Special Packaging Instrutcion AK15810635.pdf

DD FORM 2169, JUN 1997 (EG) WCT 9-99 PREVIOUS EDITIONS ARE OBSOLETE Page 1 of 4 Pages

SPECIAL PACKAGING INSTRUCTION

Form Approved OMB No. 0704-0188

-MB

The public reporting burden for this collection of information is estimated to average 30 days per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THIS ADDRESS

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CODE IDENT 3. SPI NO.

57K7250 (19207) ENGINE & CONTAINER 19207 AK15810635

4. NATIONAL STOCK NUMBER 5. DATE OF DRAWING 6. REVISION

2815-01-581-0635 03-15-2010 -

7. QUP 8. ICQ 9. UNIT PACK WT. (LB) 10. UNIT PACK CU (CU FT) 11. UNIT PACK SIZE (INCHES)

1 EA NONE 4845.0 136.997 76.0 X 49.6 X 62.8

12. MILITARY PRESERVATION (METHOD) 18.

STEPS

19.

REQ’D

20.

DESCRIPTION

MIL-STD-2073-1D, METHOD 55 1-B PRESERVATIVE, FUEL SYSTEM: MIL-PRF 46002, GR 1

13. CLEANING 2-B PRESERVATIVE, CRANKCASE & EXTERIOR:

MIL-STD-2073-1D MIL-PRF-21260, TY 1, GR PE 15-40

14. DRYING 3-B PRESERVATIVE, COOLING SYSTEM: USE A

MIL-STD-2073-1D COOLANT WITH NON-CHROMATE INHIBITORS

4-E DESICCANT: MIL-D-3464

15. PACKING 5-D CONTAINER: P/N 12389942

a. LEVEL A 6 SEE NOTES FOR DETAILED ENGINE PROCESSING

MIL-STD-2073-1D AND NOTE G

b. LEVEL B

NOT APPLICABLE

16. MARKING

MIL-STD-129 AND NOTE H

17. NOTES / DRAWING

CONSISTS OF: 1 EA ENGINE SERIES 60 DDEC IV W/SERPENTINE BELT, P/N 12512470; 1EA CONTAINER, P/N 12389942.

QUALITY CONFORMANCE FOR THE CONTAINER SHALL BE IAW A-A-52462; INSPECT THE PRESERVATION

AND UNIT PACK IAW MIL-STD-2073-1D.

THIS PROCEDURE IS FOR NEW ENGINES ONLY.

A. SPECIAL EQUIPMENT:

1. A PRESERVATIVE SUPPLY HOSE EQUIPPED WITH A FITTING THAT WILL MATE WITH THE INLET FITTING OF THE PRIMARY FUEL FILTER. AN AUXILIARY LOW PRESSURE PUMP WITH NO MORE THAN

15 PSI MAY BE USED TO IMPROVE THE INTRODUCTION OF THE PRESERVATIVE FUEL OIL.

2. A TRANSPARENT PLASTIC LINE FOR CONNECTION FROM THE ENGINE FUEL RETURN TO A

RECOVERY CONTAINER.

3. AN AIR TIGHT RESTRICTOR PLATE FOR THE AIR INTAKE MANIFOLD.

4. A TURBOCHARGER COMPRESSOR INLET SHIELD (I.E. KENT MOORE P/N/ J26554-A).

5. A PRESERVATIVE LUBE OIL SUPPLY HOSE WITH INLINE PUMP, WITH FITTINGS TO ALLOW

CONNECTION TO THE OIL ENGINE PRESSURE GALLERY.

6. ACCESS TO COMPATIBLE DDEC ELECTRICAL INTERFACE TO ALLOW DDEC TO BE ACTIVATED DURING

THE ENGINE CRANKING PRESERVATION CYCLE.

7. A SERIES 60 COMPATIBLE SLAVE FLYWHEEL TO ALLOW THE ENGINE TO BE CRANKED OVER DURING

THE PRESERVATION CYCLE.

8. A 24 VOLT DC POWER SUPPLY TO POWER THE ENGINE STARTING MOTOR, WITH SWITCH TO

ENGAGE/DISENGAGE THE STARTER SOLENOID.

DD FORM 2169C, JUN 1997 (EG) WCT 9-99 PREVIOUS EDITIONS ARE OBSOLETE Page 2 of 4 Pages

SPECIAL PACKAGING INSTRUCTION

FORM APPROVED

OMB NO. 0704-0188

-MB

THE PUBLIC REPORTING BURDEN FOR THIS COLLECTION OF INFORMATION IS ESTIMATED TO AVERAGE 30 DAYS PER RESPONSE, INCLUDING THE TIME FOR REVIEWING INSTRUCTIONS, SEARCHING EXISTING DATA SOURCES, GATHERING AND MAINTAINING THE DATA NEEDED, AND COMPLETING AND REVIEWING THE COLLECTION OF INFORMATION. SEND COMMENTS REGARDING THIS BURDEN ESTIMATE OR ANY OTHER ASPECT OF THIS COLLECTION OF INFORMATION, INCLUDING SUGGESTIONS FOR REDUCING THIS BURDEN, TO DEPARTMENT OF DEFENSE, WASHINGTON HEADQUARTERS SERVICES, DIRECTORATE FOR INFORMATION OPERATIONS AND REPORTS (0704-0188), 1215 JEFFERSON DAVIS HIGHWAY, SUITE 1204, ARLINGTON, VA 22202-4302. RESPONDENTS SHOULD BE AWARE THAT NOTWITHSTANDING ANY OTHER PROVISION OF LAW, NO PERSON SHALL BE SUBJECT TO ANY PENALTY FOR FAILING TO COMPLY WITH A COLLECTION OF INFORMATION IF IT DOES NOT DISPLAY A CURRENTLY VALID OMB CONTROL NUMBER. PLEASE DO NOT RETURN YOUR FORM TO THIS

ADDRESS

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CODE IDENT 3. SPI NO.

57K7250 (19207) ENGINE & CONTAINER 19207 AK15810635

4. NATIONAL STOCK NUMBER 5. DATE OF DRAWING 6. REVISION

2815-01-581-0635 03-15-2010 -

17. NOTES / DRAWING

B. ENGINE SET-UP:

(NOTE: IT IS ASSUMED THIS ENGINE HAS BEEN PREVIOUSLY RUN WITH COOLANT UTILIZING NON-

CHROMATE INHIBITORS BY THE MANUFACTURER).

1. REMOVE THE EXISTING TRANSMISSION FLEX PLATE ASSEMBLY AND INSTALL SLAVE FLYWHEEL.

2. CONNECT THE TRANSPARENT PLASTIC LINE FROM THE FUEL RETURN FITTING TO A SUITABLE

RECOVERY CONTAINER.

3. CONNECT THE PRESERVATIVE SUPPLY TO THE PRIMARY FUEL FILTER INLET AND INSERT THE OPPOSITE END INTO A CONTAINER OF PRESERVATIVE OIL CONFORMING TO MIL-PRF-46002, GRADE 1.

4. INSTALL THE AIR INLET RESTRICTOR PLATE DESCRIBED IN SECTION A, ITEM 3 TO SEAL OFF THE AIR

SUPPLY INTO THE AIR INTAKE MANIFOLD.

5. CONNECT SUPPLY OF MIL-PRF-21260, TYPE 1, GRADE PE 15-40 TO ENGINE OIL PRESSURE GALLERY.

USE AN INLINE PUMP (MAXIMUM 50 PSI) TO ENSURE ADEQUATE DISTRIBUTION OF THE

PRESERVATIVE LUBE OIL WHILE CRANKING ENGINE.

6. CONNECT COMPATIBLE DDEC INTERFACE (I.E. KENT MOORE P/N J38640-A) TO THE ENGINE

MOUNTED ELECTRONIC CONTROL MODULE TO ALLOW THE ELECTRONIC FUEL INJECTORS TO BE

ACTIVATED DURING THE ENGINE PRESERVATION CRANKING CYCLE.

7. REMOVE (3) LUBE OIL FILTERS AND POUR OUT EXISTING FACTORY OIL. REINSTALL FILTERS, TIGHTEN ¼ TURN PAST SEAL CONTACT.

8. PRE-FILL PRIMARY AND SECONDARY FUEL FILTERS WITH CLEAN PRESERVATIVE OIL CONFORMING

TO MIL-PRF-46002, GRADE 1.

9. REMOVE THE AIR COMPRESSOR AIR INTAKE MANIFOLD HOSE, AT THE AIR COMPRESSOR HEAD AND

SEAL END WITH CAP/PLUG CONFORMING TO NAS847.

10. CONNECT THE 24 VOLT DC POWER SUPPLY TO THE ENGINE STARTING MOTOR.

C. PROCESSING:

1. DEPRESS THE PRIMER BULB LOCATED AT THE TOP OF THE PRIMARY FUEL FILTER UNTIL MODERATE

RESISTANCE IS ENCOUNTERED.

2. ENERGIZE THE DDEC INTERFACE TO THE ENGINE MOUNTED ELECTRONIC CONTROL MODULE.

3. ENERGIZE THE INLINE PUMP IN THE PRESERVATIVE LUBE OIL LINE TO THE ENGINE GALLERY. DO NOT CRANK ENGINE UNTIL PRESERVATIVE LUBE OIL IS VISIBLE ON THE LOW LEVEL MARKING OF THE

DIPSTICK.

4. CRANK THE ENGINE WITH THE STARTER FOR APPROXIMATELY 300 REVOLUTIONS FOR

PRESERVATION OF THE ENGINE CYLINDER WALLS. (NOTE: THE STARTER SHOULD NOT BE

ENGAGED FOR MORE THAN 30 SECONDS AT ANY ONE TIME AND SHALL BE ALLOWED TO REST FOR A MINIMUM OF TWO (2) MINUTES BEFORE RE-ENGAGING. THIS PROCEDURE SHALL BE REPEATED

UNTIL UNDILUTED PRESERVATIVE OIL ID OBSERVED FLOWING FROM THE TRANSPARENT FUEL

RETURN LINE. AN AUXILIARY LOW PRESSURE PUMP WITH NO MORE THAN 15 PSI, MAY BE

INSTALLED BETWEEN THE PRESERVATIVE FUEL OIL SUPPLY AND THE PRIMARY FUEL FILTER, TO

IMPROVE THE INTRODUCTION OF THE PRESERVATIVE FUEL OIL.

5. WHILE CRANKING THE ENGINE, ATOMIZE SPRAY ½ OUNCE OF MIL-PRF-21260, GRADE PE 15/40 INTO

THE AIR COMPRESSOR INTAKE MANIFOLD.

6. DISCONNECT THE 24 VOLT DC POWER SUPPLY TO THE ENGINE STARTER MOTOR.

DD FORM 2169C, JUN 1997 (EG) WCT 9-99 PREVIOUS EDITIONS ARE OBSOLETE Page 3 of 4

SPECIAL PACKAGING INSTRUCTION

FORM APPROVED

OMB NO. 0704-0188

-MB

THE PUBLIC REPORTING BURDEN FOR THIS COLLECTION OF INFORMATION IS ESTIMATED TO AVERAGE 30 DAYS PER RESPONSE, INCLUDING THE TIME FOR REVIEWING INSTRUCTIONS, SEARCHING EXISTING DATA SOURCES, GATHERING AND MAINTAINING THE DATA NEEDED, AND COMPLETING AND REVIEWING THE COLLECTION OF INFORMATION. SEND COMMENTS REGARDING THIS BURDEN ESTIMATE OR ANY OTHER ASPECT OF THIS COLLECTION OF INFORMATION, INCLUDING SUGGESTIONS FOR REDUCING THIS BURDEN, TO DEPARTMENT OF DEFENSE, WASHINGTON HEADQUARTERS SERVICES, DIRECTORATE FOR INFORMATION OPERATIONS AND REPORTS (0704-0188), 1215 JEFFERSON DAVIS HIGHWAY, SUITE 1204, ARLINGTON, VA 22202-4302. RESPONDENTS SHOULD BE AWARE THAT NOTWITHSTANDING ANY OTHER PROVISION OF LAW, NO PERSON SHALL BE SUBJECT TO ANY PENALTY FOR FAILING TO COMPLY WITH A COLLECTION OF INFORMATION IF IT DOES NOT DISPLAY A CURRENTLY VALID OMB CONTROL NUMBER. PLEASE DO NOT RETURN YOUR FORM TO THIS

ADDRESS

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CODE IDENT 3. SPI NO.

57K7250 (19207) ENGINE & CONTAINER 19207 AK15810635

4. NATIONAL STOCK NUMBER 5. DATE OF DRAWING 6. REVISION

2815-01-581-0635 03-15-2010 -

17. NOTES / DRAWING

7. DISCONNECT THE DDEC INTERFACE TO THE ENGINE MOUNTED ELECTRONIC CONTROL MODULE.

8. REMOVE THE SLAVE FLYWHEEL AND REINSTALL THE TRANSMISSION FLEX PLATE ASSEMBLY. APPLY

INTERNATIONAL COMPOUND NO. 2 (OR EQUIVALENT) TO THE THREADS AND TO THE BOLT HEAD

CONTACT AREA (UNDERSIDE) OF THE REMAINING BLOTS. THE BOLT THREADS MUST BE

COMPLETELY FILLED WITH INTERNATIONAL COMPOUND NO. 2 AND ANY EXCESS WIPED OFF.

INSTALL THE BOLTS AND RUN THEM IN. TIGHTEN THE BOLTS AN ADDITIONAL 120 DEGREES OR 2

FLATS ON A 6 POINT BOLT.

9. REMOVE THE TRANSPARENT PLASTIC FUEL RETURN HOSE AND REINSTALL ORIGINAL HOSE WITH OUTLET END SEALED WITH CAP/PLUG CONFORMING TO NAS847. TIE WRAP THE END OF HOSE TO

REAR LIFTER BRACKET WITH END OF HOSE FACING UP.

10. DISCONNECT THE PRESERVATIVE SUPPLY HOSE TO THE PRIMARY FUEL FILTER INLET AND SEAL

THE INLET WITH A CAP/PLUG CONFORMING TO NAS847.

11. REMOVE THE INLET RESTRICTOR PLATE.

12. DISCONNECT THE SUPPLY OF MIL-PRF-21260 TO THE ENGINE OIL PRESSURE GALLERY.

13. REMOVE LUBE OIL FILTERS AND POUR OUT PRESERVATIVE OIL. REINSTALL FILTERS, TIGHTEN ¼

TURN PAST SEAL CONTACT.

14. REMOVE OIL PAN DRAIN PLUG AND DRAIN THE CRANKCASE. REINSTALL PLUG AND TORQUE TO 33-

37 LB. FT.

15. REMOVE OIL FILL TUBE PLUG, CRANKCASE OIL DIPSTICK AND HOSE CONNECTED TO THE BREATHER

OPENING AT THE RIGHT FRONT OF THE VALVE COVER.

16. ATOMIZE SPRAY, 4 OUNCES INTO THE BREATHER OPENING AND 2 OUNCES INTO THE OIL FILL TUBE

OPENING, PRESERVATIVE CONFORMING TO MIL-PRF-21260, GRADE PE 15/40.

17. REPLACE THE DIPSTICK; FILL TUBE PLUG AND BREATHER HOSE.

18. REMOVE CAP/PLUG AND REINSTALL THE AIR COMPRESSOR INTAKE MANIFOLD HOSE AT THE

COMPRESSOR HEAD.

19. OPEN THE DRAIN COCKS LOCATED AT THE BOTTOM OF THE THERMOSTAT HOUSING AND RIGHT CORNER OF THE ENGINE. A WARNING TAG SHALL BE MADE AND ATTACHED TO EACH DRAIN COCK

STATING “DRAIN COCK OPEN, CLOSE PRIOR TO FILLING WITH COOLANT”.

20. LOOSEN HOSE CLAMPS ON THE REAR RUBBER COUPLING, ON THE TUBE BETWEEN THE OIL COOLER

HOUSING AND THE ENGINE WATER PUMP. SLIDE THE RUBBER HOSE FORWARD TO ALLOW ANY

TRAPPED COOLANT TO DRAIN OUT. SLIDE HOSE BACK INTO POSITION AND REINSTALL HOSE

CLAMPS.

21. LOOSEN TENSION ON THE ENGINE FAN BELTS.

22. APPLY MIL-PRF-21260, GRADE PE 15/40 TO ALL UNPAINTED, UNPLATED EXTERIOR METALLIC

SURFACES.

23. A PROCESSING RECORD, DD FORM 1397, SHALL BE COMPLETED AND AFFIXED IN A CONSPICUOUS

LOCATION ON THE ENGINE.

D. PACK THE ENGINE INTO THE CONTAINER IAW THE CONTAINER SPECIFICATIONS USING THE SUPPLIED

HARDWARE.

E. PLACE 128 UNITS DESICCANT INTO THE CONTAINER DESICCANT BASKET.

F. CLOSE THE CONTAINER IAW THE CONTAINER SPECIFICATIONS USING THE SUPPLIED HARDWARE.

DD FORM 2169C, JUN 1997 (EG) WCT 9-99 PREVIOUS EDITIONS ARE OBSOLETE Page 4 of 4

SPECIAL PACKAGING INSTRUCTION

FORM APPROVED

OMB NO. 0704-0188

-MB

THE PUBLIC REPORTING BURDEN FOR THIS COLLECTION OF INFORMATION IS ESTIMATED TO AVERAGE 30 DAYS PER RESPONSE, INCLUDING THE TIME FOR REVIEWING INSTRUCTIONS, SEARCHING EXISTING DATA SOURCES, GATHERING AND MAINTAINING THE DATA NEEDED, AND COMPLETING AND REVIEWING THE COLLECTION OF INFORMATION. SEND COMMENTS REGARDING THIS BURDEN ESTIMATE OR ANY OTHER ASPECT OF THIS COLLECTION OF INFORMATION, INCLUDING SUGGESTIONS FOR REDUCING THIS BURDEN, TO DEPARTMENT OF DEFENSE, WASHINGTON HEADQUARTERS SERVICES, DIRECTORATE FOR INFORMATION OPERATIONS AND REPORTS (0704-0188), 1215 JEFFERSON DAVIS HIGHWAY, SUITE 1204, ARLINGTON, VA 22202-4302. RESPONDENTS SHOULD BE AWARE THAT NOTWITHSTANDING ANY OTHER PROVISION OF LAW, NO PERSON SHALL BE SUBJECT TO ANY PENALTY FOR FAILING TO COMPLY WITH A COLLECTION OF INFORMATION IF IT DOES NOT DISPLAY A CURRENTLY VALID OMB CONTROL NUMBER. PLEASE DO NOT RETURN YOUR FORM TO THIS

ADDRESS

1. PART OR DRAWING NO. (CAGE) NOMENCLATURE 2. CODE IDENT 3. SPI NO.

57K7250 (19207) ENGINE & CONTAINER 19207 AK15810635

4. NATIONAL STOCK NUMBER 5. DATE OF DRAWING 6. REVISION

2815-01-581-0635 03-15-2010 -

17. NOTES / DRAWING

G. THE UNIT CONTAINER IS THE SHIPPING CONTAINER.

H. SPECIAL MARKING SHALL BE IAW A-A-52462 AND AS FOLLOWS:

1. THE ENGINE SERIAL NUMBER SHALL BE STENCILED ON THE CONTAINER IAW MIL-STD-129.

2. “CARC” SHALL BE MARKED WITH PAINT CONFORMING TO MIL-C-46168 OF MIL-C-53039, COLOR BLACK, IN 1” HIGH LETTERS IN AN AREA NEAR AS PRACTICAL TO THE NAMEPLATE.

3. “REUSABLE CONTAINER: DO NOT DESTROY” SHALL BE MARKED WITH PAINT CONFORMING TO MIL-C- 46168 OR MIL-C-53039, COLOR BLACK, IN ½” HIGH LETTERS IN AN AREA ON THE LOWER CONTAINER

SECTION ON THE SAME END AS THE NAMEPLATE.

4. WHEN AN ENGINE IS REBUILT, THE FOLLOWING ADDITIONAL MARKING SHALL BE STENCILED

IMMEDIATELY BELOW THE ENGINE SERIAL NUMBER.

a. BORE: (INSERT DIMENSION OF AMOUNT OVER OR UNDER, EXAMPLE: .007” UNDER).

b. MAINS: (INSERT DIMENSION OF AMOUNT OVER OR UNDER, EXAMPLE: .007” UNDER).

c. RODS: (INSERT DIMENSION OF AMOUNT OVER OR UNDER, EXAMPLE: .007” UNDER).

I. QUALITY ASSURANCE:

1. INSPECT THE PRESERVATION AND THE UNIT PACK IAW MIL-STD-2073-1.

2. INSPECT THE CONTAINER IAW A-A-52462 INCLUDING THE FIRST ARTICLE INSPECTION

REQUIREMENTS.