Examine zinc electrodes for deterioration and replace if necessary.
31 31 Clean. If cleaning is necessary , clean the cooling system according to current directives, using only
specified cleaner. Clean all dirt and trash from the exterior of the core.
31 31 Tighten. Tighten all loose mountings, plates, and clamps.
32 32 32 FRESH WATER EXPANSION TANK (Antifreeze ) ( Cap ) ( Hose ) . See that the items are in good
condition, correctly assembled , securely mounted and do not leak. Also examine the coolant to see
whether it is contaminated with rust or other foreign matter which would require the system to be
cleaned .
32 32 Clean . If cleaning is necessary, drain, taking care to save drains to put back into radiator if ethylene
glycol antifreeze is in use. Clean the cooling system according to current directives, using only
specified cleaner. Flush cleaner from entire cooling system with clean water. Refill , adding
specified inhibitor ( if required ) unless new antifreeze which contains inhibitor is used . If antifreeze
is in use, determine its protective value and record in the space provided on the reverse side of the
Work Sheet. Clan all dirt and trash from the exterior of the core .
32 32 Tighten . Tighten all loose mountings, plates, and clamps.
33 33 33 GENERATOR (Commutator) (Brushes ) ( Wiring) . Remove the brush head cover plate and check the
commutator to see that it appears to be in good condition , clean , and not excessively worn. Observe
whether the brushes are clean, free in their holder, properly spring loaded, and not excessively worn .
Check giving connections for tightness and correct alignment of generator drive.
33 33 Clean . At each 200 hour service, clean the commutator by placing a strip of very fine sand paper
( 00 to 8/0 ) over a wood block of the correct size. With the engine running slowly, press the
sand paper against the commutator until it is clean . Blow out with compressed air.
33 33 Tighten. Tighten mounting bolt, and electrical connections securely.
23
 Engine
Running
Tech . 1200 200
Insp. Hour Hour

34 34 34 REGULATOR UNIT ( Connections) ( Voltage) ( Current) (Cut Out) . See that they are in good condi
tion and all connections and mountings are secure.
34 34 Connect the low voltage circuit tester and observe whether the voltage reg lator, current regulator,
and cut-out, control the generator output properly. Follow the instructions in the craft manual
or those which accompany the test instrument. Replace if test shows faulty operation. NOTE :
This test should be made only after the regulator unit has reached normal operating temperature.
35 35 35 CARBURETOR (Choke) ( Throttle) ( Linkage) (Governor) . See that these items are in good condi
tion , correctly assembled and securely installed ; that the carburetor does not leak ; that the control
linkage, including the choke valve opens fully when the control is in its released position ; that the
throttle valve opens fully when the accelerating lever is fully depressed , and that the governor is
secure and properly sealed. Drain the carburetor bowl and clean screen .
36 36 36 COIL AND WIRING ( High and Low Voltage) ( Supports ).
Examine the coil to see that it is in good condition, clean , and securely mounted . All high voltage
ignition wiring, including shielding or conduits, should be in good condition and securely fastened
to all support mountings and terminals. See that all insulation and connections are clean. Inspect
all low voltage wiring in the engine compartment in the same manner. On engines equipped with
magnetos , examine the booster coils to see that they are in good condition , clean, and securely mounted .
Note: Do not tighten wiring connections unless actually loose , as overtightening of terminals will cause damage.
36 36 Clean . Clean all exposed ignition wiring with a dry cloth or compressed air.
37 37 37 MAGNETOS ( Points ).
Determine whether the magneto is in good condition and securely mounted . Note whether there is
evidence of oil leaks at the mounting pad gaskets. Remove the breaker point inspection covers and
check to see that the points are in good condition and clean ; that the breaker points are well alined ;
that the mating surfaces engage squarely ; and that point gaps are satisfactory ( refer to craft manual ) .
Replace unserviceable points.
37 37
Adjust. Adjust the magneto breaker-point gaps according to instructions and specifications in the
craft manual.
38 38 38 DISTRIBUTOR (Cap) ( Rotor) ( Points ) ( Shaft) ( Advance Units) . See that the distributor body and
external attachments are in good condition and secure. Inspect other parts of the distributor as follows :
Cap, Rotor, and Points. Blow or wipe the dirt or dust from the distributor cap. Remove the cap ,
and observe whether the cap, rotor arm , and the breaker-plate assembly parts are in good condition,
correctly assembled , secure, and serviceably clean . Pay particular attention to cracks in the cap and
rotor arm , to corrosion of terminals, and connections in these parts ; also to burning off of the outer
ends of the conductor strap of rotor arm . Also note whether the breaker points are in good condi
tion and well alined, and that the gap is satisfactory. If the breaker-plate assembly is unserviceably
dirty, remove the distributor, clean in dry -cleaning solvent, dry with compressed air, lubricate the
parts as specified below, and reinstall the distributor in the correct position for timing. When
cleaning the distributor, remove the wick and lubrication cup , clean and dry while removed , and
reinstall them only after distributor assembly is cleaned and blown dry with compressed air. If
the breaker points are pitted , burned , or worn to an unserviceable condition , install a new set. If
the points are badly pitted , replace the condenser also, as it is probably the cause of the pitting.
Install the new points so that they are well aligned and engage squarely. If the points are slightly
pitted or burned , dress them with an American -Swiss No. 6 File ( or equivalent) or No. 00 Sand
paper ( do not use emery cloth ) , and blow off the filings with compressed air.
Shaft. Test by hand -feel for looseness, to determine whether the distributor camshaft is excessively
worn in its bushings.
Centrifugal Advance. Install the rotor arm on the upper end of the distributor camshaft, and observe
whether the camshaft can be rotated by finger force through the nominal range of movement which
is permitted by the centrifugal advance mechanism , and whether it returns to its original position
when the fingers are removed from the rotor arm . There should be no binding or hanging up in
mechanism during these movements.
38 38 Special Lubrication . Lubricate the cam surfaces, the movable breaker-arm pin, the wick , and the
camshaft according to the craft's Lubrication Order. Take care to keep lubricant off the distributor
points, not to apply more lubricant than is specified , and to wipe the cam clean before lubricating
its surface.
38 38 Adjust. Adjust the breaker-point gap to specifications. If suitable equipment is available, adjust
dwell angle.

24
 Engine
Running
Tech . 1200 200
Insp. Hour Hour

39 39 39 BATTERY (Cables) ( Hold -Downs) (Gravity and Voltage ).

Inspect the batteries externally to see that their cases, posts, and cell straps are in good condition and
secure. Note whether the cases are leaking. Wipe dirt from and around the filler caps, remove, and
see that the cap vents are open. Note the level of electrolyte in the cells. This level should be above
the top of the plates, and may extend up to one inch above the plates . Before adding any water to
the cells, test the specific gravity of each cell, with a battery hydrometer, and record the gravity read
ings in the spaces provided on the reverse side of the work sheet. As the samples of the electrolyte
are in the hydrometer for the gravity test, observe whether the electrolyte is discolored to a reddish
brown color, which may nidicate that the battery is being overcharged due to improper regulator ac
tion. Report any gravity readings below 1.225 and variations of more than 0.025 , and any reddish
brown discoloration of the electrolyte. Also take the voltage reading of each cell , and record it in the
space provided on the reverse side of the work sheet. Examine the battery cables, terminals, and ter
minal bolts to see whether they are in good condition , secure, and not corroded ; if the battery hold
downs are securing the battery properly ; and that the battery carrier is in good condition and secure.
If the terminals are corroded, disconnect the cable terminals from the battery, clean, and lubricate the
battery posts and terminals, and reinstall them securely.
39 39 Make a high-rate discharge test of the battery to see that the cells are in a satisfactory condition, taking
care to make the test according to the insructions for a condition test which accompany the test in
strument. A true test cannot be made if the gravity of the battery is below 1.225 . If the difference in
the readings obtained from the cells is more than 30 percent, replace the battery.
39 39 Clean . Clean top of battery with water of a soda wash , if available, and dry with a clean water or
compressed air. Clean the battery carrier in the same way, and paint if corroded. Clean the bat
tery cable terminals , terminal bolts and nuts and battery posts and grease them lightly.
39 39 Serve. Bring the electrolyte to the correct level with distilled water, if it is available. If not availa
ble, use any clean fresh water in preference to letting battery run dry. Inspect bolts for serv
iceability. Tighten terminals and hold -downs carefully to avoid damage to battery.
40 40 40 AIR COMPRESSOR (Unloader Valve ) (Governor) ( Lines) (Tank ) . Examine the air compressor to
see that it is in good condition , properly aligned with its drive pulleys, and secure. Observe the
unloader valve for satisfactory valve clearence. See that the governor appears to be in good condition
and secure ; that all the compressor oil and air lines are in good condition and secure ; and that the
oil and air lines do not leak.
40 40 Clean . Clean the governor air strainer in dry -cleaning solvent; dry and reinstall . Drain water (con
densation) from air-tank and lines.
40 40 Special Lubrication. Apply a few drops of engine oil on the unloader valve fulcrum pin.
40 40 Adjust. Adjust unloader valve clearances to specifications. ( Refer to craft manual ) .
41 41 41 GEAR OIL LEVELS .
Inspect and check all gear cases to see that the lubricant is at the proper level, in good condition and
not leaking.
Note: Sufficient time should be allowed so that the normal foaming may subside. If an oil change in these units is
due, drain and refill with specified lubricant. ( Refer to craft manual for lubricant requirements and levels ) .
42 42 42 STARTING MOTOR ( Air) (Electric ) (Controls).
Start the engine, observe whether the general action of the starter is satisfactory, particularly whether
it engages or operates properly without excessive noise and has adequate cranking speed.
Note: As soon as the engine starts, note whether oil pressure gauge and ammeter indications are satisfactory. See that
the starter is in good condition and securely mounted ; that all connections are tight.
42 42 Air. See that the starting air valve, check valves, lines, and controls are properly mounted , in good
condition , and secure. Pay particular attention to air delivery pressure, to determine whether ade
quate cranking speed is developed ; examine entire system for leaks, or sticking air valve stems.
42 42 Electric. Remove the commutator inspection block and inspect the commutator to see that it is in
good condition and clean. See that the brushes are clean, free in the brush holders, and not ex
cessively worn ; that the brush connections are secure and wires neither broken nor chafed.
42 42 Handcrank Ratchet and Lever. Examine these items to see that they are in good condition and se
cure, and that the cranking box and ratchet operate satisfactorily to rotate the engine.
42 42 Clean . Clean the commutator end of the starter with very fine sandpaper or with compressed air .
42 42 Tighten . Tighten the starter mounting bolts securely.
43 TIMING ( Diesel ) ( Gasoline) . With the engine running and the neon timing - light properly connected,
determine the ignition timing of each engine according to instructions in the craft manual or current
directives to see whether it is correct. Also observe whether the automatic controls advance the
spark as the engine is accelerated gradually. When necessary, adjust the ignition timing to the
specifications in the craft manual, taking care to see that the distributor is well secured when ad
justment is completed . On engines equipped with magnetos, the timing is adjusted when the mag
netos are installed .

25
 Engine
Running

Tech . 1200 200

Insp . Hour Hour

Diesel. Bar engine over in direction of normal travel, the specified degrees ( º ) before top dead cen
ter for # 1 cylinder. Check or adjust timing of fuel injection pump and nozzles according to in
structions and specifications in craft manual.
44 44 44 BILGE PUMPS ( Drives) ( Valves) ( Control ) ( Lines) ( Strainers) . Inspect the bilge pumps to see that
they are in good condition and secure ; see that the drive belt and chain are in good condition and
properly adjusted; and that the pulleys and sprockets are in good condition, secure, properly alined,
and not excessively worn . Note whether the valve -control linkage is properly connected to the valves
and operates them freely. Also see that the bilge pump lines and strainers are in good condition ,
properly connected , and secure. Pay particular attention to the strainers to see if they are clogged .
44 44 Tighten. Tighten all pump mounting and assembly bolts securely, and pump-packing nuts cau
tiously. Over -tightening will score shafts and cause leaks.
44 44 Adjust. Adjust pump-drive chain or belt according to instructions in the craft manual.
45 45 45 PROPELLER ( Seals) ( Joints ) ( Bearings ) (Stufling Box ) . Observe whether they are in good condition,
correctly assembled and secure. Pay particular attention to the alignment, the bearing mountings,
stuffing box and propeller shaft tunnel bearings. See that the propeller drive control and coupling
are in good condition, operate correctly and are not excessively worn . Note whether the thrust or
forward bearings are excessively worn , and correctly lubricated.
45 45 Tighten . Tighten the stuffing box packing Aange cautiously . Do not overtighten since this may
cause stuffing box to run hot, score the shaft, and cause leaks.
46 46 46 RUDDER (Shafts) ( Arms ) ( Cables ) ( Cable Sheaves ) ( Rod ) ( Brackets ) ( Controls ). See that these
items are in good condition, correctly assembled and securely mounted ; that the control linkage and
cable sheaves are adequately lubricated , and that the stuffing box does not leak . Look particularly
for worn or broken cable strands . Turn the stcering wheel to its maximum right and left positions ;
see that the rudder lever has about the same clearance in each position. If not, readjust the cables
according to specifications. Check emergency steering devices.
46 46 Tighten. Tighten all rudder and control assembly and mounting bolts securely. Tighten the rudder
shaft stuffing box packing nut cautiously. Over -tightening may cause excessive binding and leaks.
Auxiliaries
47

47 47 PUMPS (Drives) ( Valves) (Controls) ( Lines ) ( Strainers ) . Inspect all pumps to see that they are in
good condition and secure . See that the drives are in good condition and properly adjusted and that
the pulleys and sprockets are in good condition, secure, properly aligned , and not excessively worn .
Note whether the valve control is properly connected and operates freely . Also see that all pump
lines and strainers are in good condition, properly connected, and secure . Inspect all strainers, screens,
valves to see whether or not they are clogged .
47 47 Tighten . Tighten all pump mounting and assembly bolts securely, and pump packing nuts cautiously .
Overtightening will score shaft and cause leaks.
47 47 Adjust. Adjust drives according to instructions in craft manual .

48 48 48 WINCH (Clutch ) ( Brake) ( Drive ) (Controls) ( Cable) (Guides ). Observe whether they are in good
condition , correctly assembled, and secure. See that the clutch moves freely to both the engaged and
disengaged positions and that it latches securely. Examine the drag brake lining to see that it is in
good condition , secure, and correctly adjusted to stop the drum . Inspect the automatic brake to see
that lining is secure and not excessively worn , and that the band is in place with its spring and ad
justing nuts. Inspect the cable for good condition , even winding, and note whether the cable chain
and hooks are securely attached and in good condition. Examine the cable guides for good condition
and secure mountings. Also check the oil level in the worm gear case . Add or drain lubricant as
necessary to bring to correct level .
48 48 Serve and Clean. Unwind the cable and inspect it for broken or frayed strands and for fat or rust
spots. Clean the entire length of the cable with a cloth saturated with fuel oil or solvent. Rewind
the cable on the drum evenly, at the same time applying a thin film of cable oil . Drain the worm
gear case and refill to correct level with specified oil. ( Refer to craft manual for correct lubricants
and levels ) .
Note: On landing craft , ramps , and ramp locks, the winches, cables , and sheaves must be inspected , served, and cleaned .
49 49 49 ELECTRIC MOTOR (Commutator) ( Brushes ) (Control Box ) ( Wiring) . Start the motor, observing
whether it starts easily and runs at normal speed , and listen for any unusual noise that might indicate
excessively worn , loose, or inadequately lubricated parts. Remove brush head cover plate and check
the commutator to see that it appears in good condition , clean, and not excessively worn. Observe
whether the brushes are clean , free in their holders, properly spring-loaded , and not excessively worn.
Inspect the control box, buttons, and wiring to see that they are in good condition, correctly assembled,
connected , and secure.
49 49 Clean . At cach 200 hour service, clean the commutator by placing a strip of very fine sandpaper
( 00 to 8/0 ) over a wood block of the correct size ; with the motor running, press the sandpaper
against the commutator until it is clean. Blow out the dust with compressed air.
 Engine
Running

Tech . 1200 200

Insp. Hour Hour

50 50 50 GENERATOR (Commutator) ( Brushes) (Control Box ) ( Wiring ) . Start the generator, observing whether
it starts easily and runs at normal speed , and listen for any unusual noise that might indicate exces
sively worn, loose, or inadequately lubricated parts. Remove brush head cover plate and check the
commutator to see that it appears in good condition, clean and not excessively worn. Check the
generator output. Inspect the control box and buttons, ammeter and wiring to see that they are in
good condition, correctly assembled and connected , and secure.
50 50 Clean. At each 200 -hour service, clean the commutator by placing a strip of very fine sandpaper
( 00 to 8/0 ) over a wood block of the correct size ; with the motor running, press the sandpaper
against the commutator until it is clean . Blow out the dust with compressed air.
51 51 51 REFRIGERATION UNITS ( Drives ) ( Controls) ( Valves) ( Refrigerant) . Inspect these items to deter
mine whether they are in good condition , correctly assembled and secure . Observe whether there are
any indications of excessively worn, loose, or improperly lubricated parts. Examine controls , regu
lating and expansion valves, diaphragms and tubes, for sei viceability and safe operating conditions.
51 51 Tighten. Tighten all mounting bolts, braces and connections . Examine for oil , water, and gas leak
age, and tighten , or repair, or report to proper authority.
51 51 Serve and Clean. Clean water condenser tubes ; see that expansion valves are properly regulated ; re
place if worn. Check for gas shortage; test refrigerant and add liquid if short. Check oil in cir
culating system and lubricate in accordance with lubrication order or instructions in craft manual.
52 52 52 VENTILATORS ( Intakes) ( Blowers ) ( Drives ) ( Ducts).
Inspct and check these items for proper operation , correct mounting, excessively worn or improperly
lubricated parts . Examine drive units for excessive vibration or excessive lash . Observe whether
drive units, controls, regulators, ducts, screens, and intakes are properly mounted , secure, and clean .
Tighten all mountings, braces, bolts, and supports. Tighten and adjust drives, belts, pulleys, and
accessories.
53 53 53 AIR COMPRESSOR ( Valves ) ( Governor ) (Lines) ( Tank) (Drive ). See that air compressor is in good
condition , properly alined with its drive pulleys, and secure . Observe whether the unloader valve
has satisfactory clearance. Inspect all valves and connections for leaks. See that the governor appears
to be in good condition and secure ; that all oil and air lines are in good condition , secure, and do
not leak .
53 53 Drain . Drain water (condensation ) , sludge, and oil from lines, separators, and tanks .
53 53 Special Lubrication . Apply a few drops of engine oil on the unloader valve fulcrum pins.
53 53 Adjust. Adjust unloader valve and governor clearances to specifications. ( Refer to craft manual).
Hull Superstructure and Accessories
54 54 54 SUPERSTRUCTURE ( Doors ) (Hardware ) ( Glass ) ( Seats ) ( Safety Straps and Grab Rails ) ( Stowage
Compartments ) (Tarpaulins) (Ventilators) ( Black -out Screens ) . Inspect these items to see that they
are in good condition and secure ; that the hardware and ventilators operate properly and are ade
quately lubricated ; and that the doors engage their bumpers and strikers and latch properly in the
closed position. Check safety straps and grab rails for correct mounting and secure them . Observe
that all black -out screens and accessories are properly mounted , operate freely and completely obstruct
any glare or reflection. Pay particular attention to tarpaulin condition and see that all fasteners, ropes ,
grommets and loops are present, in good condition and secure. See that stowage compartments ,
covers, and doors are properly alined and hinges and latches adequately lubricated .
55 55 55 HULL ( Plugs ) ( Decks) ( Ventilators ) ( Plates ) (Compartments) ( Bulkheads ) (Frame). Examine the
hull to see that it is in good condition . Pay particular attention to bulges that might cause leaks.
See that hull sea cocks and plugs are in place and secure , and note their condition . Inspect the decks
and hatch covers for good condition and see that they are properly aligned with their openings.
Check deck ventilators to the engine compartment for good condition and proper operation ; see
whether the screens are clogged and whether the cover seals properly when closed . Examine hull
compartments to see that the hull, frame, reinforcement plates, and bulkheads are in good condition
and secure. Look for indications of water leaks between the bulkheads or in the hull , and see if
the compartments and bilges are clean . All hulls should be hauled and the bottoms inspected and
serviced in April and September. Wooden hulls operated in warm waters should be hauled for bot
tom scraping and painting in July and December, as well as in April and September. Wooden hulls
operated in warm waters should be hauled for bottom service as soon as possible after any severe
grounding or bottom scraping.
56 56 56 RIGGING ( Boom ) ( Blocks) (Cable ) ( Hoist) . Inspect these items to see that they are in good condition,
correctly assembled , and secure ; note whether the drive shaft joints, controls, or any lift linkage are
excessively worn, and whether or not the lines or cylinders are leaking.
56 56 Serve and Clean . Examine blocks for serviceability and cables for any damgae or frayed spots. Clean
and lubricate blocks and cables with cable lubricant. Also apply a few drops of oil to the pin
joints of all lifting and control mechanism .

27
 Engine
Running

Tech . 1200 200

Insp . Hour 200

56 56 Tighten. Tighten all hoist mounting and assembly bolts securely. Tighten the piston rod packing
nut and any pump and control valve gland nuts, taking care not to overtighten them , as this may
score the shaft and cause leaks.
57 57 57 WIRING (Junction and Terminal Blocks) (Fuses and Spares). Observe all exposed electrical wiring
and conduits to see that they are in good condition , well supported, and whether or not the wiring is
securely connected to its terminals. Also make sure that all junction and terminal blocks and boxes
are in good condition and secure , and that all necessary fuses and spares are in place and in good
condition.
58 58 58 HEATERS, FANS, AND DEFROSTERS. Note whether or not these items are in good condition and
secure . Turn the switches on to see that these items operate properly , and listen for any unusual
noise in the heater or fan motors.
58 58 Special Lubrication . Apply a few drops of light oil to the lubrication fittings of the heater and fan
motor bearings.
59 59 59 PLUMBING , FIXTURES, ETC. See that these items are in good condition, correctly assembled , and
securely mounted ; note whether there are any indications of fluid leaks in the control valves or Auid
lines. Examine all control valves, gauges, and floats ; inspect valves to determine whether they are
operating freely, not clogged or corroded, and in serviceable condition.
60 60 60 FIRE EXTINGUISHER SYSTEM (Tanks ) (Valves) (Lines and Nozzles) ( Mountings). Inspect the
tanks and valves feeding the fire extinguisher system to determine whether they are in good condition
and securely mounted and whether the tanks are fully charged. The charge may be determined on
gas type extinguishers by weighing wtih a scale; on a liquid type, by shaking. Examine the control
cables and handles to see that they are in good condition and free to operate at a moment's notice.
Note whether all the lines and nozzles are in good condition and securely mounted and connected
and whether the nozzles are clean and properly aimed at the points most likely to catch fire.
60 60 If there is any indication that the nozzles are clogged by dirt or corrosion, disconnect the main feed line
between the tank control valve and the nozzles , and apply compressed air cautiously. Caution : If
the fire extinguisher tanks are not full , they should be reported for recharge or exchanged for fully
charged tanks immediately. Any cylinder containing gas under high pressure should never be drop
ped , struck, handled roughly, or exposed to unnecessary heat.
60 60 Special Lubrication. Apply a few drops of engine oil to all of the pulleys and guides through which
the control cables operate.
60 60 Tighten . Tighten all assembly and mounting bolts and screws.
61 61 61 PAINT AND MARKINGS. Examine the paint and markings on the entire craft; see that they are in
good condition, paying particular attention to bright paint spots in the finish that might cause glare
or reflection . Inspect craft markings and identification for legibility. Include identification plates ,
signs and their mountings, if furnished .
62 62 62 COMPASS ( Fluid ) (Lamp) . Inspect the compass to see if it is in good condition and secure; look for
low level or indications of bubbles in the Auid bowl . Fill the Auid bowl with ethyl alcohol if needed.
Operate the compass lamp and switch to see that it operates properly.
63 63 63 TOW (Chain) (Cable ) (Rope) ( Block) . Inspect provided towing lines and devices to see that they are
in good condition , clean, and properly stowed. Tow chains, lines, and cables must be properly pro
tected against rust when not in use. If snatch blocks are furnished, check to see that they are in
good condition, properly lubricated and operate freely.
64 64 64 ANCHOR, HAND BILGE PUMP, AND BOAT HOOK. See that these are present, in good condition,
securely mounted , or properly stowed . Operate the hand bilge pump in water to see that it functions
properly.
65 65 65 TOOLS AND EQUIPMENT. Check against craft stowage list to see if all items are present, in service
able condition and properly stowed or mounted. Pay particular attention to see that all tool-mounting
brackets and straps are in good condition and secure ; also, that tools with cutting edges are sharp.
Sharpen if necessary. In tactical operations, any tools or equipment that are mounted on the outside
of the craft and have bright or polished surfaces should be painted or otherwise treated to prevent
glare or reflection.
Note: Tools and equipment not in use should be treated with a rust preventive compound to prevent rust and to
maintain tools in a serviceable condition .
66 66 66 FIRST AID KIT AND LIFE PRESERVERS. See that the items in the first- aid kit are present, in good
condition, and properly packed . Report any deficiencies immediately . Inspect safety devices, such as
life preservers, collapsible rafts and boats to see that they are in serviceable condition and complete with
accessories. Report any shortage or deficiencies to the proper authority.

28
 APPENDIX

GLOSSARY

Accelerate . To increase the speed of movement, ture of 1 pound of water through 1° Fahrenheit.
such as increasing the speed of an engine. Burning. Commonly substituted for combustion ,
Advance. Sometimes referred to as “ lead, or as late burning, meaning late or slow com
angle of advance", meaning the distance ahead bustion .
of top or bottom dead center of the piston as Bypass. A separate passage which permits a
measured in degrees of crank travel . liquid or gas to take a course other than nor
Air-bound . A lubricating-oil or fuel-oil system mally used .
may become air-bound when air enters the sys
Cam . Wheel-like disk, attached to shaft, only a
tem through vents or leaks. The air, by being
portion of which is circular, the remainder pro
compressed by the fluid flowing through the
truding beyond the circle . From the irregu
lines, interferes with the continuous flow of the
larity of the contour of the cam, corresponding
fuel and may cause the engine to stop running.
motion is imparted to a valve or injector by
In other cases serious damage to the engine may
means of tappet ( the roller of which rests on the
result because of lack of proper lubrication .
cam ), push rod and rocker arm .
Air - filter. A device for filtering the air, before it
Cam follower. That part of the push rod that
goes into the engine, to prevent particles of dust rubs, bears on or follows the cam .
from entering the engine.
Camshaft. The shaft which carries the various
Air- starter. A system whereby an engine is turned
cams required for the operation of inlet valves,
over by admitting compressed air into the
exhaust valves, and starting-air valves.
cylinders.
Carbon . One of the elements which when prop
A.P.I. American Petroleum Institute . An arbi
erly combined with oxygen will burn . Residual
trary scale used to designate the specific gravity
substance left after fuel oil or gasoline has
of fuel oils. Diesel fuels usually range from
24 to 36 A.P.I. gravity. burned is commonly called “ carbon .” This car
bon usually contains non-combustible impuri
Atmospheric pressure. The pressure of the at ties such as dust taken into the engine with the
mosphere measured from absolute zero pressure. air and also unburned carbon from the oil .
At sea level atmospheric pressure is about 14.7
Carbon dioxide. A gas composed of molecules
lbs. per square inch , decreasing as the altitude made up of one atom of carbon and two atoms
increases.
of oxygen .
Atomize . To reduce to extremely fine particles .
Carbon monoxide. A gas composed of molecules
Axially. Parallel to the center line of a cylinder or
consisting of one atom of carbon and one
shaft.
oxygen . Combustion is not complete if carbon
Axis. A center line . A line about which some monoxide is present.
thing rotates or about which it is evenly ar
Carbon residue. The carbon remaining after
ranged .
evaporation of the volatile portion of a fuel oil
Babbitt. An anti-friction metal used to line bear by heating it in the absence of air under con
ings. trolled test conditions. It is an indication of the

Back pressure . The result of resistance to the nor amount of carbon that may be deposited in an
mal flow of gases and liquids . engine.
Bore. The interior diameter of an engine cylin Centrifugal force. The force acting on a rotating
der. ( See “ Stroke” .) body which tends to throw it farther from the
axis of its rotation .
British thermal unit ( B.T.U. ) . A unit for meas
uring heat. One British thermal unit equals Cetane rating. A system of numbers for indi
778 foot-pounds of work ( or energy ) . It rep cating the ignition quality of Diesel fuels.
resents the heat required to change the tempera Chamfer. A beveled corner .

29
Check valve. A device that permits passage of a Connecting-rod oil pipe. The passageway in the
fluid or gas in one direction only. It stops ( or connecting rod by which the oil is taken to the
checks ) reverse flow . piston pin .
Clearance. The space between a moving and a Contraction . Becoming smaller in size. Usually,
stationary part or between two moving parts . in metals , a result of cooling or a lowering of
Clearance is usually allowed between two sur temperature.
faces to provide for expansion , and contraction , Cooling water. The Auid which circulates through
and for lubrication .
the jacket space of cylinders and cylinder heads
Clearance volume. The amount of space confined to prevent excessive heating of the castings.
within the engine cylinder and related parts Craft. A term usually applied to small ships, in
when the piston is at its top dead center position . cluding all boats, launches , tankers, tugs, ships,
Coefficient. A ratio ; a known factor or quantity and vessels under the jurisdiction and responsi
that is always constant. bility of the Transportation Corps.
Combustion. The rapid oxidation or combina Crank. That part of the crankshaft which is in
tion of a combustible such as carbon , hydrogen the form of a crank and crankpin . The con
and sulphur, with oxygen in the air . necting -rod is connected to the crank.
Combustion chamber. The space within a cylin
Crankcase. Lower part of the engine structure
der in which the fuel mixture is burned . surrounding the working parts.
Compression. Pressure developed within the cyl Crankpin. That part of the crank to which the
inder as the piston moves from bottom to top connecting rod is connected.
center with all valves closed .
Crankshaft. That part of the engine which trans
Compression -ignition. Ignition of a fuel charge
mits the reciprocating motion of the pistol to
by heat of the air in a cylinder, generated by the driven unit in the form of rotary motion .
compression of the air, as in the diesel .
That part to which the connecting rod and fly
Compression pressure. The amount of pressure wheel are attached . That part which actually
resulting from the compression stroke of a piston does the delivering of the power developed
when it has reached top dead center . above the piston.
Compression ratio. A ratio expressing the extent Crankshaft main bearing. That part of the shaft
to which a fuel mixture or air charge is com which revolves in the bearing placed in the
pressed. It is a relationship between clearance crankcase.
and displacement volumes and is found as
Crankshaft pin bearing or journal. That part of
follows:
the crankshaft on which the connecting rod is
Piston displacement + clearance volume = attached and rotates.
Compression Ratio Clearance Volume
Crankshaft web. That part of the crankshaft that
Compression stroke. The stroke of the piston connects the crankpin with the main bearing of
during which the air is compressed in the cylin the crankshaft, also called crank arm or crank
der by the piston movement. cheek.
Compressor. The air “ pump ”, which furnishes Crown. Term often used to designate the top of
compressed air for starting the engine. an engine piston .
Concentric. Having a common center . Cycle. The complete series of operations which
Condensation. The process by which a vapor is occur until the original positions of all moving
reduced to a liquid . parts are restored and the operations start over
Connecting rod . That part which connects the again in regular order. In the 4 -cycle, or
piston to the crankshaft and which takes the 4 - stroke cycle engine, this requires 4 strokes of
thrust of expansion of the burnt gases . It the piston , hence the designation ; in the 2-cycle
changes reciprocating motion of the piston into engine only 2 strokes are needed to complete
rotary motion at the crankshaft. the cycle .

Connecting -rod bearing. The bearing located in Cylinder . The cylindrical part of the engine in
the large end of the connecting rod by which it which the piston moves, and in which combus
is attached to the crankshaft. tion takes place.

30
Cylinder block. A number of cylinder bores all scope of, the maintenance of its equipment in
cast in line and in one piece. the forward areas.

Cylinder bore . The part of the cylinder in which Echelon , Third. The operations usually per
the piston slides or moves. formed by mobile ( light and medium ) main
Cylinder head. The part which covers and seals tenance organizations attached to, designated
the end of the cylinder and usually contains the for, or an organic part of troop units. ( In
valves. cludes Post and Port Shops).

Cylinder head stud. A threaded round piece of Echelon , Fourth. The operations usually per
material, one end of which screws into the formed by an established pool, of variable num
cylinder block ; the other end has a nut screwed bers and types, of heavy maintenance and supply
on it which holds the cylinder head in correct units , formed as a semi-mobile shop, serving an
position . area. ( Includes designated Post and Service

Cylinder liner. A cylindrical lining that is pressed Command Shops ) . Its main function is the re
building of items, usually from serviceable parts
into the cylinder block and in which the piston
on hand .
slides .
Echelon , Fifth . The operations performed in
Delivery stroke. The stroke of a pump during fixed installations designated as Base Shops or
which the fuid in the pump is forced out of Depots. It has equipment for the complete re
the cylinder. building of matériel . It manufactures items
Diesel. An internal -combustion engine differing when no other source of supply is available.
from other internal-combustion engines in that Efficiency, volumetric. The ratio of the volume
its compression is high enough to cause com of air or fuel mixture actually taken into the
bustion to be spontaneous.
cylinder to the volume of the piston displace
Diesel cycle. A cycle of events which occur in ment.
Diesel engines similar to gasoline ( Otto cycle ) Efficiency, mechanical. The ratio between the
engines except that air without fuel is com brake horsepower ( bhp ) and the indicated or
pressed to a high pressure. At the end of the total horsepower ( ihp ).
compression stroke, fuel is injected into the hot Electrolyte. A solution of sulphuric acid and dis
compressed air and burns immediately . tilled water, normally have a specific gravity of
Distillation. Separation of the more volatile parts 1.300 and used in storage batteries .
of a petroleum oil from those less volatile by Energy. Capacity for doing work.
vaporization and , subsequently , condensation . Engine. A machine which produces power to do
Dribbling. A characteristic of an injection nozzle work , particularly one that converts heat into
in which the fuel seeps slowly from the nozzle mechanical power; the term " engine" should be
tip. used in referring to the power plant of a craft,
and the term " motor " should be used in con
Eccentric. A circle not having the same center as
another within it. A device mounted off-center nection with electric motors .
Exhaust cam . The cam which controls the opera
for converting rotary motion into reciprocating
tion of the exhaust valve. The exhaust cam is
motion .
part of the camshaft.
The preventive maintenance per
Echelon , First.
Exhaust gases . Products of combustion which are
formed by the user, wearer or operator of the
exhausted from the cylinder.
equipment. Includes care, use, operation, clean
ing, preservation and lubrication . Exhaust manifold. The pipe that collects the

Echelon , Second. burned gases as they are expelled from the cyl
The maintenance operations
inders.
performed by a maintenance platoon, or section ,
of the combat company, battalion , or regiment Exhaust pipe. Piping through which exhaust
( i.e., by the using organization ). This mainte gases from an engine pass out to the atmosphere.

nance unit carries a predetermined stock of parts Exhaust valve. The unit by which the burned
called “ Organizational Spare Parts Set,” and has gases are allowed to pass out of the exhaust
skilled mechanics, suitable for, and within the manifold.

31
Exhaust pyrometer. An instrument to measure Header. A pipe provided with branch connec
temperature of the exhaust, by the small electri tions . Similar to a manifold but of smaller size.
cal current developed at the junction of two Heat. A form of energy .
dissimilar metals when exposed to heat.
Heat units. The unit of heat ( 1 British Thermal
Expansion period. The portion of the power Unit ) .
stroke during which the combustion gases exert
Helical. A point rotating about a fixed axis and at
pressure on the moving piston, and expand
the same time moving uniformly along the axis,
while the pressure falls.
is said to follow a helix, and its path is said to be
helical. A thread on a bolt or nut is of helical
F.P.M. Abbreviation for feet per minute ..
form . Some gears are made with teeth of heli
Filter cartridge. Element in filter through which cal form to insure more continuous contact be
lubricating oil or fuel oil passes and which re tween the teeth .
tains the impurities of the oil .
Helix . A line shaped like a screw thread.
Fit. A fit may be considered as the desired clear
Horsepower. A unit for measuring power . It is
ance between the surfaces of machine parts .
the rate at which work is done . One horse
Flash point. The temperature, ° F . , at which oil power is 33,000 foot-pounds per minute .
must be heated before the oil vapor over the oil
Horsepower, brake ( BHP ). Amount of net avail
will ignite when a fire is passed across the oil's
able power produced by an engine as measured
surface .
at the crankshaft.
Fluctuations. Variations in value, such as of pres
Horsepower, friction ( FHP ). The horsepower
sure, velocity, etc.
consumed by the engine in running itself ; that
Flywheel. The wheel on the end of the crank
is, the power lost within the engine due to its
shaft which gives the crankshaft momentum to internal friction .
carry the pistons through their stroke when no
Horsepower, indicated ( IHP ). Total power de
expansion is taking place above the piston .
veloped by the engine ; or brake horsepower
Foot-pound. ( ft- lb ) . Unit of measurement equiv
( bhp ) added to friction horsepower ( fhp ) .
alent to the work of raising one pound verti
Hunting. Erratic engine operation ; caused by the
cally a distance of one foot or moving an object
inability of a governor to respond accurately to
one foot against a resistance of one pound .
changes in engine speed.
Frame. The part of an engine between the cylin
Hydraulics. The science of using liquids under
ders and bed plate .
pressure to do work .
Friction. The action between two bodies at the
surfaces of contact, which opposes movement .. Idling . Engine running at a very low speed with
or without load .
Fuel injection . The forcing of fuel oil into the
Ignition . Fuel starts to burn .
combustion chamber of a Diesel engine by
means of high pressure. Impeller. The rotating part of a blower or pump
which imparts motion to air or a liquid by
Fuel pump. A small pump for delivering fuel to
the engine. A Diesel fuel pump operates at a forcing it outward from the center of the part.

fixed ratio to engine speed and may be of the Impulse. Force produced by the combustion of
constant volume or of the metering type. fuel and used to drive the piston on the expan
sion stroke.
Fulcrum . The support on which a lever turns .
Inertia . The property of a body which causes it
G.P.M. Abbreviation for gallons per minute . to persist in a state of rest or in uniform motion .
Injection pump. A pump used to inject fuel into
Gasket. Packing placed between two surfaces
which must have a leak -proof joint . the engine cylinder.
Inlet cam . That part of the camshaft that con
Governor. On engines the governor is a device
trols the operation of the inlet valve.
whereby the speed is held approximately con
Inlet manifold. The pipe which conducts air into
stant regardless of the load , brought about by
the cylinders.
the governor altering the amount of fuel intro
Inlet valve. That unit which allows air to pass
duced into the cylinder .
into the cylinders.

32
Intermittent. Occurring at intervals . Nitrogen . A gas that makes up approximately
Internal combustion . In Diesel engines, the burn four- fifths of the atmospheric air. Nitrogen
ing of fuel oil inside the engine cylinders by will unite with certain substances, but it does
means of highly compressed air, which is at a not give off heat in so doing .
sufficiently high temperature to ignite the oil . Nozzle . The part of the injector or spray valve
Combustion within a gasoline engine is also in in which are located the holes through which
ternal combustion . the fuel is injected into the cylinder .

Jacket. An outer metallic casting forming a space Oil filter. A device for removing impurities from
around the cylinder liners to permit the circula lubricating oil or fuel oil by causing the oil to
tion of water for cooling purposes. flow through cloth or fabric elements in the
Jet. A metered opening in an air or fuel passage filter casing .
to control the flow of air or fuel. Oil pump . The unit which circulates the lubri
Journal. The finished part of a shaft which ro cating oil through the engine . Also the fuel -oil
tates in or against a bearing. pump which keeps the fuel system full .

Jumper. A water- pipe connection between a cyl Oil ring. A ring located at the lower part of a
inder head and the cylinder jacket or the water piston to prevent an excess amount of oil from
jacketed exhaust manifold ; also called a “ goose being drawn up into the piston during the suc
neck . " tion stroke.
Oil way or oil groove. The passageway through
Key. A square or rectangular piece of metal ,
which the lubricating oil flows. Grooves or
usually steel , used to secure a collar or flywheel
passages cut in bearings for oil distribution .
to a shaft.
Orifice. An opening of any kind . Usually re
Key -way. A machined slot in a shaft or hub of a
fers to the hole in the spray nozzle.
wheel to take a steel key.
Oil strainer. Device in which impurities are re
Laminated. Made of thin layers such as " lam moved from lubricating oil or fuel oil by causing
inated shims, ” “ laminated cores ,” etc. the oil to flow through closely spaced metal disks
Laminated shims. A series of thin metallic sheets or ribbons assembled in a suitable casing.

placed between two halves of a bearing to main Otto cycle. A cycle of four events which occur
tain a predetermined clearance between the in a gasoline engine in the following order :
bearing and shaft. Intake, Compression, Power, and Exhaust .

Lands. The portions of a piston between the Outboard bearing. A bearing outside the engine
grooves carrying the piston rings . proper, carrying an extension of the crankshaft .

Liner. The inner, removable bore of the cylinder Oxygen. A gas that is highly inflammable when
in contact with the piston . mixed with certain other substances, such as car
Lubricant. Any liquid or grease employed to coat bon . It makes up about one- fifth of atmospheric
air.
a surface upon which another surface rotates or
slides, in order to reduce the friction .
Packing. A material used to seal a joint against
Manifold. A common pipe with a number of in leakage.
lets to, or outlets from, the several cylinders of an Packing rings. Rubber rings used at the bottom
engine. of the cylinder liner to form a watertight joint .
Mechanical injection. ( See “ Solid injection .” ) Piston . A cylindrical part of an engine which
Motor. Technically, an electric motor . ( See reciprocates in the cylinder bore and transmits
" Engine.” ) the force of the gas pressure exerted upon its
Muffler. Sometimes referred to as silencer. Used crown, to the connecting rod and crank .
to diminish noise either of the intake or exhaust. Piston crown. The top of the piston , same as pis
ton head.
Needle valve. A long rod with a tip which seats
against an outlet and prevents oil from entering Piston head. The top of the piston or that part of
the engine cylinder until the needle is lifted by a the piston against which the combustion pres
cam or otherwise. sure acts.

33
Piston pin. A pin which rests in two bored holes cycle ( before the spark in a gas engine ) ; con
in the piston and passes through the eye of the sidered almost impossible in engines using fuel
connecting rod to join the two together flexibly. injection unless the timing is deranged .
Piston pin bearing. The bearing either in the eye Pressure . The force due to the action of a gas or
of the connecting rod or in the bored bosses of liquid , in terms of pounds per square inch , or
the piston, in which the piston pin rotates. kilograms per square centimeter when metric

Piston pin boss. The part of the piston on the in measurements are employed .
side , through which the hole is made to allow P.S.I.Abbreviation for pounds per square inch .
the installation of the piston pin in the piston. Push rod . The rod moved by the cam and cam
Piston pin lock. The device used to hold or lock shaft to operate the rocker arm on the top of the
the piston pin in the piston. cylinder.
Piston ring. A split ring placed in the upper part Pyrometer. An instrument for measuring tem
of the piston to form a leakproof joint between peratures, either by means of heat -produced ex
the piston and cylinder wall . Piston rings are pansion and movement of one of its parts ( as in
also found in the skirt of the piston . mechanical or direct- acting pyrometers) or by
Piston - ring gap. The space between the ends of electrical currents generated in a thermocouple,
as in the electric pyrometer.
the piston rings when they are in the cylinder
bore.
Radial. Radiating from a common center , as the
Piston - ring land. The part of the piston on the
spokes of a wheel.
outside surface located between the piston-ring
grooves. Rebuild . To restore a major item to a condition
equivalent to its original state by the replace
Piston skirt. That part of the piston below the
ment of unserviceable subassemblies or assem
piston ring grooves. That part of the piston in
blies and by repair. Includes welding, riveting,
which is located the piston-pin hole.
machining, fitting, aligning, balancing, assem
Piston stroke. The movement of the piston from
bly, and testing.
one end to the other of the piston travel in the
Reclaimer. An apparatus which treats dirty oil
cylinder bore . The piston stroke is equal to
and makes it usable again.
twice the throw of the crankshaft.
Reclamation . Process of restoring, repairing and
Plunger. The piston of a pump, such as a fuel
injection pump. refabricating salvaged articles or components
thereof.
Pneumatic control. Control system operated by
compressed air . Rectilinear motion . A motion in a straight line .
Relief, compression . A device which reduces the
Poppet valve. A valve opened by the action of a
cam and closed by a strong spring. This type of compression in a cylinder to make cranking
valve is used almost exclusively in the automo easy.
tive industry. Relief valve.A valve, usually held closed by a
Port. An opening, hole, or passage ; also, side of spring which is forced open when pressure in
vessel on left of a person who stands on board the connecting vessel rises above the desirable
facing the bow ( as opposed to “ starboard ” ). value .

Pour point. The lowest temperature, ° F., at Repair. To restore to a serviceable condition, such
which oil will remain in the liquid state. Below parts, assemblies, or sub-assemblies as can be ac
this temperature the oil will congeal or assume complished without completely disassembling
a jelly -like composition . the assembly or sub -assembly, and where heavy
Power. The capacity to do work . riveting, or precision machining, fitting, bal

Precombustion chamber. A chamber in the cyl ancing, or aligning is not required .

inder head of some engines into which the oil is Replace. To remove an unserviceable part, sub
sprayed , and where it is partly burned when assembly, or assembly and replace it with a new,
mixing with the small amount of air present . reconditioned , or rebuilt part, sub -assembly, or
Preignition. Refers to ignition taking place be assembly
fore the designed time in an engine's operating Rings, compression. Piston rings placed in the

34
 upper section of the piston barrel to seal against steel plate, joined together by small pins, which
loss of compression and gas blowing. by engaging teeth on sprockets, enables one
shaft to drive a second shaft.
Ring grooves. Grooves cut in the piston barrel to
hold the piston rings. Sludge. A tar-like formation in oil resulting from
Ring, oil. See Oil ring. the oxidation of a portion of the oil .

Ring, piston. See Piston ring. Solid injection ( also Mechanical or Pump injec
tion ) . A method of forcing fuel charges into
Rocker arm . A lever usually mounted on a shaft
the combustion space of an internal- combustion
on the cylinder head, which has one end resting
engine by mechanical action or by direct pump
on the valve-stem top and the other resting on a pressure .
push rod, the motion of which lifts the rocker
Specific gravity. Weight of a given volume of
arm, which in turn, pushes the valve open .
substance compared to that of an equal volume
Rocker -arm shaft. The shaft at the top of the
of chemically pure water at 4 ° C. ( 39.2 ° F . ) .
cylinder which serves as a fulcrum on which the
Example : Pure commercial sulphuric acid has a
rocker arm moves to actuate the valve .
specific gravity of 1.8 as compared to distilled
R.P.M. Revolutions per minute. water, which has a specific gravity of 1.00.
Rotary. Revolving or circular . Rotary motion is Spray valve . See Valve, spray.
considered the opposite of linear reciprocating Spring. A coiled piece of round steel which is
( up and down or back and forth ) motion in used to close valves of an engine .
power transfer.
Stability. Ability of lubricating oil to stand up
without physical change under severe operating
Scavenging. The sweeping out of an engine cyl
conditions.
inder, by piston movement or a blast of air, of
Starboard . See Port.
all or most of the gaseous products of the pre
Stress. The forces exerted on, within , or by a
ceding fuel combustion .
body during either tension or compression .
Seal. Any method of preventing leakage. Usual
ly the word is used to describe a method of pack Stroke. The distance a piston travels up or down
inside a cylinder.
ing around a crankshaft when it extends outside
the crankcase, to prevent oil leaking out of the Suction stroke. ( Also called Intake Stroke ).
crankcase. The stroke of the piston during which, in a

Seat, valve. That part of the valve mechanism four-cycle engine, fresh combustion air is forced
by atmospheric pressure into a space vacated by
upon which the valve face rests to close the port.
piston; if assisted by some type of pump or
Servo -motor. A small hydraulic motor for oper
blower , this is called the supercharging period .
ating heavy control mechanisms .
Sump tank. Storage or supply tank for lubri
Shaft. A round section of steel or iron, which
cating oil or fuel oil .
has a rotating or revolving action . An example
is the crankshaft of an engine .
Tachometer. An instrument for indicating rota
Shaft horsepower, ship. Power applied to turn tive speed in terms of revolutions per minute.
ing propeller shaft in marine installations.
Tappet. That portion of a valve operating
Shell. A term used to designate the steel or mechanism which rides against the cam and
bronze backing into which the babbitt of a shaft lifts the valve or push rod ; also termed “ cam
bearing is fixed. It may be considered as the follower.”
bearing itself .
Temperature. The intensity (or degree ) of heat .
Shim . A thin sheet of metal or other material
Thermodynamics. The theory of changing heat
which is placed between the two halves of a into mechanical work .
bearing. When the bearing wears, removal of Thermostat. A mechanism to convert expansion
the shim brings the two bearing halves closer of heated metal or fluid into movement and
together and so compensates for wear .
power sufficient to operate small devices, con
Silencer. See Muffler.
trol electric circuits or small valves, etc. Can be
Silent chain . A chain made of small pieces of set to operate at definite temperatures.

35
Throw or crankshaft. The distance between the Vacuum . A space devoid of matter ; accordingly ,
center of the crankpins and the center of the one in which the pressure is zero .
main bearing of the crankshaft. It is equal to Valve, air. A valve ( usually composed of a disk
half the stroke of the engine . and a stem ) opened by a cam and closed by
Thrust. A force exerted against an engine part, spring pressure, which admits air into the en
usually a shaft, tending to move it endwise. gine cylinder. Also called “ inlet" or " intake "
valve .
Timing. With Diesel engines, timing is the angle
made by the crank at either top or bottom dead Valve, exhaust. A valve similar to an air valve
center, where some valve either opens or closes. ( see above ) , operating to release exhaust gases
Timing chain . A chain used to connect the from a cylinder .

crankshaft and camshaft, by which the cam Valve guide. That part in the cylinder block in
shaft is made to rotate. which the valve stem moves .
Tolerance. An allowable variation in dimensions . Valve, relief. See Relief valve .
For example: A standard measurement of .025 Valve , spray A valve which allows the fuel
with a tolerance of minus .003 or plus .003 in charge to be sprayed into the engine cylinder .
dicates that dimensions between .022 or .028 are
Valve spring. The spring which is used to close
allowed . the valve.
Top dead center ( T.D.C. ) . This is the farthest
Valve spring disk. The part against which the
point reached by piston in its movement away
valve spring bears.
from the crankshaft, or toward the cylinder head
in a vertical engine . Vanes. Baffles employed to deflect currents of air,
gas, or liquids .
Torque. A twisting or wrenching effort. Torque
Velocity . The rate of motion or speed of a body
is the product of force multiplied by the dis at any instant .
tance from the center of rotation at which it is
Venturi . A tube with a narrowing throat or con
exerted . For example : A force of 40 pounds
striction to increase the velocity of the gas or
applied on the end of a 1 - foot pipe wrench
fluid flowing through it.
would be 40 pounds X 1 foot, or 40 foot-pounds
of torque ; on the end of a 2 -foot pipe wrench, Viscosity. Resistance to flow , measured by a num
there would be 40 pounds x 2 feet, or 80 foot ber of systems ( Saybolt-Furol, Saybolt-Univer
pounds of torque . This indicates why it is sal , Engler, Redwood -Admiralty, etc.) and rated
easier to unscrew a pipe coupling with the 2 -foot by the number of seconds ( S ) required for a
wrench than with the 1 -foot wrench , the torque definite quantity of liquid to flow through a
incident to the 2-foot lever ( wrench ) being standard orifice under stated test conditions.

greater. Thus , an oil rated as 100 S.S.U. would require

Torsion . The deformation in a body caused by 100 seconds to flow through the Saybolt-Univer
twisting sal Viscometer . Saybolt is a standard American
instrument.
Transfer pump. A pump employed to force oil
Viscosity index. A number given to a certain
from storage to the small engine tank ; also to
force oil to fuel- injection pumps . lubricating oil to indicate its performance, par
ţicularly as to change of viscosity with tempera
Turbulence . A high -velocity swirling of air, fuel
vapor or a mixture of both within the combus ture variation , as compared to the average of two
groups of test oils.
tion chamber or cylinder.
Volatility. Ability of a liquid to vaporize or turn
Two cycle ( properly two-stroke cycle ) . An en into gas.
gine operating method utilizing a regularly re
peated series or cycle of events, each cycle com Water jacket. The space around the cylinder
pleted in two strokes of the piston, providing a through which the cooling medium circulates.
power impulse per cylinder for each shaft revo Working stroke ( also power, combustion, or ex
lution . One stroke includes the last part of the pansion stroke ) . Piston stroke during which
scavenging and all of the compression phases ; the combustion gases exert force on the moving
the other, expansion, exhaust and the early part piston .
of the scavenging period . Wrist pin . Same as “ Piston Pin . ”
U. S. GOVERNMENT PRINTING OFFICE : 1944_617853
36
UC SOUTHERN REGIONAL LIBRARY FACILITY

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