UNIT MAINTENANCE INSTRUCTIONS PAGE 2-1 DIRECT SUPPORT

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1 TECHNICAL MANUAL TABLE OF CONTENTS PAGE i INTRODUCTION PAGE 1-1 UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL UNIT MAINTENANCE INSTRUCTIONS PAGE 2-1 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS PAGE 3-1 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS PAGE 4-1 REFERENCES PAGE A-1 MAINTENANCE ALLOCATION CHART PAGE B-1 ALPHABETICAL INDEX PAGE INDEX 1 BARGE, LIQUID CARGO, NON-PROPELLED, STEEL 120 FEET, DESIGN 231C NSN Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY 26 March 1990

2 TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY NO WASHINGTON, D.C. 26 MARCH, 1990 UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL BARGE, LIQUID CARGO, NON-PROPELLED, STEEL 120 FEET, DESIGN 231C NSN REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form located in the back of this manual direct to: Commander, U.S. Army Troop Support Command, ATTN: AMSTR-MCTS, 4300 Goodfellow Boulevard, St. Louis, MO A reply will be furnished directly to you. Approved for public release; distribution is unlimited. TABLE OF CONTENTS Page CHAPTER 1 INTRODUCTION Section I General Information Section II Equipment Description CHAPTER 2 UNIT MAINTENANCE CHAPTER 3 DIRECT SUPPORT MAINTENANCE Section I Repair Parts, Special Tools, TMDE, and Support Equipment Section II Maintenance of Hull Section III Maintenance of Machinery House Section IV Maintenance of Boom, Cargo Section V Maintenance of Gear, Deck Section VI Maintenance of Hydraulic Start System Section VII Maintenance of Engine Section VIII Maintenance of Clutch Section IX Maintenance of Speed Reducer Section X Maintenance of Pump, Transfer i

3 TABLE OF CONTENTS - Continued CHAPTER 4 GENERAL SUPPORT MAINTENANCE Section I Repair Parts, Special Tools, TMDE, and Support Equipment Section II Maintenance of Hull Section III Maintenance of Machinery House Section IV Maintenance of Davit, Anchor Section V Maintenance of Engine Section VI Maintenance of Clutch APPENDIX A REFERENCES... A-1 APPENDIX B MAINTENANCE ALLOCATION CHART... B-1 APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST... C-1 APPENDIX D TORQUE SPECIFICATIONS... D-1 ALPHABETICAL INDEX... Index 1 LIST OF ILLUSTRATIONS 3-1 Ullage, Disassembly/Reassembly Relief Valve, Removal/Installation Engine Shutdown, Removal/Installation Exhaust Fan, Removal/Installation Fuel Oil Tank, Removal/Installation Cargo Boom, Removal/Installation Bilge Pump and Piping, Removal/Installation Bilge Pump, Disassembly/Reassembly Cranking Motor, Disassembly/Reassembly Hydraulic Pump, Disassembly/Reassembly Accumulator, Removal/Installation Accumulator, Disassembly/Reassembly Accumulator Charging Set-Up Hydraulic Reservoir, Removal/Installation Diesel Engine, Removal/Installation Throttle Controls, Removal/Installation Governor, Removal/Installation Top View of Governor with Cover Removed Governor Subcap, Disassembly/Reassembly Governor Housing and Base, Disassembly/Reassembly Governor Drive Assembly, Disassembly/Reassembly Adjusting Load Limit Adjusting Speed Droop Adjusting Maximum No-Load Speed Air Intake, Removal, Disassembly, Reassembly, and Installation Page ii

4 3-26 Blower, Removal/Installation Blower End Cover, Removal Water Pump Drive Coupling, Removal Drive Gears, Removal Installation of Gear Pullers End Plate and Rotor, Removal End Plate Removal Using Tool Set J6270F Bearing and Oil Seal Removal Using Tool J Oil Seals, Installation Front End Plate, Installation Rotor, Installation Rear End Plate, Installation Bearings, Retainers, and Front Cover, Installation Bearing, Installation Blower Gears, Installation Rotor Timing Drive Hub, Installation End Covers, Installation Blower Drive, Removal, Disassembly, Reassembly and Installation Fuel Pump, Removal/Installation Fuel Pump, Disassembly/Reassembly Oil Seal Remover Tool Inner Oil Seal, Installation Outer Oil Seal, Installation Fuel Pump, Assembly Fuel Injector, Removal/Installation Checking Rack for Freeness in Tester J Injector Installed in Tester J Injector in Position for Testing Injector in Calibrator J Fuel Injector, Disassembly/Reassembly Lube Oil Cooler, Removal/Installation Water Pump, Removal, Disassembly, Reassembly, and Installation Fan Belts, Removal, Installation, and Adjustment Radiator, Removal/Installation Water Manifold, Removal/Installation Thermostat and Housing, Removal/Installation Tachometer, Removal/Installation Crankshaft Pulley and Damper, Removal/Installation Balance Weight Cover, Removal/Installation Balance Weight Cover, Bolt Tightening Sequence Engine Lifting Brackets, Removal/Installation Exhaust Manifold, Removal/Installation Rocker Arm Cover, Removal/Installation Injector Controls, Removal, Disassembly, Reassembly, and Installation Control Rack Lever Adjustment Positioning No.1 Injector Rack Control Lever Checking Rotating Movement of Injector Control Rack Checking Injector Control Rack "Spring" iii

5 LIST OF ILLUSTRATIONS - Continued 3-75 Rocker Arms, Removal/Installation Oil Pan, Removal/Installation Cylinder Head, Removal/Installation Cylinder Head Bolt Tightening Sequence Removing Push Rod from Upper Side of Cylinder Head Using Tool J Cam Followers, Push Rods, and Springs, Removal/Installation Cam Roller Clearance Testing Cam Follower Spring Checking Cam Follower to Guide Clearance Adjusting Cam Follower Guide Valve Spring Compressor Use Valves, Removal/Installation Exhaust Valve Positioning Balance Weight, Removal/Installation Camshaft and Balance Shaft, Removal/Installation Gear Train Idler Gear, Removal/Installation Flywheel, Removal/Installation Flywheel Housing, Removal Flywheel Housing, Installation Flywheel Housing, First Torque Flywheel Housing, Final Torque Oil Pressure Regulator, Removal/Installation Oil Pump, Removal/Installation Oil Pump, Disassembly/Reassembly Instrument Panel, Removal/Installation Inspection Hole Cover, Removal Clutch Adjustment Clutch Replacement, Removal/Installation Speed Reducer Cover and High Speed Shaft Speed Reducer Low Speed and Intermediate Shaft Bevel Pinion Measurement Measuring Pinion Backlash Coupling Guard, Removal/Installation Coupling Assembly, Removal Coupling Assembly, Installation Shaft Assembly, Removal, Disassembly, Reassembly, and Installation Transfer Pump, Removal/Installation Transfer Pump, Disassembly/Reassembly Pressure Relief Valve, Removal/Installation Pressure Relief Valve, Disassembly/Reassembly Pressure Gages, Removal/Installation Frame and Exterior Covering, Removal/Installation Doors, Removal/Installation Anchor Davit, Removal/Installation Anchor Winch, Removal, Disassembly, Reassembly and Installation Valve Guide, Removal iv

6 4-6 Bridge Guide Notch Grinding Bridge Guide Removal Tool, Installation Bridge Guide, Removal Valve Seat Insert, Removal Injector Tube, Removal Pressure Test of Cylinder Head Using Tool J Checking Fire Deck of Cylinder Head Minimum Distance Between Top and Bottom Faces Correct Installation of Water Nozzles Injector Tube, Installation Injector Tube, Upsetting Injector Tube, Reaming Bevel Gage Measurement Injector Tube, Finish Ream Valve Guide, Installation Valve Seat Insert, Installation Pistons and Connecting Rods, Removal/Installation Removing or Installing Piston Rings Using Tool J Checking Fire Ring Groove in Piston Crown Using Tool J Magnetic Particle Inspection Limits for Connecting Rod Connecting Rod Bolt Hole Reamer Installing Seal Ring Installing Piston Pin Installing Piston Pin Retainer Using Tool J Checking Piston Pin Retainer for Proper Sealing Using Tool J Measuring Piston-to-Liner Clearance Using Tool J Measuring Piston Ring Gap Comparison of Fire Rings Measuring Piston Ring Side Clearance Piston Ring Installation Instructions Installing Piston and Connecting Rod Assembly in Ring Compressor and Cylinder Liner Removing Cylinder Liner Using Tool J Cylinder Liner Ridge Due to Wear Cylinder Liner Measurement Diagram Checking Bore of Cylinder Liner Using Tool J Cylinder Liner Mounting in Block Checking Distance of Liner Flange Below Top Face of Block Main Bearing Shells, Bearing Caps, and Crankshaft Thrust Washers, Removal/Installation Main Bearing Cap, Removal/Installation Measuring Thickness of Bearing Shell Crankshaft Front Cover, Removal/Installation Crankshaft, Removal/Installation Measuring of Main and Connecting Rod Bearing Journals Measuring Crankshaft Thrust Surfaces Checking Crankshaft End Play Sealing Plate Details for Pressure Testing Cylinder Block Cylinder Block Prepared for Pressure Test Honing Bore of Cylinder Block v

7 LIST OF ILLUSTRATIONS - Continued 4-54 Checking Bore of Cylinder Block Cylinder Bore Measurement Diagram Checking Top Face of Cylinder Block Clutch Repair, Disassembly/Reassembly Loosening 14 Inch Diameter Clutch Assembly from Clutch Drive Shaft Supports on the Bed of Arbor Press Clutch Release Levers Placing Steel Ring Over End of the Shaft Guiding Fingers of Release Yoke Over Release Sleeve Collar Remote Valve Control, Removal/Installation Transfer and Valves Piping, Removal/Installation Transfer Piping, Removal/Installation vi

8 CHAPTER 1 INTRODUCTION Section I. Section II. GENERAL INFORMATION EQUIPMENT DESCRIPTION Section I. GENERAL INFORMATION Para. Destruction of Army Materiel to Prevent Enemy Use Maintenance Forms and Records, and Reports Para. Preparation for Storage or Shipment Reporting Equipment Improvement Recommendations (EIR) Scope SCOPE. a. Type of Manual. Unit, Direct Support and General Support Maintenance. b. Model Number and Equipment Name. Barge, Liquid Cargo, Non-propelled, Steel, 120 Feet, Design 231C. c. Purpose of Equipment. Designed to transport bulk petroleum products on rivers and in harbors MAINTENANCE FORMS AND RECORDS, AND REPORTS. a. Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM , The Army Maintenance Management System (TAMMS). b. The following record and report forms are to be used by the operational personnel for recording and reporting operations: DD Form 314 DA Form 2404 DA Form 2407 DA Form DA Form 2408 DA Form DA Form Preventive Maintenance Schedule and Record Equipment Inspection and Maintenance Worksheet Maintenance Request Maintenance Request (Continuation Sheet) Equipment Log Assembly (Record) Equipment Modification Record Uncorrected Fault Record 1-1

9 1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE. Refer to TM for instructions covering the destruction of the barge to prevent enemy use PREPARATION FOR STORAGE OR SHIPMENT. For storage requirements or for shipment instructions, refer to Chapter 3, Section VII. Administrative storage requirements will be in accordance with the following: a. Placement of equipment in administrative storage should be for short periods of time when a shortage of maintenance effort exists. Items should be in mission readiness within 24 hours or within the time factors as determined by the directing authority. During the storage period appropriate maintenance records will be kept. b. Before placing equipment in administrative storage, current maintenance services and equipment serviceable criteria (ESC) evaluations should be completed, shortcomings and deficiencies should be corrected, and all modification work orders (MWO's) should be applied REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR). If the barge or associated equipment needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you don't like the design. Put it on an SF 368 (Quality Deficiency Report). Mail it to us at Commander, U.S. Army Troop Support Command, ATTN: AMSTR-QX, 4300 Goodfellow Blvd., St. Louis, MO We'll send you a reply. Section II. EQUIPMENT DESCRIPTION Para. Diesel Engine Controls and Indicators Differences Between Models Equipment Characteristics, Capabilities, and Features Para. Equipment Data Location and Description of Major Components EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES. a. The barge is a large vessel of the nonpropulsion type and must be towed to desired locations. b. Designed to transport bulk petroleum products in rivers and harbors. c. There are six cargo compartments in the hull with a total cargo capacity of 4,495 bbls. or long tons or short tons. 1-2