A52023_0.pdf

U.S. COAST GUARD

ASSET COMPUTERIZED MAINTENANCE SYSTEM

CB-OTH IV

A52023.0

REV’D: 02/19/15

ASSET NUMBER OPERATING ACTIVITY MAINTENANCE ACCOMPLISHED MAINTENANCE DUE

DATE ASSET

HOURS

DATE ASSET

HOURS

MO DAY YEAR MO DAY YEAR

ZULU DATE ZULU TIME

MO DAY YEAR

ITEM

NO.

[ ] DUE

CMS CODE ACTION DESCRIPTION CEINUM

A52023 REPLACE EXHAUST SYSTEM COMPONENTS OH-B000-001

SCHEDULED UNSCHEDULED

MAN HOURS: MK_ DC___.___ EM___.___ ET___.__ GM_____ BM___.___ FN___.___ SN___.___ OTHER

REMARKS INDICATING THE REASON FOR REMOVAL ARE REQUIRED

REMARKS:

TECHNICIAN’S

SIGNATURE___________________________________________________

TECHNICIAN’S

ID_______________________________

*ASTERISK INDICATES QA

REQUIRED

QA (1)

QA (2)

QA (3)

QA (4)

QA (5)

QA (6)

QA (7)

REFERENCES:

Tech Pub Cummins Marine QSB 6.7 CM2250 Service Manual

REVIEWED

BY

LOG YN DATA ENTRY

COMPLETED

CB-OTH IV

MK FN

NAME: TECH ID/TH: _______/_____ NAME: TECH ID/TH: _______/_____

NAME: TECH ID/TH: _______/_____ NAME: TECH ID/TH: _______/_____

NAME: TECH ID/TH: _______/_____ NAME: TECH ID/TH: _______/_____

DC SN

NAME: TECH ID/TH: _______/_____ NAME: TECH ID/TH: _______/_____

NAME: TECH ID/TH: _______/_____ NAME: TECH ID/TH: _______/_____

NAME: TECH ID/TH: _______/_____ NAME: TECH ID/TH: _______/_____

EM OTHER

NAME: TECH ID/TH: _______/_____ NAME: TECH ID/TH: _______/_____

NAME: TECH ID/TH: _______/_____ NAME: TECH ID/TH: _______/_____

NAME: TECH ID/TH: _______/_____ NAME: TECH ID/TH: _______/_____

ET

NAME: TECH ID/TH: _______/_____

GM

BM

CB-OTH IV

1. EXHAUST SYSTEM COMPONENT REPLACE

REFERENCES:

COMDTINST 9077.1 (series) Equipment Tag-Out Procedure

TOOL/TEST EQUIPMENT:

Wrench, Torque 5-100 in-lb

EXPENDABLES:

2” Bellowflex 7910 Yellow Stripe Hose, P/N: BRP2BELLOWSFLEX, CAGE: 8H961, NIIN: N/A

6” T-Bar Clamp, P/N: 720-6000HT, CAGE: 8P112, NIIN: N/A (If required)

6” FRP Surge Tube 22” Long, P/N: X14091, CAGE: 1PZ81, NIIN: N/A

Cap Assembly, Protective, Muffler-Exhaust, P/N: 18-4458, CAGE: 0ZET4, NIIN: 015886228

Clamp, T-Bolt 2.76”-3.062”SS. P/N: STBC-300, CAGE: 8H961, NIIN: N/A (If required)

Dry Exhaust Riser W/6” Spray Ring, P/N: QSB 5.9 6INCHRISER, CAGE: 1PZ81, NIIN: N/A

Hose, 6” Blue Hump Hose W/Clamps (NLB), P/N: 272V6000-S/S, CAGE: 8P112, NIIN: N/A

Muffler, Exhaust, P/N: EDLIFT6060-NFRC SCB, CAGE: 0S5G0, NIIN: 016160451

Tubing, Nonmetallic, P/N: 1100507, CAGE: 29208, NIIN: 014869989

CONSUMABLES:

Wire, Non-Electrical, P/N: MS9226.03, CAGE: 96906. NIIN: 008782958

A. PRELIMINARY STEPS

1. Ensure area is safe for maintenance.

WARNING

ENSURE EQUIPMENT IS PROPERLY

TAGGED OUT. FAILURE TO COMPLY MAY

RESULT IN SERIOUS INJURY OR DEATH.

2. Complete Red Danger Tags IAW COMDTINST 9077.1(series).

CB-OTH IV

3. Proceed to step 1B, if replacing 6” Bello Flex Hose.

4. Proceed to step 1C, if replacing 6” exhaust riser.

5. Proceed to step 1D, if replacing 6” Blue Hump Hose.

6. Proceed to step 1 E, if replacing 6” FRP Surge Tube.

7. Proceed to step 1 F, if replacing 6” Fiberglass exhaust tube.

8. Proceed to step 1 G, if replacing 6” Muffler.

9. Proceed to step 1 H, if replacing exhaust protective cap.

B. REPLACE 6” BELLOWS FLEX HOSE

1. Remove exhaust bellow flex hose(s), (Refer to Figure 1).

WARNING

HEALTH AND SAFETY PRECAUTIONS SHALL BE

STRICTLY FOLLOWED WHEN HANDLING INSULATION

AND LAGGING CONTAINING FIBERGLASS. EXTRA

CARE SHALL BE EXERCISED TO ENSURE THAT

PERSONNEL DO NOT COME IN CONTACT WITH

INSULATION AND LAGGING MATERIALS. FAILURE TO

COMPLY MAY RESULT IN PERSONAL INJURY.

a. Remove exhaust blankets as needed.

(1) Cut the wire lace on the exhaust blanket with wire cutters.

(2) Pull the exhaust blanket free of the exhaust fitting.

b. Remove V band clamp connecting bellow flex hose to the turbo.

c. Loosen T-bar clamps holding 6” exhaust riser to bellow flex hose.

d. Remove bellow flex hose from between 6” exhaust riser and turbo.

(1) Discard old 6” bellow flex hose.

e. Clean all sealing surfaces.

2. Install 6” bellow flex hose, P/N: BRP2BELLOWSFLEX, between the 6” exhaust riser and the turbo charger exhaust outlet.

a. Install v band clamp between turbo and 6” exhaust bellow.

(1) Torque V band clamps to 50-70 in-lb using torque wrench.

b. Install 6” T-bar clamps between 6” exhaust riser and 6” bellow flex

(1) Torque clamps 50-70 in-lb using torque wrench.

3. Proceed to Step 1 I 1. if no other components has to be replace.

∗ QA REQUIRED (1)

a. Install exhaust blanket,( If required).

(1) Wrap blanket around fitting with lace hooks facing up.

(2) Lace the blanket with wire, P/N: MS9226.03, by running the wire in an x pattern though the lace hooks.

(3) Twist the wire to tighten the exhaust blanket snug against the fitting.

C. REPLACE 6” EXHAUST RISER

CB-OTH IV

1. Remove 6” exhaust riser.

a. Loosen the T-bar clamps on each end of the 6” exhaust riser T’s.

b. Remove both bellow flex hoses from the 6” exhaust riser.

c. Remove the 6” exhaust riser from the 6” blue hump hose.

(1) Discard the old 6” exhaust riser.

d. Clean all sealing surfaces.

2. Install a 6” exhaust riser, P/N: QSB 5.9 6INCHRISER, to the bellow flex hose coming from the turbo using the 6” T-bar clamp.

(1) Torque clamps 50- 70 in-lb using torque wrench.

b. Install the 6” exhaust riser to the 6” blue hump hose using the clamps provided with the 6” blue hump hose.

(1) Torque clamps 50- 70 in-lb using torque wrench.

3. Proceed to Step 1 I 1. if no other components has to be replace.

∗ QA REQUIRED (2)

D. REPLACE 6” BLUE HUMP HOSE

1. Remove the 6” blue hump hose.

a. Loosen clamps on both ends of the 6” blue hump hose.

b. Remove 6” blue hump hose from each exhaust component.

(1) Discard 6” blue hump hose.

c. Clean all sealing surfaces.

2. Install a 6” blue hump hose, P/N: 272V6000-S/S, to appropriate component using the clamps provided with the 6” blue hump hose.

a. Install a 6” T-bar clamp onto the 6” blue hump hose.

(1) Torque clamps 50-70 in-lb using torque wrench.

* QA REQUIRED (3)

E. REPLACE 6” FRP SURGE TUBE

1. Remove 6” FRP surge tube.

a. Loosen the 6” T-bar clamps on both ends of the 6” FRP surge tube.

b. Replace 6” t-bar clamps as needed.

c. Loosen the 6” Blue hump hose clamps on both ends of the 6” FRP surge tube.

d. Remove the 6” FRP surge tube from the 6” blue hump hoses.

(1) Discard of 6” FRP surge tube.

e. Clean all sealing surfaces.

2. Install a 6” FRP, P/N: X14091, surge tube into the 6” blue hump hoses.

a. Install 6” T-bar camps on the FRP surge tube.

CB-OTH IV

∗ QA REQUIRED (4)

F. REPLACE 6” FIBERGLASS EXHAUST TUBE

1. Remove 6” fiberglass exhaust tube.

a. Loosen the 6” T-bar clamps P/N: STBC-300 on both ends of appropriate 6” fiberglass exhaust tube. (replace as needed).

b. Loosen the clamps on the 6” blue hump hoses.

c. Remove the 6” fiberglass exhaust tube from the two 6” blue hump hoses.

(1) Discard the 6” fiber glass exhaust tube.

d. Clean all sealing surfaces.

2. Install the new 6” fiberglass exhaust tube, P/N: 1100507, into the 6” blue hump hoses.

a. Install 6” T-bar camps on the fiberglass exhaust tube.

∗ QA REQUIRED (5)

G. REPLACE 6” MUFFLER

1. Remove 6” muffler.

a. Loosen the 6” T-bar clamps on both ends of the 6” muffler, (Refer to Figure 2).

b. Loosen the clamps on the 6” blue hump hoses.

c. Remove the 6” muffler from the two 6” blue hump hoses.

(1) Discard 6” muffler.

d. Clean all sealing surfaces.

2. Install 6” muffler, P/N: EDLIFT6060-NFRC SCB, into the 6” blue hump hoses.

a. Install 6” T-bar clamp on to the muffler.

∗ QA REQUIRED (6)

H. REPLACE MUFFLER EXHAUST PROTECTIVE CAP ASSEMBLY

1. Remove muffler exhaust protective cap assembly.

a. Loosen the clamp that attaches the 6” protective cap assembly to the 6” aluminum pipe that transitions through the transom from the exterior to the interior.

b. Remove the exhaust protective cap assembly by sliding it off the 6” aluminum pipe.

(1) Discard exhaust protective cap assembly.

2. Install the new exhaust protective cap assembly with clamp, P/N: 18-4458, over the 6” aluminum pipe on the back of the transom.

CB-OTH IV

a. Torque clamps 50-70 in-lb, using a torque wrench.

∗ QA REQUIRED (7)

I. FINAL STEPS

1. Remove Red Danger Tags IAW COMDTINST 9077.1 (series).

2. Perform an operational check.

3. Record maintenance actions by completing appropriate sign off, and adding pertinent remarks.

CB-OTH IV

EXHAUST SYSTEM

Figure 1

CB-OTH IV

MUFFLER AND EXHAUST SCUPPER

FIGURE 2

1. EXHAUST SYSTEM COMPONENT REPLACE