Navsea s0600 Aa Pro 120

S0600-AA-PRO-120
0910-LP-019-9270
REVISION 1
UNDERWATER SHIP HUSBANDRY MANUAL
CHAPTER 12
CONTROLLABLE PITCH PROPELLERS
DISTRIBUTION STATEMENT A: This document has been approved for public release and sale; its
distribution is unlimited.
PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND
30 OCTOBER 1998
Change 1 Dated 15 November 1999
S0600-AA-PRO-120
LIST OF EFFECTIVE PAGES

Date of original pages is: 30 October 1998
Date of Change 1 is: 15 November 1999
Page No.
* Change No.
Title, A, and B. . . . . . . . . . . . . . . . . . . . . . . . .1
Certification Sheet . . . . . . . . . . . . . . . . . . . . .1
blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
Flyleaf-1 (Flyleaf-2 blank) . . . . . . . . . . . . . . .1
i through v . . . . . . . . . . . . . . . . . . . . . . . . . . O
vi blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
vii through viii . . . . . . . . . . . . . . . . . . . . . . . . .1
ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
x through xiv. . . . . . . . . . . . . . . . . . . . . . . . . .1
12-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-2 through 12-6 . . . . . . . . . . . . . . . . . . . . O
12-6A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-6B blank . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-7 through 12-15 . . . . . . . . . . . . . . . . . . . O
12-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-17 through 12-46 . . . . . . . . . . . . . . . . . . O
12-46A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-46B blank . . . . . . . . . . . . . . . . . . . . . . . . .1
12-47 through 12-54 . . . . . . . . . . . . . . . . . . O
12-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-56 through 12-71 . . . . . . . . . . . . . . . . . . O
12-72 blank . . . . . . . . . . . . . . . . . . . . . . . . . O
12-73 through 12-81 . . . . . . . . . . . . . . . . . . O
12-82 blank . . . . . . . . . . . . . . . . . . . . . . . . . O
12-83 through 12-84 . . . . . . . . . . . . . . . . . . O
12-84A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-84B blank . . . . . . . . . . . . . . . . . . . . . . . . .1
12-85 through 12-90 . . . . . . . . . . . . . . . . . . O
12-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-92 through 12-107 . . . . . . . . . . . . . . . . . O
12-108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
A-1 through A-13 . . . . . . . . . . . . . . . . . . . . . O
A-14 blank . . . . . . . . . . . . . . . . . . . . . . . . . . O
B-1 through B-22 . . . . . . . . . . . . . . . . . . . . . O
B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
B-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
B-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Page No.
* Change No.
B-10 through B-13 . . . . . . . . . . . . . . . . . . . . O

B-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B-14A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B-14B blank . . . . . . . . . . . . . . . . . . . . . . . . . 1
C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
C-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
C-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
C-4 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
C-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
C-6 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
C-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
C-8 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
C-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
C-10 blank . . . . . . . . . . . . . . . . . . . . . . . . . . O
D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
D-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
D-4 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
D-6 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
E-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-4 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-6 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-8 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
F-10 blank . . . . . . . . . . . . . . . . . . . . . . . . . . O
G-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
G-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
G-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
G-4 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
G-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
G-6 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
G-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
* O in this column indicates an original page.
Change 1
S0600-AA-PRO-120
Page No.
* Change No.
G-8 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-4 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-6 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
* O in this column indicates an original page.
Change 1
Page No.
* Change No.
I-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
I-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
J-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
J-2 blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . O
K-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
K-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
S0600-AA-PRO-120
RECORD OF CHANGES
ACN/FORMAL
*CHANGE
ACN NO.
DATE
OF
CHANGE
11/15/99
TITLE AND/OR BRIEF DESCRIPTION**
ENTERED
BY
Incorporate warning blade bolt installation

operation
Incorporate chain hoist caution
Make changes to Hex Bolt Elongation
Measurement Procedure
*When a formal change supersedes an ACN, draw a line through the ACN number
**Only message or letter reference need be cited for ACNs
Flyleaf-1/(Flyleaf-2 blank)
S0600-AA-PRO-120
TABLE OF CONTENTS
Paragraph
Page
SECTION 1 INTRODUCTION 1
12-1.1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-1.2
PURPOSE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-1.3
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-1.4
APPLICABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-1.5
CONTROLLABLE PITCH PROPELLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
SECTION 2 FFG 7 BLADE REMOVAL, RETRIEVAL, AND REPLACEMENT PROCEDURE

12-2.1
REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12-2.2
PROCEDURE SYNOPSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12-2.3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
12-2.4
SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
12-2.5
RIG SHIPS HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
12-2.6
ROTATE BLADE TO BE REMOVED INTO THE 12 O'CLOCK POSITION . . . . . 12-11
12-2.7
REMOVE MORGRIP BLADE BOLT CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
12-2.8
REMOVE MORGRIP BLADE BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
12-2.9
BLADE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
12-2.10
BLADE PORT AND BLADE INSPECTION AND PREPARATION. . . . . . . . . . . . 12-20
12-2.11
BLADE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23
12-2.12
MORGRIP BOLT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28
12-2.13
MEASURE INSTALLED BOLT LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
12-2.14
BOLT CAP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
12-2.15
TEST THE CPP AND PRAIRIE AIR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . 12-31
12-2.16
FINAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31
SECTION 3 FFG 7, DD 963, DDG 993, CG 47, AND DDG 51 CLASS PROPELLER HUB
PRAIRIE AIR CHECK VALVE REPAIR
12-3.1
FFG 7 CLASS REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33
12-3.2
DD 963, DDG 993, AND CG 47 CLASS REPAIR PROCEDURE . . . . . . . . . . . . 12-33
12-3.3
DDG 51, CG 47 (CG 66 AND ABOVE), AND MODIFIED EARLIER

CLASS SHIPS REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33
SECTION 4 FFG 7 CLASS WATERBORNE BLADE PORT HUB SEAL REPAIR

12-4.1
REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35
S0600-AA-PRO-120
12-4.2
SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35
12-4.3
REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35
SECTION 5 DD 963, AND CG 47 BLADE REMOVAL, RETRIEVAL, AND REPLACEMENT

PROCEDURE
12-5.1
REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-45
12-5.2
PROCEDURE SYNOPSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-45
12-5.3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46
12-5.4
12-5.5
RIG SHIPS HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-49
12-5.6
ROTATE BLADE TO BE REMOVED INTO THE 12 O'CLOCK POSITION . . . . . 12-49
12-5.7
REMOVE MORGRIP BLADE BOLT CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-50
12-5.8
REMOVE MORGRIP BLADE BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-51
12-5.9
BLADE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-55
12-5.10
12-5.11
BLADE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-62
12-5.12
MORGRIP BOLT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-67
12-5.13
MEASURE INSTALLED BOLT LENGTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-69
12-5.14
BOLT CAP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-70
12-5.15
TEST THE CPP AND PRAIRIE AIR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . 12-70
12-5.16
FINAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-70
SECTION 6 DD 963, DDG 993, AND CG 47 CLASS WATERBORNE BLADE PORT HUB SEAL
REPAIR
12-6.1
REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-73
12-6.2
12-6.3
REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-73
SECTION 7 DDG 51 "FLEET" TYPE BLADE REMOVAL, RETRIEVAL, AND REPLACEMENT

PROCEDURE
12-7.1
REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-83
12-7.2
PROCEDURE SYNOPSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-83
12-7.3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-84
12-7.4
12-7.5
RIG SHIPS HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-87
12-7.6
ROTATE BLADE TO BE REMOVED INTO THE 12 OCLOCK POSITION. . . . . 12-87
12-7.7
REMOVE BLADE BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-88
ii
S0600-AA-PRO-120
12-7.8
BLADE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-91
12-7.9
12-7.10
BLADE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-99
12-7.11
BLADE BOLT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-105
12-7.12
MEASURE INSTALLED BOLT LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-108
12-7.13
REMOVE THREE-POINT LIFTING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 12-109
12-7.14
BOLT NYLON PLUG AND SCREW INSTALLATION . . . . . . . . . . . . . . . . . . . . 12-109
12-7.15
TEST THE CPP AND PRAIRIE AIR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . 12-109
12-7.16
FINAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-109
LIST OF APPENDICES
APPENDIX A MORGRIP BOLT ELONGATION MEASUREMENT PROCEDURE
A-1
TUTORIAL DISCUSSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
A-1.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
A-1.2
PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
A-1.3
COMPENSATION FOR TEMPERATURE AND SALINITY CHANGES . . . . . . . . . .A-2
A-1.4
POTENTIAL PROBLEM AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
A-1.5
OUT-OF-RANGE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
A-1.6
DIVER TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
A-2
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
A-3
REFERENCED DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
A-4
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
A-4.1
DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
A-4.2
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
A-4.3
EQUIPMENT AND MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
A-4.4
POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
A-5
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
A-5.1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
A-5.2
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
A-5.3
BASELINE DIMENSION MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11
A-5.4
UNDERWATER MEASUREMENTS AFTER INSTALLATION. . . . . . . . . . . . . . . .A-11
A-5.5
ELONGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12
A-6
EVALUATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12
iii
S0600-AA-PRO-120
A-6.1
EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12
A-7
RECORDING AND REPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12
A-8
PERSONNEL QUALIFICATION AND CERTIFICATION REQUIREMENTS . . . . .A-13
APPENDIX B HEX SOCKET BOLT ELONGATION MEASUREMENT PROCEDURE

B-1
TUTORIAL DISCUSSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
B-1.1
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B-1.2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
B-1.3
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
B-1.4
COMPENSATION FOR TEMPERATURE AND SALINITY CHANGES. . . . . . . . . .B-5
B-1.5
OFFSETS DUE TO DIMENSIONAL VARIATIONS . . . . . . . . . . . . . . . . . . . . . . . . .B-5
B-1.6
POTENTIAL PROBLEM AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
B-1.7
OUT-OF-RANGE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
B-1.8
DIVER TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
B-2
MEASUREMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
B-2.1
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
B-2.2
BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
B-2.3
REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
B-2.4
PERSONNEL QUALIFICATION AND CERTIFICATION REQUIREMENTS . . . . .B-10
B-2.5
DESCRIPTION OF MEASUREMENT SYSTEM COMPONENTS . . . . . . . . . . . . .B-10
B-2.6
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11
B-2.7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-13
B-3
EPOCH II ADDENDUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-13
B-3.1
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-15
B-3.2
INSTRUMENT CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-16
B-3.3
BASELINE MEASUREMMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-19
B-3.4
IN-PROCESS MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-20
B-3.5
FINAL LENGTH MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-21
B-3.6
PERSONNEL QUALIFICATION AND CERTIFICATION REQUIREMENTS . . . . .B-22
APPENDIX C HYDRAULIC INTENSIFIER

APPENDIX D BLADE BOLT CAP WRENCH
APPENDIX E MORGRIP TEMPORARY BOLT HYDRAULIC JACKING SYSTEM
APPENDIX F PROPELLER BLADE LIFTING FIXTURE
APPENDIX G BLADE RIGHTING FIXTURE
iv
S0600-AA-PRO-120
APPENDIX H CENTER POST SLEEVE

APPENDIX I MONOBLOCK PROPELLER PRESERVATION & CPP HUB PRESSURE TEST
S0600-AA-PRO-120
THIS PAGE INTENTIONALLY LEFT BLANK
vi
S0600-AA-PRO-120
LIST OF ILLUSTRATIONS
Figure
Page
12-1
12-2
12-3
12-3A
12-4
12-5
12-6
12-7
12-8
12-9
12-10
12-11
12-12
12-13
12-14
12-14A
12-15
12-16
12-17
12-18
12-19
12-20
12-21
12-22
12-23
12-24
12-24A
12-25
12-26
12-27
12-28
12-29
12-30
12-31
12-32
12-33
12-34
12-35
A-1
A-2
A-3
B-1
B-2
B-3
B-4
B-5
CPP Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

Top View of Clockwise Rotating Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Blade Palm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Tugit Lever Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6A
Ships Hull Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
Blade Bolt Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Power Head/Morgrip Bolt Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
Morgrip Bolt Hole Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
Righting Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21
Blade Port Inspection Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22
Hydraulic Hose Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-27
Location of Nylok Pellets in the Morgrip Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31
Prairie Air Check Valve Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
Blade Port Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
Shim Requirement Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40
Tugit Lever Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-46A
Ships Hull Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-50
Power Head/Morgrip Bolt Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-53
Morgrip Bolt Hole Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-58
Righting Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-60
Blade Port Inspection Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-61
Hydraulic Hose Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-66
Location of Nylok Pellets in the Morgrip Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-69
Blade Port Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-75
Shim Requirement Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-78
Tugit Lever Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-84A
Blade Rigging Detail, Key Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-88
Blade Rigging Details, Hold Back Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-89
Blade Rigging Details, View at FR 448 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-90
Hex Socket Bolt With Hydraulic Torque Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-91
Blade Bolt Hole Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-98
Righting Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-100
Blade Port Inspection Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-101
Bolt Elongation Measurement Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-107
Blade Bolt and Transducer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-107
Blade Bolt Plug and Screw Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-110
Bolt Elongation Measurement Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Bolt Elongation Measurement Calibration Standard . . . . . . . . . . . . . . . . . . . . . . . .A-7
Bolt Elongation Measurement Inspection Report and Worksheet . . . . . . . . . . . . . .A-8
Bolt Elongation Measurement Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Hex Socket Bolt Elongation Measurement Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Hex Socket Bolt Calibration Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Hex Socket Bolt Baseline and Post-Elongation Measurement Worksheet . . . . . .B-14
Hex Socket Bolt Elongation Measurement During Installation Worksheet. . . . . . .B-15
Change 1
vii
S0600-AA-PRO-120
B-6
B-7
rf Ultrasonic Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-18

Full Wave Rectified Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-18
NAVSEA Drawing 6698050 Rev E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
NAVSEA Drawing 6698073 Rev A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
NAVSEA Drawing 6698018 Rev C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
NAVSEA Drawing 6699569 Rev E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
NAVSEA Drawing 6699571 Rev E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
NAVSEA Drawing 6699590 Rev B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-1
NAVSEA Drawing 6699591 Rev B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-5
NAVSEA Drawing 6697839 Rev D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
NAVSEA Drawing 6698352 Rev (-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
NAVSEA Drawing 6698342 Rev (-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K-1
LIST OF TABLES
Table
Page
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-8
12-9
12-10
B-1
viii
Material To Be Provided by the Repair Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

FFG 7 Quality Assurance Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
FFG 7 Class Waterborne Blade Port Hub Seal Repair
Quality Assurance Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-37
Material To Be Provided by the Repair Activity . . . . . . . . . . . . . . . . . . . . . . . . . . 12-47
DD 963, DDG 993, and CG 47 Quality Assurance Points . . . . . . . . . . . . . . . . . . 12-48
DD 963, DDG 993, and CG 47 Class Waterborne Blade Port
Hub Seal Repair Quality Assurance Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-74
Material To Be Provided by the Repair Activity . . . . . . . . . . . . . . . . . . . . . . . . . . 12-85
DDG 51 Quality Assurance Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-86
Sweeney Tool Fit-Up DDG 51: Right Hand Blade . . . . . . . . . . . . . . . . . . . . . . . . 12-93
Sweeney Tool Fit-Up CG 66 and Higher: Right Hand Blade . . . . . . . . . . . . . . . . 12-94
EPOCH II Initial Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-17
Change 1
S0600-AA-PRO-120
SAFETY SUMMARY
GENERAL SAFETY PRECAUTIONS. The
following general safety precautions supplement the specific warnings and cautions
throughout this chapter. These general precautions are related to the task of underwater
Sonar Rubber Dome (SRD) repair. They are
precautions that must be understood and applied before and during work on the SRD. In
addition to the following precautions, personnel must be familiar with and observe safety
precautions set forth in the following publications:
a. Navy Occupational Safety and Health
Program Manual for Forces Afloat,
OPNAVINST 5000.19 (Series)
b. Naval Ships
(NSTM)
Technical
c. Technical/operating
equipment
Manual
manuals
Equipment in Motion.
Remain clear of equipment in motion. A safety
watch will be posted if equipment requires adjustment while in motion. The safety watch
shall have a full view of operations and immediate access to controls that are capable of
stopping equipment. If at any time the equipment appears to be moving out of control, stop
it immediately.
Limit Switches and Interlocks.
Limit switches and interlocks are provided to
protect personnel and equipm ent. They
should not be overridden or modified except
by an authorized person. Do not depend
solely upon limit switches for protection. Disconnect power at the power distribution
source before adjusting limit switches if possible.
for
e. U.S. Navy Diving Manual, Volume I,

NAVSEA-0944-LP-001-9010.
First Aid.
Attend to all injuries, however slight, by obtaining first aid or medical attention immediately.
Resuscitation.
Do Not Repair or Adjust Alone.

Do not repair or adjust energized equipment
alone. The presence of a qualified individual
capable of rendering aid is required. Always
protect against grounding hazards and make
adjustments with one hand free and clear of
equipment. Be aware that even after equipment has been de-energized, dangerous electrical hazards can exist due to capacitors
retaining electrical charges. Circuits must be
grounded and capacitors discharged.
Test Equipment.
Make certain electrical test equipment is in
good condition and personnel are familiar with
its safe operation. Handheld equipment must
be grounded, if possible, to prevent shock injury. Because some types of equipment cannot be grounded, avoid holding them.
Personnel working with or near high voltage

shall be familiar with approved resuscitation
methods. Begin resuscitation immediately if
someone is injured and stops breathing. A delay could cost the victims life. Resuscitation
procedures shall be posted where electrical
hazards exist.
Minimizing Relative Motion.
Relative motion is the movement of two or
more objects in relation to each other. This
poses unique hazards to divers. A common
example is a group of ships swaying and
bouncing against each other because of wind
and wave action. This motion would easily
crush a diver caught between the two ships.
To reduce the hazards of relative motion and
to simplify the task, suspend the work platform
and rigging from fittings on the ship.
ix
S0600-AA-PRO-120
WARNINGS AND CAUTIONS.

Specific Warnings and Cautions appearing in this chapter
are summarized below for
emphasis and review.
WARNINGS
All CPP blade bolt installation
operations require a NAVSEA
00C technical representative
on-site (page 12-1).
Rotating the propeller while
divers are in the vicinity may
result in serious injury to or
death of divers. Divers must be
clear of the propeller blades
and verify that dive hoses and
rigging lines are clear of the
propeller blades. Divers must
be warned when the propeller
will be rotating (pages 12-11,
12-17, 12-18, 12-23, 12-24, 1225, 12-49, 12-56, 12-57, 12-62,
12-63, 12-64, 12-87, 12-95, 1297, 12-99, 12-103).
The power head must have full
thread engagement with the
blade bolt to avoid catastrophic
failure and possible personnel
injury when the bolt is pressurized. Ensure seven full turns.
Record each power head pressurization in the log book provided (pages 12-12, 12-28, 1251, 12-67).
High pressure oil jets can penetr ate th e ski n. E nsu re tha t
divers are aware that the power
head is about to be pressurized. Divers should be clear of
the power head (pages 12-13,
12-54).
High pressure oil jets can penetrate the ski n. Di ver s must
ensure that topside personnel
Change 1
have depressurized the intensifier before disconnecting the

HP tube (pages 12-15, 12-54).
High pressure oil jets can penetrate the skin. Ensure that topside personnel are clear of the
valve opening when depressurizing the power head (pages
12-15, 12-55).
Pr o p e l l e r bl ad e e dg e s a r e
sharp. Avoid injury while handling blades (pages 12-18, 1225, 12-56, 12-64, 12-95, 12104).
Rotating the hub with the rigging attached poses a serious
hazard. Rigging loads will easily be exceeded if the jacking
gear pulls against the rigging.
Direct communication between
the Diving Supervisor and the
Ships Force personnel operating the jacking gear is required
(pages 12-18, 12-57, 12-95,
12-97).
Divers must not place hands or
fingers between the blade palm
and hub (page 12-25, 12-64,
12-103).
and hub. Follow all safety precautions concerning rotation of
blades (pages 12-26, 12-65,
12-104).
Maximum pressure for hydraulic temporary bolts is 3,000 psi
and must not be exceeded.
Serious injury to a diver could
occur if hydraulic temporary
bolts were to fail (pages 12-27,
12-66).
High pressure oil jets can penetrate the skin (pages 12-29, 1268).
High pressure oil jets can penetrate the skin. Ensure divers
S0600-AA-PRO-120
are clear of the valve opening

when bleeding the power head
(pages 12-30, 12-69).
over into the chain loops creating chain twist while deploying
and
rigging
the
chain
hoists/falls.
CAUTIONS
To check for chain twist in the

chain loop:
It is essential that all tools and

materials brought to the underwater job site are accounted for
and removed at the completion
of the job. Tools and materials
inadvertently left at the job site
can generate unacceptable
noise and possibly cause
severe damage to shipboard
components. Locally generated
work packages shall ensure
that a general tool and material
log sheet is prepared and maintained during all UWSH operations (pages 12-6, 12-35, 1246, 12-73).
Chain twist in the working chain
loops of manual chain hoists
and chain falls will cause chain
failure. Chain twist in the working chain loop occurs when the
chain has an improper reeve
through the chain sprockets
OR (more often) the running
block has flipped up and
through any of the chain loops
(see figure 12-3A 12-14A, and
12-24A).
All chain hoists and chain falls
issued with NAVSEA SUPSALV
Underwater Ship Husbandry
equipment kits have been
checked for chain twist and the
chain hoist/fall has been
loosely two-blocked so that the
running block can not flip over
into the working chain loops
during shipment.
OPERATORS must ensure that
the running block is not flipped
Hang the hoist from the top

hook in a safe, accessible location. Tighten the hoist until less
then one foot of separation
exists between the hoist body
and the running block. The
short throw allows for much
easier visual detection of twist
in the individual chain reeves.
Confirm that none of the chain
lengths running from the working chain sprocket to the running chain sprocket (chain
reeves) have any twist caused
by the running block being
flipped over and through the
loop of the chain. If ANY chain
twist is detected, flip the running block back through the
chain loop until the twist is
removed. If ANY twist can not
be removed by flipping the running block, the hoist chain
MUST be removed from the
hoist body and re-reeve exercising care not to twist the
chain during installation (pages
12-6A, 12-46A, and 12-84A).
Before removing the blade bolt
caps, measures must be taken
for oil containment and abatement in accordance with local
Senior Officer Present Afloat
(SOPA) Manuals and reference
c. of section 12-2.1, Requirements (page 12-11).
Hydraulic fluid pressure must
not exceed 37,500 psi. Exceeding 37,500 psi may damage
power head or intensifier
(pages 12-15, 12-29, 12-54,
Change 1
xi
S0600-AA-PRO-120
pended blade is clear of the

hub in order to ensure that no
damage is done to the propeller
blade palm, blade port or connecting hardware when the hub
is rotated (pages 12-24, 12-63).
1- To n
4- To n
Typical
R unning
B lock
Flip
3 To n
6 Ton
Fig. 12-3A, 12-14A, and 12-24A Tugit Lever

Hoists (Harrington Pull-Chain Type have a two
part Reeve)
12-68).
Blade edges are easily damaged. Do not strike blade
edges with air cylinders, tools,
or other equipment (pages 1218, 12-56, 12-95).
Careless use of tools or equipment may nick or gouge the
shaft and propeller and cause
noise or cavitation problems.
Extreme care must be taken to
ensure that the propeller blade
and shaft are not damaged
(pages 12-18, 12-57, 12-95).
Ensure that new O-rings are
used for all installations (pages
12-20, 12-23, 12-59, 12-62, 1299, 12-102).
Divers must verify that the sus-
xii
Change 1
Divers must verify that the suspended blade is clear of the

dowel pins for a small rotation
in order to ensure that no damage is done to the propeller
blade palm, blade port, or connecting hardware when the hub
is rotated (pages 12-25, 12-64,
12-103).
Be careful not to lower a blade
so rapidly onto the hub as to
wash out the cover plate Oring. Never allow the forward
lever hoist to go completely
slack during the lowering process because this could lead to
a sudden drop of the blade,
causing O-ring washout (pages
12-25, 12-64, 12-104).
Ultrasonic measurement procedures and equipment are
required to achieve the accuracy required in blade bolt measurement. Any ultrasonic blade
bolt measurement procedures
and equipment utilized must be
approved by NAVSEA or its
authorized representative in
accordance
with
NAVSEA
Technical
Publication
271
(pages 12-28, 12-67, 12-105).
Before removing the blade,
measures must be taken for oil
containment and abatement in
accordance with local Senior
Officer Present Afloat (SOPA)
Manuals and reference c (page
12-35).
If the jack pressure increases
rapidly without movement of
the sleeve right at the start,
S0600-AA-PRO-120
stop jacking and inspect for

misalignment. Retract the jack
and remove the sleeve from the
center post. If the sleeve
remains serviceable, align the
jacking assembly and restart
(page 12-39, 12-77).
DO NOT attempt to measure
dimension B between an
existing shim laying on the
crank pin ring and the bearing
ring. Dimension B must be
measured between the actual
crank pin ring surface and the
bearing ring. The elastic shim
surface makes the diver measurements with the outside
depth micrometer unrepeatable
(pages 12-40, 12-77).
The reduction of shim thickness or removal of shim as
detailed above is at best an
interim method to regain a
blade port seal when bearing
ring wear has begun. Once
begun, bearing ring wear will
continue eventually causing
blade port leaking to resume.
Careful consideration of the
ships operational schedule and
drydock availabilities to perform
the eventual replacement of the
worn bearing ring is essential
(pages 12-40, 12-78).
The blade seal base ring is
held in place only by a friction
fit at the 6 o'clock position. During the jacking removal process
the ring will drop out under its
own weight (32 lbs.). Divers
must be prepared for the ring's
weight and to recover the 18
springs which are retained by
the ring and may fall loose with
the ring (pages 12-41, 12-79).

d. of section 12-5.1, Requirements (page 12-50).
Manuals and reference d (page
12-73).
Torque vs. applied pressure
charts for the specific operating
head and pump utilized must
be available during operation
(pages 12-85).
charts for the Sweeney RSL8
operating head must be available during operation (page 1289).
Careful attention must be paid
to connection of the hydraulic
hoses between topside pump
and
underwater
hydraulic
torque link. The hoses must be
connected in accordance with
manufacturer's
instructions
(pages 12-85, 12-89).
Before removing the blade
bolts, measures must be taken
d of Section 12-7.1, Requirements (page 12-88).
Review the manufacturers
instruction manual for proper
use of the topside hydraulic
pump (page 12-89).
Do NOT use emery cloth or
sandpaper for polishing the
blade bolts (page 12-91).
Change 1
xiii
S0600-AA-PRO-120
With the hoist under load,

inspect the rigging beam installation. Confirm that the beam
is snug against the hull at the
lifting tunnels. If any gap is
observed, slack the hoist and
retighten the U-bolts (page 1295).
Before installation, the bolt
threads and the shoulder must
be coated with nickel based
antiseize compound (page 12105, 12-106).
The counter bore of the hex
stock must face down during
assembly to avoid damaging
the transducer assembly (page
12-106).
If the hydraulic tool is not properly aligned, the UT inspector
will see an initial rise in bolt
stretch on pressurization, followed by a drop in stretch during the return cycle. If this
occurs, the alignment of the
tool must be fixed to prevent
damage to the ultrasonic sensor (page 12-108).
The pace of the operation must
be slow enough to ensure the
UT operator has sufficient time
to monitor bolt elongation,
record ALL data and make calculations. The diver must leave
the transducer in place until
data is logged and the UT operator calls for the transducer to
be moved (page 12-108).
In order to protect the precision
lead screw threads from corrosion, a waterproof cap is supplied with the calibration
standard. Before lowering the
standard into the local seawater, this cap must be installed,
and before removing the cap,
topside, excess seawater must
xiv
Change 1
be wiped off the standard. In

placing the standard in its rotatable base, an O-ring seal is
formed to protect the lead
screw from seawater spill-over
(page B-20).
S0600-AA-PRO-120
CHAPTER 12
CONTROLLABLE PITCH PROPELLERS
SECTION 1 INTRODUCTION
12-1.1 GENERAL INFORMATION.
As in all underwater ship husbandry, there are
advantages to removing and replacing controllable pitch propeller (CPP) blades while the
ship is afloat. The most obvious advantage is
the elimination of costly dry-docking and the
expeditious return of the ship to operational
status. Another advantage is that the CPP
blade can be removed and replaced virtually
anywhere the ship is berthed.
12-1.2 PURPOSE.
This chapter provides commands with technical information and NAVSEA-approved procedures for the underwater replacement of CPP
blades. Strict adherence to the procedures in
this chapter will provide the best assurance
that all tasks, both underwater and topside,
are safely and efficiently completed and that
stringent quality control requirements are met.
12-1.3.2 The remaining sections of this chapter provide step-by-step procedures for specific CPP system repairs to specific classes of
ships.
12-1.4 APPLICABILITY.
Blade replacement and blade port hub seal
repair procedures are provided for FFG 7, CG
47, DDG 993, and DD 963 Class ships. A hub
prairie air check valve repair procedure is provided for FFG 7 Class ships. The prairie air
check valve procedure can easily be applied
to CG 47, DDG 993, DD 963, and DDG 51
Class ships. Blade replacement procedures
for DDG 51 Class ships with "Fleet" type
blades are also provided. The DDG 51 Class
blade bolt removal and installation procedures
are also applicable to CG 47 Class ships with
hull numbers CG 66 and higher.
12-1.5 CONTROLLABLE PITCH PROPELLERS.
WARNING
All CPP blade bolt installation

operations require a NAVSEA
00C technical representative
on-site.
12-1.3 SCOPE.
This chapter provides step-by-step procedures for the planning and execution of waterborne CPP repair. This chapter does not
supersede information contained in the U.S.
Navy Diving Manual or the Naval Ships Technical Manual (NSTM). NAVSEA 00C5 is available for consultation or technical assistance
during CPP blade replacement planning and
execution.
12-1.3.1 Section 1 of this chapter describes
CPP systems, discusses the components of
the CPP blade and hub, explains the purpose
of the CPP propulsion system, and introduces
terminology commonly used in performing
CPP blade change-out.
12-1.5.1 Description. CPP systems (Figures

12-1 and 12-2) have blades that can pivot on
the hub to allow the pitch of the blades to be
changed. Blades are lettered A through E
and are installed in balanced sets of five.
Blade identification information is stamped on
the propeller blade palm. Each blade is
installed in the blade port of the same letter.
On several ship classes, a blade port cover
plate and cover plate O-ring are installed
where the blade mates to the hub, which prevents seawater from leaking in or oil from leaking out. Some older ship classes do not have
blade port cover plate seals, which forces
blade changes at the 6 oclock position. Each
blade has two dowel pin holes and a prairie air
nipple orifice. Likewise, each of the five blade
ports on the hub has corresponding dowel pin
holes and a prairie air nipple orifice. Two
dowel pins and a prairie air nipple are installed
where the blade mates to the hub. Each blade
is secured to the hub with blade bolts. The
bolts are stretched or torqued for installation.
Change 1
12-1
S0600-AA-PRO-120
Figure 12-1. CPP Terminology.
12-1.5.2 Purpose. The CPP propulsion system uses actuating mechanisms controlled
from the bridge or engine room to provide a
full range of ahead and astern thrust to the
vessel while the main propulsion machinery
operates at a constant speed. Maximum
ahead thrust is provided with blades in the full
ahead pitch position. By reversing the pitch
into the full astern pitch position, maximum
astern thrust is provided without reversing the
turning direction of the main propulsion
machinery, including the propeller shaft.
12-1.5.3 Terminology. Figures 12-1 and
12-2 are labeled illustrations of a typical CPP
12-2
hub/blade assembly. The terms shown in Figures 12-1 and 12-2 are defined below:
Hub. The center section of the propeller
bolted onto the propeller shaft.
Pressure Face. The aft face of the propeller
blade when the blade pitch is in the ahead
position.
Suction Face. The forward face of the propeller blade when the blade pitch is in the ahead
position.
S0600-AA-PRO-120
Figure 12-2. Top View of Clockwise Rotating Blade.
NOTE
The pressure face and suction
face are reversed when the
blade pitch is in the astern position.
Leading Edge. The blade edge adjacent to
the forward end of the propeller hub when the
blade pitch is in the ahead position.
Trailing Edge. The blade edge adjacent to
the aft end of the propeller hub when the blade
pitch is in the ahead position.
Blade Tip. The blade edge on the outermost
radius of the propeller.
Blade Palm. As shown in Figure 12-3.
Blade Port. Recessed area of hub where the

propeller blade mates to the hub.
Emitter Holes. Holes drilled into a channel
near the leading edge of the blade that distribute the prairie air.
Dowel Pins. Pins between the blade port and
the blade palm that transmit rotational torque
of the hub to the propeller blades and locate
the propeller blade in the blade port.
Hydrolube. A heavier than water hydraulic
fluid used to dewater the blade bolt holes.
Prairie Air Nipple. Nipple that connects the
prairie air tube located in the hub to the prairie
air system located in the blade palm.
12-3
S0600-AA-PRO-120
Figure 12-3. Blade Palm.
Morgrip Bolts. Bolts used to secure blades to

the hub on FFG 7, DD 963, DD 993 and CG
47 Class ships. These bolts are hydraulically
elongated during installation and removal.
After they are installed, the bolts retain a residual stretch that provides a clamping force to
hold the blades on the hub.
12-4
Hex Socket Bolts. Bolts used to secure

blades to the hub on DDG 51 "Fleet" type
blades, and CG 47 Class ships with hull numbers CG 66 and higher. These bolts are
hydraulically torqued in place during installation. The torquing process provides the clamping force to hold the blades on the hub.
S0600-AA-PRO-120
SECTION 2 FFG 7 BLADE REMOVAL, RETRIEVAL, AND

REPLACEMENT PROCEDURE
12-2.1 REQUIREMENTS.
12-2.2 PROCEDURE SYNOPSIS.
Commands that perform propeller blade

replacements must consider all requirements.
If shop facilities are not available at the Command with the overall tasking, the Command
must arrange for them. A successful blade set
change requires one week. Provision must be
made for breasting the ship out by the stern so
the blades can be lifted between the ship and
the pier. Crane service, floating or pierside,
must be available for propeller blade lifting
and must have the required reach and angle
to handle the propeller blades. An oil boom is
required for oil abatement and containment in
accordance with local instructions. Also, the
following references provide specific information relevant to removing and replacing CPP
blades:
12-2.2.1 Rig the ships hull with two belly

bands near the projection line and install
hoists onto the belly bands at the keel.
a. NAVSEA 0941-LP-053-7010, FFG 7

CP Propeller and Propulsion Shafting
System.
b. S9086-00-STM-000, Naval Ships'
Technical Manual (NSTM), Chapter
245, Propellers.
c. NAVSEA Best Management Practices
(BMP) to Prevent/Mitigate Oil Spills
Related to Waterborne Removal(s) of
Blades on Variable Pitch Propellers for
Naval Vessels.
d. MIL-STD-2035(SH) 04 July 1991, Nondestructive Testing Criteria.
e. NAVSEA T9074-AS-GIB-010/271, 30
April 1997, NAVSEA Technical Publication, Requirements for Nondestructive Testing Methods (referred to as
NAVSEA Technical Publication 271).
12-2.2.2 Prepare each blade for removal by

rotating the blade into the 12 oclock position
and removing the Morgrip bolts connecting the
blade palm to the hub.
12-2.2.3 Remove each blade from the 12
oclock position by rigging the blade with a
three-point lifting assembly; relieving dowel
pin binding until the blade clears the hub; and
retrieving the blade to the surface.
12-2.2.4 Install each replacement blade by
rigging the blade with the three-point lifting
assembly; lowering the blade into position;
seating the blade onto the hub; connecting the
blade palm to the hub with four temporary
bolts; and removing the three-point lifting
assembly for return to the surface.
12-2.2.5 Secure each blade to the hub by:
dewatering the open blade bolt holes; installing Morgrip bolts into the four open blade bolt
holes; removing the temporary bolts; dewatering the remaining bolt holes; installing the
remaining four Morgrip bolts; measuring
installed bolt lengths to determine proper
residual stretch; dewatering installed Morgrip
bolts; and capping the bolts.
NOTE
While the following procedure
requires that the topside personnel and the divers work
closely together, certain steps
must be carried out by particular personnel. To clarify these
steps, abbreviations are placed
12-5
S0600-AA-PRO-120
at the beginning of each step

where the specific party needs
to be identified: (DV) represents diver, (TOP) represents
topside personnel, and (SF)
represents Ships Force personnel and (UT) represents
Level II Ultrasonic Inspector.
12-2.3 PREPARATION.
12-2.3.1 Ships List and Trim. Ensure that
the ship has no more than one degree of list
and minimum possible trim during the actual
blade removal. Excessive list or trim will
adversely impact insertion of replacement
blades into the propeller hub port.
CAUTION
log sheet is prepared and maintained during all UWSH operations.
12-2.3.2 Inventory Tools, Materials and
Equipment. NAVSEA 00C5 maintains a CPP
blade change kit that contains most of the
tools and equipment necessary to replace
CPP blades. This blade change kit should be
obtained and positioned on site before beginning the task. An inventory of the items in this
kit is available from NAVSEA 00C5. Table 12-1
identifies additional items that must be provided by the repair activity. Ensure the availability of all technical information, manuals,
and drawings.
12-6
12-2.3.3 Prepare Quality Assurance (QA)

Package. Prepare QA forms in accordance
with Table 12-2.
12-2.3.4 Review Bolt Elongation Measurement Procedure and Equipment. It is very
important that both the divers and the NDT
inspection personnel study and understand all
aspects of bolt elongation measurement as
detailed in Appendix A. Review of the tutorial
discussion provided in Appendix A first will
provide a good general understanding of the
responsibilities for the divers and NDT inspectors. See Appendix J for NAVSEA NDT equipment details.
12-2.4 SPECIAL TOOLS AND EQUIPMENT.
Removal and replacement of the CPP blade
requires some special tools and equipment.
The find numbers (FN) in the following paragraphs correspond to the find numbers in the
NAVSEA CPP Blade Change Kit, the inventory
for this kit is available from NAVSEA 00C5.
The quantities of items contained in the CPP
Kit are the minimum recommended to be on
hand prior to CPP blade removal and replacement. Their functions are described in the following paragraphs.
12-2.4.1 Intensifier. The intensifier assembly
(FN 37) pressurizes hydraulic fluid that is used
to install and remove Morgrip bolts and
hydraulic temporary bolts. Low pressure (LP)
air is the power source for the intensifier. The
intensifier is connected with a high pressure
(HP) flexible tube to the Morgrip bolt power
head tool and with a quick-connect hydraulic
hose to the hydraulic temporary bolts (see
Appendix C)
12-2.4.2 Morgrip Bolt Power Head Tool with
Bullets. The Morgrip bolt power head tool
assembly (FN 38) is used to remove and
install Morgrip bolts. This is accomplished by
inserting the bullet rod into the Morgrip bolt;
attaching the power head onto the bolt with a
spanner wrench; connecting the power head
to the intensifier with the HP tube; and pressurizing the hydraulic fluid in the power head
S0600-AA-PRO-120
CAUTION

(see figure 12-3A).
issued with NAVSEA SUPSALV Underwater Ship Husbandry equipment kits have
been checked for chain twist
and the chain hoist/fall has
been loosely two-blocked so
that the running block can not
flip over into the working chain
loops during shipment.
ning chain sprocket (chain

chain during installation.
1- To n
OPERATORS must ensure

that the running block is not
flipped over into the chain loops
creating chain twist while
deploying and rigging the chain
hoists/falls.
Typical
R unning
B lock
Flip
3 To n

chain loop:
lengths running from the working chain sprocket to the run-
4- To n
6 Ton
Fig. 12-3A Tugit Lever Hoists (Harrington PullChain Type have a two part Reeve)
Change 1
12-6A
S0600-AA-PRO-120
12-6B
Change 1
S0600-AA-PRO-120
.
Table 12-1. Material To Be Provided by the Repair Activity.
Item No.
Quantity
Component Description
Transfer Line, 5/8 x 100
Commercial
Diver Tool Bag
Commercial
Gallon of Hydraulic Fluid
Tellus #15, Code 65203 (Shell Oil

Company) or equal
Bag of Assorted Shop Rags
Commercial
as required
Timbers, 4 x 4 x 4 (to set blades upright)
Commercial
Combination Wrench, 1/2
Commercial
Screwdriver, Flat Blade
Commercial
as required
Scotch-Brite Abrasive Pads
Commercial
as required
Grease Pencils
Commercial
10
Tape Measure 8 Minimum
Commercial
11
as required
Chafing Material
Commercial
12
Degreaser/Carburetor Cleaner
Commercial
which forces the bullet rod into the bolt, thus

stretching the bolt.
12-2.4.3 Bullet Rod Removal Tool. The
bullet rod is removed from the Morgrip bolt
with the bullet rod removal tool (FN 38.4).
12-2.4.4 Morgrip Bolt. Morgrip bolts (FN 2)
are used to secure the propeller blade to the
hub. The Morgrip bolt contains a bored cavity
that enables the bolt to be stretched during
installation. After they are installed, the bolts
retain a residual stretch that provides a clamping force to hold the blades on the hub.
12-2.4.5 Blade Bolt Cap Wrench.
The
blade bolt cap is threaded onto the head of the
Morgrip bolt using the blade bolt cap wrench
(FN 5). (See Appendix D).
12-2.4.6 Hydraulic Temporary Bolts.
Hydraulic temporary bolts (FN 9) have two
quick-connect nipples so that pressurized
hydraulic fluid is directly connected from the
bolts to the intensifier via a quick-connect
hose assembly. Hydraulic temporary bolts
contain a hydraulic chamber. Pressurized
Technical Specification
hydraulic fluid in the chamber pushes the jacking body of the bolt down onto the blade palm.
Simultaneously, the threaded portion of the
bolt in the Morgrip bolt hole is pulled toward
the blade palm. This tension provides a tight
fit. Hydraulic temporary bolts can be connected in series with short quick-connect
hoses so that several bolts can be pressurized
at the same time (see Appendix E).
12-2.4.7 Lifting Assembly. The
lifting
assembly (FN 152) is attached to a propeller
blade so the blade can be lifted and lowered
with the hook of a lever hoist (see Appendix
F).
12-2.4.8 Righting Fixture. The righting fixture (FN 151) is installed onto the propeller
blade and connected to the pier crane hook.
The righting fixture is used to lift the propeller
blade out of its shipping container and to stand
the blade on its palm on wood timbers,
enabling the blade to be outfitted with the lifting assembly (see Appendix G).
12-2.4.9 Modified Channel Lock Pliers. The
rounded head of the channel lock pliers (FN
12-7
S0600-AA-PRO-120
Table 12-2. FFG 7 Quality Assurance Points.

Blade Removal
1.
Ensure pitch is set at 110% full ahead [12-2.6.2].
2.
Inspect removed blade bolt caps and plugs for damage [12-2.7.5].
3.
Check Mapeco power head rupture disc torque at 100 ft.-lbs. [note prior to 12-2.8.2].
4.
Remove blade bolts in the order: 2, 6, 3, 7, 1, 5, 4, 8 [Note prior to 12-2.8.3].
5.
Clean blade bolts IAW Appendix A, [A-5.3.1], and conduct liquid penetrant inspection of
removed blade bolts [12-2.8.27].
6.
Ensure lifting fixture is installed with head clamp 64 inches from blade tip [12-2.9.11].
7.
Check forward lever hoist centered with respect to keel and the forward shackle in the head
clamp [12-2.9.16].
8.
Measure blade palm spacing to relieve binding (if required) [12-2.9.24].
9.
Benchmark the shaft [12-2.9.29].
Blade Installation
1.
Inspect blade port and blade [12-2.10].
2.
Ensure edge guard material is used for lifting fixture clamps [12-2.11.5].
3.
Check prairie air nipple fully inserted [12-2.11.8].
4.
Check dowel pins fully inserted [12-2.11.9].
5.
Ensure O-ring installed in blade port cover [12-2.11.13].
6.
7.
Check for cover plate O-ring washout [Caution prior to 12-2.11.32].
8.
Check blade seating with 0.002-inch feeler gauge [12-2.11.51].
9.
Record serial numbers and initial lengths of blade bolts to be installed. Use Inspection
Report and Work Sheet, Figure A-3, Appendix A [12-2.12.1 and 12-2.12.3].
10. Apply thread lubricant to blade bolt shoulder and threads [12-2.12.15].
11. Dewater the blade bolt holes with Hydrolube [12-2.12.17].
12. Record final length and residual stretch when all eight bolts are installed. Residual stretch
must be between 0.006 and 0.0084 inches. Use Inspection Report and Work Sheet Figure
A-3 [12-2.13.1 and 12-2.13.2].
13. Ensure blade bolt cap seal is installed on blade bolt [12-2.14.5].
14. Torque blade bolt caps to 170 ft.-lbs. [12-2.14.7]
15. Dewater Morgrip bolt with Hydrolube [12-2.14.8].
16. Ensure blade bolt cap plugs are installed [12-2.14.9].
17. Test the CPP system performance [12-2.15].
12-8
Initials
Initials
S0600-AA-PRO-120
12) is ground off to a flat surface approximately -inch thick to allow for better access
to the Morgrip bolt Nylok pellet hole as
described in the note following step 12-2.14.2.
12-2.4.10 Spanner Wrench. The spanner
wrench (FN 23) is used to tighten or loosen
the Morgrip blade bolts, attached to the power
head assembly, into or out of the blade palm.
12-2.4.11 Dowel Pin Removal Tool. The
dowel pin removal tool (FN 13) is used to
remove stuck dowel pins that cannot be
removed by hand.
12-2.4.12 Blade Guide Pins.
The blade
guide pins (FN 14) are used to align the dowel
pins with the blade palm at installation.
12-2.4.13 Bolt Elongation Measurement
Tool. The bolt elongation measurement tool
(FN 43) is a transducer assembly and ultrasonic instrument specially designed to measure the elongation of the Morgrip bolts. The
tutorial in Appendix A allows any Intermediate
Maintenance Activity (IMA) Level II Ultrasonic
Testing (UT) inspector to perform measurements with this equipment.
12-2.4.14 Hydrolube. A heavier than water
hydraulic fluid used to dewater the blade bolt
holes.
12-2.5 RIG SHIPS HULL.
Rig the ships hull with forward and aft belly
bands and two 3-ton hoists in accordance with
Figure 12-4 and the following procedure.
12-2.5.1 Rig Forward Belly Band. (TOP)
Attach a line to one end of the belly band (FN
157). Lower the line from the ships outboard
aft deck to the diver.
12-2.5.2 (DV, TOP) Swim the line under the
ships hull to the inboard side and pass the bitter end of the line to topside personnel.
12-2.5.3 (TOP) With the belly band passing

around the hull of the ship, bring both ends of
the belly band together on the aft deck.
12-2.5.4 (TOP) Join both ends of the belly
band with a 6-ton lever hoist (FN 156).
12-2.5.5 (TOP, DV) Working together, initially
position the forward belly band as indicated in
Figure 12-4. Final adjustment will be made
later.
12-2.5.6 (TOP) Place a 12-inch half section of
6-inch diameter pipe (FN 159) under the belly
band at the starboard and port locations
where the belly band leaves the ships deck.
Place each half section of pipe perpendicular
to the belly band with circular side up. This will
prevent chafing of the belly band cable caused
by the edges of the deck when the weight of
the blade is applied.
12-2.5.7 (TOP) Run both 3-ton lever hoists
(10 and 30 foot throw) (FN 153 and FN 154) to
the "two blocked" position in order to confirm
the chain is not twisted.
12-2.5.8 (TOP, DV) Install a 1-inch safety
shackle (FN 161) on the belly band at the
main deck. Attach a 3-ton lever hoist (10 ft.
throw forward, 30 ft. throw aft) and an easing
out line to the shackle. Lower the lever hoist to
the keel along the belly band.
12-2.5.9 (TOP) Tighten the 6-ton lever hoist
joining both ends of the belly band.
12-2.5.10 Rig Aft Belly Band. (TOP, DV) Rig
the aft belly band 30 inches aft of the forward
belly band by repeating steps 12-2.5.1 through
12-2.5.9. To prevent hazardous inboard
movement of the aft keel shackle during yard
and stay of the blade to the surface, install a
preventer wire rope pendant (FN 158) from
the keel shackle along the 7/8 belly band in
the direction away from the pier to the main
12-9
S0600-AA-PRO-120
Figure 12-4. Ships Hull Rigging.
12-10
S0600-AA-PRO-120
deck. Ensure the wire rope preventer is

cinched tight at the main deck connection.
12-2.7 REMOVE MORGRIP BLADE BOLT

CAPS.
WARNING
12-2.7.1 (DV) Remove the caps from all eight

Morgrip blade bolts in any order in accordance
with steps 12-2.7.2 through 12-2.7.4.

will be rotating.
12-2.6 ROTATE BLADE TO BE REMOVED
INTO THE 12 O'CLOCK POSITION.
12-2.6.1 (SF) Rotate the shaft as directed by
the diver to bring the blade to the 12 oclock
position.
12-2.6.2 (DV, SF) Ensure blade pitch is in the
110% full ahead position. Benchmarks for
pitch alignment are located adjacent to blade
#1. Danger-tag the pitch controls in the locked
position.
12-2.6.3 (SF) Danger tag the shaft in the
locked position.
CAUTION

c. of section 12-2.1, Requirements.
NOTE
Morgrip blade bolt caps should
be installed at 170 ft.-lbs. (the
in sta lla tion tor que re quir ement) but they may be overtorqued and require a hydraulic
wrench to remove.
12-2.7.2 (DV) Remove the 1/8-27 NPTF pipe
plugs in the blade bolt caps using a 3/16-inch
Allen wrench (FN 7.1). Retain caps and plugs
for reinstallation.
12-2.7.3 (DV) Place the blade bolt cap
wrench (FN 5) in the blade bolt cap spanner
holes and tighten into the pipe plug hole.
NOTE
In some cases, the blade bolt
cap plugs are improperly
installed and cannot be
removed. If this occurs, the
blade bolt cap wrench may be
modified (by removing items 1,
2, 3, and 4 from drawing in
Appendix D) so that the wrench
will set on top of the blade bolt
cap and engage the locking pin
holes in the cap. Exercise care
when using the tool in this manner, because the blade bolt cap
wrench is not positively
secured on the blade bolt cap.
12-2.7.4 (DV) Using a breaker bar (FN 6.1)
and 1 1/8-inch socket (FN 6.2) attached to the
blade bolt cap wrench, remove the cap from
the blade bolt.
12-11
S0600-AA-PRO-120
12-2.7.5 (DV, TOP) Pass the blade bolt caps,

the blade bolt cap plugs, the blade bolt cap
wrench, the breaker bar, the 1 1/8-inch socket,
and the 3/16-inch Allen wrench topside.
Inspect caps and plugs for damage (nicks,
deformity, thread damage, improper fit of cap
plugs). The blade bolt caps and the blade bolt
cap plugs should be reused if not damaged.
12-2.8 REMOVE MORGRIP BLADE BOLTS.
12-2.8.1 (TOP) Set up the intensifier for
Mapeco power head pressurization in accordance with the instructions provided in Appendix C.
NOTE
The Mapeco power head is
equipped with a pressure rupture disc to ensure that the
power head is not pressurized
above 40,000 psi. It is important that the rupture disc holddown nut (see drawing that
accompanies the power head)
be torqued to 100 ft.-lbs. before
using the power head. The
torque has been checked on
the power heads delivered with
the NAVSEA kit.
12-2.8.4 (DV) Open the power head stop

valve one half turn to prevent hydraulic lock.
WARNING

Record each power head pressurization in the log book provided.
12-2.8.5 (DV) Thread the power head onto
the bolt head and seat firmly using the spanner wrench. Count the number of turns as the
power head screws on. Seven to eight turns
should seat the power head. Figure 12-6
shows the power head/Morgrip bolt assembly.
12-2.8.6 (DV) Back the power head off from
the bolt head to 1 turn and retighten by
hand to ensure that false bottoming has not
occurred since the bolt head flange and the
power head interface are not visible on the
installed bolt. Seat the power head firmly
using the spanner wrench.
12-2.8.2 (TOP) Pass the Mapeco power head

tool (FN 38.1), bullet rod (FN 38.5), spanner
wrench (FN 23), and 5/8-inch open end
wrench (FN 24) to the divers.
12-2.8.7 (DV) Close the power head stop

valve, then open it no more than to turn.
NOTE
The HP tube end fitting is a

special design for extremely
high pressures. As illustrated in
Figure 12-6, an internally
threaded ferrule must be positioned on the threaded end of
the fitting so that 2 to 3 threads
are exposed at the end of the
fitting before the hose is
inserted into the power head
connection port. The ferrule
position must be checked prior
to each connection of the hose.
Remove Morgrip blade bolts in

the following order: 2, 6, 3, 7, 1,
5, 4, 8. Figure 12-5 shows the
blade bolt numbering on the
blade palm. Bolt hole numbers
are stamped on the top of the
blade palm next to the respective hole.
12-2.8.3 (DV) Insert the bullet rod, cone end
first, into the blade bolt.
12-12
NOTE
S0600-AA-PRO-120
Figure 12-5 Blade Bolt Numbering
12-2.8.8 (DV) Remove the sealing plug from

the most accessible power head connection
port and connect the HP tube from the surface, as shown in Figure 12-6. Inform topside
when ready to purge the HP tube.
12-2.8.9 (TOP, DV) Start and operate the
intensifier pump by opening the air supply
valve until a steady stream of hydraulic fluid
(no air) bleeds from the loosened connection
opposite the HP tube in the power head. Fill
the intensifier reservoir with hydraulic fluid as
the tank level drops. Tighten the bleeding con-
nection with the 5/8-inch wrench to seat firmly

(DO NOT OVERTIGHTEN).
WARNING
the power head.
12-13
S0600-AA-PRO-120
Figure 12-6. Power Head/Morgrip Bolt Assembly.
12-14
S0600-AA-PRO-120
12-2.8.10 (DV) Swim clear of the power head

and inform topside that the HP tube is purged
and connected securely.
failed the tire must be replaced. Reassemble

the power head, test in accordance with the
drawing, and return to step 12-2.8.1.
12-2.8.18 (DV) When a blade bolt has been
loosened, close the power head stop valve to
isolate the pressure in the power head from
the pressure in the HP tube.
CAUTION
power head or intensifier.
12-2.8.11 (TOP) Increase the intensifier pressure to 35,000 psi by slowly opening the air
supply valve. Secure the air supply valve
when pressure is reached.
12-2.8.19 (TOP) Depressurize the intensifier

and the HP tube by slowly opening the
hydraulic bypass valve on the intensifier.
Inform the divers that the intensifier and HP
tube have been depressurized.
WARNING
12-2.8.12 (TOP) Notify

35,000 psi is reached.
the
divers
when
12-2.8.13 (DV) Apply the spanner wrench to

the power head and attempt to loosen the
pressurized blade bolt. If the bolt loosens, proceed to step 12-2.8.18.
12-2.8.14 (DV, TOP) If the bolt does not
come loose, increase the pressure in 500-psi
increments and try again. Do not exceed
37,500 psi.
12-2.8.15 (DV, TOP) If the attempt to remove
the first bolt is unsuccessful, bleed pressure at
the intensifier, check connections, and repressurize for another attempt. Cycling the power
head through several pressurization cycles
may loosen the bolt.
12-2.8.16 (DV, TOP) If the removal of any
remaining bolt becomes difficult, install a
hydraulic temporary bolt in accordance with
steps 12-2.9.1 through 12-2.9.8 next to the
problem bolt and repeat the removal attempt.
12-2.8.17 (TOP) If no bolts can be loosened
at 37,500 psi, on-deck personnel must disassemble, inspect, and clean all component
parts of the power head in accordance with
the drawing provided with the power head to
ensure their proper function. If the internal
pressure tire seal to the valve stem has
High pressure oil jets can penetrate the ski n. Di ver s must
HP tube.
12-2.8.20 (DV) Disconnect the HP tube from
the power head. Reinstall the sealing plug into
the exposed tubing connection fitting.
12-2.8.21 (DV) Remove the blade bolt and
attached power head assembly from the
blade. Lift the entire assembly to the surface in
a diver tool bag. Do not loosen the power
head stop valve underwater.
WARNING
High pressure oil jets can penetrate the skin. Ensure that topside personnel are clear of the
valve opening when depressurizing the power head.
12-2.8.22 (TOP) Remove one of the sealing
plugs from a pressure connection port. Direct
the orifice of the power head stop valve away
from personnel into a proper waste oil con-
12-15
S0600-AA-PRO-120
tainer. Open the power head stop valve to

depressurize the power head.
12-2.8.23 (TOP) Remove the bolt from the
depressurized power head using the spanner
wrench and strap wrench (FN 25). Sheet rubber wrapped around the shank of the bolt facilitates a better grip with the strap wrench.
12-2.8.24 (TOP) Remove the bullet rod from
the bolt. A special removal tool (part of FN
38.4) is provided if suction makes bullet rod
removal difficult.
12-2.8.25 Repeat steps 12-2.8.2 through
12-2.8.24 for the remaining blade bolts.
the two shackles joining the leg assemblies

(both sides) to the trailing edge clamp. Lower
the trailing edge clamp to the divers.
12-2.9.3 (TOP) Connect one 3/4-inch shackle
(FN 162) to the forward hole of the head
clamp.
to the aft hole of the head clamp.
12-2.9.5 (TOP) Connect the aft shackle on
the head clamp to the transfer line. Lower the
lifting assembly down the transfer line.
NOTE
12-2.8.26 (TOP) Remove the used Nylok pellet (see Figure 12-11) from each bolt. Use a
1/16-inch drill bit to center drill the pellet and
then stick a scribe into the hole to pry out the
pellet.
12-2.8.27 (TOP) Prior to use, all unthreaded,
polished, external bolt surfaces must be liquidpenetrant inspected in accordance with
NAVSEA Technical Publication 271. Group VII
(solvent-removable) and Group IV (waterwashable) fluorescent penetrant systems are
permitted for this application. Acceptance criteria shall be in accordance with MIL-STD2035A, paragraph 7.6. Surface blemishes or
scratches on the bolts polished surfaces may
be removed by rotating the bolt in a lathe while
polishing with a Scotch-Brite pad. Do NOT use
emery cloth or sand paper for polishing. All
polished bolts must be reinspected as detailed
above. The Morgrip blade bolts that pass inspection are to be reused with the replacement blades.
12-2.9 BLADE REMOVAL.
12-2.9.1 (TOP) Construct the lifting assembly
(FN 152) in accordance with Appendix F.
Ensure that the trailing edge clamp has the
FFG 7 delrin pads installed.
12-2.9.2 (TOP) Disconnect the trailing edge
clamp from the lifting assembly by removing
12-16
Change 1
Divers should mark each blade

for installation of the lifting
assembly in accordance with
step 12-2.9.8.
12-2.9.6 (DV) Connect the single hook of the
forward manual lever hoist to the 3/4-inch
shackle attached to the forward hole of the
head clamp.
12-2.9.7 (DV) Using the forward manual lever
hoist, rig the lifting assembly onto the blade.
One diver should be guiding the leading edge
clamp onto the blade while another operates
the lever hoist.
12-2.9.8 (DV) Ensure that the closest edge of
the head clamp to the tip of the blade is 64
inches from the tip of the blade. Position the
trailing edge clamp 18 inches up from the bottom of the blade edge. Measure along the
pressure face (see Appendix F)
NOTE
The 18 inch dimension for positioning the trailing edge clamp
provides a good starting point
to set the length of the turn
buckles. During tightening, the
clam ps may m ove approximately 1/2 to 1 inch.
S0600-AA-PRO-120
12-2.9.9 (DV) Attach the trailing edge clamp

to the shackles joining the legs of the lifting
assembly (both sides) as shown in Appendix
F.
12-2.9.10 Ensuring slack is in the forward
lever hoist, diver #1 maintains the head clamp
at the 64 inches mark on the blade. Diver #2
tightens the head clamp to trailing edge clamp
turnbuckles on the aft and forward faces until
snug at the 18 inch mark. This will assist in
keeping the head clamp from sliding along the
edge towards the leading edge. Diver #2 then
tightens the head clamp to leading edge
clamp turnbuckles until snug. Once this is
complete, diver #2 tightens the trailing edge
clamp to leading edge clamp turnbuckles on
the aft and forward faces until snug.
12-2.9.11 (DV) Recheck the location of the
head clamp relative to the tip of the blade.
12-2.9.12 (DV) Take a strain on the head
clamp with the forward lever hoist to seat the
leading and trailing edge clamps on the blade.
12-2.9.13 (DV) Slacken the forward lever
hoist and retighten the turnbuckles in the
same order as step 12-2.9.10.
12-2.9.14 (DV) Because the blade must be
lifted straight up to avoid binding, the vertical
hang of the forward lever hoist must be
checked against the actual blade position.
12-2.9.15 (DV) Check the center keel position
of the forward manual lever hoist. Adjust the
belly band shackle to the center of the 14inch-wide flat keel plate.
WARNING


will be rotating.
12-2.9.16 (DV, TOP) Remove the forward
lever hoist hook from the head clamp of the
lifting assembly and allow the hook to hang
plumb. Check to ensure that the hook is
directly above the forward shackle of the head
clamp. If the hook is not directly above and in
line with the forward shackle of the head
clamp, then rotate the shaft the required distance and direction to correct for port and starboard misalignment. Move the belly band to
correct for fore and aft misalignment. The belly
band will need to be slackened to move forward or aft as required. Time spent to correctly
position the belly band is usually paid back
and then some in time to remove the blade.
12-2.9.17 (DV) Reconnect the forward lever
hoist hook to the forward shackle of the head
clamp.
12-2.9.18 Lifting Blade. (DV)
Diver
#1
moves into position at the forward lever hoist.
Diver #2 moves to the blade palm/hub interface.
12-2.9.19 (DV) Diver #1 takes the slack out of
the forward lever hoist. Diver #2 places both
hands on the blade palm/hub in the vicinity of
bolt holes #1 and #4.
12-2.9.20 (DV) Diver #1 takes up on the forward lever hoist. At the same time, diver #2
reports movement of the blade palm (indicating that the blade palm made true upward
progress from the hub or that the trailing or
leading edge of the blade palm moved first).
12-2.9.21 (DV) Diver #1 continues taking up
on the forward lever hoist until diver #2 reports
no blade palm movement. Do not exceed a
12-17
S0600-AA-PRO-120
heavy strain (belly band 12-18 inches away

from the hull) with the lever hoist.
WARNING
Propeller blade edges are

sharp. Avoid injury while handling blades.
CAUTION
or other equipment.
CAUTION
and shaft are not damaged.
12-2.9.22 (DV) If diver #2 reports that the
blade palm initially moved but that the blade
palm is no longer moving, then diver #1 needs
to shake the blade tip VIGOROUSLY while
diver #2 reports any upward travel of the blade
palm. As long as steady upward progress is
made, continue with the shake and pull
approach.
12-2.9.23 (DV/TOP) If diver #2 reports that
the blade palm did not initially move or the
shake and pull approach is not moving the
blade palm, the dowel pins are binding and the
shaft must be rotated in an attempt to locate
the position where binding is relieved. This is a
trial and error process that may need to be
repeated several times to find the appropriate
position. If diver #2 reported that the blade
palm did not initially move, the direction of
shaft rotation must be selected arbitrarily.
12-18
12-2.9.24 (DV) If a good degree of upward

movement was encountered and ceased
before the blade became free, then divers are
required to measure the spacing between the
blade palm and propeller hub to assist in
determining the best direction to rotate the
shaft. Using a 1/16-inch increment steel ruler
(FN 15), record the distance between the hub
face and the shoulder recess of the blade bolt
hole as shown in Figure 12-7. These measurements need to be taken through bolt positions #1, #4, #5, and #8.
12-2.9.25 (DV, TOP) If the starboard side
measurements are greater than the port side,
then the starboard side of the hub may be
down so the shaft should be rotated to port. If
the port side measurements are greater, then
the shaft should be rotated to starboard. If
there is no clear difference between port and
starboard measurements, then arbitrarily
select the direction of rotation. Record and
keep all measurements for the duration of the
removal process in order to monitor progress.
WARNING

be warned when propeller will
be rotating.
12-2.9.26 (DV) Slack the forward lever hoist
hook from the head clamp and prepare with
Ships Force to rotate the shaft.
WARNING
S0600-AA-PRO-120
Figure 12-7. Morgrip Bolt Hole Measurements.

Ships Force personnel operating the jacking gear is required.
12-2.9.27 (SF) Rotate the shaft for a count of
one second (bump) in the desired direction.
12-2.9.28 (DV, TOP) Try again to lift the
blade. Again, the shaft rotation method of
relieving dowel pin binding is often trial and
error to find the right position, so adjustments
may need to be repeated.
12-2.9.29 Benchmark the Shaft. (SF) Once
the first successful blade removal shaft rota-
tion position is found inside the ship, within

communication range of the jacking operator,
benchmark the position on the shaft and a location that does not rotate with the shaft. Then
measure the shaft circumference and mark
five equally spaced marks on the shaft to identify the other blade removal locations. Label
each mark with corresponding blade number.
12-2.9.30 Retrieve Blade to Surface. (DV)
Note the location of the dowel pins and the
prairie air nipple (in the hub or blade palm).
Report the locations topside.
12-2.9.31 (DV) Connect the hook of the aft
lever hoist to the aft 3/4-inch shackle of the
head clamp.
12-19
S0600-AA-PRO-120
12-2.9.32 (DV) Yard and stay the blade aft

until the blade palm has cleared the propeller
hub.
12-2.9.33 (DV) Remove the dowel pins and
the prairie air nipple from either the hub or the
blade palm and send them topside. A special
dowel pin removal tool (FN 13) is available for
use on dowel pins that are hard to remove.
12-2.9.34 (DV) Continue the yard and stay
process until the full weight of the blade is
taken by the aft hoist.
12-2.9.35 (DV) Disconnect the forward lever
hoist hook from the forward 3/4-inch shackle
on the head clamp. Lower the blade to just
below the hub with the aft lever hoist.
12-2.9.36 (TOP, DV) Install a pendant onto
the pier crane. Connect the crane pendant to
the same shackle of the head clamp that the
aft lever hoist is attached. Use an additional
shackle to attach if required. This will help prevent rotation of the blade during the yard and
stay to the crane.
12-2.9.37 (DV, TOP) Take the slack out of the
crane. Check all shackle arrangements for
binding. Yard and stay the blade until the full
weight of the blade is taken by the pier crane.
When the pier crane has the full weight of the
blade, disconnect the aft lever hoist. Raise the
blade to the pier.
12-2.9.38 (TOP) Set the blade upright onto
two 4 by 4 timbers on the pier.
2.9.38) as they are removed,

topside personnel will have
plenty of time to shift removed
blades to the special shipping
pallets as new blades are
removed from the shipping pallets for installation.
12-2.9.41 (TOP) Later, after the new blade
has been prepared and removed from its special container, install the righting fixture (FN
151) onto the old blade. Install the shackles
and wire rope pendants onto the righting fixture as shown in Figure 12-8.
12-2.9.42 (TOP) Flip the blade into a horizontal position using a two-part lift.
12-2.9.43 (TOP) Position it onto the special
shipping pallet the new blades were sent on.
12-2.10 BLADE PORT AND BLADE
INSPECTION AND PREPARATION.
12-2.10.1 (DV/SF) For each empty hub blade
port, clean and inspect the cover plate, dowel
pin holes, prairie air nipple orifice, center post
sleeve, and O-ring groove. Figure 12-9 details
the hub blade port inspections. Scotch-Brite
greenie pads work well for cleaning.
12-2.10.2 (TOP) Inspect the bottom of the
replacement blade, clean it if necessary, and
remove the plug from the prairie air nipple orifice. Leave the protective shrink wrap on the
blades until installation is complete.

clamp from the assembly by removing the two
shackles joining the leg assemblies (both
sides) to the trailing edge clamp.
12-2.10.3 (TOP) Inspect and clean the previously removed dowel pins and prairie air nipple with an emery cloth (FN 29). Dowel pins
must not be mushroomed or peened at either
end.
12-2.9.40 (TOP) Remove the lifting assembly

from the blade.
CAUTION
NOTE

used for all installations.
If all five removed blades are

set within reach of the crane
upright on timbers (step 1212-20
12-2.10.4 (TOP) Lubricate the four new prairie air nipple O-rings (FN 16.2) with silicone
S0600-AA-PRO-120
Figure 12-8. Righting Fixture.
12-21
S0600-AA-PRO-120
Figure 12-9. Blade Port Inspection Details.
12-22
S0600-AA-PRO-120
grease (FN 17). Install the four O-rings onto

the prairie air nipple.
12-2.10.5 (TOP) Lightly coat the two dowel
pins with oil. Confirm that both ends of each
dowel pin will fit in both blade palm holes.
12-2.10.6 (TOP) Inspect the two threaded
plug holes in the blade palm. As required,
install a blade palm plug (FN 18) into each
vacant plug hole using a 3/4-inch Allen wrench
(FN 18.1).
12-2.11 BLADE INSTALLATION.
12-2.11.5 (TOP) Install the three-point lifting

assembly onto the blade as shown in Appendix F. Ensure that the head clamp is 64 inches
from the tip of the blade. Position the trailing
edge clamp 18 inches up from the bottom of
the blade edge. Measure along the pressure
face. If edge guards are removed from new
blades, cut a piece of metal edge guard and
rubber material to insert between the clamps
and the blade for protection. Cover any
exposed sharp edge of the edge guard piece
with tape to protect the diver.
12-2.11.6 (TOP) Take a strain on the head
clamp with the crane chain fall to seat the
WARNING
12-2.11.7 (TOP) Slack the crane and retighten the turnbuckles.
will be rotating.
12-2.11.1 (DV, SF) Rotate the propeller hub
blade port targeted for installation into the 12
oclock position. Align the bench mark made
during the removal process to ease installation.
12-2.11.2 (TOP) Send the dowel pins (FN
19), prairie air nipple (FN 16.1), two tapered
blade guide pins (FN 14.2) and blade guide
pin turning bar (FN 14.1) down to the divers.
12-2.11.3 (TOP) Using the righting fixture,
stand the replacement blade to be installed
upright on the blade palm resting on two 4" x
4" wood timbers.
12-2.11.4 (TOP) Remove the righting fixture
from the blade.
12-2.11.8 (DV) Install the prairie air nipple

into the prairie air nipple orifice in the hub until
it is fully seated. A mallet may be required to
fully seat the double O-ring seal. When fully
seated, the nipple should extend 4 1/2 inches
out from the center post.
12-2.11.9 (DV) Press the dowel pins into the
dowel pin holes by hand until fully seated.
Measure to ensure that the dowel pins stick
out of the hub no more than 3 3/8 inches.
NOTE
Dowel pins are extremely tight
fitting and often present difficulty seating in water because
of the small hydraulic relief.
Care and continuous steady
pressure should be applied.
12-2.11.10 (DV) Install the blade guide pins
into bolt holes #2 and #6 of the blade port.
CAUTION
12-23
S0600-AA-PRO-120
12-2.11.11 (TOP) Send the blade port cover

plate O-ring (FN 20) and the heavy grease
(FN 21) to the divers.
12-2.11.12 (DV) Partially fill the O-ring groove
in the cover plate with heavy grease. The Oring groove is indicated in Figure 12-9.
NOTE
Do not overfill the O-ring
groove. Excess grease can
lead to seating problems.
12-2.11.13 (DV) Install the O-ring firmly into
the cover plate groove. Remove excess
grease.
12-2.11.14 (TOP) Connect the pier crane to
the forward 3/4-inch shackle of the head
clamp.
12-2.11.15 (TOP) Using the crane, lower the
rigged blade to 10-15 feet below the water surface adjacent to the aft belly band.
12-2.11.16 (DV) Attach the aft lever hoist to
the aft shackle on the head clamp.
12-2.11.17 (DV) Yard and stay the blade until
the full weight of the blade is taken by the aft
lever hoist.
12-2.11.18 (DV, TOP) Slack the crane and
unhook it from the forward shackle of the head
clamp.
12-2.11.19 (DV) Attach the forward lever
clamp and take the slack out of the forward
lever hoist.
12-2.11.20 (DV) Check the shackle/hook
arrangement on the forward end of the head
clamp to ensure that it does not bind on the
forward corner of the head clamp.
12-2.11.21 (DV) With diver #1 operating the
forward lever hoist and diver #2 operating the
aft lever hoist, yard and stay the blade forward
12-24
until the blade palm is approximately 2 inches

aft of the propeller hub.
12-2.11.22 (DV) Inspect the dowel pins, prairie air nipple, guide pins, and the cover plate
O-ring for proper installation. Using diver
pneumo, dewater the dowel pin holes in the
blade palm to make penetration of the dowel
pins easier.
12-2.11.23 (DV) Position the blade fully over
the propeller blade port. Ensure that the guide
pins in bolt holes #2 and #6 align with the corresponding bolt holes in the blade palm.
12-2.11.24 (DV) Detach the aft lever hoist.
WARNING

will be rotating.
CAUTION
is rotated.
12-2.11.25 (DV, TOP) Check to ensure that
the blade is fully over the propeller blade port
and that the guide pins in bolt holes #2 and #6
align with the corresponding bolt holes in the
blade palm. If the diver reports that the blade
port is not aligned with the suspended blade,
then coordinate with Ships Force and rotate
S0600-AA-PRO-120
the shaft the required distance and direction

until the proper position is achieved.
12-2.11.26 (DV) Diver #1 moves into position
for operating the forward lever hoist, and diver
#2 moves into position at the blade port to
report the progress of the installation.
12-2.11.27 (DV) Slowly lower the blade with
the forward lever hoist onto the guide pins until
the blade palm is approximately 1 inch above
the top of the dowel pins.
WARNING

will be rotating.
CAUTION
is rotated.
12-2.11.28 (DV) Visually check the O-ring
placement. Ensure that the top of each dowel
pin is the same distance from the blade palm.
If not, then rotate the shaft to balance the distance.
Using a 1/16-inch increment steel ruler, record

the distance between the hub face and the
shoulder recess of the blade bolt hole as
shown in Figure 12-7. These measurements
need to be taken through bolt positions #1, #4,
#5, and #8.
12-2.11.30 (DV, TOP) If the blade palm and
hub are not aligned, then from the measurements determine the direction for rotating the
shaft. If the starboard side measurements are
greater than the port side, the starboard side
of the hub is down and the shaft should be
rotated to port. If the port side measurements
are greater, the shaft should be rotated to starboard. Record and keep all measurements for
the duration of the installation process in order
to monitor progress.
WARNING

and hub.
12-2.11.31 (DV) Diver #1 lowers the blade by
letting out on the forward lever hoist until diver
#2 reports no downward movement.
CAUTION
causing O-ring washout.
WARNING
12-2.11.29 (DV) If poor visibility makes the

visual dowel pin check (detailed in the previous step) impossible, ensure that the blade
palm and hub are aligned by measuring the
spacing between the blade palm and the hub.

12-25
S0600-AA-PRO-120
12-2.11.32 (DV) When downward progress

has ceased, slack the forward lever hoist to a
light strain and have both divers commence
shaking the blade VIGOROUSLY at the tip.
12-2.11.33 (DV) If downward movement is
encountered, diver #2 continues shaking the
blade, while diver #1 slowly lets down on the
forward lever hoist.
12-2.11.34 (DV) To establish if progress is
being made, divers must measure the spacing
between the blade palm and the hub. Using
the 1/16-inch increment steel ruler, record the
distance between the hub face and the shoulder recess of the blade bolt hole as shown in
Figure 12-7. These measurements need to be
taken through bolt positions #1, #4, #5, and
#8.
12-2.11.35 (DV, TOP) If no downward movement can be achieved by shaking the blade,
then from the measurements determine the
best direction for rotating the shaft. If the starboard side measurements are greater than the
port side, the starboard side of the hub may be
the port side measurements are greater, the
shaft should be rotated to starboard. If there is
no clear difference between port and starboard measurements, arbitrarily select the
direction of rotation. Record and keep all measurements for the duration of the installation
process in order to monitor progress.
12-2.11.36 (DV) Lift the blade until both dowel
pins are disengaged from the blade.
WARNING

blades.
12-2.11.37 (SF) Rotate the shaft in the direction determined in step 12-2.11.35 until the
12-26
measurements are equal on the port and starboard sides.

12-2.11.38 (DV, TOP) Repeat steps 122.11.31 through 12-2.11.37 until the blade is
fully seated.
12-2.11.39 Examine Morgrip Bolt Holes.
(DV) Examine the blade bolt holes to see if the
cover plate O-ring is visible, that is, washed
out of the O-ring groove.
12-2.11.40 (DV) If the O-ring is visible, then
the blade must be removed clear of the hub
and reinstalled after the O-ring is replaced.
12-2.11.41 Install Hydraulic Temporary
Bolts. Temporary bolts are used to secure
the blades onto the hub until the Morgrip bolts
are installed. This is necessary to ensure the
blade is properly seated.
12-2.11.42 (TOP) Pass four hydraulic temporary bolt assemblies and the temporary bolt
turning bar to the divers. See Appendix E for a
drawing of the temporary bolts.
12-2.11.43 (DV) Install the temporary bolt
assemblies into holes #1, #4, #5, and #8. Figure 12-5 shows the blade bolt numbering on
the blade palm. Bolt hole numbers are stenciled on top of the blade palm next to the
respective hole.
12-2.11.44 (TOP) Pass the two 2-foot hoses
(FN 9.2) and one 6-foot hose (FN 9.3) down to
the divers.
12-2.11.45 (DV) Connect the hydraulic hoses
into the temporary bolts as follows: 2-foot
hose from position 1 to 4, 6-foot hose from
position 4 to 5, 2-foot hose from position 5 to
8, and 100-foot hose to position 8. This allows
for simultaneous pressurization of all four temporary bolts. Figure 12-10 shows the arrangement for the hydraulic hoses. Inform topside
that the hydraulic hoses are connected
securely. The hose quick-disconnects have
S0600-AA-PRO-120
Figure 12-10. Hydraulic Hose Schematic.
locking collars that are screwed down by hand

to ensure that the connection is secure.
12-2.11.50 Remove Blade Guide Pins. (DV)

Remove the blade guide pins from bolt holes
#2 and #6.
WARNING
12-2.11.46 (TOP) Operate the intensifier to a

pressure of 1500 psi.
12-2.11.51 Check Blade Seating. (DV) Using a 0.002-inch feeler gauge (FN 22), check
the gap between the blade palm and the hub
at bolt holes #2, #3, #6, and #7. If the feeler
gauge penetrates at all, it should have a snug
(touching both sides) fit. Check the gap in two
places along the line of the bolt circle. The
purpose of this check is to determine the final
seating of the blade and that the O-ring installed between the blade palm and the blade
port cover has not been washed out of its
groove during the final seating of the blade.
12-2.11.47 (DV) Hand tighten the temporary

bolt collars onto the bolt shoulders using the
temporary bolt turning bar.
12-2.11.52 Remove Three-Point Lifting

Assembly. (DV) Loosen all of the turnbuckles on the lifting assembly.

by slowly opening the hydraulic bypass valve
on the intensifier. Inform the divers that the
intensifier has been depressurized.
12-2.11.53 (DV) Remove the trailing edge

clamp and send to the surface.

bolts were to fail.
12-2.11.49 (DV) Disconnect the hydraulic

hoses from the temporary bolts.
12-2.11.54 (DV) Remove the lifting assembly

from the blade with the forward manual lever
hoist. One diver must operate the lever hoist
while the other diver guides the lifting assem-
12-27
S0600-AA-PRO-120
bly off the blade so as not to damage the

blade.
12-2.11.55 (DV) Yard and stay the lifting
assembly to the aft lever hoist and then out to
the crane and to the surface.
12-2.12 MORGRIP BOLT INSTALLATION.
It is very important that both the divers and the
NDT inspection personnel study and understand all aspects of bolt elongation measurement as detailed in Appendix A. Review of the
tutorial discussion provided in Appendix A will
12-2.12.1 (UT) Record the serial number of
each of the eight Morgrip blade bolts (FN 2) on
the Inspection Report and Work Sheet in
Appendix A.
12-2.12.2 (UT) Set up the bolts in the installation order (#2, #6, #3, #7, #1, #5, #4, and #8).
CAUTION
a c c o r d a n c e w i t h N AV S E A
Technical Publication 271.
12-2.12.3 (UT) Using NAVSEA-approved
ultrasonic measurement procedure and equipment, record baseline dimension measurements for all eight bolts. A sample procedure
using NAVSEA-developed equipment is provided in Appendix A.
12-28
12-2.12.4 (TOP) Set up intensifier for Mapeco

power head pressurization in accordance with
the instructions provided in Appendix C.
12-2.12.5 (TOP) Insert the bullet rod into the
#2 blade bolt, cone end first.
NOTE
the NAVSEA kit.
12-2.12.6 (TOP) Open the power head stop
WARNING

12-2.12.7 (TOP) Thread the power head onto
12-2.12.8 (TOP) Close the power head stop
valve, then open it no more than 1/4 to 1/2
turn.
S0600-AA-PRO-120
NOTE
Figure 12-6, an internally
12-2.12.9 (TOP) Remove the pressure port
sealing plug and connect the HP tube from the
intensifier to the power head as shown in Figure 12-6.
12-2.12.10 (TOP) Pump the intensifier until a
steady stream of hydraulic fluid (no air) bleeds
from the loosened connection opposite the HP
tube in the power head. Fill the intensifier reservoir with hydraulic fluid as the tank level
drops. Tighten the bleeding connection with
the 5/8-inch wrench to seat firmly (DO NOT
OVERTIGHTEN).
WARNING
close the power head stop valve to isolate the

pressure in the power head from the pressure
in the HP tube.
tank and the HP tube by slowly opening the
12-2.12.14 (TOP) Disconnect the HP tube
from the power head using the 5/8-inch
wrench. Reinstall the sealing plug into the
exposed tubing connection fitting.
12-2.12.15 (TOP) Apply thread lubricant (FN
26) to the threads and shoulder of the Morgrip
blade bolt.
12-2.12.16 (TOP) Fill and clamp Hydrolube
dispensers, one for each bolt hole, (FN 163.1)
with 200 cc of Hydrolube (FN 163) each and
pass to the divers.
12-2.12.17 (DV) Dewater blade bolt holes #2,
#3, #6, and #7 by displacing the water in the
holes with Hydrolube. Insert the dispenser
nozzle into the bolt hole so the Hydrolube
(heavier than water) fills from the bottom of the
bolt hole. This will displace the water with minimum mixing action.
High pressure oil jets can penetrate the skin.
12-2.12.18 (TOP) Send bolt #2 (with power

head attached) and a spanner wrench to the
divers.
CAUTION
12-2.12.19 (DV) Insert the bolt into bolt hole

#2.

12-2.12.11 (TOP) Increase the intensifier
pressure to 35,000 psi by slowly opening the
air supply valve. Secure the air supply valve
12-2.12.12 (TOP) Confirm stable 35,000 psi
reading on the hydraulic pressure gauge, then
12-2.12.20 (DV) Seat the bolt using the spanner wrench.

NOTE
Length of cheater pipe must be
consistent for all bolts.
12-2.12.21 (DV) Attach a 4-foot cheater pipe
(FN 44) to the spanner wrench and tighten the
bolt.
12-29
S0600-AA-PRO-120
NOTE
A one-minute delay is required
to allow hydraulic lock to relieve
itself. It is critical to repeat until
each bolt will no longer tighten.
12-2.12.22 (DV) Wait one minute, then
tighten the bolt again. Continue tightening the
bolt, with a one minute pause between efforts,
until the bolt stops advancing.
WARNING
when bleeding the power head.
12-2.12.23 (DV) Loosen one of the pressure
port sealing plugs. Open the power head stop
valve to depressurize the power head and the
Morgrip bolt.
12-2.12.24 (DV) Remove the depressurized
power head from the bolt using the spanner
wrench.
12-2.12.25 (DV) Remove the bullet rod from
the bolt. The special removal tool is provided if
suction makes the bullet rod removal difficult.
Send the power head and the bullet rod to the
surface.
12-2.12.26 (DV, TOP) Repeat the bolt installation procedure in the following bolt
sequence: #6, #3, and #7.
12-2.12.27 Remove Hydraulic Temporary
Bolts (DV) Remove the temporary bolts from
bolt holes #1, #5, #4, and #8 by reversing
steps 12-2.11.41 through 12-2.11.49.
12-2.12.28 Complete Morgrip Bolt Installation. (DV, TOP) Repeat bolt installation procedure (steps 12-2.12.1 through 12-2.12.25)
for the following bolt sequence: #1, #5, #4,
and #8.
12-30
12-2.13 MEASURE
LENGTH.
INSTALLED
BOLT
12-2.13.1 (UT/DV) Using NAVSEA-approved

ultrasonic measurement procedures and equipment, record the final measurements for all
eight bolts.
12-2.13.2 Using the Inspection Report and
Work Sheet, Figure A-3, compare the initial
and final bolt lengths to determine residual
stretch of bolts #1 through #8. Residual
stretch must be between 0.006 and 0.0084
inches.
12-2.13.3 (TOP) If any bolts are outside the
residual stretch required, corrections must be
made as follows. If residual stretch is too low,
reinstall the power head and pressurize to
35,500 psi, then reseat the bolt. If residual
stretch is too high, reinstall the power head
and pressurize to 35,000 psi. Loosen the bolt
and then reseat without the 4-foot cheater bar
on the power head spanner wrench.
12-2.13.4 (UT) Re-measure all eight bolts.
Compare initial and final lengths to determine
residual stretch of all eight bolts. All final residual stretch must be within the specified range
(0.006-0.0084 inches).
12-2.14 BOLT CAP INSTALLATION.
12-2.14.1 (TOP) Prepare two Nylok pellets
(1/4-inch diameter, 9/32 inch long) (FN 10) for
each bolt and pass them to the divers (one to
be installed and one as a spare).
12-2.14.2 (DV) Install one Nylok pellet into
the hole in the side of the threaded portion of
Morgrip bolt where the bolt cap is to be
installed. Figure 12-11 shows the location of
the Nylok pellet in the Morgrip bolt.
NOTE
Because access to the Nylok
pellet hole is often partially
obscured by the bolt recess in
the blade palm, one installation
S0600-AA-PRO-120
Figure 12-11. Location of Nylok Pellets in the Morgrip Bolt.
method is to grab the pellet

with needle nose pliers (FN 11)
in order to hold the pellet in line
with the hole and then squeeze
the pellet into the hole with
modified channel lock pliers
(FN 12).
12-2.14.7 (DV) Install the blade bolt caps on

all eight bolts using the blade bolt cap wrench.
Torque to 170 ft.-lbs. using the torque wrench
(FN 6.5) with the 1/2-inch drive to 3/4-inch
drive socket adapter (FN 6.6) and the impact
socket (FN 6.2). See Appendix D for details of
the blade bolt cap wrench.
12-2.14.3 (TOP) Apply silicone grease to the

blade bolt cap seals (FN 8).
12-2.14.8 (DV) Dewater the Morgrip bolt

through the pipe plug hole in the cap by displacing the water with 200 cc of Hydrolube.
12-2.14.4 (TOP) Pass the blade bolt cap

seals and a flat-blade screwdriver to the diver.
12-2.14.5 (DV) Install the blade bolt cap seal
around the blade bolt flange as shown in Figure 12-11. Using the screwdriver, ensure that
the seal is seated at the bottom of the blade
flange hole as shown in Figure 12-11.
NOTE
Check the fit and threads of all
cap plugs in the blade bolt caps
prior to sending the caps to the
divers.
12-2.14.6 (TOP) Pass the blade bolt caps (FN
4), blade bolt cap plugs (FN 7), blade bolt cap
wrench (FN 5), and a 3/16-inch Allen wrench
(FN 7.1) to the divers.
12-2.14.9 (DV) Install the blade bolt cap

plugs. Tighten the plugs flush with the caps.
12-2.15 TEST THE CPP AND PRAIRIE AIR
SYSTEMS.
12-2.15.1 (DV, SF) Divers must watch for
hydraulic leaks and smooth operation during
the full range of pitch variation. Divers must
watch for air leaks at the hub/blade palm during operation of the prairie air system.
12-2.16 FINAL PROCEDURES.
12-2.16.1 (DV) Remove all tools and equipment.
12-2.16.2 Take Inventory. (TOP) Collect, inventory, and pack equipment and tools. Mark
12-31
S0600-AA-PRO-120
or red tag damaged or malfunctioning tools

or equipment.
12-2.16.3 Debrief Ship's Force. (TOP) The
lead dive supervisor should debrief the pertinent ships officers on the final status of the
blade replacement. Ship systems that were
closed and tagged out may be returned to
operation.
12-2.16.4 Prepare Final Report. (TOP) Prepare a final report documenting the accomplished repair. Documentation which NAVSEA
00C54 needs to help improve the procedure
is: blade bolt liquid penetrate inspection
results, blade bolt ultrasonic measurement
inspection results, a description of any lost,
damaged or malfunctioning tools or equipment
in the NAVSEA CPP Kit, a list of all consumables taken from the kit for the job, details
12-32
regarding any problems encountered, and recommendations for new or special tools
needed. The final report should be faxed or emailed to NAVSEA 00C54.
S0600-AA-PRO-120
SECTION 3 FFG 7, DD 963, DDG 993, CG 47, AND DDG 51 CLASS PROPELLER HUB PRAIRIE AIR CHECK VALVE REPAIR
12-3.1 FFG 7 CLASS REPAIR PROCEDURE.
12-3.1.1 NAVSEA 0941-LP-053-7010, FFG 7
Class CP Propeller and Propulsion Shafting
System, should be used by repair personnel
when accomplishing repairs to the FFG 7
Class propeller hub prairie air system. The following steps refer to sections of that manual.
12-3.1.2 Foldout 9 (Prairie Air Assembly) provides a diagram of the prairie air assembly.
Detail 14-A and View 17-B detail the configuration of the hub check valve.
12-3.1.3 Most often, the check valve spring
(item 16) fails before the check valve (item
10). When the spring fails, the check valve will
not reseat when air is secured and the prairie
air tubing is flooded. Replacement of the
spring is normally all that is required. If the
check valve is damaged and must be
replaced, the check valve may need to be fitted to the prairie air tube (item 8) because
each check valve and tube are matched pairs.
12-3.1.4 To access the check valve, the prairie air adapter plug (item 17) must be removed
from the aft end of the propeller hub. Remove
the retaining set screw (item 30) so the
adapter plug can be removed using a spanner
wrench.
12-3.1.5 Once the adapter plug is removed,
the check valve and spring can be pulled from
the cavity. Slide the spring off the check valve
stem and replace with a new spring.
12-3.1.6 Reinstall the check valve and the
adapter plug. Ensure that the O-ring (item 22)
on the adapter plug is checked. Replace if
necessary.
12-3.1.7 Check the condition of the nylon set

screw (item 30), replace if necessary and reinstall.
12-3.1.8 Table 7-1, page 7-6 contains a parts
list for the applicable replacement parts.
12-3.2 DD 963, DDG 993, AND CG 47
CLASS REPAIR PROCEDURE.
DD 963, DDG 993, and CG 47 Class ships
have the exact same configuration prairie air
hub check valve, so the FFG 7 procedure in
Section 12-3.1 may be applied directly.
12-3.3 DDG 51, CG 47 (CG 66 AND ABOVE),
AND MODIFIED EARLIER CLASS SHIPS
REPAIR PROCEDURE.
DDG 51 and CG 47 (CG 66 and above) Class
ships, and some modified earlier ship classes,
have adapter plugs retained by a Nylok insert
in the threads instead of a retaining set screw.
Once the adapter plug is removed the spring
and check valve can be removed and
replaced. This procedure is similar to the FFG
7 procedure outlined above and is specified in
the applicable ship class technical manuals
and repair standards. The after prairie air
check valve assemblies on these ships also
have replaceable valve seats. These valve
seats can be removed and taken topside for a
more accurate fit-up before reinstallation. See
Figure 12-12 for an illustrative comparison of
the old and the new check valve configurations.
12-33
S0600-AA-PRO-120
Figure 12-12. Prairie Air Check Valve Configuration.
12-34
S0600-AA-PRO-120
SECTION 4 FFG 7 CLASS WATERBORNE BLADE PORT HUB SEAL

REPAIR
12-4.1 REFERENCES.
a. NAVSEA 0941-LP-053-7010, Technical Manual, FFG 7 Class CP Propeller
and Propulsion Shafting System.
b. NAVSEA S9245-AF-TRS-010/FFG-7
CL, Technical Repair Standard, Propeller Hub Assembly and Blades FFG
7 Class.
c. NAVSEA Best Management Practices
Naval Vessels.
blade port hub seal repair. Replacement parts

for five complete blade seal replacements are
included in the NAVSEA CPP kit. Table 12-3
lists quality assurance points when repairs are
to be made.
12-4.3 REPAIR PROCEDURE.
NOTE
All item numbers in parenthesis
( ) refer to Figure 12-13 unless
otherwise noted. Find Numbers
(FN) refer to Parts List of the
NAVSEA Blade Change Kit.
CAUTION
CAUTION

Manuals and reference c.
12-4.3.1 (DV) Remove affected propeller
blade in accordance with Section 12-2 of this
manual.
12-4.3.2 (DV) Install a quick disconnect hub

pressure test fitting (FN 51.2) (see Appendix I)
into the lower of the two 1/2-inch pipe plug fittings on the forward end of the hub. The two
1/2-inch fittings are approximately 180
degrees apart from each other. DO NOT use
the two 1 1/4-inch pipe plug fittings which are
also located on the forward end of the hub.
Waterborne repair of the blade port hub seal

requires special tools and materials. The find
numbers (FN) in the following paragraphs correspond to the find numbers in the NAVSEA
CPP Blade Change Kit, the inventory is available from NAVSEA 00C5. The qualities of
items contained in the CPP kit are the minimum recommended to be on hand prior to a
12-4.3.3 (DV) Rotate the blade port to the 6

o'clock position. Confirm that the hub center
post sleeve (1) is not loose or cracked. See
Figure 12-13 for identification of the center
post sleeve. If the center post sleeve is
cracked, locate and record the center post (2)
outer diameter measurement which is
stamped on the top of the center post and
12-35
S0600-AA-PRO-120
Item
Name
Reference
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Center Post Sleeve

Center Post
O-ring (dynamic)
O-ring (static)
Blade Port Cover
Capscrew
O-ring (static)
O-ring (dynamic)
Blade Seal Base Ring
O-ring (static)
Spring
Bearing Ring
Crank Pin Ring
Mylar Shim
FN 52.13
FN 54
FN 55
Item 24 of fold-out 2 in reference a
FN 60
FN 20
FN 56
FN 57
FN 53
FN 66 (FFG 7 set)
Figure 12-13. Blade Port Assembly.
12-36
S0600-AA-PRO-120
Table12-3. FFG 7 Class Waterborne Blade Port Hub Seal Repair Quality Assurance Points.
Quality Assurance Point
Initial
1.
Check for cracked center post sleeve. If cracked, record OD measurement stamped on the
top of center post [12-4.3.3].
2.
Confirm final machined dimensions of the replacement center post sleeve [12-4.3.14d].
3.
Check alignment of the center post sleeve jacking assembly [12-4.3.14m].
4.
Verify replacement center post sleeve is flush with the center post and did not crack during
installation [12-4.3.14p].
5.
Measure blade port cover to bearing ring clearance and determine shim requirements [124.3.15].
6.
Ensure blade seal base ring positioning dowel is in position [12-4.3.19].
7.
Inspect the blade seal base ring [12-4.3.20].
8.
Reseat the blade seal base ring [12-4.3.23].
9.
Remove excess O-ring seating grease and ensure Mylar shim is flat [12-4.3.24].
10. Ensure stable oil/water interface is level with hub port opening [12-4.3.25].
11. Observe O-rings in proper position during final seating of blade port cover [12-4.3.26].
12. Check distance between blade port cover and crank pin ring with 0.002-inch feeler gauge
[12-4.3.29].
13. Check dowel pin fit and torque blade port cover cap screws to 33 ft.-lbs. [12-4.3.31].
14. Vent any air trapped in the hub [12-4.3.34].
15. Pressurize the system to check for leaks [12-4.3.36 and 12-4.3.40].
16. Final system test [12-4.3.39].
machine a replacement sleeve in accordance

with NAVSEA Drawing 6699591, Center Post
Sleeve (see Appendix H). Should the outer
diameter measurement not be stamped on the
top of the center post sleeve, divers must
make a repeatable measurement of the center
post outer diameter using a 12-inch outside
vernier caliper (FN 63). Experience indicates
that special eight-jaw chuck vice four-jaw
chuck lathe equipment is required to hold
machining tolerances on the thin walled center
post sleeve blanks (FN 52.13). The center
post sleeve can be machined out of solid
round stock material on a standard four-jaw
chuck lathe if an eight-jaw chuck lathe is not
available.
other (opposite the one used in step 12-4.3.2)

1/2-inch pipe plug fitting on the forward end of
the hub.
12-4.3.4 (DV) Install the second quick disconnect hub pressure test fitting (FN 51.2) into the
12-4.3.7 (TOP, DV) Rig staging to the propeller under the 6 o'clock blade port or an alterna-
12-4.3.5 (SF, DV) Secure the discharge valve

at the ship's internal CPP head tank. This will
prevent the head tank from emptying to the
sea when the blade port cover is removed at
the 6 o'clock position. When the blade port
cover is first removed, the oil entrapped in the
CPP system will establish internal oil head
pressure equal to outside seawater pressure
at the 6 o'clock hub position.
12-4.3.6 (SF) Secure and tag out the CPP
system.
12-37
S0600-AA-PRO-120
tive method so the diver(s) can work from a

stable position for hub component removal.
Wherever the stage is secured to the hub or
blade bases, ensure that adequate chafing
gear is used to prevent damage to any propeller surface. The diver must be stable to make
the required detailed measurements.
12-4.3.8 (DV) Remove every other cap screw
(6) holding the blade port cover (5) (unit
weight of cover is 183 lbs.) onto the crank pin
ring (13).
12-4.3.9 (DV) Install a handle nut approximately four inches from the top of each of the
four 5/8-11 UNC 30-inch long all-thread rods.
Make sure the handle on the handle nut is
angled downward. The top of the all-thread
rod is opposite the end with the flats machined
for a 1/2-inch wrench. Installing the handle
nuts onto the top of the all-thread rods prior to
installing the all-thread rods avoids the need
to run the handle nut all the way up the 30inch length of the rods. Install a 5/8-inch flat
washer onto the rod so the handle nut will
bear against the washer and not the blade port
cover. Install the rod assemblies into the holes
emptied in the previous step. Using the flats,
tighten the rod assemblies in place with a 1/2inch wrench.
12-4.3.10 (DV) Run the handle nuts back up
the all-thread rods until they are approximately
1/4 inch from the surface of the blade port
cover.
12-4.3.11 (DV) Remove the remaining four
cap screws holding the blade port cover to the
crank pin ring. The blade port cover should
settle onto the handle nuts installed on the
5/8-inch all-thread rod assemblies.
NOTE
As the blade port cover is lowered, watch for any of the four
O-rings (items 3, 4, 7, and 8)
held in place under the blade
port cover. Also, watch for a
Mylar shim (14), if installed.
12-38
12-4.3.12 (DV) Lower the blade port cover

evenly using the four handle nuts until the
blade port cover is approximately 18 inches
from the blade port.
12-4.3.13 (DV) Remove the four O-rings
accessible at this point (see Figure 12-13). If a
Mylar shim is found and is undamaged, leave
it in place. Measurements taken in step 124.3.15 will determine if the Mylar shim should
remain in place, be removed, or be replaced
with a Mylar shim of different thickness.
12-4.3.14 (DV) If the center post sleeve is
cracked or loose, replace it as detailed in this
step. If the center post sleeve is not damaged,
proceed with the next step.
a. Lower the blade port cover and remove
it from the all-thread rods.
b. Remove the damaged center post
sl e eve fro m the cen ter po st. Th e
cracked sleeve should slide easily off
the center post.
c. Clean the center post using 360-grit
wet/dry sand paper or Scotch-Brite
pads.
d. In accordance with step 12-4.3.3, the
new sleeve should already be
machined to obtain a 0.002 0.0005inch press fit onto the center post (see
NAVSEA drawing 6699591, Center
Post Sleeve, Appendix H).
e. Install the base plate (FN 52.3) on the
four all-thread rods using the handle
nuts. Ensure that the handle nuts have
full thread engagement.
f.
Place the Enerpac jack set (FN 9 of

NAVSEA Drawing 6699590, Appendix
H) inside the tabs on the base plate.
g. Place the jacking plate (FN 52.2) on top

of the Enerpac jack set so that the
jacks flat base rests in the indentation
S0600-AA-PRO-120
in the jacking plate and the tabs on the

jacking plate are facing up.
n. Extend the jack until the sleeve

touches the center post. Verify alignment of the sleeve with the center post.
h. Spray the inside diameter of the new

center post sleeve with a lubricant that
will not be displaced by the water (LPS3 or equivalent) before the sleeve is
sent to the divers.
i.
Place the new center post sleeve on

the j acking pl ate i nsid e the ta bs.
Ensure that the end of the sleeve with
the taper on the inside diameter is facing up towards the center post.
j.
Place the pipe stand-offs (FN 52.4)

over each of the base plates empty
ho le s an d sli de a n a ll - thr ea d r o d
(wrench flat end on the bottom) through
the base plate and the pipe stand-offs,
threading the end of the rod into the
aligning hole in the crank pin ring. Four
all-thread rods with pipe stand-offs
must be installed. A total of eight allthread rods are required, four with pipe
stand-offs and four without pipe standoffs.
k. Ensure that the all-thread rods just

installed are bottomed out in the crank
pin ring bolt holes. Use a wrench on the
wrench flats cut into the end of the rod.
Install a handle nut on each rod.
l.
Using all eight handle nuts, raise the

base plate until it is restrained by all
four pipe stand-offs. The pipe standoffs will ensure that the base plate is
parallel with the crank pin ring and the
jacking plate is set at the proper height.
m. Check the entire setup prior to jacking

the new sleeve. Ensure that the taper
on the inside diameter of the sleeve is
facing up tow ard the center post.
Ensure that the whole jacking assembly is centered under the center post.
CAUTION
jacking assembly and restart.
o. Jack the sleeve into place. Do not stop
jacking until the sleeve is flush with the
center post.
p. Retract the jack and verify that the
sleeve is flush with the center post.
Verify that the new sleeve did not crack
during the press fit.
q. Remove the center post sleeve
replacement assembly from the hub
port. Leave four of the all-thread rods in
the crank pin ring.
r.
Install the blade port cover onto the allthread rods.
s. Continue with the next step in the procedure.

12-4.3.15 (DV) Prior to reseating the blade
port cover, the measurements shown in Figure
12-14 must be taken to determine if the
required 0.002-0.007-inch clearance will exist
between the bearing ring and the blade port
cover after the blade port cover is bolted to the
crank pin ring. These same measurements
are made when the new hub is first assembled
on the ship and often a Mylar shim must be
added between the blade port cover and the
crank pin ring to ensure that the required
clearance is achieved between the blade port
cover and the bearing ring after assembly.
12-39
S0600-AA-PRO-120
Figure 12-14. Shim Requirement Measurements.
Over time, the rotation of the crank pin ring will

cause wear on the bearing ring. As the bearing ring wears, dimension B in Figure 12-14
will decrease. Since the blade port cover has
no wearing surface, dimension A on Figure
12-14 stays the same. Therefore, over time,
the thickness of Mylar shim required to maintain the required clearance will decrease until
no shim is required and eventually the clearance will exceed the maximum, even with no
shim.
CAUTION
dimension B between an
ring. Dimension B must be
crank pin ring surface and the
depth micrometer unrepeat-
12-40
able.
CAUTION
continue eventually causing
worn bearing ring is essential.
NOTE
Mylar shims are very delicate.
They are shipped with the CPP
equipment kit in a PVC tube for
protection (FN 66). Shims of
0.002, 0.003, 0.004, and 0.005inch thickness are included
S0600-AA-PRO-120
with the kit. The shims are also

ava i la bl e fr om th e o r ig i na l
equipment manufacturer
(OEM), Bird-Johnson.
Referring to Figure 12-14, proceed with the
measurements as follows:
h. If B is less then A by more then

0.002 inch, no shim is required. However, if B is less then A by more then
0.007 inch, the maximum required
clearance will be exceeded even without a shim.
i.
If a shim is required, measure the thickness of any existing shim to determine

if it meets the criteria above. Use a
thickness micrometer to measure the
shim thickness. If an existing shim
does not meet the above criteria,
replace it with a new shim. Selection of
shim stock thickness should be based
on an ideal blade port cover to bearing
ring clearance of 0.005 inch.
j.
If no shim is required, any existing shim

must be removed.
a. Perform all measurements to the nearest 0.001 inch and with the blade port
at the 6 oclock position.
b. It is essential that the same diver experienced in the use of a depth micrometer perform all dimension A and B
measurements. This will ensure that
variation based on measurement technique will not effect the difference
between A and B.
c. Perform eight measurements around
both the blade port and blade port
cover, one adjacent to each Morgrip
bolt hole. Record the results. Because
of access limitations, dimension B is
more difficult to measure. It is most
important to be consistent with the
alignment and placement of the depth
micrometer at each location measured.
d. After the most repeatable measurements achievable have been recorded,
average the eight measurements taken
for B.
e. Average the
taken for A.
f.
eight
measurements
If B is greater then A a shim is

required. The minimum shim thickness
is (B - A) + 0.002 inch. The maximum shim thickness is (B - A) +
0.007 inch.
g. If B is equal to A, or less than A by

up to 0.002 inch, a shim is required.
The shim thickness must be 0.0020.005 inch.
12-4.3.16 (DV) Install four 5/16-18 UNC, 4inch long jacking bolts 90 degrees apart into
the threaded through-holes provided in the
blade seal base ring (9). Note the depth of
insertion of the ring relative to the lip of the
hub blade port opening. This will allow the ring
to be reinstalled into the same position.
CAUTION

the ring.
12-4.3.17 (DV) Jack the blade seal base ring
out evenly, taking care to avoid warping the
ring. Be prepared to recover the 18 springs
(11) held in place by the blade seal base ring.
12-41
S0600-AA-PRO-120
12-4.3.18 (TOP, DV) Send the blade seal

base ring and the 18 springs to the surface.
Work the blade seal base ring free of the all
thread rods by removing each rod one at a
time and reinstalling them outside the blade
seal base ring.
12-4.3.19 (TOP) Ensure that the blade seal
base ring positioning dowel pin (3/8-inch diameter, 1 1/4 inch long) remains press fit into the
bearing ring (12).
12-4.3.20 (TOP, DV) Clean and inspect the
blade seal base ring. Inspection tolerances
are specified in reference b. Install a new Oring (10) onto the OD of the blade seal base
ring and send it to the divers with 18 new
springs.
12-4.3.21 (DV) Work the blade seal base ring
back over the all-thread rods by removing and
reinstalling the rods one at a time. Ensure that
the blade seal base ring rests on the cover
plate with the dynamic O-ring groove facing
down against the cover plate.
12-4.3.22 (DV) Install the 18 springs into the
bearing ring. Use grease (FN 61), injected into
the bearing ring spring holes with the grease
gun, to hold the springs in position overhead
while the blade seal base ring is positioned in
place. An alternative method to retain the
springs is to dip the first three coils of each
spring in melted beeswax so the OD is
increased just enough to make for a tight
insertion (bearing ring hole is 3/4-inch diameter). If this method is used, ensure that all wax
is removed from the end of the spring so that
the spring will make metal-to-metal contact
with the bottom of the hole.
12-4.3.23 (DV) Push the blade seal base ring
into the groove in the bearing ring by hand,
making sure to align the blade seal base ring
with the positioning dowel pin. Push the ring
evenly into the groove to avoid warping the
ring or damaging the O-ring. Two divers are
required to align and push in the blade seal
base ring far enough to ensure that it stays in
place.
12-42
NOTE
Ensure that items (3) and (8)
(dynamically loaded O-rings)
are replaced with fully molded
instead of spliced O-rings. Orings supplied by the stock system for items (3) and (8) are
often spliced instead of fully
molded.
12-4.3.24 (DV) Fill the empty O-ring grooves
on the blade port cover ID, the inner and outer
Morgrip bolt hole diameters on the crank pin
ring, and the blade seal base ring (four O-ring
grooves total) with grease and remove any
excess. Seat four new O-rings (3, 4, 7 and 8)
into their appropriate grooves and allow the
grease to hold them in place. Again, remove
any excess grease. If a Mylar shim is installed,
ensure that the shim lays flat against the crank
pin ring or blade port cover.
12-4.3.25 (SF, DV) Allow the oil/seawater
interface at the blade port to settle out and
have Ships Force release oil from the head
tank until all sea water is displaced from the
hub.
12-4.3.26 (DV) Raise the blade port cover
evenly with the handle nuts until it is carefully
seated into place. Be careful to ensure that all
the O-rings remain seated in their proper locations during the final seating of the blade port
cover.
12-4.3.27 (DV) Install four 5/8-inch cap
screws into the available holes to secure the
blade port cover in place.
12-4.3.28 (DV) Remove the four 5/8-inch allthread rods and install the remaining four 5/8inch cap screws. Tighten all cap screws
snugly.
12-4.3.29 (DV) Check the clearance between
the blade port cover and the crank pin ring in
all eight Morgrip holes with the 0.002-inch
feeler gauge. Confirm no fit or very tight fit of
feeler gauge between the blade port cover
and the crank pin ring. If the feeler gauge is
tight proceed with the next step. If the feeler
S0600-AA-PRO-120
gauge is not tight, one or more of the O-rings

has jumped its groove. Lower the blade port
cover and check the four overhead O-rings.
Repeat O-ring and blade port cover installation until 0.002-inch feeler gauge is tight.
12-4.3.30 (SF, DV) Rotate the blade port to
the 12 oclock position.
12-4.3.31 (DV) Ensure that the blade dowel
pins will be able to slide through the blade port
cover into the crank pin ring by placing them
into the blade dowel pin holes. If either is
unable to fit, loosen the blade port cover cap
screws to allow for minor rotational alignment
of the blade port cover with the crank pin ring
until the dowel pins are able to slide in
smoothly. Initial alignment of the two dowel pin
holes will be evidenced by over an inch of
dowel pin insertion. Then, torque all the cap
screws evenly to 33 ft.-lbs. using the torque
wrench (FN 58) and the 1/2-inch Allen socket
(FN 58.4). Recheck the dowel pin fit after the
cap screws are tight. The dowel pins should
drop the rest of the way into the hole.
12-4.3.32 (DV) Connect the hub pressure test
system hoses detailed in Appendix I into the
quick disconnect fittings that were installed in
the hub earlier.
12-4.3.33 (SF) Open head tank valve.
12-4.3.34 (TOP) Vent any air trapped in the
hub from the hose installed at the 12 oclock
position.
12-4.3.35 (SF) Shut the head tank valve. During the hub pressure test, the return oil side of
the system will be pressurized as the hub
crosshead chamber is pressurized by the
divers.
12-4.3.36 (TOP, DV) Using the barrel pump in
a barrel of clean CPP system oil, pressurize
the hub crosshead chamber to 20 psig. Maintain pressure at 20 psig for 10 minutes while
divers check for leaks at the blade port cover
and the other blades.
NOTE
A value of 20 psig should be
low enough to not lift the cross
head chamber relief valve. In
cases where the pressure consistently drops to some lower
value (10 to 11 psig), use this
new value for the pressure test.
Hold pressure for 10 minutes
and have the divers confirm no
leaks. This will confirm that the
hub seal has been reestablished.
12-4.3.37 (TOP) If leakage is NOT observed,
proceed to the next step. If leakage is
observed, changes to the Mylar shim thickness based on measurements may not have
been enough to regain sufficient blade port
cover O-ring compression to get a seal. The
procedure may be repeated to confirm measurements and perhaps reduce shim thickness. However, if bearing ring wear is
indicated and the hub already has a long service life, the only alternative may be drydock
replacement of the worn bearing ring.
12-4.3.38 Replace the blade in accordance
with Section 12-2 of this manual.
12-4.3.39 (SF, DV) Remove out-of-service
tags. Cycle the blade pitch through normal
range of operation several times. Test and
purge the system in accordance with section
6-14 (Testing of the System) of reference a,
MRC 77 6WBM N (R-2W) and paragraph 124.3.40). Have divers check for leaks around
the blade palm and hub interface of all blades
during the testing.
12-4.3.40 In performing system test and
purge, supplement the procedure outlined in
MRC 77 6WBM N (R-2W) with the following.
Purge for approximately 15 to 30 minutes. To
open purge valve, (located in hub) take manual control (joystick) and slew pitch astern until
the main system relief valve lifts (1000 psi).
Slew pitch ahead just enough to reset the
12-43
S0600-AA-PRO-120
main relief valve. Purge valve is now open

allowing oil from the hub crosshead cavity to
be flushed out and returned to the sump for
purification. It should be noted that, if the main
shaft is rotated (turning gear) in conjunction
with the hub purge, this will improve the crosshead cavity flushing operation. Rotating the
shaft during a hub purge is not mandatory and
is left to the Chief Engineer/Main Propulsion
Assistant discretion. Recommend hub purge
be conducted upon each return to port prior to
securing the CPP system.
12-44
S0600-AA-PRO-120
SECTION 5 DD 963, AND CG 47 BLADE REMOVAL, RETRIEVAL, AND

REPLACEMENT PROCEDURE
replacements must consider all requirements.
If shop facilities are not available at the Command with the overall tasking, the Command
must arrange for them. A successful blade set
change requires one week. Provision must be
made for breasting the ship out by the stern so
the blades can be lifted between the ship and
the pier. Crane service, floating or pierside,
must be available for propeller blade lifting
and must have the required reach and angle
to handle the propeller blades. An oil boom is
required for oil abatement and containment in
accordance with local instructions. Also, the
following references provide specific information relevant to removing and replacing CPP
blades:
a. NAVSEA S9245-BF-MMM-010, Maintenance Manual for Controllable Pitch
Propeller in DD 963 Class.
b. NAVSEA S9245-AH-MMA-010, Installation, Operation, Maintenance and
Repair Instructions with Parts List,
Controllable Pitch Propeller for CG 47
Class Ships.
c. S9086-00-STM-000, Naval Ships'
245, Propellers.
d. NAVSEA Best Management Practices
Naval Vessels.
e. MIL-STD-2035(SH) 04 July 1991, Nondestructive Testing Criteria
f.
NAVSEA T9074-AS-GIB-010/271, 30
April 1997, NAVSEA Technical Publication, Requirements for Nondestruc-
tive Testing Methods (referred to as

NAVSEA Technical Publication 271).
12-5.1.1 Applicability.
This
procedure
applies to all DD 963, DDG 993 and CG 47
Class ships. Within the CG 47 Class, CG 66
and higher have torque-in-place blade bolts
removed and installed in accordance with the
procedure of Section 7 of this manual. The
blade rigging procedure for all CG 47 Class
ships is covered in this section.
12-5.2.1 Rig the ships hull with forward and
aft 3-ton lever hoists.
rotating the blade into the 12 oclock position
and removing the Morgrip bolts connecting the
assembly; lowering the blade into position;
seating the blade onto the hub; connecting the
blade palm to the hub with four temporary
bolts; and removing the three-point lifting
assembly for return to the surface.
12-5.2.5 Secure each blade to the hub by:
dewatering open blade bolt holes; installing
Morgrip bolts into the four open blade bolt
holes, removing the temporary bolts; dewatering the remaining bolt holes; installing the
remaining four Morgrip bolts; measuring the
installed bolt lengths to determine the proper
residual stretch; dewatering the installed Morgrip bolts; and capping the bolts.
12-45
S0600-AA-PRO-120
NOTE
closely together, certain steps
must be carried out by particular personnel. To clarify these
steps, abbreviations are placed
at the beginning of each step
where the specific party needs
to be identified: (DV) represents diver, (TOP) represents
topside personnel, (SF) represents Ships Force personneland (UT) represents Level II
Ultrasonic Inspector.
12-5.3 PREPARATION.
kit is available from NAVSEA 00C5. Table 124 identifies additional items that must be provided by the repair activity. Ensure the availability of all technical information, manuals,
and drawings.
with Table 12-5.
detailed in Appendix A. Review of the tutorial
discussion provided in Appendix A first will
CAUTION

log sheet is prepare and maintained during all UWSH operations.
Equipment. NAVSEA 00C5 maintains a CPP
blade change kit that contains most of the
tools and equipment necessary to replace
12-46

NAVSEA CPP Blade Change Kit, the inventory for this kit is available from NAVSEA
00C5. The quantities of items contained in the
CPP Kit are the minimum recommended to be
on hand prior to CPP blade removal and
replacement. Their functions are described in
the following paragraphs.
12-5.4.1 Intensifier. The intensifier assembly (FN 37) pressurizes hydraulic fluid that is
used to install and remove Morgrip bolts and
hydraulic temporary bolts. Low pressure (LP)
air is the power source for the intensifier. The
intensifier is connected with a high pressure
(HP) flexible tube to the Morgrip bolt power
head tool and with a quick-connect hydraulic
hose to the hydraulic temporary bolts (see
Appendix C).
S0600-AA-PRO-120
CAUTION

(see figure 12-14A).

1- To n

hoists/falls.
Typical
R unning
B lock
Flip
3 To n

chain loop:
4- To n
6 Ton
Change 1
12-46A
S0600-AA-PRO-120
12-46B
Change 1
S0600-AA-PRO-120

Item No.
Quantity
Commercial
Diver Tool Bag
Commercial
Gallon of Hydraulic Fluid
Tellus #15, Code 65203

(Shell Oil Company) or equal
Commercial
as required
Commercial
Combination Wrench, 1/2
Commercial
Screwdriver, Flat Blade
Commercial
as required
Commercial
as required
Grease Pencils
Commercial
10
Commercial
11
as required
Chafing Material
Commercial
12
Commercial
12-5.4.2 Morgrip Bolt Power Head Tool with

Bullets. The Morgrip bolt power head tool
assembly (FN 38) is used to remove and
install Morgrip bolts. This is accomplished by
inserting the bullet rod into the Morgrip bolt;
attaching the power head onto the bolt with a
spanner wrench; connecting the power head
to the intensifier with the HP tube; and pressurizing the hydraulic fluid in the power head
which forces the bullet rod into the bolt, thus
stretching the bolt.
12-5.4.3 Bullet Rod Removal Tool. The bullet rod is removed from the Morgrip bolt with
the bullet rod removal tool (FN 38.4).
12-5.4.4 Morgrip Bolt. Morgrip bolts (FN 2)
are used to secure the propeller blade to the
hub. The Morgrip bolt contains a bored cavity
that enables the bolt to be stretched during
installation. After they are installed, the bolts
retain a residual stretch that provides a clamping force to hold the blades on the hub.
12-5.4.5 Blade Bolt Cap Wrench.
The
blade bolt cap is threaded onto the head of the
Morgrip bolt using the blade bolt cap wrench
(FN 5). (See Appendix D).
Technical Specifications
12-5.4.6 Hydraulic Temporary Bolts.

Hydraulic temporary bolts (FN 9) have two
quick-connect nipples so that pressurized
hydraulic fluid is directly connected from the
bolts to the intensifier via a quick-connect
hose assembly. Hydraulic temporary bolts
contain a hydraulic chamber. Pressurized
hydraulic fluid in the chamber pushes the jacking body of the bolt down onto the blade palm.
Simultaneously, the threaded portion of the
bolt in the Morgrip bolt hole is pulled toward
the blade palm. This tension provides a tight
fit. Hydraulic temporary bolts can be connected in series with short quick-connect
hoses so that several bolts can be pressurized
at the same time (see Appendix E).
12-5.4.7 Lifting Assembly. The lifting assembly (FN 152) is attached to a propeller
blade so the blade can be lifted and lowered
with the hook of a lever hoist (see Appendix
F).
12-5.4.8 Righting Fixture. The righting fixture (FN 151) is installed onto the propeller
blade and connected to the pier crane hook.
The righting fixture is used to lift the propeller
blade out of its shipping container and to stand
12-47
S0600-AA-PRO-120
Table 12-5. DD 963, DDG 993, and CG 47 Quality Assurance Points.

Blade Removal:
1.
Ensure pitch is set at zero pitch position [12-5.6.1].
2.
Inspect removed blade bolt caps and plugs for damage [12-5.7.5].
3.
Check Mapeco power head rupture disc torque at 100 ft.-lbs. [Note prior to 12-5.8.2].
4.
Remove blade bolts in the order: 2,6,3,7,1,5,4,8 [Note prior to 12-5.8.3].
5.
Clean blade bolts IAW Appendix A [A-5.3.1] and conduct liquid penetrant inspection of
removed blade bolts [12-5.8.27].
6.
Ensure lifting fixture is installed with head clamp centered on the blade [12-5.9.8].
7.
Measure blade palm spacing to relieve binding (if required). [12-5.9.23].
8.
Benchmark the shaft [12-5.9.28].
Blade Installation:
1.
Inspect blade port and blade [12-5.10].
2.
Ensure edge guard material is used for lifting fixture clamps [12-5.11.5].
3.
Check prairie air nipple fully inserted [12-5.11.8].
4.
Check dowel pins fully inserted [12-5.11.9].
5.
Ensure O-ring installed in blade port cover [12-5.11.13].
6.
7.
Check for cover plate O-ring washout [Caution prior to 12-5.11.32].
8.
Check blade seating with 0.002-inch feeler gauge [12-5.11.51].
9.
Record serial numbers and initial lengths of blade bolts to be installed. Use Inspection
Report and Work Sheet, Figure A-3, Appendix A [12-5.12.1 and 12-5.12.3].
10. Apply thread lubricant to blade bolt threads and shoulders [12-5.12.15].
11. Dewater the blade bolt holes with Hydrolube [12-5.12.17].
12. Record final length and residual stretch when all eight bolts are installed. Residual stretch
must be between 0.006-0.0084 inches. Use Inspection Report and Work Sheet Figure A-3
[12-5.13.1 and 12-5.13.2].
13. Ensure blade bolt cap seal is installed on blade bolt [12-5.14.5].
14. Torque blade bolt caps to 170 ft.-lbs. [12-5.14.7]
15. Dewater Morgrip bolt with Hydrolube [12-5.14.8].
16. Ensure blade bolt cap plugs are installed [12-5.14.9].
17. Test the CPP system performance [12-5.15].
12-48
Initials
Initials
S0600-AA-PRO-120
the blade by its palm onto wood timbers,

enabling the blade to be outfitted with the lifting assembly (see Appendix G).
12-5.4.9 Modified Channel Lock Pliers. The
rounded head of the channel lock pliers (FN
12) is ground off to a flat surface approximately -inch thick in order to allow for better
access to the Morgrip bolt Nylok pellet hole as
described in the note following step 12-5.15.2.
12-5.4.10 Spanner Wrench. The spanner
wrench (FN 23) is used to tighten or loosen
the Morgrip blade bolts, attached to the power
head assembly, into or out of the blade palm.
dowel pin removal tool (FN 13) is used to
remove stuck dowel pins that cannot be
removed by hand.
12-5.4.12 Blade Guide Pins.
The blade
guide pins (FN 14) are used to align the dowel
pins with the blade palm at installation.
(FN 43) is a transducer assembly and ultrasonic instrument specially designed to measure the elongation of the Morgrip bolts. The
tutorial in Appendix A allows any Intermediate
Maintenance Activity (IMA) Level II Ultrasonic
Testing (UT) inspector to perform measurements with this equipment.
holes.
Rig the ships hull with forward and aft 3-ton
lever hoists (FN 153) in accordance with Figure 12-15 and the following procedure.
12-5.5.1 Rig Forward Lever Hoist. Loop the
nylon sling (FN 168) through the forward lifting
tunnel (frame 496, over the propeller hub).
Attach the eyes of the sling together with a 1inch safety shackle (FN 161). Run both 3-ton
lever hoists (10 and 30 foot throw) to the two

blocked position in order to confirm the chain
is not twisted. Hang the 10-foot throw 3-ton
manual lever hoist from the 1-inch safety
shackle. The manual lever hoist must be used
in the forward position to avoid over- stressing
the lifting assembly during blade removal.
12-5.5.2 Rig Aft Lever Hoist. Loop the
nylon sling (FN 168) through the aft lifting tunnel (frame 503, 7 feet aft of the forward tunnel). Attach the eyes of the sling together with
a 1-inch safety shackle (FN 161). Hang the
30-foot throw manual lever hoist or hydraulic
chain fall from the 1-inch safety shackle.
Hydraulic hoist in the aft position eases the
yard and stay of the blade to the surface.
WARNING

will be rotating.
INTO THE 12 O'CLOCK POSITION.
zero pitch position. Benchmarks for pitch
alignment are located adjacent to blade #1.
Danger tag the pitch controls in the locked
position.
12-5.6.2 Attach head clamp (middle shackle
position) to the forward chainfall. Using the
head clamp as a plumb bob, verify centering
of the head clamp on the blade. Rotate the
shaft if required to center the blade with the
hanging head clamp. Benchmark the final
shaft position.
12-49
S0600-AA-PRO-120
Figure 12-15. Ships Hull Rigging.
12-5.6.3 Return the head clamp to the surface.
12-5.7 REMOVE MORGRIP BLADE BOLT

CAPS.

locked position.
NOTE
CAUTION
d. of section 12-5.1, Requirements.
12-50
For CG 66 use Paragraph 127.7 for bolt removal.

12-5.7.1 (DV) Remove the caps from all eight
Morgrip blade bolts in any order in accordance
with steps 12-5.7.2 through 12-5.7.4.
NOTE
Morgrip blade bolt caps should
be installed at 170 ft.-lbs. (the
install atio n to rqu e r equi rement) but they may be overtorqued and require a hydraulic
wrench to remove.
S0600-AA-PRO-120
12-5.7.2 (DV) Remove the 1/8-27 NPTF pipe

plugs in the blade bolt caps using a 3/16-inch
Allen wrench (FN 7.1). Retain plugs and caps
for reinstallation.
12-5.7.3 (DV) Place the blade bolt cap
wrench (FN 5) in the blade bolt cap spanner
holes and tighten into the pipe plug hole.
NOTE
In some cases, the blade bolt
cap plugs are improperly
installed and cannot be
removed. If this occurs, the
blade bolt cap wrench may be
modified (by removing items 1,
2, 3, and 4 from drawing in
Appendix D) so that the wrench
will set on top of the blade bolt
cap and engage the locking pin
holes in the cap. Exercise care
when using the tool in this manner because the blade bolt cap
wrench is not positively
secured on the blade bolt cap.
12-5.7.4 (DV) Using a breaker bar (FN 6.1)
and 1 1/8-inch socket (FN 6.2) attached to the
blade bolt cap wrench, remove the cap from
the blade bolt.
12-5.7.5 (DV, TOP) Pass the blade bolt caps,
the blade bolt cap plugs, the blade bolt cap
wrench, the breaker bar, the 1 1/8-inch socket,
and the 3/16-inch Allen wrench topside.
Inspect caps and plugs for damage (nicks,
deformity, thread damage, improper fit of cap
plugs). The blade bolt caps and the blade bolt
cap plugs should be reused if not damaged.
12-5.8 REMOVE MORGRIP BLADE BOLTS.
12-5.8.1 (TOP) Set up the intensifier for
Mapeco power head pressurization in accordance with the instructions provided in Appendix C.
NOTE

the NAVSEA kit.
12-5.8.2 (TOP) Pass the Mapeco power head
tool, bullet rod, spanner wrench, and 5/8-inch
open end wrench (FN 38.1, 38.5 and 23) to
the divers.
NOTE
Remove Morgrip blade bolts in
the following order: 2, 6, 3, 7, 1,
5, 4, 8. Figure 12-16 shows the
blade bolt numbering on the
blade palm. Bolt hole numbers
a r e s ta m p e d o n to p o f t h e
blade palm next to the respective hole.
12-5.8.3 (DV) Insert the bullet rod, cone end
first, into the blade bolt.
12-5.8.4 (DV) Open the power head stop
WARNING
The power head must have full thread

engagement with the blade bolt to avoid catastrophic failure and possible personnel injury
when the bolt is pressurized. Ensure seven full
turns. Record each power head pressurization
in the logbook provided..
12-5.8.5 (DV) Thread the power head onto
shows the power head/Morgrip bolt assembly
12-51
S0600-AA-PRO-120
Figure 12-16. Blade Bolt Numbering.
12-5.8.6 (DV) Back the power head off from

the bolt head to 1 turn and retighten by
hand to ensure that false bottoming has not
occurred since the bolt head flange and the
power head interface are not visible on the
installed bolt. Seat the power head firmly
using the spanner wrench.

12-5.8.7 (DV) Close the power head stop

valve, then open it no more than to turn.
12-5.8.8 (DV) Remove the sealing plug from

the most accessible power head connection
and connect the HP tube from the surface as
shown in Figure 12-17. Inform topside when
ready to purge the HP tube.
NOTE
Figure 12 -17, an i nter nally
12-52
12-5.8.9 (TOP, DV) Start and operate the

intensifier pump by opening the air supply
valve until a steady stream of hydraulic fluid
(no air) bleeds from the loosened connection
opposite the HP tube in the power head. Fill
S0600-AA-PRO-120
Figure 12-17 Power Head/Morgrip Bolt Assembly.
12-53
S0600-AA-PRO-120
the intensifier reservoir with hydraulic fluid as

tank level drops. Tighten the bleed connection
with the 5/8-inch wrench to seat firmly (DO
NOT OVERTIGHTEN).
surize for another attempt. Cycling the power

head through several pressurizations may
loosen the bolt.
12-5.8.16 (DV, TOP) If the removal of any
remaining bolt becomes difficult, install a
hydraulic temporary bolt in accordance with
steps 12-5.9.1 through 12-5.9.8 next to the
problem bolt and repeat the removal attempt.
WARNING
the power head.
12-5.8.10 (DV) Swim clear of the power head
and inform topside that HP tube is purged and
connected securely.
12-5.8.17 (TOP) If no bolts can be loosened

at 37,500 psi, on deck personnel must disassemble, inspect, and clean all component
parts of the power head in accordance with
the drawing provided with the power head to
ensure their proper function. If the internal
pressure tire seal to the valve stem has
failed, the tire must be replaced. Reassemble
the power head, test in accordance with the
drawing, and return to step 12-5.8.1.
CAUTION
12-5.8.18 (DV) When a blade bolt has been
loosened, close the power head stop valve to
isolate the pressure in the power head from
the pressure in the HP tube.

12-5.8.11 (TOP) Increase the intensifier pressure to 35,000 psi by slowly opening the air
supply valve. Secure the air supply valve
12-5.8.12 (TOP) Notify
35,000 psi is reached.
the
divers
when
12-5.8.13 (DV) Apply the spanner wrench to

the power head and attempt to loosen the
pressurized blade bolt. If bolt loosens, proceed to step 12-5.8.18.
12-5.8.14 (DV, TOP) If the bolt does not come
loose, increase the pressure in 500-psi increments, and try again. Do not exceed 37,500
psi.
12-5.8.15 (DV, TOP) If the attempt to remove
the first bolt is unsuccessful, bleed pressure at
the intensifier, check connections, and repres-
12-54

and the HP tube by slowly opening the
Inform the divers that the intensifier and HP
tube have been depressurized.
WARNING
High pressure oil jets can penetra te the skin. D ivers m ust
HP tube.
12-5.8.20 (DV) Disconnect the HP tube from
the power head. Reinstall the sealing plug into
the exposed tubing connection fitting.
12-5.8.21 (DV) Remove the blade bolt and
attached power head assembly from the
S0600-AA-PRO-120
blade. Lift the entire assembly to the surface in

a diver tool bag. Do not loosen the power
head stop valve underwater.
WARNING
High pressure oil jets can penetrate the skin. Ensure topside
personnel are clear of the valve
opening when depressurizing
the power head.
12-5.8.22 (TOP) Remove one of the sealing
plugs from a pressure connection port. Direct
the orifice of the power head stop valve away
from personnel into a proper waste oil container. Open the power head stop valve to
depressurize the power head.
12-5.8.23 (TOP) Remove the bolt from the
depressurized power head using the spanner
wrench (FN 23) and strap wrench (FN 25).
Sheet rubber wrapped around the shank of
the bolt may give a better grip with the strap
wrench.
12-5.8.24 (TOP) Remove the bullet rod from
the bolt. A special removal tool (FN 38.4) is
provided if suction makes bullet rod removal
difficult.
12-5.8.25 Repeat steps 12-5.8.2
12-5.8.24 for remaining blade bolts.
through
12-5.8.26 (TOP) Remove the used Nylok pellet (see Figure 12-22) from each bolt. Use a
1/16-inch drill bit to center drill the pellet and
then stick a scribe into the hole to pry out the
pellet.
polished, external bolt surfaces must be liquidpenetrant inspected in accordance with
NAVSEA Technical Publication 271. Group VII
(solvent-removable) and Group IV (waterwashable) fluorescent penetrant systems are
permitted for this application. Acceptance criteria shall be in accordance with MIL-STD-
2035A, paragraph 7.6. Surface blemishes or

polishing with a Scotch-Brite pad. Do NOT use
emery cloth or sand paper for polishing. All
polished bolts must be reinspected as detailed
above. The Morgrip blade bolts that pass
inspection are to be reused with the replacement blades.
(FN 152) in accordance with Appendix E.
Ensure that the trailing edge clamp has DD
963/DDG 993/CG 47 pads installed.
(FN 162) to the forward hole of the head
clamp.
to the aft hole of the head clamp.
12-5.9.5 (TOP) Connect the aft shackle on
the head clamp to the transfer line. Lower the
lifting assembly down the transfer line.
12-5.9.6 (DV) Connect the single hook of the
forward manual lever hoist to the 3/4-inch
shackle attached to the forward hole of the
head clamp.
12-5.9.7 (DV) Using the forward manual lever
hoist, rig the lifting assembly onto the blade.
One diver should be guiding the leading edge
clamp onto the blade while another operates
the lever hoist.
12-5.9.8 (DV) Ensure the head clamp is centered on the blade.
Change 1
12-55
S0600-AA-PRO-120

F.
12-5.9.10 Ensuring slack is in the forward
lever hoist, diver #1 maintains the center of
the head clamp at the center of the blade.
Diver #2 tightens the head clamp to trailing
edge clamp turnbuckles on the aft and forward
faces until snug. This will assist in keeping the
head clamp from sliding along the edge
towards the leading edge. Diver #2 then tightens the head clamp to leading edge clamp
turnbuckles until snug. Once this is complete,
diver #2 tightens the trailing edge clamp to
leading edge clamp turnbuckles on the aft and
forward faces until snug.
12-5.9.11 (DV) Recheck that the head clamp
is still centered on the blade.
clamp with the forward lever hoist to seat the
12-5.9.13 (DV) Slacken the forward lever
12-5.9.14 Check Forward Lever Hoist.
Because the blade must be lifted directly up to
avoid binding, the vertical hang of the lever
hoist must be checked against the actual
blade position.
WARNING

will be rotating.
12-5.9.15 (DV, TOP) Remove the forward
lever hoist hook from the head clamp of the
12-56
lifting assembly and allow the hook to hang

plumb. Check to ensure that the hook is
directly above one of the head clamp shackle
positions. If the hook is not directly above and
in line with a head clamp shackle position,
rotate the shaft the required distance and
direction to correct for port and starboard misalignment.
12-5.9.16 (DV) Reconnect the forward lever
hoist hook to the shackle position on the head
clamp with the best alignment.
12-5.9.17 Lifting Blade. (DV)
Diver
#1
moves into position at the forward lever hoist.
Diver #2 moves to the blade palm/hub interface.
12-5.9.18 (DV) Diver #1 takes the slack out of
the forward lever hoist. Diver #2 places both
hands on the blade palm/hub in the vicinity of
bolt holes #1 and #4.
12-5.9.19 (DV) Diver #1 takes up on forward
lever hoist. At the same time Diver #2 reports
movement of the blade palm (indicating that
the blade palm made true upward progress
from the hub or that the trailing or leading
edge of the blade palm moved first).
12-5.9.20 (DV) Diver #1 continues taking up
on the forward lever hoist until diver #2 reports
no blade palm movement. Do not exceed a
heavy strain (manual lever hoist too tight to
move) with the lever hoist.
WARNING
CAUTION
S0600-AA-PRO-120
or other equipment.
CAUTION
12-5.9.21 (DV) If diver #2 reports that the
blade palm initially moved but that the blade
palm is no longer moving, then diver #1 needs
to shake the blade tip VIGOROUSLY while
diver #2 reports any upward travel of the blade
palm. As long as steady upward progress is
made, continue with the shake and pull
approach.
12-5.9.22 (DV/TOP) If diver #2 reports that
the blade palm did not initially move or the
shake and pull approach is not moving the
blade palm, the dowel pins are binding and the
binding must be relieved. The dowel pin binding may be caused by fore or aft misalignment
of the forward lifting tunnel with the center of
the propeller hub. If observation indicates that
fore or aft misalignment may be a problem,
lower the blade and try repositioning the head
clamp shackle to a more forward or aft position. If the above fore or aft adjustment does
not relieve the dowel pin binding, proceed with
the shaft rotation method. This is a trial-anderror process that may need to be repeated
several times to find the appropriate position.
If diver #2 reports that the blade palm did not
initially move, the direction of shaft rotation
must be selected arbitrarily.
12-5.9.23 Relieve Dowel Pin Binding. (DV)
If a good degree of upward movement was
encountered and ceased before the blade
became free, then divers are required to measure the spacing between the blade palm and
propeller hub to assist in determining the best
direction to rotate the shaft. Using a 1/16-inch
increment steel ruler (FN 15), record the dis-
tance between the hub face and the shoulder

recess of the blade bolt hole as shown in Figure 12-18. These measurements need to be
#8.
12-5.9.24 (DV, TOP) If the starboard side
measurements are greater than the port side,
then the starboard side of the hub may be
the port side measurements are greater, then
the shaft should be rotated to starboard. If
there is no clear difference between port and
starboard measurements, then arbitrarily
select the direction of rotation. Record and
keep all measurements for the duration of the
removal process in order to monitor progress.
WARNING

will be rotating.
12-5.9.25 (DV) Slack the forward lever hoist
hook from the head clamp and prepare with
Ships Force to rotate the shaft.
WARNING

12-57
S0600-AA-PRO-120
Figure 12-18. Morgrip Bolt Hole Measurements.
12-5.9.26 (SF) Rotate the shaft for a count of

one second (bump) in the desired direction.
12-5.9.27 (DV, TOP) Try again to lift the
blade. Again, the shaft rotation method of
relieving dowel pin binding is often trial and
error to find the right position, so adjustments
may need to be repeated.
the first successful blade removal shaft rotation position is found inside the ship, within
communication range of the jacking gear operator, benchmark the position on the shaft and
a location that does not rotate with the shaft.
Then measure the shaft circumference and
mark five equally spaced marks on the shaft to
identify the other blade removal locations. Label each mark with corresponding blade number.
12-58
12-5.9.29 Retrieve Blade to Surface. (DV)

Note the location of the dowel pins and the
prairie air nipple (in the hub or blade palm).
Report the locations topside.
12-5.9.30 (DV) Connect the hook of the aft
lever hoist to the aft 3/4-inch shackle of the
head clamp.
12-5.9.31 (DV) Yard and stay the blade aft
until the blade palm has cleared the propeller
hub.
12-5.9.32 (DV) Remove the dowel pins and
the prairie air nipple from either the hub or the
blade palm and send them topside. A special
dowel pin removal tool (FN 13) is available for
use on dowel pins that are hard to remove.
12-5.9.33 (DV) Continue the yard-and-stay
process until the full weight of the blade is
S0600-AA-PRO-120
12-5.9.34 (DV) Disconnect the forward lever

hoist hook from the forward 3/4-inch shackle
on the head clamp. Lower the blade just below
the hub with the aft lever hoist.
12-5.9.35 (TOP, DV) Install a pendant onto
the pier crane. Connect the crane pendant to
the same shackle of the head clamp that the
aft lever hoist is attached. Use an additional
shackle to attach if required. This will help prevent rotation of the blade during the yard and
stay to the crane.
12-5.9.36 (DV, TOP) Take the slack out of the
crane. Check all shackle arrangements for
binding. Yard and stay the blade until the full
weight of the blade is taken by the pier crane.
When the pier crane has the full weight of the
blade, disconnect the aft lever hoist. Raise the
blade to the pier.
12-5.9.37 (TOP) Set the blade upright onto
two 4 x 4 timbers on the pier.
clamp from the assembly by removing the two
shackles joining the leg assemblies (both
sides) to the trailing edge clamp.
12-5.9.39 (TOP) Remove the lifting assembly
from the blade.
NOTE
If all removed blades are set
within reach of the crane
upright on timbers (step 125.9.37) as they are removed,
topside will have plenty of time
to shift removed blades to the
special shipping pallets as new
blades are removed from the
shipping pallets for installation.
12-5.9.40 (TOP) Later, after the new blade
has been prepared and removed from its special container, install the righting fixture (FN
151) onto the old blade. Install three shackles
onto the righting fixture as shown in Figure 1219.
12-5.9.41 (TOP) Flip the blade to a horizontal

position using a two-part lift.
12-5.9.42 (TOP) Position it onto the special
shipping pallet that the new blades were sent
on.
12-5.10 BLADE PORT AND BLADE

INSPECTION AND PREPARATION.
12-5.10.1 (DV) For each empty hub blade
sleeve, and O-ring groove. Figure 12-20
details the hub blade port inspections. ScotchBrite greenie pads work well for cleaning.
12-5.10.3 (TOP) Inspect and clean the previously removed dowel pins and prairie air nipple with an emery cloth (FN 124). Dowel pins
must not be mushroomed or peened at either
end.
CAUTION
12-5.10.4 (TOP) Lubricate the four new prairie air nipple O-rings (FN 16.2, FN 114 for CG
66) with silicone grease (FN 17, FN 115 for
CG 66). Install the four O-rings onto the prairie
air nipple.
12-5.10.6 (TOP) Inspect the two threaded
plug holes in the blade palm. As required,
install a blade palm plug (FN 18, FN 84 for CG
66) into each vacant plug hole using a 3/4-inch
Allen wrench (FN 18.1, FN 116 for CG 66).
12-59
S0600-AA-PRO-120
12-60
S0600-AA-PRO-120
12-61
S0600-AA-PRO-120

WARNING

clamp with the crane chain fall to seat the

will be rotating.
oclock position. Align the bench mark made
12-5.11.2 (TOP) Send the dowel pins (FN 19,
FN 85 for CG 66), prairie air nipple (FN 16.1,
FN 83 for CG 66), two tapered blade guide
pins (FN 14.1, FN 81 for CG 66) and blade
guide pin turning bar (FN 14.2, FN 118 for CG
66) down to the divers.
12-5.11.3 (TOP) Using the righting fixture,
stand the replacement blade to be installed
upright on the blade palm resting on two 4 x
4 wood timbers.
from the blade.
assembly onto the blade as shown in Appendix F. Ensure the head clamp is centered on
the blade. If edge guards are removed from
new blades, ensure a piece of metal edge
guard and rubber material is inserted between
the clamps and the blade for protection. Cover
the sharp edge of the edge guard piece with
tape to protect the diver.
12-62

seated the nipple should extend 4 1/2 inches
12-5.11.9 (DV) Press the dowel pins into the
dowel pin holes by hand until fully seated.
Measure to ensure the dowel pins stick out of
the hub no more than 3 3/8 inches.
NOTE
pressure should be applied.
into bolt holes #2 and #6 of the blade port.
CAUTION
plate O-ring (FN 20, FN 120 for CG 66) and
the heavy grease (FN 21, FN 121 for CG 66)
to the divers.
12-5.11.12 (DV) Partially fill the O-ring groove
in the cover plate with heavy grease. The Oring groove is indicated in Figure 12-20.
NOTE
S0600-AA-PRO-120

grease.
the forward 3/4-inch shackle of the head
clamp.
rigged blade to 10-15 feet below the water surface adjacent to the aft lever hoist, frame 503.
the aft shackle on the head clamp.
lever hoist.
unhook it from the forward shackle of the head
clamp.
12-5.11.19 (DV) Attach the forward lever
clamp and take the slack out of the forward
lever hoist.
12-5.11.20 (DV) Check the shackle/hook
arrangement on the forward end of the head
clamp to ensure that it does not bind on the
forward corner of the head clamp.
forward lever hoist and diver #2 operating the
aft lever hoist, yard and stay the blade forward
until the blade palm is approximately 2 inches
aft of the propeller hub.
12-5.11.22 (DV) Inspect the dowel pins, prairie air nipple, guide pins, and the cover plate
O-ring for proper installation. Using divers
pneumo, dewater the dowel pin holes in the
blade palm to make penetration of the dowel
pins easier.
the propeller blade port. Ensure that the guide
pins in bolt holes #2 and #6 align with the corresponding bolt holes in the blade palm.

WARNING

will be rotating.
CAUTION

is rotated.
blade palm. If the diver reports the blade port
is not aligned with the suspended blade, then
coordinate with Ships Force and rotate the
shaft the required distance and direction until
the proper position is achieved.
for operating the forward lever hoist, and diver
#2 moves into position at the blade port to
report the progress of the installation.
the forward lever hoist onto the guide pins until
12-63
S0600-AA-PRO-120
the blade palm is approximately 1 inch above

the top of the dowel pins.
WARNING

will be rotating.
CAUTION

is rotated.
12-5.11.28 (DV) Visually check the O-ring
placement. Ensure that the top of each dowel
pin is the same distance from the blade palm.
If not, then rotate the shaft to balance the distance.
visual dowel pin check in the previous step
impossible, ensure blade palm and hub are
aligned by measuring the spacing between the
blade palm and the hub. Using a 1/16-inch
increment steel ruler, record the distance
between the hub face and the shoulder recess
of the blade bolt hole as shown in Figure 1218. These measurements need to be taken
through bolt positions #1, #4, #5, and #8.
12-64

WARNING

and hub.
letting out on the forward lever hoist until diver
#2 reports no downward movement.
CAUTION
WARNING
has ceased, slack the forward lever hoist to a
light strain and have both divers commence
forward lever hoist.
S0600-AA-PRO-120

Figure 12-18. These measurements need to
be taken through bolt positions #1, #4, #5, and
#8.
12-5.11.39 Examine Morgrip Bolt Holes.

12-5.11.40 (DV) If the O-ring is visible, the
blade must be removed clear of the hub and
reinstalled after the O-ring is replaced.
NOTE
12-5.11.35 (DV, TOP) If no downward movement can be achieved by shaking the blade,
down and the shaft should be rotated to port. If
the port side measurements are greater, the
shaft should be rotated to starboard. If there is
no clear difference between port and starboard measurements, arbitrarily select the
direction of rotation. Record and keep all measurements for the duration of the installation
process in order to monitor progress.
12-5.11.36 (DV) Lift the blade until both dowel
pins are disengaged from the blade.
WARNING

blades.
fully seated.
For CG 66 use Paragraph 127.11 through 12-7.14 for bolt

installation.
12-5.11.41 Install Hydraulic Temporary
Bolts. Temporary bolts are used to secure
the blades onto the hub until the Morgrip bolts
are installed. This is necessary to ensure the
blade is properly seated.
12-5.11.42 (TOP) Pass four hydraulic temporary bolt assemblies and the temporary bolt
turning bar to the divers. See Appendix E for a
drawing of the temporary bolts.
12-5.11.43 (DV) Install the temporary bolt
assemblies into holes #1, #4, #5, and #8. Figure 12-16 shows the blade bolt numbering on
the blade palm. Bolt hole numbers are stenciled on top of the blade palm next to the
respective hole.
12-5.11.44 (TOP) Pass the two 2-foot hoses
(FN 9.2) and one 6-foot hose (FN 9.3) down to
the divers.
12-5.11.45 (DV) Connect the hydraulic hoses
into the temporary bolts as follows: 2-foot
hose from position 1 to 4, 6-foot hose from
position 4 to 5, 2-foot hose from position 5 to
8, and 100-foot hose to position 8. This allows
for simultaneous pressurization of all four temporary bolts. Figure 12-21 shows the arrangement for the hydraulic hoses. Inform topside
that the hydraulic hoses are connected
securely. The hose quick-disconnects have
12-65
S0600-AA-PRO-120
Figure 12-21. Hydraulic Hose Schematic.
locking collars that are screwed down by hand

to ensure the connection is secure.
12-5.11.50 Remove Blade Guide Pins. (DV)

Remove the blade guide pins from bolt holes
#2 and #6.
WARNING
12-5.11.46 (TOP) Operate the intensifier to a

pressure of 1500 psi.
12-5.11.51 Check Blade Seating. (DV) Using a 0.002-inch feeler gauge (FN 22), check
the gap between the blade palm and the hub
at bolt holes #2, #3, #6, and #7. If the feeler
gauge penetrates at all, it should have a snug
(touching both sides) fit. Check the gap in two
places along the line of the bolt circle. The
purpose of this check is to determine the final
seating of the blade and that the O-ring installed between the blade palm and the blade
port cover has not been washed out of its
groove during the final seating of the blade.
12-5.11.47 (DV) Hand tighten the temporary

bolt collars onto the bolt shoulders using the
temporary bolt turning bar.
12-5.11.52 Remove Three-Point Lifting

Assembly. (DV) Loosen all of the turnbuckles
on the lifting assembly.

by slowly opening the hydraulic bypass valve
on the intensifier. Inform the divers that the
intensifier has been depressurized.


bolts were to fail.
12-5.11.49 (DV) Disconnect the hydraulic

hoses from the temporary bolts.
12-66

from the blade with the forward manual lever
while the other diver guides the lifting assem-
S0600-AA-PRO-120
bly off the blade so as not to damage the

blade.
12-5.12 MORGRIP BOLT INSTALLATION.
It is very important that both the divers and the
NDT inspection personnel study and understand all aspects of bolt elongation measurement as detailed in Appendix A. Review of the
tutorial discussion provided in Appendix A will
12-5.12.1 (UT) Record the serial number of
each of the eight Morgrip blade bolts (FN 2)
onto the Inspection Report and Worksheet,
Figure A-3 in Appendix A.
12-5.12.2 (UT) Set up the bolts in the installation order (#2, #6, #3, #7, #1, #5, #4, and #8).
12-5.12.4 (TOP) Set up intensifier for Mapeco

Power head pressurization in accordance with
the instructions provided in Appendix C.
12-5.12.5 (TOP) Insert the bullet rod into the
#2 blade bolt, cone end first.
NOTE
above 40,000 psi. It is important that the rupture disc hold
down nut (see drawing that
the NAVSEA kit.
12-5.12.6 (TOP) Open the power head stop
WARNING
CAUTION
a c c o r d a n c e w i t h N AV S E A
12-5.12.3 (UT) Using NAVSEA-approved
ultrasonic measurement procedures and
equipment, record baseline dimension measurements for all eight bolts on the Inspection
Report and Worksheet, Figure A-3. A sample
procedure using NAVSEA-developed equipment is provided in Appendix A.

12-5.12.7 (TOP) Thread the power head onto
12-5.12.8 (TOP) Close the power head stop
valve, then open it no more than 1/4 to 1/2
turn.
12-67
S0600-AA-PRO-120
NOTE
Figure 12 -17, an i nter nally
12-5.12.9 (TOP) Remove a pressure port
sealing plug and connect the HP tube from the
intensifier to the power head as shown in Figure 12-17.
12-5.12.10 (TOP) Pump the intensifier until a
steady stream of hydraulic fluid (no air) bleeds
from the loosened connection opposite the HP
tube in the power head. Fill the intensifier reservoir with hydraulic fluid as tank level drops.
Tighten the bleeding connection with the 5/8inch wrench to seat firmly (DO NOT OVERTIGHTEN).
close the power head stop valve to isolate the

pressure in the power head from the pressure
in the HP tube.
tank and the HP tube by slowly opening the
12-5.12.14 (TOP) Disconnect the HP tube
from the power head using the 5/8-inch
wrench. Reinstall the sealing plug into the
exposed tubing connection fitting.
12-5.12.15 (TOP) Apply thread lubricant (FN
26) to the threads and shoulder of the Morgrip
blade bolt.
12-5.12.16 (TOP) Fill and clamp Hydrolube
dispensers, one for each bolt (FN 163.1) with
200 cc of Hydrolube (FN 163) each and pass
to the divers.
12-5.12.17 (DV) Dewater blade bolt holes #2,
#3, #6, and #7 by displacing the water in the
holes with Hydrolube. Insert the dispenser
nozzle into the bolt hole so the Hydrolube
(heavier than water) fills from the bottom of the
bolt hole. This will displace the water with minimum mixing action.
WARNING
High pressure oil jets can penetrate the skin.

CAUTION
12-5.12.11 (TOP) Increase the intensifier
pressure to 35,000 psi by slowly opening the
air supply valve. Secure the air supply valve
12-5.12.12 (TOP) Confirm stable 35,000 psi
reading on hydraulic pressure gauge, then
12-68
12-5.12.18 (TOP) Send bolt #2 (with power

head attached) and a spanner wrench to the
divers.
12-5.12.19 (DV) Insert the bolt into bolt hole
#2.
12-5.12.20 (DV) Seat the bolt using the spanner wrench.
NOTE
Length of cheater pipe must be
consistent for all bolts.
12-5.12.21 (DV) Attach a 4-foot cheater pipe
(FN 44) to the spanner wrench and tighten the
bolt.
S0600-AA-PRO-120
Figure 12-22. Location of Nylok Pellets in the Morgrip Bolt.
NOTE
A one minute delay is required
to allow hydraulic lock to relieve
itself. It is critical to repeat until
each bolt will no longer tighten.
Send the power head and the bullet rod to the

surface.
12-5.12.26 (DV, TOP) Repeat the bolt installation procedure in the following bolt
sequence: #6, #3, and #7.
12-5.12.22 (DV) Wait one minute, then

tighten the bolt again. Continue tightening the
bolt, with a one-minute pause between efforts,
until the bolt stops advancing.
12-5.12.27 Remove Hydraulic Temporary

Bolts. (DV) Remove the temporary bolts from
bolt holes #1, #5, #4, and #8 by reversing
steps 12-5.11.41 through 12-5.11.49.
WARNING
12-5.12.28 Complete Morgrip Bolt Installation. (DV, TOP) Repeat bolt installation procedure (steps 12-5.12.1 through 12-5.12.25)
for the following bolt sequence: #1, #5, #4,
and #8.
when bleeding the power head.
12-5.12.23 (DV) Loosen one of the pressure
port sealing plugs. Open the power head stop
valve to depressurize the power head and the
Morgrip bolt.
12-5.12.24 (DV) Remove the depressurized
power head from the bolt using the spanner
wrench.
12-5.12.25 (DV) Remove the bullet rod from
the bolt. The special removal tool is provided if
suction makes the bullet rod removal difficult.
12-5.13 MEASURE
LENGTH.
INSTALLED
BOLT

equipment, record the final measurements for
all eight bolts.
12-5.13.2 (UT) Using the Inspection Report
and Work Sheet, Figure A-3, compare the initial and final bolt lengths to determine residual
stretch of bolts #1 through #8. Residual
stretch must be between 0.006 and 0.0084
inches.
12-69
S0600-AA-PRO-120
12-5.13.3 (TOP) If any bolts are outside the

residual stretch required, corrections must be
made as follows. If residual stretch is too low,
reinstall the power head and pressurize to
35,500 psi, then reseat the bolt. If residual
stretch is too high, reinstall the power head
and pressurize to 35,000 psi. Loosen the bolt
and then reseat without the 4-foot cheater bar
on the power head spanner wrench.
12-5.13.4 (UT) Re-measure all eight bolts.
Compare initial and final lengths to determine
residual stretch of all eight bolts. All final residual stretch must be within the specified range
(0.006-0.0084 inches).
12-5.14 BOLT CAP INSTALLATION.
12-5.14.1 (TOP) Prepare two Nylok pellets
(1/4-inch diameter, 9/32 inch long) (FN 10) for
each bolt and pass to divers (one to be
installed and one as a spare).
12-5.14.2 (DV) Install one Nylok pellet into
the hole in the side of the threaded portion of
Morgrip bolt where the bolt cap is to be
installed. Figure 12-22 shows the location of
the Nylok pellet in the Morgrip bolt.
12-5.14.5 (DV) Install the blade bolt cap seal

around the blade bolt flange as shown in Figure 12-22. Using the screwdriver, ensure the
seal is seated at the bottom of the blade
flange hole as shown in Figure 12-22.
NOTE
Check the fit and threads of all
cap plugs in the blade bolt caps
prior to sending the caps to the
divers.
12-5.14.6 (TOP) Pass the blade bolt caps (FN
4), blade bolt cap plugs (FN 7), blade bolt cap
wrench (FN 5), and a 3/16-inch Allen wrench
(FN 7.1) to the divers.
12-5.14.7 (DV) Install the blade bolt caps on
all eight bolts using the blade bolt cap wrench.
Torque to 170 ft.-lbs. using the torque wrench
(FN 6.5) with the 1/2-inch drive to 3/4-inch
drive socket adapter (FN 6.6) and the impact
socket (FN 6.2). See Appendix D for details of
the blade bolt cap wrench.
12-5.14.8 (DV) Dewater the Morgrip bolt
through the pipe plug hole in the cap by displacing the water with 200 cc of Hydrolube.
NOTE
Because access to the Nylok
pellet hole is often partially
obscured by the bolt recess in
the blade palm, one installation
method is to grab the pellet
with needle nose pliers (FN 11)
in order to hold the pellet in line
with the hole and then squeeze
the pellet into the hole with
modified channel lock pliers
(FN 12).
12-5.14.3 (TOP) Apply silicone grease to the
blade bolt cap seals. (FN 8)
12-5.14.4 (TOP) Pass the blade bolt cap
seals and a flat-blade screw driver to the diver.
12-70
12-5.14.9 (DV) Install the blade bolt cap

plugs. Tighten the plugs flush with the caps.
SYSTEMS.
12-5.16.1 (DV/TOP) Remove all tools and
equipment. Derig the transfer line for retrieval
topside.
S0600-AA-PRO-120
12-5.16.2 Take Inventory. (TOP)

Collect,
inventory, and pack equipment and tools.
Mark or red tag damaged or malfunctioning
tools or equipment.
operation.
is: blade bolt liquid penetrate inspection

regarding any problems encountered, new or
special tools needed. The final report should
be faxed or e-mailed to NAVSEA 00C54.
12-71
S0600-AA-PRO-120
12-72
S0600-AA-PRO-120
SECTION 6 DD 963, DDG 993, AND CG 47 CLASS WATERBORNE

BLADE PORT HUB SEAL REPAIR
12-6.1 REFERENCES.
a. NAVSEA S9245-BF-MMM-010, Maintenance Manual for Controllable Pitch
Propeller in DD 963 and DDG 993
Classes.
b. NAVSEA S9245-AF-TRS-010, Technical Repair Standard, Propeller Hub
Assembly and Blades DD 963 and
DDG 993 Classes.
c. NAVSEA S9245-AH-MMA-010, Technical Manual for Controllable Reversible Pitch Propeller for CG 47 Class
Ships.
Naval Vessels.
CAUTION
Removal and replacement of the blade hub
seal requires some special tools and equip-
ment. The find numbers (FN) in the following

paragraphs correspond to the find numbers in
the NAVSEA CPP Blade Change Kit, the
inventory for this kit is available from NAVSEA
00C5. The quantities of items contained in the
CPP Kit are the minimum recommended to be
on hand prior to blade port hub seal repairs.
Replacement parts for five complete blade
seal replacements are included in the
NAVSEA CPP kit. Table 12-6 lists quality
assurance points when repairs are to be
made.
12-6.3 REPAIR PROCEDURE
Note
All item numbers in parenthesis
( ) refer to Figure 12-23 unless
otherwise noted. Find Numbers
(FN) refer to parts list of the
NAVSEA Blade Change Kit.
CAUTION

Manuals and reference d.
12-6.3.1 (DV) Remove affected propeller
blade in accordance with Section 12-5 of this
manual.
12-6.3.2 (DV) Install a quick disconnect hub
pressure test fitting (FN 51.2) (see Appendix I)
into the lower of the two 1/2-inch pipe plug fittings on the forward end of the hub. The two
1/2-inch fittings are approximately 180
degrees apart from each other. DO NOT use
the two 1-1/4 inch pipe plug fittings which are
also located on the forward end of the hub.
12-73
S0600-AA-PRO-120
Table 12-6. DD 963, DDG 993, and CG 47 Class Waterborne Blade Port Hub Seal Repair
Quality Assurance Points.
Quality Assurance Point
Initial
1.
Check for cracked center post sleeve. If cracked, record OD measurement stamped on the
top of center post [12-6.3.3].
2.
Confirm final machined dimensions of the replacement center post sleeve [12-6.3.14(d)].
3.
Check alignment of the center post sleeve jacking assembly [12-6.3.14m].
4.
Verify replacement center post sleeve is flush with the center post [12-6.3.14p].
5.
Measure blade port cover to bearing ring clearance and determine shim requirements [126.3.15].
6.
Ensure blade seal base ring positioning dowel is in position [12-6.3.19].
7.
Inspect the blade seal base ring [12-6.3.20].
8.
Reseat the blade seal base ring [12-6.3.23].
9.
Remove excess O-ring seating grease and ensure Mylar shim is flat [12-6.3.24].
10. Ensure stable oil/water interface is level with hub port opening [12-6.3.25].
11. Observe O-rings in proper position during final seating of blade port cover [12-6.3.26].
12. Check distance between blade port cover and crank pin ring with 0.002-inch feeler gauge
[12-6.3.29].
13. Check dowel pin fit and torque blade port cover cap screws to 33 ft.-lbs. [12-6.3.31].
14. Vent any air trapped in the hub [12-6.3.34].
15. Pressurize the system to check for leaks [12-6.3.36].
16. Final system test [12-6.3.39].
12-6.3.3 (DV) Rotate blade port to the 6

o'clock position. Confirm that the hub center
post sleeve (1) is not loose or cracked. See
Figure 12-23 for identification of the center
post sleeve. If the center post sleeve is
cracked, locate and record the center post (2)
outer diameter measurement which is
stamped on the top of the center post and
have a replacement sleeve machined in
accordance with NAVSEA drawing 6699591,
Center Post Sleeve (see Appendix H). Should
the outer diameter measurement not be
stamped on the top of the center post sleeve,
divers must make a repeatable measurement
of the center post outer diameter using a 12inch outside vernier caliper (FN 63). Experience indicates that special eight-jaw chuck
vice four-jaw chuck lathe equipment is
required to hold machining tolerances on the
thin walled center post sleeve blanks (FN
12-74
52.13). The center post sleeve can be

machined out of solid round stock material on
a standard four-jaw chuck lathe if an eight-jaw
chuck lathe is not available.
12-6.3.4 (DV) Install the second quick disconnect hub pressure test fitting (FN 51.2) into the
other (opposite the one used in step 12-6.3.2)
1/2 inch pipe plug fitting on the forward end of
the hub.
12-6.3.5 (SF, DV) Secure the discharge valve
(1CRP-31 on the hydraulic schematic Figure
2-12 of reference (a)) at the ship's internal
CPP head tank. This will prevent the head
tank from emptying to the sea when the blade
port cover is removed at the 6 o'clock position.
When the blade port cover is first removed,
the oil entrapped in the CPP system will establish internal oil head pressure equal to outside
S0600-AA-PRO-120
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Name
Center Post Sleeve
Center Post
O-ring (dynamic)
O-ring (static)
Blade Port Cover
Capscrew
O-ring (static)
O-ring (dynamic)
Blade Seal Base Ring
O-ring (static)
Spring
Bearing Ring
Crank Pin Ring
Mylar Shim
Reference
FN 52.13
FN 54
FN 55
Item 24 of Figure 8-15a in reference a or FO2 in reference c
FN 60
FN 20, FN 120 for CG 66
FN 56
FN 57
FN 53
FN 67 (DD 963, DD 993, and CG 47 set)
Figure 12-23. Blade Port Assembly.
seawater pressure at the 6 o'clock hub position.
face. The diver must be stable to make the

required detailed measurements.
12-6.3.6 (SF) Secure and tag out the CPP

system.
12-6.3.8 (DV) Remove every other cap screw

(6) holding the blade port cover (5) (unit
weight of cover is 183 lbs.) onto the crank pin
ring (13).
12-6.3.7 (TOP, DV) Rig staging to the propeller under the 6 o'clock blade port or an alternative method for the diver(s) to work from a
stable position for hub component removal.
Wherever the stage is secured to the hub or
blade bases ensure adequate chafing gear is
used to prevent damage to any propeller sur-
12-6.3.9 (DV) Install a handle nut approximately four inches from the top on each of the
four 5/8-11 UNC 30-inch long, all-thread rods.
Make sure the handle on the handle nut is
angled downward. The top of the all-thread
12-75
S0600-AA-PRO-120
rods are opposite the end with the flats

machined for a 1/2-inch wrench. Installing the
handle nuts onto the top of the all-thread rods
prior to installing the all-thread rods avoids the
need to run the handle nut all the way up the
30-inch length of the rods. Install a 5/8-inch
flat washer onto the rod so the handle nut will
bear against the washer and not the blade port
cover. Install the rod assemblies into the holes
emptied in the previous step. Using the flats,
tighten the rod assemblies in place with a 1/2inch wrench.
12-6.3.10 (DV) Run the handle nuts back up
the all-thread rods until they are approximately
1/4 inch from the surface of the blade port
cover.
12-6.3.11 (DV) Remove the remaining four
cap screws holding the blade port cover to the
crank pin ring. The blade port cover should
settle onto the handle nuts installed on the
5/8-inch all-thread rod assemblies.
NOTE
As the blade port cover is lowered, watch for any of the four
O-rings (items 3, 4, 7, and 8)
held in place under the blade
port cover. Also, watch for a
Mylar shim (14), if installed.
12-6.3.12 (DV) Lower the blade port cover
evenly using the four handle nuts until the
blade port cover is approximately 18 inches
from the blade port.
12-6.3.13 (DV) Remove the four O-rings
accessible at this point (see Figure 12-23). If a
Mylar shim is found and is undamaged, leave
it in place. Measurements taken in step 126.3.15 will determine if the Mylar shim should
remain in place, be removed, or be replaced
with a Mylar shim of different thickness.
12-6.3.14 (DV) If the center post sleeve is
cracked or loose, replace as detailed in this
step. If the center post sleeve is not damaged,
proceed with the next step.
12-76
a. Lower the blade port cover and remove

from the all-thread rods.
b. Remove the damaged center post
sl e eve fro m the cen ter po st. Th e
cracked sleeve should slide easily off
the center post.
c. Clean the center post using 360-grit
wet/dry sand paper or Scotch-Brite
pads.
d. In accordance with step 12-6.3.3, the
new sleeve should already be
machined to obtain a 0.002+/-0.0005inch press fit onto the center post (see
NAVSEA drawing 6699591, Center
Post Sleeve, Appendix H).
e. Install the base plate (FN 52.3) on the
four all-thread rods using the handle
nuts. Ensure the handle nuts have full
thread engagement.
f.
Place the Enerpac jack set (FN 9 of

NAVSEA Drawing 6699590, Appendix
H) inside the tabs on the base plate.
g. Place the jacking plate (FN 52.2) on top

of the Enerpac jack set so that the
jacks flat base rests in the indentation
in the jacking plate and the tabs on the
jacking plate are facing up.
h. Spray the inside diameter of the new
center post sleeve with a lubricant that
will not be displaced by the water (LPS3 or equivalent) before the sleeve is
sent to the divers.
i.
Place the new center post sleeve on

th e j acking pla te i nsid e the ta bs.
Ensure that the end of the sleeve with
the taper on the inside diameter is facing up towards the center post.
j.
Place the pipe stand-offs (FN 52.4)

over each of the base plates empty
ho l es a n d sli d e an a l l thr e ad r o d
(wrench flat end on the bottom) through
S0600-AA-PRO-120
the base plate and the pipe stand-offs

threading the end of the rod into the
aligning hole in the crank pin ring. Four
all-thread rods with pipe stand-offs
must be installed. A total of eight allthread rods are required, four with pipe
stand-offs and four without pipe standoffs.
k. Ensure the all-thread rods just installed
are bottomed out in the crank pin ring
bolt holes. Use a wrench on the wrench
flats cut into the end of the rod. Install a
handle nut on each rod.
l.
Using all eight handle nuts, raise the

base plate until it is restrained by all
four pipe stand-offs. The pipe standoffs will ensure the base plate is parallel with the crank pin ring and the jacking plate is set at the proper height.
m. Check the entire setup prior to jacking

the new sleeve. Ensure the taper on
the inside diameter of the sleeve is facing up toward the center post. Ensure
the whole jacking assembly is centered
under the center post.
n. Extend the jack until the sleeve
touches the center post. Verify alignment of the sleeve with the center post.
CAUTION
jacking assembly and restart.
o. Jack the sleeve into place. Do not stop
jacking until the sleeve is flush with the
center post.
p. Retract the jack and verify that the

sleeve is flush with the center post.
Verify that the new sleeve did not crack
during the press fit.
q. Remove the center post sleeve
replacement assembly from the hub
port. Leave four of the all-thread rods in
the crank pin ring.
r.
Install the blade port cover onto the allthread rods.
s. Continue with the next step in the procedure.

12-6.3.15 (DV) Prior to reseating the blade
port cover the measurements shown in Figure
12-24 must be taken to determine if the
required 0.002-0.007-inch clearance will exist
between the bearing ring and the blade port
cover after the blade port cover is bolted to the
crank pin ring. These same measurements
are made when the new hub is first assembled
on the ship and often a Mylar shim must be
added between the blade port cover and the
crank pin ring to ensure that the required
clearance is achieved between the blade port
cover and the bearing ring after assembly.
Over time, the rotation of the crank pin ring will
cause wear on the bearing ring. As the bearing ring wears, dimension B in Figure 12-24
will shorten. Since the blade port cover has no
wearing surface, dimension A on Figure 1224 stays the same. Therefore, over time, the
thickness of Mylar shim required to maintain
the required clearance will decrease until no
shim is required and eventually the clearance
will exceed the maximum, even with no shim.
CAUTION

dimension "B" between an
ring. Dimension "B" must be
12-77
S0600-AA-PRO-120
Figure 12-24. Shim Requirement Measurements.
crankpin ring surface and the

depth micrometer unrepeatable.
CAUTION
equipment kit in a PVC tube for

protection (FN 67). Shims of
0.002, 0.003, 0.004 and 0.005inch thickness are included
with the kit. The shims are also
ava i la bl e fr om th e o r ig i na l
equipment manufacturer
(OEM), Bird-Johnson.
Referring to Figure 12-24, proceed with the
measurements as follows:

continue, eventually causing
worn bearing ring is essential.
NOTE
Mylar shims are very delicate.
They are shipped with the CPP
12-78
a. Perform all measurements to the nearest 0.001 inch and with the blade port
at the 6 oclock position.
b. It is essential that the same diver,
experienced in the use of a depth
micrometer, perform all dimension A
an d B m e a su r e m en t s. Th i s w il l
ensure that variation based on measurement technique will not effect the
difference between A and B.
c. Perform eight measurements around
both the blade port and blade port
cover, one adjacent to each Morgrip
bolt hole. Record the results. Because
of access limitations, dimension B is
more difficult to measure. It is most
S0600-AA-PRO-120
important to be consistent with the

alignment and placement of the depth
micrometer at each location measured.
d. After the most repeatable measurements achievable have been recorded,
average the eight measurements taken
for B.
e. Average the
taken for A.
f.
eight
measurements
If B is greater then A, a shim is

required. The minimum shim thickness
is (B - A) + 0.002 inch. The maximum shim thickness is (B - A) +
0.007 inch.
hub blade port opening. This will allow the ring

to be reinstalled into the same position.
CAUTION
the ring.
g. If B is equal to A or less then A by

up to 0.002 inch, a shim is required.
The shim thickness must be 0.0020.005 inch.
12-6.3.17 (DV) Jack the blade seal base ring

out evenly taking care to avoid warping the
ring. Be prepared to recover the 18 springs
(11) held in place by the blade seal base ring.
h. If B is less then A by more then

0.002 inch, no shim is required. However, if B is less then A by more then
0.007 inch the maximum required
clearance will be exceeded even without a shim.
12-6.3.18 (TOP, DV) Send the blade seal

base ring and the 18 springs to the surface.
Work the blade seal base ring free of the all
thread rods by removing each rod one at a
time and reinstalling outside the blade seal
base ring.
i.
j.
If a shim is required, measure the thickness of any existing shim to determine

if it meets the criteria above. Use a
thickness micrometer to measure the
shim thickness. If an existing shim
does not meet the above criteria,
replace with a new shim. Selection of
shim stock thickness should be based
on an ideal blade port cover to bearing
ring clearance of 0.005 inch.
If no shim is required, any existing shim
must be removed.
12-6.3.16 (DV) Install four 5/16-18 UNC, 4inch long jacking bolts 90 degrees apart into
the threaded through-holes provided in the
blade seal base ring (9). Note the depth of
insertion of the ring relative to the lip of the
12-6.3.19 (TOP) Ensure that the blade seal

base ring positioning dowel pin (3/8-inch diameter x 1 1/4 inch long) remains press fit into
the bearing ring (12).
12-6.3.20 (TOP, DV) Clean and inspect the
blade seal base ring. Inspection tolerances
are specified in reference (b). Install a new Oring (10) onto the OD of the blade seal base
ring and send it to the divers with 18 new
springs.
12-6.3.21 (DV) Work the blade seal base ring
back over the all thread rods by removing and
reinstalling the rods one at a time. Ensure that
the blade seal base ring rests on the cover
plate with the dynamic O-ring groove facing
down against the cover plate.
12-79
S0600-AA-PRO-120
12-6.3.22 (DV) Install the 18 springs into the

bearing ring. Use grease (FN 61), injected into
the bearing ring spring holes with the grease
gun, to hold the springs in position overhead
while the blade seal base ring is positioned in
place. An alternative method to retain the
springs is to dip the first three coils of each
spring in melted beeswax so the OD is
increased just enough to make for a tight
insertion (bearing ring hole is 3/4-inch diameter). If this method is used, ensure that all wax
is removed from the end of the spring so that
the spring will make metal-to-metal contact
with the bottom of the hole.
tank until all seawater is displaced from the

hub.
12-6.3.23 (DV) Push the blade seal base ring

into the groove in the bearing ring by hand,
making sure to align the blade seal base ring
with the positioning dowel pin. Evenly push
the ring into the groove to avoid warping the
ring or damage to the O-ring. Two divers are
required to align and push in the blade seal
base ring far enough to ensure that it stays in
place.
12-6.3.28 (DV) Remove the four 5/8-inch allthread rods and install the remaining four 5/8inch cap screws. Tighten all cap screws
snugly.
NOTE
Ensure that items (3) and (8)
(dynamically loaded O-rings)
are replaced with fully molded
instead of spliced O-rings. Orings supplied by the stock system for items (3) and (8) are
often spliced instead of fully
molded.
12-6.3.24 (DV) Fill the empty O-ring grooves
on the blade port cover ID, the inner and outer
Morgrip bolt hole diameters on the crank pin
ring, and the blade seal base ring (four O-ring
grooves total) with grease and remove any
excess. Seat four new O-rings (3, 4, 7 and 8)
into their appropriate grooves and allow the
grease to hold them in place. Again, remove
any excess grease. If a Mylar shim is installed,
ensure the shim lays flat against the crank pin
ring or blade port cover.
12-6.3.25 (SF, DV) Allow the oil/seawater
interface at the blade port to settle out and
have Ships Force release oil from the head
12-80
12-6.3.26 (DV) Raise the blade port cover

evenly with the handle nuts until it is carefully
seated into place. Be careful to ensure that all
the O-rings remain seated in their proper locations during the final seating of the blade port
cover.
12-6.3.27 (DV) Install four 5/8-inch cap
screws into the available holes to secure the
blade port cover in place.
12-6.3.29 (DV) Check clearance between

blade port cover and crank pin ring in all eight
Morgrip holes with the 0.002-inch feeler
gauge. Confirm no fit or very tight fit of feeler
gauge between the blade port cover and the
crank pin ring. If the feeler gauge is tight, proceed with the next step. If the feeler gauge is
not tight, one or more of the O-rings has
jumped its groove. Lower the blade port cover
and check the four overhead O-rings. Repeat
O-ring and blade port cover installation until
0.002-inch feeler gauge is tight.
12-6.3.30 (SF, DV) Rotate the blade port to
the 12 oclock position.
12-6.3.31 (DV) Ensure that the blade dowel
pins will be able to slide through the blade port
cover into the crank pin ring by placing them
into the blade dowel pin holes. If either is
unable to fit, loosen the blade port cover cap
screws to allow for minor rotational alignment
of the blade port cover with the crank pin ring
until the dowel pins are able to slide in
smoothly. Initial alignment of the two dowel pin
holes will be evidenced by over an inch of
dowel pin insertion. Then, evenly torque all the
cap screws to 33 ft.-lbs. using the torque
wrench (FN 58) and the 1/2-inch Allen socket
(FN 58.4). Recheck the dowel pin fit after the
S0600-AA-PRO-120
cap screws are tight. The dowel pins should

drop the rest of the way into the holes.
12-6.3.32. (DV) Connect hub pressure test
system hoses detailed in Appendix I into the
quick disconnect fittings that where installed in
the hub earlier.
12-6.3.33. (SF) Open head tank valve.
12-6.3.34. (TOP) Vent any air trapped in the
hub from the hose installed at the 12 oclock
position.
12-6.3.35. (SF) Secure the head tank valve.
During the hub pressure test, the return oil
side of the system will be pressurized as the
hub crosshead chamber is pressurized by the
divers.
12-6.3.36. (TOP, DV) Using the barrel pump in
a barrel of clean CPP system oil, pressurize
the hub crosshead chamber to 20 psig. Maintain pressure at 20 psig for 10 minutes while
divers check for leaks at the blade port cover
and the other blades.
NOTE
A value of 20 psig should be
low enough to not lift the cross
head chamber relief valve. In
cases where the pressure consistently drops to some lower
value (10 to 11 psig), use this
new value for the pressure test.
Hold pressure for 10 minutes
and have the divers confirm no
leaks. This will confirm that the
hub seal has been re-established.
surements and perhaps reduce shim thickness. However, if bearing ring wear is
indicated and the hub already has a long service life, the only alternative may be drydock
replacement of the worn bearing ring.
12-6.3.38. Replace blade in accordance with
Section 12-5 of this manual.
12-6.3.39. (SF, DV) Remove out-of-service
tags. Cycle the blade pitch through normal
range of operation several times. Test and
purge the system in accordance with section
6-7 of reference a for the DD 963 and DDG
993 Classes or Section 6-3d of reference c for
the CG 47 Class, MRC 77 6WBM N (R-2W)
and paragraph 12-4.3.40. Have divers check
for leaks around the blade palm and hub interface of all blades during the testing.
12-6.3.40. In performing system test and
purge, supplement the procedure outlined in
MRC 77 6WBM N (R-2W) with the following.
Purge for approximately 15 to 30 minutes. To
open purge valve, (located in hub) take manual control (joystick) and slew pitch astern until
the main system relief valve lifts (1000 psi).
Slew pitch ahead just enough to reset the
main relief valve. Purge valve is now open
allowing oil from the hub crosshead cavity to
be flushed out and returned to the sump for
purification. It should be noted that, if the main
shaft is rotated (turning gear) in conjunction
with the hub purge, this will improve the crosshead cavity flushing operation. Rotating the
shaft during a hub purge is not mandatory and
is left to the Chief Engineer/Main Propulsion
Assistant discretion. Recommend hub purge
be conducted upon each return to port prior to
securing the CPP system.
12-6.3.37. (TOP) If leaking is NOT observed,

proceed to the next step. If leaking is
observed, changes to the Mylar shim thickness based on measurements may not have
been enough to regain sufficient blade port
cover O-ring compression to get a seal. The
procedure may be repeated to confirm mea-
12-81
S0600-AA-PRO-120
12-82
S0600-AA-PRO-120
SECTION 7 DDG 51 "FLEET" TYPE BLADE REMOVAL, RETRIEVAL,

AND REPLACEMENT PROCEDURE
replacements must consider all requirements. If shop facilities are not available at
the Command with the overall tasking, the
Command must arrange for them. A successful blade set change requires one week. Provision must be made for breasting the ship out
by the stern so the blades can be lifted
between the ship and the pier. Crane service,
floating or pierside, must be available for propeller blade lifting and must have the required
reach and angle to handle the propeller
blades. An oil boom is required for oil abatement and containment in accordance with
local instructions. Personnel performing bolt
elongation measurements in accordance with
this procedure shall be certified in accordance
with NAVSEA Technical Publication T9074AS-GIB-010/271 as Ultrasonic Inspector
(Level II , or Level II Limited) or Examiner
(Level III). The following references provide
specific information relevant to removing and
replacing CPP blades:
a. NAVSEA S9245-AM-MMA-010, System Manual for Controllable Pitch Propeller System, DDG 51 Class, Model
156, S1/5.
b. NAVSEA S9245-AT-TRS-010/07309,
Technical Repair Standard for Overhaul Procedures, Propeller Hub and
Blade Assembly.
c. S9086-00-STM-000, Naval Ships'
245, Propellers.
Naval Vessels.
e. MIL-STD-2035(SH) 04 July 1991, Nondestructive Testing Criteria

f.
NAVSEA T9074-AS-GIB-010/271, 30 April

1997, NAVSEA Technical Publication,
Requirements for Nondestructive Testing
Methods (referred to as NAVSEA Technical Publication 271),
12-7.1.1 Applicability. This

procedure
applies to DDG 51 class ships with Fleet
type blades. Within the CG 47 class, CG 66
and higher have torque in place blade bolts
removed and installed in accordance with this
procedure. The blade rigging procedure for all
CG 47 class ships is covered in Section 5 of
this manual.
12-7.2.1 Rig the ships hull with the rigging
beam and the 4.5 ton lever hoist, forward, the
6.0 ton lever hoist, aft, and blade holdback rigging.
rotating the blade into the 12 oclock position,
removing all eight blade bolts connecting the
assembly; lowering the blade into position and
seating the blade onto the hub. Dewater four
blade bolt holes. Install and tighten the four
bolts to 800 ft-lbs. Check the blade for proper
seating.
12-7.2.5 Secure each blade to the hub by
dewatering the four open blade bolt holes,
12-83
S0600-AA-PRO-120
installing remaining blade bolts into the lubricated holes, and fully tightening all bolts.
Measure the installed bolt lengths to determine the proper residual stretch, and install
fairing/sealing plug in blade bolt measurement
cavities.
NOTE
closely together, there are certain steps that must be carried
out by particular personnel. To
clarify these steps, abbreviations are placed at the beginning of each step where the
specific party needs to be identified: (DV) represents diver,
(TOP) represents topside personnel, (SF) represents Ships
Force personnel and (UT) represen ts L evel II Ul tra so ni c
Inspector.
12-7.3 PREPARATION.
NOTE
components. Locally generated work packages shall
ensure that a general tool and
material log sheet is prepared
12-84
and maintained during all

UWSH operations.
Equipment. NAVSEA 00C5 maintains a
CPP blade change kit that contains most of
the tools and equipment necessary to replace
kit is included in the kit and available from
NAVSEA 00C5. Table 12-7 identifies additional items that must be provided by the
repair activity. Ensure the availability of all
technical information, manuals, and drawings.
detailed in Appendix B. Review of the tutorial
discussion provided in Appendix B first will
with Table 12-8.
NAVSEA CPP Blade Change Kit, the inventory for this kit is included in the kit and available from NAVSEA 00C5. The quantities of
items contained in the CPP Kit are the minimum recommended to be on hand prior to
CPP blade removal and replacement. Their
functions are described in the following paragraphs.
S0600-AA-PRO-120
CAUTION

(see figure 12-24A).

1- To n

hoists/falls.
Typical
R unning
B lock
Flip
3 To n

chain loop:
4- To n
6 Ton
Change 1
12-84A
S0600-AA-PRO-120
12-84B
Change 1
S0600-AA-PRO-120

Item No.
Quantity
Technical Specifications
Commercial
Diver Tool Bag
Commercial
Commercial
as required
Commercial
as required
Commercial
as required
Grease Pencils
Commercial
Commercial
as required
Chafing Material
Commercial
Commercial
12-7.4.1 Hydraulic Bolt Torquing Equipment. The hydraulic bolt torquing equipment
is used to tighten the blade bolts. The equipment must be operated in accordance with
manufacturer's instructions.
propeller blade and connected to the pier

crane hook. The righting fixture is used to lift
the propeller blade out of its shipping container and to stand the blade by its palm onto
wood timbers, enabling the blade to be outfitted with the lifting assembly.
CAUTION

dowel pin removal tool is used to remove
stuck dowel pins that cannot be removed by
hand.

charts for the specific operating
head and pump utilized must
be available during operation.
12-7.4.5 Blade Guide Pins. The

blade
guide pins are used to align the blade palm
with the dowel pins at installation.
CAUTION
and
underwater
hydraulic
manufacturer's instructions.
12-7.4.2 Lifting Assembly. The
lifting
assembly (See Appendix F) is attached to a
propeller blade so the blade can be lifted and
lowered with the hook of a lever hoist.
12-7.4.3 Righting Fixture. The righting fixture (See Appendix G) is installed onto the

is a transducer assembly and ultrasonic instrument specially designed to measure the elongation of the blade bolts. The bolt elongation
measurement procedure outlined in Appendix
B allows any Intermediate Maintenance Activity (IMA) Level II Ultrasonic Testing (UT)
inspector to perform measurements with this
equipment.
12-7.4.7 Overhead Rigging Beam. The
overhead rigging beam is installed with the Ubolts on to the lifting tunnels at Frame 442.
This beam provides a single lifting point to
remove and install the blades from the hub.
12-85
S0600-AA-PRO-120
Table 12-8. DDG 51 Quality Assurance Points.

Blade Removal
1.
Inspect rigging [12-7.5]
2.
Ensure pitch is set at full ahead pitch position [12-7.6.1].
3.
Discard used Teflon blade bolt O-ring [12-7.7.6]
4.
Clean blade bolts [Appendix B, B-2.6.2 and 12-7.7.7]
5.
Conduct liquid penetrant inspection of removed blade bolts [12-7.7.8]
6.
Ensure lifting fixture is installed with head clamp 67" from blade tip[12-7.8.9]
7.
Confirm orientation of lifting rigging [12-7.8.16]
8.
Measure blade palm spacing to relieve binding (if required) [12-7.8.18a]
9.
Benchmark the shaft [12-7.8.19]
Blade Installation
1.
Inspect blade port and blade [12-7.9]
2.
Ensure edge guard material is used for lifting fixture clamps [12-7.10.6]
3.
Check prairie air nipple fully inserted [12-7.10.9]
4.
Check dowel pins fully inserted [12-7.10.10]
5.
Ensure O-ring installed in blade port cover [12-7.10.31]
6.
Measure blade palm spacing to relieve binding (if required) [12-7.10.35]
7.
Check for cover plate O-ring washout [Caution prior to 12-7.10.40]
8.
Check blade seating with 0.002-inch feeler gauge [12-7.10.43]
9.
Record serial numbers, hub position, and initial lengths of blade bolts to be installed.
Use Hex Socket Bolt Baseline and Post-Elongation Measurement Worksheet, Figure B4 [12-7.11.2]
10. Install new Teflon Blade Bolt O-Ring and apply lubricant to blade bolt threads and shoulder [12-7.11.4 and 12-7.11.11]
11. Record actual measured bolt elongation as each bolt is torqued. Use Hex Socket Bolt
Elongation Measurement During Installation Worksheet, Figure B-5 [12-7.11.15]
12. Record final length and residual stretch when all eight bolts are installed. Hex Socket
Bolt Baseline and Post-Elongation Measurement Worksheet on Figure B-4 [12-7.12.1]
13. Compare final with baseline and confirm proper residual stretch [12-7.12.2]
14. Ensure blade bolt 2-1/4-inch hex plug, rubber washer, and retaining screw are installed
[12-7.14.1]
15. Test the CPP system performance [12-7.15]
12-86
Initials
Initials
S0600-AA-PRO-120

holes.
Hang the hoist from the 1 1/4-inch safety

shackle. Install a tool bag onto the lever hoist
to stow excess chain out of the way of the
blades.

Rig the ships hull in accordance with Figures
12-25, 12-26, 12-27 with an overhead 4.5-ton
and aft 6-ton lever hoist and the following procedure.
12.7.5.1 Assemble Rigging Beam. Bolt the
two sections of the rigging beam (FN 139)
together in accordance with Appendix K.
12-7.5.2 Overhead Rigging Beam. Feed Ubolts (FN 139.7) through offset lifting tunnels
at frame 442, 9 ft and 17 ft 11-1/4 inches off
centerline. Attach a tagline to the rigging
beam and lower the beam into the water. The
beam is positively buoyant underwater. Have
the divers swim the beam to the work area
and fit the beam onto the U-bolts. Place flat
washers, split washers and nuts on the Ubolts and tighten until the beam is snug
against the hull. Verify that the beam mounting
plates are flush against the lifting tunnels,
reposition as necessary. Securely tighten the
nuts. Place a 7/8-inch anchor shackle in the
forward hole of the lifting padeye on the beam.
12-7.5.3 Overhead Lifting Hoist. Run a 4.5
ton lever hoist (FN 155) to the two blocked
position in order to confirm the chain is not
twisted. Install a tool bag onto the lever hoist
to stow excess chain out of the way of divers.
Pass the lever hoist to the divers and hang
from the 7/8-inch anchor shackle (FN 165) on
the rigging beam.
12-7.5.4 Rig Aft Lever Hoist. Loop one 84
long synthetic sling (FN 143) (ensure the sling
is protected from chaffing using old firehose or
suitable material) through the aft lifting tunnel
at frame 448, 13 ft 8-1/8 inch off centerline.
Attach the ends of the sling together with a 1
1/4-inch safety shackle (FN 166). Run a 6 ton
lever hoist (FN 156) to the two blocked position in order to confirm the chain is not twisted.
12-7.5.5 Rig Forward Holdback Hoist. Fabricate a bridle to attach to the master links on
the forward (suction) face side of the trailing
and leading edge blade lifting fixture clamps.
As close as possible try to have the bridle center the pull approximately 3.5 inches outboard
of the port to starboard centerline of the blade
(blade CG location). The bridle may have to
be adjusted to find the sweet spot when the
blade is lifted. Choker rig a 10 ft synthetic
sling (6000 LB capacity) (FN 144) around the
inboard main bearing strut as the forward
attachment point for the holdback hoist. Position the choke point (hoist attachment point) of
the synthetic sling at the middle of the outboard side of the inboard strut. This position
will act to center the holdback hoist pull with
the port to starboard CG of the blade as much
as possible. Attach a 3 ton lever hoist (FN
153) between the special bridle and the synthetic sling.
WARNING

will be rotating.
INTO THE 12 OCLOCK POSITION.
full ahead pitch position. Benchmarks for
pitch alignment are located adjacent to blade
12-87
S0600-AA-PRO-120
Figure 12-25. Blade Rigging Detail, Key Detail.
#1. Danger tag the pitch controls in the locked

position.
locked position.
CAUTION
Before removing the blade

bolts, measures must be taken
d of Section 12-7.1, Requirements.
12-88
12-7.7 REMOVE BLADE BOLTS.

12-7.7.1 (DV) Remove nylon plug, washer and
retaining screw from 2-1/4 inch hex hole in top
of each blade bolt. Discard the used washers.
12-7.7.2 (TOP) Rig the SWEENEY model
RSL8 female 2 1/4-inch hydraulic torque link.
(FN 78.4). On the surface, test operate the
Sweeney link so that the topside operator and
the diver can become familiar with the operating characteristics of the tool, i.e. short rotation, release switch, allow tool to recycle, and
start again. Note that without a load the tool
hex socket may travel in both directions during
cycle and release, this will not happen under
load and also, the cycle time will be longer
S0600-AA-PRO-120
Figure 12-26. Blade Rigging Details, Hold Back Detail.
under full load and pressure. Position the

Sweeney tool with the hose marked with blue
tape down to tighten and up to loosen.
12-7.7.3 (TOP) In a divers tool bag place two
6 1/2 inch pieces of 2 1/4-inch hex stock, (FN
78.9) two shims (1 and 3 inch) (FN 78.10,
78.11) and pass to the divers along with the
Sweeney Tool. See Figure 12-28.
CAUTION

charts for the Sweeney RSL8
operating head must be available during operation.
CAUTION

and
underwater
hydraulic
manufacturers instructions.
CAUTION
Review the manufacturers
instruction manual for proper
use of the topside hydraulic
pump.
NOTE
Proper shim size and tool reaction location are provided in
Table 12-9 or 12-10 for proper
seating of the tool. Values are
different for right vs. left hand
blades and for tightening vs.
loosening bolts.
12-89
S0600-AA-PRO-120
Figure 12-27. Blade Rigging Details, View at FR 448.
12-7.7.4 (DV) Bolt removal is performed in

the following sequence, #1, #4, #5, #8, #2, #3,
#6, and #7 (see Figure 12-29). Insert the 6 1/2
inch long x 2 1/4 inch hex stock into #1 bolt
head. Locate the proper shim size (1 or 3
inch) and place it over the hex stock. Position
the hydraulic link over the hex stock in the
loosening mode. Adjust the reaction arm of
the hydraulic link to the proper location as
determined in Table 12-9 or 12-10.
NOTE
The diver must ensure that the
hydraulic link stays in place
during tightening and loosening
operations. Diver communication with the tool operator is
critical.
NOTE
Pa ti e n ce i s re q u i r ed w h e n
using the Sweeney tool. The
recycle time is approximately
12 seconds and 12 full cycles
are required for one revolution
of the bolt.
12-7.7.5 (TOP/DV) Apply hydraulic pressure
to the link until #1 bolt is broken loose. Repeat
process in accordance with Table 12-9 or 1210 until all bolts are broke loose. In order to
avoid damaging the bolts, individually remove
each bolt and send it to the surface.
12-7.7.6 (TOP) Discard the used blade bolt
Teflon O-ring.
polished, external bolt surfaces must be
12-90
S0600-AA-PRO-120
Figure 12-28. Hex Socket Bolt With Hydraulic Torque Link.
cleaned in accordance with Appendix B, paragraph B-2.6.2

12-7.7.8 (TOP) Liquid-penetrant inspect all
bolts in accordance with NAVSEA Technical
Publication 271. Group VII (solvent-removable) and Group IV (water-washable) fluorescent penetrant systems are permitted for this
application. Acceptance criteria shall be in
accordance with Reference e, MIL-STD2035A, paragraph 7.6. Surface blemishes or
polishing with a Scotch-Brite pad. All polished
bolts must be re-inspected as detailed above.
The blade bolts that pass inspection are to be
reused with the replacement blades.
CAUTION
Do NOT use emery cloth or
sandpaper for polishing the

blade bolts.
in accordance with Appendix F (FN 152 and
141 or 142). Ensure that the trailing edge
clamp has the appropriate size Delrin pads
installed in accordance with Appendix F.
12-7.8.3 (TOP) Connect one 3/4-inch
shackle (FN 162) capturing two 3/4-inch master links (FN 164) to the aft lifting hole in the
DDG 51 head clamp. The aft hole will be the
pressure face for blades set in the full ahead
position.
Change 1
12-91
S0600-AA-PRO-120
12-7.8.4 (TOP) Connect one 1 1/4-inch

shackle to one of the master links installed
above.
12-7.8.5 (TOP) Connect the 1 1/4-inch
shackle on the master link to the transfer line.
Lower the lifting assembly down the transfer
line.
12-7.8.6 (DV) Connect the hook of the overhead manual lever hoist to the lazy 3/4-inch
master link attached to the 3/4-inch shackle in
the head clamp.
12-7.8.7 (DV) Using the overhead manual
lever hoist, rig the lifting assembly onto the
blade. One diver should be guiding the leading edge clamp onto the blade while another
operates the lever hoist.
12-7.8.8 (DV) Use a grease pencil to mark
the position of the head clamp 67 inches from
the blade tip to the nearest corner of the head
clamp. Also mark the position of the leading
and trailing edge clamps 21 inches from the
bottom edge of the blade to the nearest corner
of each edge clamps.
Note
The 21 inch dimension for positioning the leading and trailing
edge clamps provides a good
starting point to set the length
of the turnbuckles. During
ti gh ten i ng t he cl a mp s m ay
move approximately 1/2 to 1inch.
12-7.8.9 (DV) Place the head clamp on the
blade. Ensure the head clamp is 67 inches
from the blade tip to the nearest corner of the
head clamp.
12-92

F.
12-7.8.11 (DV) Ensuring slack is in the overhead lever hoist, diver #1 maintains the head
clamp at 67 inches from the blade tip to the
nearest corner of the head clamp. Diver #2
tightens the head clamp to trailing edge clamp
snug. This will assist in keeping the head
clamp from sliding along the edge towards the
leading edge. Diver #2 then tightens the head
clamp to leading edge clamp turnbuckles until
snug. Once this is complete, Diver #2 tightens
the trailing edge clamp to leading edge clamp
snug while ensuring each clamp remains at
the marked position.
12-7.8.12 (DV) Recheck that the head clamp
is still at the marked position.
clamp with the overhead lever hoist to seat the
12-7.8.14 (DV) Slacken the overhead lever
12-7.8.15 (DV) Attach the holdback hoist bridle to the
12.7.8.16 (DV) With the lifting rigging securely
in place, confirm the alignment of the 4.5 ton
hoist. The hoist should be positioned for a vertical and slightly aft lift, not tending port or starboard. An obvious port or starboard angle in
the rigging most likely means the shaft needs
to be rotated to bring the blade into better
position if the rigging beam position and head
clamp position were checked carefully. leading
and trailing edge clamps .
S0600-AA-PRO-120
Table 12-9 Sweeney Tool Fit-Up DDG 51: Right Hand Blade
LOOSEN
TIGHTEN
Bolt Position
Shim Size
React Against
Shim Size
React Against
1 inch
Hex in bolt 2
1 inch
Blade*
1 inch
Hex in bolt 3
1 inch
Hex in bolt 1
1 inch
Hex in bolt 4
1 inch
Hex in bolt 2
3 inch
Blade *
1 inch
Hex in bolt 3
1 inch
Hex in bolt 6
3 inch
Blade*
1 inch
Hex in bolt 7
1 inch
Hex in bolt 5
1 inch
Hex in bolt 8
1 inch
Hex in bolt 6
1 inch
Blade*
1 inch
Hex in bolt 7
*Reaction arm may be re-positioned on the hydraulic torque link to achieve a best fit against the blade palm.
Sweeney Tool Fit-Up DDG 51: Left Hand Blade.

LOOSEN
TIGHTEN
Bolt Position
Shim Size
React Against
Shim Size
React Against
1 inch
Blade*
1 inch
Hex in bolt 2
1 inch
Hex in bolt 1
1 inch
Hex in bolt 3
1 inch
Hex in bolt 2
1 inch
Hex in bolt 4
1 inch
Hex in bolt 3
3 inch
Blade*
3 inch
Blade*
1 inch
Hex in bolt 6
1 inch
Hex in bolt 5
1 inch
Hex in bolt 7
1 inch
Hex in bolt 6
1 inch
Hex in bolt 8
1 inch
Hex in bolt 7
1 inch
Blade*
12-93
S0600-AA-PRO-120
Table 12-10. Sweeney Tool Fit-Up CG 66 and Higher: Right Hand Blade.
LOOSEN
TIGHTEN
Bolt Position
Shim Size
React Against
Shim Size
React Against
1 inch
Hex in bolt 2
1 inch
Blade*
1 inch
Hex in bolt 3
1 inch
Hex in bolt 1
1 inch
Hex in bolt 4
1 inch
Hex in bolt 2
3 inch
Blade*
1 inch
Hex in bolt 3
1 inch
Hex in bolt 6
3 inch
Blade*
1 inch
Hex in bolt 7
1 inch
Hex in bolt 5
1 inch
Hex in bolt 8
1 inch
Hex in bolt 6
3 inch
Blade*
1 inch
Hex in bolt 7
Sweeney Tool Fit-Up CG 66 and Higher: Left Hand Blade.

LOOSEN
TIGHTEN
Bolt Position
Shim Size
React Against
Shim Size
React Against
1 inch
Blade*
1 inch
Hex in bolt 2
1 inch
Hex in bolt 1
1 inch
Hex in bolt 3
1 inch
Hex in bolt 2
1 inch
Hex in bolt 4
1 inch
Hex in bolt 3
3 inch
Blade*
3 inch
Blade*
1 inch
Hex in bolt 6
1 inch
Hex in bolt 5
1 inch
Hex in bolt 7
1 inch
Hex in bolt 6
1 inch
Hex in bolt 8
1 inch
Hex in bolt 7
3 inch
Blade*
12-94
S0600-AA-PRO-120
WARNING

WARNING

will be rotating.
lation. Confirm that the beam

is snug against the hull at the
lifting tunnels. If any gap is
observed, slack the hoist and
retighten the U-bolts.
d. (DV) Diver #1 takes up on overhead
lever hoist. At the same time Diver #2
reports movement of the blade palm
(indicating that the blade palm made
true upward progress from the hub or
that the trailing or leading edge of the
blade palm moved first).
e. (DV) Diver #1 continues taking up on
the overhead lever hoist until diver #2
reports no blade palm movement. Do
not exceed a heavy strain (manual
lever hoist too tight to move) with the
lever hoist.
WARNING

CAUTION
12-7.8.17 Lifting Blade.

a. (DV) Take a strain on the holdback
hoist.
b. (DV) Diver #1 moves into position at the
overhead lever hoist. Diver #2 moves
to the blade palm/hub interface.
c. (DV) Diver #1 takes the slack out of the
overhead lever hoist. Diver #2 places
both hands on the blade palm/hub in
the vicinity of bolt holes #1 and #4.
CAUTION
With the hoist under load,

inspect the rigging beam instal-
Blade edges are easily damaged.

Do not strike blade
or other equipment.
CAUTION
f. (DV) If diver #2 reports that the blade
palm initially moved but that the blade
12-95
S0600-AA-PRO-120
Figure 12-29. Blade Bolt Numbering.
palm is no longer moving, then diver #1

needs to shake the blade tip VIGOROUSLY while the lever hoist has a
strain to see if any additional movement can be gotten diver #2 reports
any upward travel of the blade palm.
As long as steady upward progress is
made, continue with the shake and
pull approach. If the blade shows no
sign of movement discontinue the
shake and pull approach.
g. (DV/TOP) If diver #2 reports that the
blade palm did not initially move or the
shake and pull approach is not moving the blade palm, the dowel pins are
b i n d i n g a n d th e b i n d i n g m u s t b e
relieved. The dowel pin binding may
be caused by the holdback hoist being
too loose or too tight. The divers may
want to try loosing or tightening the
12-96
holdback hoist to relieve dowel pin

binding. The holdback hoist rig may
need to be shifted to improve the pull
angle. If the above holdback hoist
adjustment does not relieve the dowel
pin binding, proceed with the shaft rotation method. This is a trial-and-error
process that may need to be repeated
several times to find the appropriate
position. If diver #2 reports that the
blade palm did not initially move, the
direction of shaft rotation must be
selected arbitrarily.
12-7.8.18 Relieve Dowel Pin Binding.
a. (DV) If a good degree of upward movement was encountered and ceased
before the blade became free, then
divers are required to measure the
spacing between the blade palm and
S0600-AA-PRO-120
propeller hub to assist in determining

the best direction to rotate the shaft.
Using a 1/16-inch increment steel ruler
(FN 113), record the distance between
the hub face and the shoulder recess of
the blade bolt hole as shown in Figure
12-30. These measurements need to
be taken through bolt positions #1, #4,
#5, and #8.
b. (DV, TOP) If the starboard side measurements are greater than the port
side, then the starboard side of the hub
may be down so the shaft should be
rotated to port. If the port side measurements are greater, then the shaft
should be rotated to starboard. If there
is no clear difference between port and
starboard measurements, then arbitrarily select the direction of rotation.
Record and keep all measurements for
the duration of the removal process in
order to monitor progress.
WARNING

will be rotating.
c. (DV) Slack the overhead lever hoist
hook from the head clamp and prepare
with Ships Force to rotate the shaft.
WARNING

hazard. Rigging loads will eas-
ily be exceeded if the jacking

d. (SF) Rotate the shaft for a count of one
second (bump) in the desired direction.
e. (DV, TOP) Try again to lift the blade.
Again, the shaft rotation method of
relieving dowel pin binding is often trial
and error to find the right position, so
adjustments may need to be repeated.
the first successful blade removal shaft rotation position is found inside the ship within
communication range of the jacking gear operator, benchmark the position on the shaft and
a location that does not rotate with the shaft.
Then measure the shaft circumference and
mark five equally spaced marks on the shaft to
identify the other blade removal locations.
Label each mark with the corresponding blade
number.
12-7.8.20 Retrieve Blade to Surface.
a. (DV) Note the location of the dowel
pins and the prairie air nipple (in the
hub or blade palm). Report the locations topside. Slack the holdback hoist
until the blade hangs from the overhead hoist. Detach the holdback hoist.
b. (DV) Connect the hook of the aft lever
hoist to the aft 1 1/4-inch shackle of the
head clamp.
c. (DV) Yard and stay the blade aft, until
the blade palm has cleared the propeller hub.
d. (DV) Remove the dowel pins and the
prairie air nipple from either the hub or
the blade palm and send them topside.
A special dowel pin removal tool (FN
12-97
S0600-AA-PRO-120
Figure 12-30. Blade Bolt Hole Measurements.
80) is available for use on dowel pins

that are hard to remove.
e. (DV) Continue the yard-and-stay process until the full weight of the blade is
f.
(DV) Disconnect the overhead lever

hoist hook from the forward 3/4-inch
master link on the head clamp. Lower
the blade just below the hub with the aft
lever hoist.
g. (TOP, DV) Install a pendant onto the

pier crane. Connect the crane pendant
to the same shackle of the head clamp
that the aft lever hoist is attached. Use
an additional shackle attached to the
3/4-inch master link if required. This
will help prevent rotation of the blade
during the yard and stay to the crane.
12-98
h. (DV, TOP) Take the slack out of the

crane. Check all shackle arrangements for binding. Yard and stay the
blade until the full weight of the blade is
taken by the pier crane. When the pier
crane has the full weight of the blade,
disconnect the aft lever hoist. Raise
the blade to the pier.
i.
(TOP) Set the blade upright onto two

4x 4 timbers on the pier.
j.
(TOP) Disconnect the trailing edge

clamp from the assembly by removing
the two shackles joining the leg assemblies (both sides) to the trailing edge
clamp.
k. (TOP) Remove the lifting assembly

from the blade.
S0600-AA-PRO-120
NOTE
If all removed blades are set
within reach of the crane
upright on timbers (step 127.8.20i) as they are removed,
topside will have plenty of time
to shift removed blades to the
special shipping pallets as new
blades are removed from the
shipping pallets for installation.
l.
(TOP) Later, after the new blade has

been prepared and removed from its
special container, install the righting fixture onto the blade. Install two 3/4-inch
and one 1-inch shackle (FN 151.19 &
151.18) onto the righting fixture as
shown in Figure 12-31.
m. (TOP) Flip the blade to a horizontal

position using a two-part lift.
n. (TOP) Flip the blade and position it
onto the special shipping pallet that the
new blades were sent on.
12-7.9 BLADE PORT AND BLADE INSPECTION AND PREPARATION.
12-7.9.1 (DV) For each empty hub blade
sleeve, and O-ring groove. Figure 12-32
details the hub blade port inspections.
Scotch-Brite greenie pads work well for
cleaning.
12-7.9.3 (TOP) Inspect and clean the previously removed dowel pins and prairie air nipple with an emery cloth. Dowel pins must not
be mushroomed or peened at either end.
Ensure new O-rings are used for all installations.

CAUTION

12-7.9.4 (TOP) Lubricate the four new prairie
air nipple O-rings (FN 114) with silicone
grease (FN 115). Install the four O-rings onto
the prairie air nipple.
WARNING

will be rotating.
oclock position. Align the benchmark made
12-7.10.2 (TOP) Send the dowel pins (FN
85), prairie air nipple (FN 82), two tapered
blade guide pins (FN 81) and blade guide pin
turning bar (FN 118) down to the divers.
12-7.10.3 (TOP) Using the righting fixture
(FN 140), stand the replacement blade to be
installed upright on the blade palm resting on
two 4 x 4 wood timbers.
12-99
S0600-AA-PRO-120

from the blade.
12-7.10.5 (TOP) Use a grease pencil to mark
the position of the head clamp 67 inches from
the blade tip to the nearest corner of the head
clamp. Also mark the position of the leading
and trailing edge clamps 21 inches from the
bottom edge of the blade to the nearest corner
of each edge clamps.
assembly (FN 141 or 142 and 152) onto the
blade as shown in Appendix E. Ensure the
head clamp is 67 inches from the tip of the
trailing edge and the leading and trailing edge
clamps are 21 up from the blade palm. If
edge guards are removed from new blades,
cut a piece of metal edge guard and rubber
material to insert between the clamps and the
12-100
blade for protection. Cover any exposed

sharp edges of the edge guard piece with tape
to protect the diver.
NOTE
The blade must be lifted from
the aft hole of the head clamp.
This is the pressure face for left
and right hand blades.
clamp with the crane to seat the leading and
trailing edge clamps on the blade.
S0600-AA-PRO-120
12-101
S0600-AA-PRO-120

seated the nipple should extend 6 1/2 inches
12-7.10.10 (DV) Press the dowel pins into
the dowel pin holes by hand until fully seated.
Measure to ensure the dowel pins stick out of
the hub no more than 3 3/8 inches.
NOTE
pressure should be applied. A
honing tool may be needed to
clean out the dowel pin hole in
the hub.
CAUTION

plate O-ring (FN 120) and the heavy grease
(FN 121) to the divers.
12-7.10.12 (DV) Partially fill the O-ring
groove in the cover plate with heavy grease.
The O-ring groove is indicated in Figure 1232.
NOTE
grease.
the masterlink without the 1 1/4-inch shackle
on the head clamp.
12-102

rigged blade to 10-15 feet below the water surface adjacent to the aft lever hoist.
the 1 -inch shackle in the other masterlink on
the head clamp.
lever hoist.
unhook it from the masterlink on the head
clamp.
12-7.10.19 (DV) Attach the overhead lever
hoist hook to the masterlink on the head clamp
and take the slack out of the overhead lever
hoist.
overhead lever hoist and diver #2 operating
the aft lever hoist, yard and stay the blade forward until the blade is hanging from the overhead hoist aft of the propeller hub. Slack the
aft lever hoist.
12-7.10.21 (DV) Attach the holdback hoist
rigging to the blade.
12-7.10.22 (DV) Inspect the dowel pins, prairie air nipple, and the cover plate O-ring for
proper installation. Using divers pneumo,
dewater the dowel pin holes in the blade palm
to make penetration of the dowel pins easier.
the propeller blade port by taking a strain on
the holdback hoist.
(FN 81) into bolt holes #2 and #6 of the blade
port after the blade is positioned over the hub.
Ensure that the guide pins in bolt holes #2 and
#6 align with the corresponding bolt holes in
the blade palm.
S0600-AA-PRO-120
NOTE
Guide pins need to be installed
through the holes after the
blade is positioned over the
hub. The rigging will not allow
the blade to clear the hub if the
guide pins are in place.
WARNING

will be rotating.
CAUTION
is rotated.
blade palm. Check that the blade port is
aligned with the suspended blade by ensuring
the top of both dowel pins are the same distance from the blade palm. If alignment is
incorrect, first try repositioning or adjusting the
holdback lever hoist to correct the alignment.
If that does not work, coordinate with Ships
Force and bump the shaft the required dis-
tance and direction until the proper position is

achieved.
visual dowel pin check in the previous step
impossible, ensure blade palm and hub are
aligned by measuring the spacing between the
blade palm and the hub. Using a 1/16-inch
increment steel ruler (FN 113), record the distance between the hub face and the shoulder
recess of the blade bolt hole as shown in Figure 12-30. These measurements need to be
#8.
for operating the overhead lever hoist, and
diver #2 moves into position at the blade port
to report the progress of the installation.
WARNING

and hub.
the overhead lever hoist onto the dowel pins.
12-7.10.31 (DV) Make a final visually check
to ensure the O-ring is still in place as the
blade is lowered into position.
12-103
S0600-AA-PRO-120

letting out on the overhead lever hoist until
diver #2 reports no downward movement.
CAUTION

wash out the cover plate Oring. Never allow the overhead
WARNING

has ceased, slack the overhead lever hoist to
a light strain and have both divers commence
The holdback hoist tension will need to be
adjusted during the blade lowering to avoid
dowel pin binding.
overhead lever hoist.
by adjusting/re-positioning the holdback hoist,

down and the shaft should be rotated to port.
If the port side measurements are greater, the
shaft should be rotated to starboard. If there
is no clear difference between port and starboard measurements, arbitrarily select the
direction of rotation. Record and keep all
measurements for the duration of the installation process in order to monitor progress.
12-7.10.37 (DV) Lift the blade until both
dowel pins are disengaged from the blade for
rotation of the shaft.
WARNING

blades.
fully seated.

Figure 12-30. These measurements need to
be taken through bolt positions #1, #4, #5, and
#8.
12-7.10.40 Examine Blade Bolt Holes.
12-7.10.36 (DV, TOP) If no downward movement can be achieved by shaking the blade, or
12-7.10.42 (DV) Remove the blade guide

pins from bolt holes #2 and #6.
12-104

12-7.10.41 (DV) If the O-ring is visible, the
blade must be removed clear of the hub and
reinstalled after the O-ring is replaced.
S0600-AA-PRO-120
12-7.10.43 Check Blade Seating. (DV)

Using a 0.002-inch feeler gauge (FN 122),
check the gap between the blade palm and
the hub at bolt holes #2, #3, #6, and #7. If the
feeler gauge penetrates at all, it should have a
snug (touching both sides) fit. Check the gap
in two places along the line of the bolt circle.
The purpose of this check is to determine the
final seating of the blade and that the O-ring
installed between the blade palm and the
blade port cover has not been washed out of
its groove during the final seating of the blade.
12-7.11 BLADE BOLT INSTALLATION.
NOTE
All blade bolts by now should
have been cleaned and
inspected and returned by the
NDT lab. If all bolts are determined good, reuse all bolts for
installation of the replacement
blade. Replace any bolt that is
proven defective.

detailed in Appendix B. Review of the tutorial
discussion provided in Appendix B will provide
a good general understanding of the responsibilities for the divers and NDT inspectors. See
Appendix J for NAVSEA NDT equipment
details.
12-7.11.2 (TOP/UT)
Using
NAVSEAapproved ultrasonic measurement procedures
and equipment (FN 167 & 112), record baseline (un-stretched) dimension measurements
for all eight bolts. Use Hex Socket Bolt Baseline and Post-Elongation Measurement Worksheet, Figure B-4. A sample procedure using
NAVSEA-developed equipment is provided in
Appendix B.
12-7.11.3 (TOP) Fill and cap four lubricant
dispensers (FN 163.1), one for each of the first
four bolt holes, with 200 cc of Hydrolube (FN
163) each and pass to the divers.
CAUTION

accordance
with
NAVSEA
NOTE
The ultrasonic inspector must
control the flow of work. The
hydraulic pump operator must
wait for direction from the UT
in sp ec tor. Th e di ve r m ust
leave the transducer in place
until the UT inspector calls to
have it moved.
12-7.11.4 (TOP) Install an O-ring (FN 107) in

the O-ring groove on blade bolts #1, #4, #5,
and #8. The special teflon O-ring must be
carefully stretched slightly to fit tightly in the Oring groove on the outer diameter of the bolt
head. Coat the blade bolt threads and the
shoulder on these bolts with nickel based antiseize compound (FN 123).
CAUTION

antiseize compound.
12-7.11.5 (DV) Inject one full dispenser of
Hydrolube into each of bolt holes #1, #4, #5,
and #8. Insert the dispenser nozzle into the
bolt hole so the Hydrolube (heavier than
water) will fill from the bottom of the bolt hole.
This will displace the water with minimum mix12-105
S0600-AA-PRO-120
ing action. Pass dispensers to surface after

use.
ing action. Pass dispensers to surface after

use.
12-7.11.6 (DV) Install blade bolts #1, #4, #5,

and #8 in their respective bolt holes. Insert
hex stock (FN 78.9) in bolt head of #1 and with
a ratchet or speed wrench (FN 111), snug up
tight to seal the bolt hole. Repeat this process
for bolts #4, #5, and #8.
12-7.11.11 (TOP) Install an O-ring (FN 107)

in the O-ring groove on blade bolts #2, #3, #6,
and #7. The special teflon O-ring must be
carefully stretched slightly to fit tightly in the Oring groove on the outer diameter of the bolt
head. Coat the blade bolt threads and the
shoulder on these bolts with nickel based antiseize compound (FN 123).
NOTE
For the Sweeney RSL-8 Link,
set the pump to 1100 psi to
obtain 800 ft-lbs.
12-7.11.7 (DV/TOP) Use the Sweeney Tool
(FN 78) to torque bolts #1, #4, #5, and #8 to
800 ft-lbs. Note that since not all bolts are in
place the tool will have to react against the
blade. The diver should position the tool
and/or adjust the reaction arm on the tool for a
"best fit".
12-7.11.8 (DV) Insert a .002 feeler gauge
(FN 122) into bolt holes #2, #3, #6, and #7
between the blade palm and port cover plate.
This step will verify that blade is, or is not
seated on the port cover. If the feeler gauge
can be inserted at all, it should be a snug
(touching both sides) fit. Any looser fit indicates that the blade is not seated and the
most probable cause is that the port cover Oring is not properly inserted. This problem will
have to be corrected before continuing with
the installation.
CAUTION

antiseize compound.
12-7.11.12 (DV) Install these bolts in their
respective bolt holes. Insert a hex stock (FN
78.9) in bolt head of #2 and with a ratchet or
speed wrench (FN 111), snug up tight to seal
the bolt hole. Repeat this process for blade
bolts #6, #3, and #7.
12-7.11.13 (UT) Assemble the bolt elongation measurement assembly as shown in Figure 12-33. Insert the transducer into the
center hole of the hex stock. Secure the housing hand wheel on the top of the transducer.
Pass the assembly to the divers.
CAUTION
12-7.11.9 (TOP) Fill and cap lubricant dispensers (FN 163.1), one for each of the
remaining four blade bolt holes, with 200 cc of
Hydrolube (FN 163) each and pass to the
divers.
The counter bore of the hex

stock must face down during
assembly to avoid damaging
the transducer assembly.
12-7.11.10 (DV) Inject one full dispenser of

Hydrolube into each of bolt holes #2, #3, #6,
and #7. Insert the dispenser nozzle into the
bolt hole so the Hydrolube (heavier than
water) will fill from the bottom of the bolt hole.
This will displace the water with minimum mix-
12-7.11.14 (DV/UT) As shown in Figure 1233 and 12-34, place the bolt elongation measurement assembly into bolt head #2. Screw
the transducer into the bolt head finger tight
until it comes to an abrupt halt. Using the correct shim and reaction arm location (see
12-106
S0600-AA-PRO-120
Figure 12-33. Bolt Elongation Measurement Assembly.
Figure 12-34. Blade Bolt and Transducer Interface.
12-107
S0600-AA-PRO-120
Tables 12-9 and 12-10), position the hydraulic

torque link over the hex stock in the tightening
mode (blue taped hose down). The weight of
the hydraulic torque link should rest on the
shim. The diver should only have to lightly
hold the link reaction arm against the appropriate reaction arm location. Anything else indicates misalignment of the installation.
Lubricate the underwater matable connector
on the transducer lead with antiseize compound and plug it into the transducer.
CAUTION
If the hydraulic tool is not properly aligned, the UT inspector

will see an initial rise in bolt
stretch on pressurization, followed by a drop in stretch during the return cycle. If this
occurs, the alignment of the
tool must be fixed to prevent
damage to the ultrasonic sensor.
NOTE
Clear communication must be
maintained between the UT
inspector, hydraulic pump operator and diver. The diver must
ensure that the hydraulic link is
properly seated and only
moves to rotate the bolt . The
U T i n sp e ct o r m u s t t e l l t h e
hydraulic pump operator to
start and stop the hydraulic
pump until he observes the correct bolt elongation.
NOTE
Patience is required in the tightening mode. Several cycles of
the hydraulic link may be
required before stretch is
o b s e r ve d . R e m e m b e r th e
hydraulic pump operator must
release the switch and allow
12-108
Change 1
time (approximately 12 seconds) for the tool to reset to

complete a cycle.
12-7.11.15 (DV/UT/TOP) In accordance with
Appendix B, the ultrasonic inspector calls for
hydraulic pressure while ultrasonically measuring bolt elongation for bolt #2. Repeat this
process for bolts #6, #3, #7, #1, #5, #4 and #8
in that order. The required stretch for bolts is
.005 to .007 inch. Record data on the Hex
Socket Bolt Elongation Measurement During
Installation Worksheet, Figure B-5 of Appendix B. This measurement of bolt elongation
(residual stretch) is taken while the bolt is
being installed, this allows the UT operator to
stop the torque when the residual stretch is
just right for each bolt. Record the final torque
applied in figure B-4, Appendix B.
CAUTION
The pace of the operation must

be slow enough to ensure the
UT operator has sufficient time
to monitor bolt elongation,
record ALL data and make calculations. The diver must leave
the transducer in place until
data is logged and the UT operator calls for the transducer to
be moved.
12-7.12 MEASURE
LENGTH.
INSTALLED
BOLT

equipment, record the final measurements for
all eight bolts on the same data sheet used to
record baseline measurements, Figure B-4
Appendix B. The final measurement compared with the baseline measurements will
provide a second measure of the final residual
stretch.
This measurement should be
S0600-AA-PRO-120
extremely close to the measurement taken

while the bolt was being torqued.
12-7.12.2 (UT) Compare the baseline and
final bolt lengths to determine residual stretch
of bolts 1 through 8 using the worksheet, Figure B-4 of Appendix B. Residual stretch must
be between 0.005 and 0.007 inches for all
bolts.
12-7.12.3 (UT/TOP/DV) Since all the bolts
were installed with a correct measured residual stretch, all the final-baseline measures
should simply confirm the correct residual
stretch. The purpose of the second measurement is to confirm that installation of any
adjoining or opposite bolt did not affect the
final stretch of another bolt.
12-7.12.4 (UT/TOP/DV) If any final residual
stretch is outside the specified range contact
NAVSEA 00C5 for further guidance.
12-7.13 REMOVE THREE-POINT LIFTING
ASSEMBLY
12-7.13.1 (DV) Detach the holdback hoist.
Loosen all of the turnbuckles on the lifting
assembly.
from the blade with the overhead manual lever
while the other diver guides the lifting assembly from the blade so as not to damage the
blade.
12-7.14 BOLT NYLON PLUG AND SCREW
INSTALLATION.
12-7.14.1 (DV) As shown in Figure 12-35,
install new rubber washer in base of a polyethylene plug. Install polyethylene plug with
retaining screw into the 2-1/4-inch hex hole in

top of blade bolt. Tighten screw only until
polyethylene plug is flush with top of blade bolt
well.
SYSTEMS.
12-7.16.1 (UT/TOP/DV) Remove all tools
and equipment. De-rig the transfer line for
retrieval topside.
12-7.16.2 Take Inventory. (TOP) Collect,
inventory, clean, and pack equipment and
tools. Mark or "red tag" damaged or malfunctioning tools or equipment.
operation.
is:
blade bolt liquid penetrate inspection
regarding any problems encountered, and recommendations for new or special tools
needed. The final report should be faxed or emailed to NAVSEA 00C54.
Change 1
12-109
S0600-AA-PRO-120
Figure 12-35. Blade Bolt Plug and Screw Installation.
12-110
S0600-AA-PRO-120
APPENDIX A
MORGRIP BOLT ELONGATION MEASUREMENT PROCEDURE
A-1 TUTORIAL DISCUSSION
A-1.1 INTRODUCTION.
This procedure for measuring the elongation
of Controllable Reversible Pitch Propeller
Blade Bolts is a variation of standard ultrasonic thickness gauging. We assume that
inspectors using this procedure are already
proficient in ultrasonic thickness gauging, and
understand the underlying principles. This discussion is a "self-help" document which
explains some of the reasoning behind the
measurement procedure. It should take
approximately four hours of reading and practice to master the measurement procedure.
A-1.1.1 In this tutorial discussion we attempt
to highlight the similarities and differences
between conventional thickness gauging and
bolt elongation measurement. Discussion of
the differences will serve to deepen the
inspector's understanding of the measurement
process, and help avoid problems areas that
can arise from improper application of the procedure.
A-1.2 PRINCIPLES OF OPERATION.
The Bolt Elongation Measurement (BEM) process measures the waterpath that exists
between the face of the BEM transducer and
the bottom of a blade bolt cavity. By comparing this dimension before and after installation,
elongation can be detected and measured.
Velocity variations due to temperature and
salinity changes are compensated by use of a
reference bolt at each stage of the measurement process. When properly applied, the
measurement process is accurate to better
than half a thousandth of an inch.
A-1.2.1 When the Bolt Elongation Measurement tool is inserted into a blade bolt, the
small transducer at the tip of the tool is
brought within about a tenth of an inch of the

bottom of the bolt's cavity. Each ultrasonic
pulse therefore travels through approximately
0.1 inch of water before it reflects back to the
transducer, and shows up as the first interface
echo (IFE). The returning pulse is also
reflected off the face of the transducer, and it
travels back to the bottom of the cavity,
reflects again off the metal surface, and
returns to the transducer as the second IFE.
This process continues, with each signal
attenuated a bit more than the previous one.
In conventional thickness gauging by the contact method, the ultrasonic instrument shows a
series of backwall echoes from the part being
measured, while in this test we display a
series of interface echoes. This test is very
much like a contact thickness test, where the
part being measured is the "piece of water"
that lies between the transducer and the bottom of the bolt. Cleanliness of the transducer
face and the bottom of the blade bolt cavity
are very important since debris which we
would normally ignore cannot be ignored for a
measurement with only half a thousandth of
an inch tolerance.
A-1.2.2 Calibration of the ultrasonic instrument results in an A-scan screen on which
each major division of the screen represents
0.005 inch of waterpath length, and each
minor tick mark along the baseline represents
0.001 inch. Calibration is accomplished by
using a calibration standard that allows the
transducer height above the bottom of the bolt
cavity to be changed by exactly 0.015 inch,
0.020 inch, or 0.025 inch. Changing height of
the transducer adds to the waterpath length,
and causes the ultrasonic echo to move 3, 4,
or 5 major screen divisions, respectively.
A-1.2.3 When properly calibrated, full screen
represents just 0.050 inch, or one twentieth of
an inch. This is very different from conventional thickness gauging setups, where full
A-1
S0600-AA-PRO-120
screen may more typically represent one or

several inches of metal thickness. The very
expanded screen looks different in that the
shape of each pulse is quite visible, and is not
very much of a sharp spike. To increase the
sharpness of the signal, without sacrificing
sensitivity, we have chosen to monitor the
position of the second IFE rather than the first
IFE. The reasoning for this choice follows.
When the waterpath being measured
increases by 0.005 inch (one CRT screen division), the round trip pathlength for the first
interface echo increases by 0.010 inch. For
the second IFE two round trips are involved;
the total pathlength increases by 0.020 inch,
and the echo moves twice as far on the CRT.
Using this echo allows us to get one full
screen division for each 0.005 inch waterpath
change with a less expanded signal, which
makes reading the signal's position easier.
A-1.2.4 To see the increased sensitivity of the
second IFE in practice, follow the Calibration
Procedure through Section A-5.2.1.3, where
the CRT is roughly set up with the main bang
at the left edge of the screen and several interface echoes are visible. Carefully raise the
transducer carrier a few thousandths of an
inch and note that the second IFE moves
twice as fast as the first IFE. The third interface echo, which travels three round trips,
moves three times as fast; it would be an even
more sensitive echo to use, but its signal
strength is unreliable.
A-1.2.5 Each bolt is slightly different, so baseline measurements must be made before
installation. The baseline measurements
establish how much longer or shorter each
bolt is than the reference bolt. Measurements
made after installation will also show each bolt
to be different from the reference bolt, and different from the way it was before installation.
Thus, a bolt which was manufactured 0.0015
inch shorter than the reference bolt, and
ended up 0.0050 inch longer than the reference bolt, would have stretched 0.0065 inch
during installation.
A-2
A-1.3 COMPENSATION FOR TEMPERATURE AND SALINITY CHANGES.

The process of calibrating the BEM system
creates a correspondence between bolt length
and screen position of the interface echo. This
correspondence is based on the velocity of
sound in the water that fills the blade bolt cavity, but velocity can change if temperature or
salinity changes. To see this in practice, calibrate the system in accordance with section
A-5.2, and note that the second interface echo
is at 5.00 screen divisions. Now empty the bolt
and refill it with hot water. The echo will no
longer be at 5.00 screen divisions, but as the
hot water cools down, the echo will drift back
toward 5.00 screen divisions.
A-1.3.1 We assume that the reference bolt
and all of the blade bolts can be kept at about
the same temperature as each other during
baseline measurements. Temperature underwater may be quite a bit different than the
bolt's temperature during baseline measurements, but for measurements on the installed
bolts, we assume that the reference bolt and
the installed bolts are all at about the same
temperature. It is absolutely mandatory that
the reference bolt be right at the underwater
work site in order to achieve the required
accuracy.
A-1.3.2 Accuracy better than 0.0005 inch
can be achieved when these conditions are
met, despite wide differences between baseline and underwater conditions. The key is to
have the reference bolt in exactly the same
condition as the other bolts whenever a measurement is taken.
A-1.4 POTENTIAL PROBLEM AREAS.
Because the required measurement accuracy
is far smaller than an ultrasonic wavelength, it
is crucial that exactly the same part of the
ultrasonic waveform be used for all measurements. The ultrasonic instrument's receiver
section performs a number of functions: amplification of the rf signal, rectification (to produce the "video" signal), and filtering. Reject is
S0600-AA-PRO-120
also available to clip low amplitude portions of

the signal. The point at which the signal
"breaks the baseline" depends on which half
cycle of the waveform is used, and that
depends on gain, reject, and filter choices. As
a general rule, all signals should be brought to
about full screen height using gain, and once a
filter has been selected it should not be
changed. To see the impact of filter choice, set
up on the reference bolt and compare the
echo position when the positive half of the
waveform is used to the position when the
negative half is used - the difference should be
about 0.3 screen divisions (1.5 tick marks).
Also try adjusting the reject level to completely
suppress one or more of the initial peaks;
each time one peak is suppressed the point of
measurement moves over to the next peak the difference should be about 0.6 screen divisions (3 tick marks) when either the positive or
negative half wave rectification is used, and
half that much when full wave rectification is
used. None of these errors are acceptable;
exactly the same part of the waveform must
be measured every time.
A-1.4.1 The bottom of each bolt's cavity is
machined with a cutting tool that may leave a
slightly uneven surface or a tiny bump right in
the center of the flat-bottomed cavity. Certain
bolts may not reflect the ultrasonic pulse as
well as others, leading to a weaker signal from
those bolts. Gain adjustments are required to
ensure that the same part of the waveform is
being measured for each bolt. All signals
should be brought to about full screen height
before looking for the position of the echo. To
see the effect of gain, set up properly on the
reference bolt, with the IFE at 5.000 screen
divisions, and the peak echo at full screen.
Then reduce the peak echo height to about
20% of full screen height and note the position
of the echo. If the part of the signal being used
for measurement was the peak before the
largest peak in the waveform, it may be lost
completely, shifting the reading about 3 tick
marks to the right. Even if this does not occur,
there will be a small shift to the right since the
echo does not rise straight up from the baseline. Note that bolts that are troublesome in
this respect during baseline measurements

will also be troublesome underwater. It is wise
to note those bolts which required extra gain
during baseline measurements, and prepare
to add gain for the same bolts when they are
measured underwater.
A-1.4.2 The BEM tool rests with three legs on
the bolt's upper reference surface, and there
should, theoretically, be only one stable position. However, because some clearance is
required between the tool and the bolt cavity it
is possible to lean on the tool and rock it
slightly, lifting one leg off the bolt's reference
surface. During baseline measurements this is
not likely, since the inspector will not generally
be holding the tool while reading the ultasonic
instrument. Underwater, however, the diver
may keep hold of the knurled part of the tool
while the inspector reads the ultrasonic instrument, and this may tilt the tool. The diver
should be instructed to let go of the BEM tool
after inserting it.
A-1.4.3 The bottom of each bolt's cavity may
not be perfectly flat, and certain rotational
positions may be a bit different from others. To
see this potential problem, set up on any bolt,
and note what happens when you rotate the
transducer carrier through 360q. This is handled in the procedure by requiring alignment of
a scribe line on the transducer carrier with the
thread-lock on the bolt. It is important to
prompt the driver to properly align the tool on
each bolt, including the reference bolt.
A-1.4.4 Debris in the bottom of the bolt cavity
can cause serious errors in the waterpath
measurement, since even the smallest bit of
flotsam is likely to be more than 0.001 inch
thick. Presuming that the bolt cavity is properly
cleaned before baseline measurements are
attempted, it is still possible that a bit of trash
is introduced in the water used to fill the cavity.
The signal will normally be degraded in amplitude, and may change if the BEM tool is
moved. This kind of problem is easily eliminated during baseline measurements, but at
the underwater site it may be necessary to
have the diver "pump" the BEM tool in and out
A-3
S0600-AA-PRO-120
of the bolt cavity or purge the cavity with a

blast of air from the pneumofathometer.
A-1.4.5 It is absolutely essential that the
inspector have full confidence in baseline values; there will be no opportunity to later reconfirm them. Repeated measurements are
recommended, and if any variations over
0.001 inch (i.e. 0.0005 inch) are noted for a
given bolt, the cause of this variation should
be determined and eliminated. Should it be
impossible to get consistent readings, seek
technical support form NAVSEA or the Coastal
Systems Station, Panama City, FL.
A-1.4.6 Elongation measurements are made
by comparing each bolt to the reference bolt,
before and after installation. If the reference
bolt is lost between baseline measurements
and the underwater measurements, the comparison cannot be made. Warn the divers that
the reference bolt is priceless. If at all possible, take the precautionary step of measuring
a spare bolt during baseline measurements.
Should the reference bolt disappear, it may be
possible to obtain a waiver form NAVSEA to
use the spare bolt as a basis for comparisons.
Should this be necessary, seek technical support from NAVSEA or the Coastal Systems
Station.
A-1.5 OUT-OF-RANGE READINGS.
Specifications require 0.006 inch to 0.0084
inch residual elongation, measured with a system accurate to within about 0.0005 inch. It is
generally felt that the specification on residual
elongation accounts for any measurement
uncertainty. There is no reason to restrict the
range of acceptable readings more tightly
within this band of 0.006 inch to 0.0084 inch.
A-1.5.1 When out-of-range readings are
encountered the offending bolts must be
retightened in an attempt to produce acceptable readings. All of the factors that contribute
to bolt elongation are not well understood, but
it is clear that the following variables are
important:
A-4
Seating the blade with temporary bolts
Hydraulic pressure used to stretch the

bolt
Diver-applied torque to seat the bolt
Thread lubrication
Seating surface flatness
A-1.5.2 It is not the inspector's job to produce

acceptable readings. If, at any time, the accuracy of the inspection process comes into
question, the inspector should verify that all
procedural steps have been performed properly (bolt cleanliness, rotational alignment, not
tilting the BEM tool, etc.) and that signal quality is essentially unchanged from baseline
measurements to in-water measurements.
Proof of proper operation can always be supplied by taking the calibration standard underwater and demonstrating that the system
properly measures waterpaths different from
the reference bolt waterpath. Once these
steps have been taken to ensure and demonstrate the measurement process, the actual
value for bolt elongation is up to the divers and
the project engineer.
A-1.6 DIVER TRAINING
The diver is responsible for:
Ensuring that all bolts are clean (free of

oil, air bubbles and debris).
Placing the BEM tool in the bolt specified by the inspector.
Ensuring proper rotational alignment.
Ensuring that the BEM tool is resting

firmly on its three legs.
A-1.6.1 It is useful to familiarize the divers

with the tool and the ultrasonic instrument,
and to show them how sensitive it is. To this
end the system should be set up on site, and
calibrated in accordance with section A-5.2.
A-1.6.2 Show the divers the bolt elongation
measurement tool, or transducer carrier, and
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explain that the transducer sends out ultrasonic pulses much like the fathometer or
depth finder on a boat.
A-1.6.3 Show the divers the reference bolt
and point out that the very bottom of the cavity
is milled flat, and serves as a reflector for the
ultrasound. Point out that the flat surface on
top of the bolt is a reference surface and that
the bolt's elongation is measured from that
surface to the bottom of the cavity.
A-1.6.4 Place the transducer in the reference
bolt, and as you do, explain that the transducer carrier puts the tip of the transducer
about a tenth of an inch away from the flat bottom of the cavity.
have the reference bolt with him. Each reading

on an installed bolt will be preceded by a reading on the reference bolt. After the diver establishes the correct rotational alignment, you will
adjust the signal to 5.00 screen divisions. You
will then ask the diver to put the tool in a specific bolt identified by its position on the hub.
Again the diver will align rotation, and let you
know when it's ready. You will take a reading
and then ask for the transducer to be put back
in the reference bolt and aligned. When all
eight bolts are finished you may call for
repeated measurements on one or more of
them. When all measurements are complete,
the diver will return to the surface with the
BEM tool and the reference bolt.
A-2 SCOPE
A-1.6.5 Pull the transducer out of the cavity

and show the divers that the tip of the transducer is fragile ... warn against bumping it on
the bolt. Put the transducer back into the bolt,
and show that as you insert the tool into the
bolt, it centers the transducer, protecting it
from damage.
A-1.6.6 Show the scribe mark on the transducer carrier and the thread insert hole in the
upper threads on the bolt. Demonstrate proper
rotational alignment.
A-1.6.7 Rock the transducer and show the
divers how the signal moves on the CRT.
Explain that the amount of motion they see is
far more than the allowable 0.0005 inch.
A-1.6.8 Rotate the transducer 360 in the reference bolt to show that the signal may move
due to improper rotational alignment. Emphasize that the required tolerance, 0.0005 inch,
is very tight, and that there is no room for inattention to details.
A-1.6.9 Lift the transducer carrier a bit and
slide a piece of paper under one leg to show
how much the signal is affected. Reiterate that
the system is very sensitive.
A-1.6.10 Explain that when the diver gets in
the water to take elongation readings, he will
This appendix contains a sample procedure

for performing bolt elongation measurements
in accordance with NAVSEA Technical Publication 271, Requirements for Nondestructive
Testing Methods using equipment developed
for this task by the Naval Sea Systems Command (NAVSEA 00C5). The hardware
required by this procedure is completely specified by the referenced engineering drawings.
The following list of components and subassemblies is depicted in NAVSEA Drawing
6698352 as an aid to field operations:
Ultrasonic Test Instrument
Transducer Assembly (pre-assembled)
Bolt Elongation Cable Assembly
Transducer
Transducer Carrier
Transducer Carrier Cap
Calibration Standard
Reference Bolt
This procedure establishes requirements for
ultrasonic measurement of Morgrip bolts used
to attach Controllable Pitch Propeller (CPP)
blades to the hub. These bolts are stretched
prior to installation, and must retain a specific
elongation when properly installed. This procedure establishes the change in length by
measuring both the bolt being installed and a
A-5
S0600-AA-PRO-120
reference bolt which undergoes the same temperature changes as the bolt being installed,
but is not stretched. This procedure also
establishes personnel qualification requirements, inspection material requirements, test
procedures, acceptance standards, and
reporting requirements. Hardware is defined
by NAVSEA Drawing 6698352. NAVSEA 00C
maintains a limited number of systems for use
by field activities.
Note
It is essential that all Ultrasonic
Technicians, especially those
with no bo lt measuremen t
experience carefully review all
of Appendix A and the applicable bolt installation portion of
the blade replacement procedure prior to commencing measurements. A good place to
start your review is Section A-1
of this appendix (Tutorial Discussion).
A-3 REFERENCED DOCUMENTS
a. NAVSEA T9074-AS-GIB-010/271, 30
April 1997, NAVSEA Technical Publication, Requirements for Nondestructive Testing Methods
b. ASTM E 1316-95a, Standard Terminology for Nondestructive Examination
c. NAVSEA Drawing #6698352, Bolt
Elongation M easurement Sys tem,
Assembly
A-4 GENERAL
A-4.2 PRECAUTIONS.
Safety precautions contained in the Installation and Removal procedure must be
observed at all times. Additionally, ground
fault interruption must be used with all underwater equipment requiring AC power.
A-4.3 EQUIPMENT AND MATERIALS.
A-4.3.1 Ultrasonic Instrument. A standard
A-scan type instrument conforming to the
requirements of NAVSEA Technical Publication 271 shall be used. Within six months prior
to use for bolt elongation measurements, the
instrument must be qualified in accordance
with NAVSEA Technical Publication 271 paragraph 6.5.1.1. Records of this instrument qualification must be retained with records of the
bolt installation.
A-4.3.2 Transducer Carrier (Bolt Elongation
Measurement Tool). Figure A-1 shows the
bolt elongation measurement tool which has
been designed for this application. NAVSEA
approval of transducers and associated fixtures is required.
A-4.3.3 Reference Bolt. A standard blade
bolt, modified in accordance with NAVSEA
drawing 6698352, (Appendix J) is supplied by
NAVSEA as part of the Bolt Elongation Measurement system. This bolt must be reserved
for use only as a calibration standard.
A-4.3.4 Calibration Standard. A reference
standard enabling the inspector to position the
transducer carrier in direct contact with the reference bolt (slot #1), 0.015 inch above the bolt
(slot #2). 0.020 inch above the bolt (slot #3), or
0.025 inch above the bolt (slot #4). See Figure
A-2.
A-4.1 DEFINITIONS.
Standard terminology (ASTM E 1316-95a)
related to ultrasonic examination is used
throughout this document.
A-6
A-4.3.5 Couplant. Water is used as the couplant material. The reference bolt and the bolt
being measured must have the same kind of
water in them for valid readings to be taken.
S0600-AA-PRO-120
Figure A-1. Bolt Elongation Measurement Tool.
Figure A-2. Bolt Elongation Measurement Calibration Standard.
A-7
S0600-AA-PRO-120
Figure A-3. Bolt Elongation Measurement Inspection Report and Worksheet

NDT File #:
J.O.N.:
Ship:
Work Center:
System: CRP Controller
Date:
Component: Blade
Job Description: Inspect Morgrip Bolt Elongation

Type of Inspection: Ultrasonic Inspection
DWG NO. NAVSEA 6698352
Inspection STD: S0600-AA-PRO-120
Acceptance STD: S0600-AA-PRO-120
Port:
Project (Ship):
Blade Serial Number:
Ultrasonic Instrument:
Calibration Standard:
Reference Bolt:
Transducer:
Bolt Serial #
and
Position in Hub
NDT Inspector:
A-8
Installed Screen
Position
Date:
Initial Screen
Position
Level III Examiner:
Length Change
(Difference x
0.005 "/div.)
Difference
(Screen div.)
Date:
S0600-AA-PRO-120
Temperature and salinity are salient characteristics of the water.

A-4.3.6 Transducer Cables. Transducer
cables shall be of coaxial construction with a
50 ohm characteristic impedance, approximately 100 feet in length.
A-4.3.7 Ancillary Equipment.
Measuring
and marking tools required for the inspection
shall be chosen by the inspector. Ground fault
interruption is required for all equipment operating off AC power and used by the diver (for
example, lights or the ultrasonic instrument).
A-4.4 POLICY.
A-4.4.1 The Project Engineer shall specify UT
requirements by requesting inspection in
accordance with this procedure.
A-4.4.2 Personnel performing bolt elongation
measurements according to this procedure
shall be certified UT inspectors (Level II).
Additionally, prior to performing bolt elongation
measurements according to this procedure,
inspectors shall demonstrate capabilities as
specified in paragraph A-8.
A-5 PROCEDURE
A-5.1 GENERAL.
This procedure is based upon measurement
of the small gap that is formed between the
face of an ultrasonic transducer and the bottom of a Morgrip bolt's internal cavity, as
sketched in Figure A-1. This gap is filled with
water, and the measurement is essentially a
contact test, where the material to be gauged
is the water. An ultrasonic pulse is launched
into the water gap, and after reflecting from
the bottom of the bolt cavity, the pulse is
received by the same transducer. The time
required from transmission of the pulse until its
reception, multiplied by the speed of sound in
water, gives the round trip distance traveled.
By calibrating the screen of a conventional
ultrasonic instrument the gap, or waterpath,
can be determined.
A-5.1.1 Calibration Standard. As with all

ultrasonic thickness measurements, the
instrument's CRT must be calibrated by positioning echoes from samples of known dimensions. A special calibration fixture (Figure A-2)
provides the necessary water path dimensions
(0.015 inch, 0.020 inch, and 0.025 inch).
A-5.1.2 Temperature and Salinity. This procedure recognizes that the apparent value of
an ultrasonically tested dimension depends
upon temperature and composition, which
influence sound velocity. To minimize the
effect of temperature and salinity differences
in measurements taken before and after
installation, an extra (reference) bolt is measured every time the actual bolts are measured. This reference bolt stays at the same
temperature and is filled with water of the
same salinity as the bolts being installed, but
is not stretched or stressed in any way.
A-5.1.3 Rotational Alignment. Each Morgrip bolt is fabricated with a flat-bottomed hole
that is used for dimensional gauging. However, the flatness of the bottom of the hole
may not have been held to 0.0005 inch. This is
addressed procedurally by requiring that the
transducer carrier be rotationally aligned with
each bolt, for all calibration and in-situ measurements. The transducer carrier has a
scribe line on it. Each Morgrip bolt has a 1/4inch diameter flat-bottomed hole (for a thread
locking insert) in the upper threaded section.
These are to be aligned.
A-5.2 CALIBRATION.
Note
This procedure was developed
for the Stavely 132D Ultrasonic
Instrument. For other instruments, minor differences in the
description of the controls may
exist.
A-5.2.1 Coarse Alignment. This procedure
will ensure that the ultrasonic instrument and
transducer fixture settings are close enough to
A-9
S0600-AA-PRO-120
the final settings that FINE RANGE and FINE

DELAY controls can be used to complete the
calibration.
A-5.2.1.1 Set the ultrasonic instrument's
COARSE RANGE to 1 inch and the COARSE
DELAY to the minimum value. Set the
receiver's frequency selection to match the
transducer, or to wideband (WB).
A-5.2.1.2 Using a conventional 5 or 10 Mhz
contact transducer and steel calibration block,
set the CRT display to show 0.25 inch per division (2.5 inch full screen). A 1/2-inch calibration step should produce echoes at 2, 4, 6, 8,
and 10 screen divisions.
A-5.2.1.3 Change to the Bolt Elongation Measurement (BEM) transducer. Fill the bottom of
the reference bolt with water, and place the
calibration standard on the reference bolt.
Place the BEM transducer fixture in the reference bolt, ensuring proper rotational alignment. Rotate the calibration standard to place
the fixture's legs in the through slots (#1 slots).
A-5.2.1.4 Turn the COARSE RANGE control
to the minimum value (typically 0.25 inch).
A-5.2.1.5 Using the FINE RANGE ("material
calibration" or "material velocity") and FINE
DELAY controls, set the first Interface Echo
(IFE) at 0 and the second IFE at 10 divisions
on the CRT.
A-5.2.2 Fine Calibration.
This procedure
results in a calibrated system where a change
of 0.005 inch in the waterpath between the
transducer and the bottom of the Morgrip
bolt's internal cavity which results in the second interface echo shifting one major division
(five minor tick marks) on the CRT. Each minor
tick will therefore represent 0.001 inch.
A-5.2.2.1 Move the second IFE to 5.00 divisions on the CRT using only the FINE DELAY
control.
A-5.2.2.2 Using gain, filter, and reject controls, obtain an interface echo which presents
A-10
a clearly defined breakpoint. A broadband

(wideband or WB) setting on the receiver and
halfwave rectification produces the most reliable results.
A-5.2.2.3 Lift the transducer carrier slightly,
and rotate the calibration standard so that the
transducer carrier's legs rest in the shallowest
slot (#4 slot). This raises the transducer 0.025
inch above the reference surface of the reference bolt.
A-5.2.2.4 Using only the FINE RANGE (MATL
CAL) control, position the second IFE to 10.00
divisions on the CRT.
A-5.2.2.5 Return the calibration standard to
the position where the transducer carrier's
legs are in the through slots of the calibration
standard.
A-5.2.2.6 Using only the FINE DELAY control,
position the second IFE at 5.00 divisions on
the CRT.
A-5.2.2.7 Repeat steps A-5.2.2.3 through A5.2.2.6 until no further adjustments are necessary. Note that slightly overshooting the
desired positions will speed up this process.
A-5.2.2.8 The linearity of the calibration can
be verified by rotating the calibration standard
to place the transducer carrier's legs in each of
the four sets of slots on the calibration standard. These slots place the transducer directly
on the bolt, and 0.015 inch, 0.020 inch, or
0.025 inch above the reference bolt's reference surface, and should produce echoes
located at 5.0, 8.0, 9.0 and 10.0 screen divisions, plus or minus 0.05 screen divisions (
1/4 tick-marks), respectively. If this is not the
case, and calibration has been performed
properly, then the instrument's linearity is
unacceptable and it must not be used for bolt
elongation measurements.
A-5.2.2.9 Once the system has been calibrated, the FINE RANGE control must not be
moved, and all other instrument settings
except reject, gain, and fine delay must not be
S0600-AA-PRO-120
changed. Record the FINE RANGE control

position, and if possible, lock the FINE
RANGE control in this position to prevent accidental disturbance. From this point on, the
FINE DELAY control, alone, will be used to
adjust the position of the reference bolt signal
to 5.00 screen divisions before each measurement is made.
A-5.3 BASELINE DIMENSION MEASUREMENTS.
A-5.3.1 Carefully clean the internal cavities of
all Morgrip bolts to be used, including the reference bolt. This measurement procedure is
extremely sensitive, and can give erroneous
results if oil or debris is left in the bottom of the
bolts' cavities. Cotton swabs (FN 27) in the
CPP Kit are useful for cleaning the bolt internal cavities.
A-5.3.2 Pour a small amount of water into the
bottom of each bolt. Water from the harbor is
desirable since salinity affects the speed of
sound, and thus the accuracy of results. All
bolts, including the reference bolt, should be
at roughly the same temperature, to minimize
the effect of temperature-induced changes in
the speed of sound. Care should be taken to
keep bolts out of direct sunlight, where radiant
heating may raise temperatures significantly.
A-5.3.3 Place the transducer in the reference
bolt, ensuring proper rotational alignment.
Check the position of the IFE. It should be
positioned at 5 divisions on the CRT, and can
be repositioned using the FINE DELAY control
only. Gain should be set to produce an interface echo height between 80% and 100% of
full screen height.
A-5.3.4 Move the transducer to the bolt to be
measured, ensuring proper rotational alignment. Adjust gain as required to produce an
interface echo height between 80% and 100%
of full screen height. If significant adjustment
is required, the bottom of the cavity may not
be properly cleaned, there may be loose
debris in the cavity, or the reflecting surface at
the bottom of the bolt cavity may not be as flat
or smooth as the reference bolt. After correcting conditions of cleanliness and debris, make
note of bolts which remain "troublesome"
since they will also be "troublesome" when
installed. Note the position of the IFE and
record this screen position as the baseline
measurement for this bolt.
A-5.3.5 Repeat steps A-5.3.3 and A-5.3.4 for
each bolt. Note that each time the transducer
is placed in the reference bolt the IFE should
appear at 5 screen divisions. If adjustments
are required it is likely that the transducer has
not been properly aligned relative to the bolt
(see section A-5.1.3), or that the reference
bolt has not been properly cleaned (see section A-5.3.1).
A-5.4 UNDERWATER MEASUREMENTS
AFTER INSTALLATION.
A-5.4.1 Measurements will be taken with the
blade in the 12 o'clock position to ensure that
the bolt cavities are completely filled with
water. In this position, the transducer carrier
can be allowed to rest in the bolt without being
held by the diver. This helps ensure that it is
not tilted.
A-5.4.2 The diver ensures that each installed
bolt's cavity is clean, and free from oil. Immediately prior to placing the transducer carrier in
each bolt, the diver purges the bolt cavity with
air from the pneoumofathometer.
A-5.4.3 The diver places the transducer carrier in the reference bolt, and ensures proper
rotational alignment. The topside inspector
places the second IFE at 5 divisions on the
CRT using the FINE DELAY control only.
A-5.4.4 The diver moves the transducer carrier to the installed bolt specified by the topside inspector, and rotates it to the proper
position. The topside inspector records the
screen position of the second IFE.
A-5.4.5 Steps A-5.4.2 and A-5.4.3
repeated for each of the installed bolts.
are
A-11
S0600-AA-PRO-120
A-5.5 ELONGATION.
Underwater Measurements
A-5.5.1 Bolt elongation is determined by calculating the difference between the second
IFE's screen position prior to, and after installation of each bolt. Use Figure A-3 (Bolt Elongation Measurement Inspection Report and
Worksheet) to record data. Each major screen
division has been calibrated to represent
0.005 inch. See the example in paragraph A5.2.
Diver installs all bolts, rotate the blade to the

12 o'clock position, and carry the reference
bolt to the underwater work site.
A-6. EVALUATION
Bolts which show an elongation of 0.006 inch
to 0.0084 inch are acceptable. Bolts whose
elongation falls outside this range must be
reinstalled in accordance with NAVSEA procedures.
A-6.1 EXAMPLE.
Baseline Measurements
Place transducer carrier in reference bolt,
rotate to the proper position, and set IFE at 5
divisions on the CRT
..... inspector confirms IFE at 5 divisions.
Place transducer carrier in bolt number XXX,
rotate to the proper position, and read the
position of the IFE
Inspector directs the diver:

Place the transducer in the reference bolt and
align it.
Diver places the transducer carrier in the reference bolt and rotates it until the scribe mark is
aligned with the thread-lock hole.
...... inspector adjusts fine delay to position
IFE at 5 screen divisions.
Inspector directs the diver to place the transducer in the bolt at position X on the blade
palm:
Place the transducer in bolt X and align it.
Diver places the transducer carrier in the bolt
at X position and rotates it to achieve alignment.
...... inspector reads the CRT and records the
IFE position (say, 6.5 screen divisions).
Inspector calculates elongation:
..... inspector records screen position of IFE

(say, 5.8 screen divisions).
Difference:6.5 div. - 5.8 div.) = 0.7 screen divisions
Repeat previous two steps for each bolt.
Length Change:0.7 div. x 0.005"/div = 0.0035"

elongation
For each bolt, record the position on the blade

palm where the bolt will be installed. When
instructing the diver for underwater measurements, refer to the bolt's position rather than
the bolt's serial number. In this example, bolt
XXX will be placed in position X.
A-12
A-7 RECORDING AND REPORTING

All records associated with an underwater
CRP blade change will be maintained by
NAVSEA 00C54.
S0600-AA-PRO-120
A-8 PERSONNEL QUALIFICATION AND

CERTIFICATION REQUIREMENTS
Personnel performing bolt elongation measurements in accordance with this procedure
shall be certified in accordance with NAVSEA
Technical Publication 271 (latest revision) as
an Ultrasonic Inspector (Level II, or Level II
Limited) or Examiner (Level III).
Competence and familiarity with the procedure

and system hardware may be acquired by
repeated measurements on a set of
unstressed bolts. The normal variation of
readings about the mean for any one bolt is
approximately 0.0005 inch. Readings more
than 0.001 inch from the mean indicate
improper application of the procedure, or hardware deficiencies.
A-13
S0600-AA-PRO-120
A-14
S0600-AA-PRO-120
APPENDIX B
HEX SOCKET BOLT ELONGATION MEASUREMENT PROCEDURE
B-1. TUTORIAL DISCUSSION
B-1.1 SCOPE
B-1.1.1 This tutorial covers Controllable
Pitch Propeller (CPP) blade bolt measurement
for hex socket bolts used on the DDG 51
"Fleet" blade and CG 47 (CG 66 and higher)
class ships.
B-1.2 INTRODUCTION
B-1.2.1 This procedure for measuring the
elongation of Controllable Pitch Propeller
Blade Bolts is a variation of standard ultrasonic thickness gauging. We assume that
inspectors using this procedure are already
proficient in ultrasonic thickness gauging, and
understand the underlying principles. This
discussion is a "self-help" document which
explains some of the reasoning behind the
measurement procedure.
It should take
approximately four hours of reading and practice to master the measurement procedure.
B-1.2.2 In this tutorial discussion we attempt
to highlight the similarities and differences
between conventional thickness gauging and
bolt elongation measurement. Discussion of
the differences will serve to deepen the
inspector's understanding of the measurement
process, and help avoid problem areas that
can arise from improper application of the procedure.
B-1.3 PRINCIPLE OF OPERATION
B-1.3.1 The Bolt Elongation Measurement
(BEM) process measures the waterpath that
exists between the face of the BEM transducer and the bottom of a blade bolt cavity.
By comparing this dimension before and after
installation, elongation can be detected and
measured.
Elongation can be measured
directly, during the installation process. Veloc-
ity variations due to temperature and salinity

changes, as well as offsets due to transducer
and cable length variations, are compensated
by use of a reference bolt at each stage of the
measurement process. When properly
applied, the measurement process is accurate
to better than half a thousandth of an inch.
B-1.3.2 For in place measurements, the bolt
elongation measurement assembly is put
together as shown in Figure B-1. Insert the
transducer into the center hole of the hex
stock. Secure the transducer cap on the top
of the transducer. During in water operations,
the assembly is passed to the divers for use
as outlined in section 7.
B-1.3.3 As shown in figure B-1, place the bolt
elongation measurement assembly into the
bolt head. Screw the transducer into the bolt
head until it comes to an abrupt halt. Section 7
provides detailed guidance on operations and
use of in water torquing equipment.
B-1.3.4 As shown in Figure B-2, when the
Bolt Elongation Measurement tool is inserted
into a blade bolt, the small transducer at the
tip of the tool is brought within about a quarter
of an inch of the bottom of the bolt's cavity.
Each ultrasonic pulse therefore travels
through approximately 0.25" of water before it
reflects back to the transducer, and shows up
as the first interface echo (IFE). The returning
pulse is also reflected off the face of the transducer, and it travels back to the bottom of the
cavity, reflects again off the metal surface, and
returns to the transducer as the second IFE.
This process continues, with each signal
attenuated a bit more than the previous one.
In conventional thickness gauging by the contact method, the ultrasonic instrument shows a
series of backwall echoes from the part being
measured, while in this test we display a
series of interface echoes. This test is very
much like a contact thickness test, where the
B-1
S0600-AA-PRO-120
Figure B-1 Bolt Elongation Measurement Assembly
B-2
S0600-AA-PRO-120
REFERENCE
SURFACE
TRANSDUCER
ULTRASONIC INSTRUMENT
COAXIAL CABLE
WATER GAP
TRANSDUCER
FLAT BOTTOM
HOLE
Figure B-2 Hex Socket Bolt Elongation Measurement Tool
part being measured is the "piece of water"

that lies between the transducer and the bottom of the bolt. Cleanliness of the transducer
face and the bottom of the blade bolt cavity
are very important since debris which we
would normally ignore cannot be ignored for a
measurement with only half a thousandth of
an inch tolerance.
B-1.3.5 Calibration of the ultrasonic instrument results in an A-scan screen on which
each major division of the screen represents
0.0025" of waterpath length, and each minor
tick mark along the baseline represents
0.0005". As shown in Figure B-3, the calibration standard for this procedure duplicates the
bolt's geometry, with a moveable piston whose
face simulates the flat bottom of the bolt hole.
The piston is driven by a precision lead screw,
allowing the distance between the transducer
and the piston face to be accurately controlled
in increments of exactly 0.005".
B-1.3.6 When properly calibrated, full screen
represents just 0.025". This is very different
from conventional thickness gauging set-ups,
where full screen may more typically represent

one or several inches of metal thickness. The
very expanded screen looks different in that
the shape of each pulse is quite visible, and is
not very much of a sharp spike. To increase
the sharpness of the signal, without sacrificing
sensitivity, we have chosen to monitor the
position of the second IFE rather than the first
IFE. The reasoning for this choice follows.
The width of the instrument's display is calibrated for distance, but screen width is actually a specific amount of time. For a given full
scale setting, the first and second IFE waveforms will be similar in sharpness because that
depends only on the amount of time corresponding to one wavelength at the transducer's operating frequency, and how much of
the screen width that occupies. However, it
will be easier to read changes in the position
of the second IFE because the corresponding
waterpath change is twice as great as for the
first IFE: for every 0.001" of bolt elongation,
the roundtrip waterpath change for the first
IFE is 0.002", and for the second IFE (which
involves two round trips), it is 0.004" Since it
takes twice as long for the sound to make the
B-3
S0600-AA-PRO-120
BENCHMARK
TRANSDUCER
PRECISION
LEAD SCREW
CALIBRATION
BASE
LEAD SCREW
CAP
Figure B-3. Hex Socket Bolt Calibration Standard
B-4
S0600-AA-PRO-120
two round trips, the signal moves twice as far

(as the first IFE echo) across the display.
B-1.3.7 To see the increased sensitivity of
the second IFE in practice, follow the Calibration Procedure to the point where the CRT is
roughly set up with the main bang at the left
edge of the screen and several interface echoes are visible. Carefully unscrew the transducer carrier part of one revolution and note
that the second IFE moves twice as fast as the
first IFE. The third interface echo, which travels three round trips, moves three times as
fast; it would be an even more sensitive echo
to use, but its signal strength is unreliable.
B-1.3.8 Each bolt is slightly different, so
baseline measurements must be made before
installation.
The baseline measurements
establish how much longer or shorter each
bolt is than the reference bolt. Measurements
made after installation will also show each bolt
to be different from the reference bolt, and different from the way it was before installation.
Thus, a bolt which was manufactured 0.0015"
shorter than the reference bolt, and ended up
0.0050" longer than the reference bolt, would
have stretched 0.0065" during installation.
B-1.4 COMPENSATION FOR TEMPERATURE AND SALINITY CHANGES
B-1.4.1 The process of calibrating the BEM
system creates a correspondence between
bolt length and screen position of the interface
echo. This correspondence is based on the
velocity of sound in the water that fills the
blade bolt cavity, but velocity can change if
temperature or salinity changes. To see this
in practice, calibrate the system in accordance
with the written procedure, then adjust the calibration standard to place the second interface
echo at 5.00 screen divisions. Now empty the
bolt and refill it with hot water. The echo will
no longer be at 5.00 screen divisions, but as
the hot water cools down, the echo will drift
back toward 5.00 screen divisions.
B-1.4.2 We assume that the reference bolt
and all of the blade bolts can be kept at about
the same temperature as each other during

baseline measurements. Temperature underwater may be quite a bit different than the
bolts' temperature during baseline measurements, but for measurements on the installed
bolts, we assume that the reference bolt and
the installed bolts are all at about the same
temperature. It is absolutely mandatory that
the reference bolt be right at the underwater
work site in order to achieve the required
accuracy.
B-1.4.3 Accuracy better than 0.0005" can
be achieved when these conditions are met,
despite wide differences between baseline
and underwater conditions. The key is to have
the reference bolt in exactly the same condition as the other bolts whenever a measurement is taken.
B-1.5 OFFSETS DUE TO DIMENSIONAL
VARIATIONS
B-1.5.1 The total time between the main
bang and the arrival of the second interface
echo determines the position of that echo on
the instruments display. That total travel time
includes electrical propagation through the
coaxial cable, and acoustic propagation
through water between the transducer and the
reflecting surface at the bottom of the bolt or
calibration standard's cavity. It is clear that the
length of the transducer housing determines
how close the transducer is to the reflecting
surface, and will affect the absolute position of
the interface echoes. It is less obvious that
cable length also affects the echoes' positions.
In conventional inspections the effect of cable
length is entirely negligible, but with long
cables it is quite easily measured. The speed
of electrical propagation in the coaxial cable is
about 200,000,000 meters per second (as
compared to the speed of sound in water,
which is about 1500 meters per second). In a
cable 125' long (38 meters) the pulse takes
0.38 microseconds to go down and back;
that's about the same amount of time it takes
sound to travel .023" in water. That soundpath
length corresponds to physical water pathlength one quarter as long (about 0.006")
B-5
S0600-AA-PRO-120
when the position of the second IFE is monitored, since the sound must travel from the
transducer to the reflecting surface, and back,
twice. Variations in cable length will visibly
affect the absolute position of the second IFE,
but this variable is removed by the measurement procedure.
B-1.5.2 For baseline measurements, the
same transducer and the same cable are used
to measure all of the blade bolts and the reference bolt, and the length of each blade bolt is
recorded after subtracting out the length of the
reference bolt. Absolute echo position is
immaterial, since any constant offset (due to
the transducer or cable's length) is subtracted
out. Similarly, when measurements are taken
after all the bolts are installed, the procedure
calls for the reference bolt to be measured insitu, with the same transducer and cable as is
used for the blade bolt measurements. Again,
subtracting the length of the reference bolt
from the length of each blade bolt eliminates
constant offsets. In the case of in-process
measurements, the transducer and cable
remain connected to the transducer during the
entire tightening process, and changes in the
second IFE's position are monitored, not the
absolute position of this echo.
B-1.6 POTENTIAL PROBLEM AREAS
B-1.6.1 Because the required measurement
accuracy is far smaller than an ultrasonic
wavelength, it is crucial that exactly the same
part of the ultrasonic waveform be used for all
measurements. The ultrasonic instrument's
receiver section performs a number of functions: amplification of the rf signal, rectification
(to produce the "video" signal), and filtering.
Reject is also available to clip low amplitude
portions of the signal. The point at which the
signal "breaks the baseline" depends on which
half cycle of the waveform is used, and that
depends on gain, reject, and filter choices. As
a general rule, all signals should be brought to
about full screen height using gain, and once a
filter has been selected it should not be
changed. To see the impact of filter choice,
set up on the reference bolt and compare the
B-6
echo position when the positive half of the

waveform is used to the position when the
negative half is used - the difference should be
about 0.6 screen divisions (3 tick marks). Also
try adjusting the reject level to completely suppress one or more of the initial peaks; each
time one peak is suppressed the point of measurement moves over to the next peak - the
difference should be about 1.2 screen divisions (6 tick marks) when either the positive or
negative half wave rectification is used, and
half that much when full wave rectification is
used. None of these errors are acceptable;
exactly the same part of the waveform must
be measured every time.
B-1.6.2 The bottom of each bolt's cavity is
machined with a cutting tool that may leave a
slightly uneven surface or a tiny bump right in
the center of the flat bottomed cavity. Certain
bolts may not reflect the ultrasonic pulse as
well as others, leading to a weaker signal from
those bolts. Gain adjustments are required to
ensure that the same part of the waveform is
being measured for each bolt. All signals
should be brought to about full screen height
before looking for the position of the echo. To
see the effect of gain, set up properly on the
reference bolt, with the IFE at 5.000 screen
divisions, and the peak echo at full screen.
Then reduce the peak echo height to about
20% of full screen height and note the position
of the echo. If the part of the signal being
used for measurement was the peak before
the largest peak in the waveform, it may be
lost completely, shifting the reading about 6
tick marks to the right. Even if this does not
occur, there will be a small shift to the right
since the echo does not rise straight up from
the baseline. Note that bolts which are troublesome in this respect during baseline measurements
will
also
be
troublesome
underwater. It is wise to note those bolts
which required extra gain during baseline
measurements, and prepare to add gain for
the same bolts when they are measured
underwater.
B-1.6.3 The distance of the transducer
above the bottom of the bolt's flat-bottomed
S0600-AA-PRO-120
hole depends on how far it is screwed into the

bolt. The three feet on which the transducer
assembly rests should come into hard contact
with the bolt's reference surface quite abruptly,
and there should be no more tightening possible after this contact has been made. If the
transducer assembly gets tight, but can still be
turned, it is likely that the bolt's threads are not
properly cleaned; this situation must be corrected before baseline measurements are
taken.
B-1.6.4 Debris in the bottom of the bolt cavity
can cause serious errors in the waterpath
measurement, since even the smallest bit of
flotsam is likely to be more than 0.001" thick.
Presuming that the bolt cavity is properly
cleaned before baseline measurements are
attempted, it is still possible that a bit of trash
is introduced in the water used to fill the cavity.
The signal will normally be degraded in amplitude, and may change if the transducer
assembly is moved. This kind of problem is
easily eliminated during baseline measurements, but at the underwater site it may be
necessary to have the diver "pump" the transducer assembly in and out of the bolt cavity or
purge the cavity with a blast of air from the
pneumofathometer.
B-1.6.5 It is absolutely essential that the
inspector have full confidence in baseline values; there will be no opportunity to later reconfirm them.
Repeated measurements are
recommended, and if any variations over
0.001" (i.e. 0.0005") are noted for a given
bolt, the cause of this variation should be
determined and eliminated. Should it be
impossible to get consistent readings, seek
technical support from NAVSEA 00C5.
B-1.6.6 For elongation measurements that
are made by comparing each bolt to the reference bolt (as opposed to in-process measurements), the same reference bolt must be used
before and after installation. If the reference
bolt is lost between baseline measurements
and the underwater measurements, the comparison cannot be made. Warn the divers that
the reference bolt is priceless. If at all possi-
ble, take the precautionary step of measuring

a spare bolt during baseline measurements.
Should the reference bolt disappear, it may be
possible to obtain a waiver from NAVSEA to
use the spare bolt as a basis for comparisons.
Should this be necessary, seek technical support from NAVSEA or the Coastal Systems
Station.
B-1.7 OUT-OF-RANGE READINGS
B-1.7.1 Specifications require 0.005" to
0.007" residual elongation, measured with a
system accurate to within about 0.0005". It is
generally felt that the specification on residual
elongation accounts for measurement uncertainty; there is no reason to further restrict the
range of acceptable readings with logic like in
order to be real sure the stretch is between
0.005" and 0.007" we better get a reading
between 0.0055" and 0.0065". In-process
measurements typically aim for 0.0065"
stretch, but tightening may result in any
acceptable stretch.
B-1.7.2 When stretch is also calculated from
baseline and final underwater measurements,
the calculated values must also be in the
acceptable range. If the blade is not properly
seated on the hub before bolts are installed, it
is possible that in-process stretch will be
altered by the installation of subsequent bolts.
This can be caused by an improperly seated
o-ring, or other material between the hub and
the blade. If a significant difference between
in-process and before/after measurements is
found, seek technical guidance from
NAVSEA.
B-1.7.3 When out-of-range readings are
encountered the offending bolts must be
retightened in an attempt to produce acceptable readings. All of the factors that contribute
to bolt elongation are not well understood, but
it is clear that the following variables are
important:
seating the blade with temporary bolts
hydraulic pressure used to stretch the
Change 1
B-7
S0600-AA-PRO-120
bolt
diver-applied torque to seat the bolt
thread lubrication
seating surface flatness
B-1.7.4 It is not the inspector's job to produce

acceptable readings. If, at any time, the accuracy of the inspection process comes into
question, the inspector should verify that all
procedural steps have been performed properly (bolt cleanliness, rotational alignment, not
tilting the transducer assembly, etc.) and that
signal quality is essentially unchanged from
baseline measurements to in-water measurements. Proof of proper operation can always
be supplied by taking the reference bolt and
an unstressed blade bolt underwater, and replicating the baseline measurement for that
blade bolt. Once these steps have been taken
to ensure and demonstrate the measurement
process, the actual value for bolt elongation is
up to the divers and the project engineer.
B-1.8 DIVER TRAINING
The diver is responsible for:
Ensuring that all bolts are clean (free of

oil, air bubbles and debris).
Placing the transducer assembly in the

bolt specified by the inspector.
Tightening the transducer assembly in

the bolt.
Placing the hydraulic drive over the

transducer assembly.
Connecting the coaxial cable to the

transducer.
sonic pulses much like the fathometer or

depth finder on a boat.
B-1.8.3 Show the divers the reference bolt
and point out that the very bottom of the cavity
is milled flat, and serves as a reflector for the
ultrasound. Point out that the flat surface at
the bottom of the hexagonal recess is a reference surface and that the bolt's elongation is
measured from that surface to the bottom of
the cavity. Show the calibration standard and
the precision lead screw. Explain that it
advances a piston inside the standard, allowing the measured distance to be accurately
varied in increments of 0.005" per half rotation
of the base.
B-1.8.4 Place the transducer in the calibration standard, and as you do, explain that the
transducer carrier puts the tip of the transducer about a quarter of an inch away from
the flat bottom of the cavity.
B-1.8.5 Pull the transducer out of the cavity
and show the divers that the tip of the transducer is fragile and warn against bumping it on
the bolt. Put the transducer back into the
standard, and show that as you screw it in, it
comes abruptly to a stop, placing the ultrasonic signal repeatable at a particular screen
location.
B-1.8.6 Loosen the transducer slightly, to
show the motion of the ultrasonic signal. Rock
the transducer and show the divers how the
signal moves on the CRT. Explain that the
amount of motion they see is far more than the
allowable 0.0005".
B-1.8.1 It is useful to familiarize the divers

with the tool and the ultrasonic instrument,
and to show them how sensitive it is. To this
end the system should be set up on site, and
calibrated using the calibration standard.
B-1.8.7 Explain that when the diver gets in

the water to take in-process measurements,
the transducer will be in the bolt the whole
time. Inserting the transducer into a blade
bolt, show that after the transducer is installed,
you will need a moment to position the echo at
2 screen divisions.
B-1.8.2 Show the divers the bolt elongation

measurement tool, or transducer carrier, and
explain that the transducer sends out ultra-
B-1.8.8 For final length measurements, after

all bolts have been installed, explain that readings must be taken on the reference bolt, as
B-8
S0600-AA-PRO-120
well as each blade bolt. Show the process of

positioning the signal, and recording zero offset on the reference bolt, then a blade bolt, so
the diver will know about how long that process takes.
B-1.8.9 Explain that if discrepancies exist
between in-process measurements and final
measurements, it may indicate a problem with
seating the blade. In this case one or more
bolts may have to be remeasured, and possibly retightened.
B-2. MEASUREMENT PROCEDURE
1. Blades are removed in the 12 o'clock

po sit io n. B ol ts ar e sen t to psi de,
cleaned, and penetrant tested. The
internal cavity is then cleaned thoroughly, and baseline length measurements relative to a reference bolt are
recorded. These bolts are then
returned to the test site, lubricated and
set aside for reinstallation.
2. The new blade is set in place in the 12
o'clock position, Bolt holes # 1, # 4, # 5,
and # 8 are dewatered using hydrolube prior to installing and torquing the
bolts to 800 ft-lbs.
B-2.1 SCOPE
B-2.1.1 This section describes ultrasonic
measurement of bolt elongation during waterborne installation of controllable pitch propeller (CPP) blades, as required by reference (a)
for CG 47 (CG 66 and higher) class ships
(0.005-0.007 inch elongation) and reference
(b) for DDG 51 class ships with "Fleet" type
blades (0.005-0.007 inch elongation). Bolt
elongation must be measured within 0.0005
inches.
3. The four interior holes (# 2, # 3, # 6, and

# 7) are dewatered with hydrolube.
4. Bolts # 2, # 3, # 6, and # 7 are installed
and tightened with a ratchet or speed
wrench, tight enough to seal the hole,
but not stretch the bolt measurably
5. The interior bolts are torqued to achieve
the required stretch.
B-2.1.2 Program management for waterborne blade changes is under NAVSEA 00C5
cognizance (703-607-2761).
6. The initial bolts (# 1, # 4, # 5, and # 8)

are torqued to achieve the required
stretch.
B-2.2 BACKGROUND
7. The blade lifting assembly is removed

and final measurements taken on all
bolts.
B-2.2.1 Waterborne replacement of CPP

blades involves the removal and reinstallation
of eight bolts on each of five blades. These
bolts are approximately 9 inches long with 28-UNR-2A threads, and a 2 inch hex socket.
A hydraulic drive is used to install the bolts
with approximately 2700 ft-lbs. of torque. As
the bolts are tightened, they stretch several
thousandths of an inch, developing in excess
of 100,000 lb. clamping force. Ultrasonic
instrumentation is used to measure bolt
lengths before and after installation, and to
monitor bolt elongation during installation.
B-2.2.2 The typical order of events relevant
to this procedure is as follows:
B-2.3 REFERENCES
a) S9245-AV-MMA-010/07309,
Technical Manual, Installation, Operation,
Maintenance and Repair Instructions
with Parts List, Controllable Reversible
Pitch Propeller for CG 66 and Follow
Ships, 30 APR 1991
b) S9245-AM-MMA-010/07309, System
Manual for Controllable Pitch Propeller
System, DDG 51 Class, Model 156,
Type S1/5, 15 AUG 1990
Change 1
B-9
S0600-AA-PRO-120
c) T907 4-A S-G IB-01 0/27 1, N AV SEA

Technical Publication, Requirements
for Nondestructive Method, 30 April
1997
B-2.4 PERSONNEL QUALIFICATION AND
B-2.4.1 Personnel performing bolt elongation
measurements in accordance with this procedure shall be certified in accordance with
NAVSEA Technical Publication 271 (latest
revision) as an Ultrasonic Inspector (Level II,
or Level II Limited) or Examiner (Level III).
B-2.4.2 Competence and familiarity with the
procedure and system hardware may be
acquired by repeated measurements on a set
of unstressed bolts. The normal variations of
approximately + 0.0005 inch. Readings more
than 0.001 inch from the mean indicated
B-2.5 DESCRIPTION OF MEASUREMENT
SYSTEM COMPONENTS
B-2.5.1 Ultrasonic instrument - a conventional flaw detector capable of displaying the
required signals, with full screen representing
0.025" of seawater. Owing to the relatively
long cable lengths used, the instrument should
have a variable damping control that matches
instrument and cable/transducer impedance's.
B-2.5.2 Transducer- a specially fabricated 10
MHz transducer that fits into the blade bolts
and positions the active element approximately 0.25" from the flat bottom of the measurement cavity. The transducer is fitted with
an underwater matable connector. The current configuration is controlled by NAVSEA
drawings.
B-2.5.3 Cable- coaxial cable with a characteristic impedance of 50 ohms, and a rugged
exterior jacket typically neoprene or polyurethane. Cables are typically over 100 feet long
to permit operation of the ultrasonic instrument
B-10
in a location convenient for communications

with the torque tool operator.
B-2.5.4 Connectors - cables are terminated
at the topside end with a BNC connector, and
at the underwater end with an underwater
matable connector that matches the transducer's connector.
NOTE:
The underwater matable electrical connector must be lubricated. The choice of lubricant
is important because the lubricant must not interfere with signal transmission. Most O-ring
grease is insulating, which is
detrimental to signal transmissi o n ; h o w e ve r c o p p e r a n d
nickel based antiseize compounds (used on the blade
bolts) have been used successfully. In addition to lubricating the rubber and metal
connector parts, these compounds are conductive. The
small metal particles (nickel, for
instance) may be slightly abrasive; this may keep the electrical contacts clean.
B-2.5.5 Calibration Standard - the calibration standard for this procedure duplicates the
geometry of the bolts' flat-bottomed hole; however, the flat bottom is formed by the face of a
piston. This piston's position is accurately
controlled by a 100 threads-per-inch precision
lead screw. Scribe marks on the side of the
standard and the rotatable base of the standard, which turns the lead screw, allow the
face of the piston to be advanced exactly
0.005" per one-half rotation of the lead screw.
A protective cover is also provided to keep the
precision lead screw dry when the calibration
standard is lowered into the local water for onsite calibration checks.
B-2.5.6 Reference Bolts - standard
blade
bolts removed from inventory, measured and
S0600-AA-PRO-120
used as a reference during the blade bolt

installation process.
B-2.5.7 Cleaning tools - for cleaning the flat
bottom of the bolt cavity: 3/8" diameter cylindrical felt bobs, mounted on a 3/8" round stock
shaft and rotated with an electric drill motor.
For cleaning the internal walls, a 1/2" diameter
cylindrical wire brush with soft wire bristles.
For cleaning external surfaces, soft wire
brushes (typical wire diameter 0.007"). Solvent cleaner/degreaser, or carburetor/choke
cleaner.
be completely free of contaminants, as the

required measurement accuracy is 0.0005
inches. The side wall of the hole is initially
cleaned with a rotary wire brush, using solvent
cleaner as required to remove oil. The flat
bottom surface is then cleaned to bright metal.
This is accomplished with a felt polishing pad
mounted at the end of a long shaft, and powered by a rotary drill. A solvent cleaner is
used as an initial cleaning medium, followed
by a water jet rinse, and dry swabbing. The
ultimate quality of the ultrasonic signal, and
therefore the quality of the inspection process,
is dependent on this step.
B-2.6 PROCEDURE
B-2.6.1 A summary of the major procedural
elements is provided in this section. Details of
instrument set-up for calibration and measurement are included in an instrument-specific
addendum, Section B-3.
B-2.6.2 Exterior cleaning. Bolts removed
from an in-service propeller require cleaning to
remove all biofouling and corrosion prior to
penetrant testing. This cleaning may be performed with a soft wire brush (typically having
0.007" diameter wires) to avoid damage to the
bolt surface, threads or copper cladding. An
ordinary green ScotchBrite scouring pad may
also be used for exterior cleaning; however,
no form of sandpaper or abrasive cloth is permitted.
B-2.6.3 Penetrant testing. Bolts
are
inspected using a visible dye, solvent removable system. The inspection area is from the
top of the threads up to the head of the bolt,
including the underside of the head. Fluorescent systems (solvent removable, post emulsifiable, or water washable) can be used . No
linear indications in excess of 1/16" are
allowed.
B-2.6.4 INTERIOR CLEANING
B-2.6.4.1 Bolt elongation measurements are
made by reflecting ultrasound off the bottom of
a flat-bottomed hole approximately 5 inches
deep on the axis of the bolt. This surface must
B-2.6.4.2 To verify that cleaning has been

adequate, pour a small amount of water in the
bottom of each bolt, insert a transducer, and
ensure that a good clean ultrasonic signal is
produced. Note that if the signal deteriorates
when the transducer is installed underwater, it
is possible that foreign material or gas bubbles
have gotten into the cavity. These can generally be removed by having the diver vigorously
pump the cavity with a length of 3/8 inch diameter round stock.
B-2.6.5 CALIBRATION
B-2.6.5.1 The objective of this calibration is
to adjust the material velocity control (fine
range) to produce a signal motion of 2 screen
divisions (20% of screen width) for each
0.005" of relative motion between the transducer and the bottom of the flat bottomed
hole. The calibration standard for this procedure duplicates the bolt's geometry, with a
moveable piston whose face simulates the flat
bottom of the bolt hole. The piston is driven by
a precision lead screw, allowing the distance
between the transducer and the piston face to
be accurately controlled in increments of
0.005". The second interface echo from this
reflecting surface is used (in preference to the
first interface echo) to double the sensitivity of
the measurement.
B-2.6.5.2 With the screen set up with two
screen divisions representing 0.005", each
major division will represent 0.0025", and each
B-11
S0600-AA-PRO-120
minor tick (of which there are five per major

division) will represent 0.0005". On analog
instrument CRT's the signal position may be
read to half this amount quite easily, while on
digital instruments the reading accuracy may
be limited to 0.0005" by pixel size. Parallax
errors that can exist when the marked graticle
is not in the same plane as the signal can be
eliminated by lining the ultrasonic signal up
with the reflection of the inspector's pupil in the
screen. To maintain highest accuracy, the
water in the calibration standard should be as
close as possible to the same salinity and temperature as the operating environment.
B-2.6.5.3 Details of the calibration procedure, and subsequent measurement procedures, are tailored to the ultrasonic instrument
being used; an example is included as an
addendum, Section B-3, to this procedure.
The calibration procedure is a variation on the
standard calibration procedure for thickness
gauging with a dual transducer, which uses
two thickness' (in this case, two different
waterpath lengths between the transducer and
the reflecting surface), to establish the proper
RANGE and ZERO OFFSET (delay) settings.
Repetitive adjustments of ZERO OFFSET
when measuring the shorter waterpath, and
RANGE when measuring the longer waterpath, converge on settings for which no further
adjustments are necessary. At this point, the
RANGE setting is the correct value to produce
a full screen width representing 0.025", and
must not be altered for the rest of the inspection. ZERO OFFSET (delay) can be adjusted
for the operator's convenience, as described
in the instrument-specific procedure.
between each blade bolt and a reference bolt,

before the blade bolt is stretched. These will
be compared to the difference between each
blade bolt and the reference bolt, after the
blade bolts are installed.
B-2.6.6.2 With the reference bolt and the
blade bolt stabilized at the same temperature,
and filled with the same water, the difference
in their lengths is determined by noting the
screen position of the second interface echo
when the transducer is installed in the reference bolt, then the blade bolt. These data are
recorded in the chart provided as Figure B-4.
This baseline difference in lengths is recorded,
and later subtracted out of the difference in
lengths when the blade bolt is stretched. To
ensure that the "before" and "after" readings
are directly comparable, the position of the
same characteristic waveform feature must be
observed in each case. The first major positive-going peak of the rf waveform, which will
generally be the first major peak of the fullwave rectified signal, is generally a good
choice.
B-2.6.6.3 It should be noted that the flat bottomed hole depth in K-monel and Inconel bolts
may be different enough that it is impossible to
set the ZERO OFFSET (delay) to a position
for which both second interface echoes can be
viewed, since full screen represents just 0.025
inches. If the instrument-specific procedure
calls for direct on-screen comparisons
between the reference bolt and each blade
bolt, it may be necessary to use two different
reference bolts ( K-monel and Inconel).
B-2.6.6 BASELINE MEASUREMENTS
B-2.6.7 MEASUREMENTS DURING INSTALLATION
B-2.6.6.1 Baseline length measurements are

required to verify the stretch on bolts after the
entire blade change is completed. Although
the primary measurement mode for this system (i.e. measurement during torquing) does
not require baseline measurements, any afterthe-fact measurement of elongation will
require them. Baseline measurements are
measurements which determine the difference
B-2.6.7.1 After bolt holes are dewatered and

bolts have been installed and hand tightened
to seal the bolt holes, the transducer carrier,
with the hex key already in place, is installed
by screwing it into the bolt to be tightened.
The transducer carrier is designed to screw
into the bolt easily, coming to an abrupt stop
when the transducer carrier's feet contact the
bolt. Verify with the diver that this is the case;
B-12
S0600-AA-PRO-120
if not, threads in the bolt or on the transducer

carrier should be cleaned. The torque tool is
then placed over the transducer, and the electrical cable is connected. At this point the second interface echo is positioned exactly at a
convenient graticle mark on the screen. If the
signal is not as crisp as it was immediately
after cleaning the flat bottomed hole, the
transducer should be removed and the hole
cleaned out before proceeding.
B-2.6.7.2 Bolt elongation will be measured
by a shift in the signal position caused by relative motion between the transducer (which is
screwed into, and fixed relative to the top of
the flat bottomed hole) and the bottom of the
flat bottomed hole as the bolt is stretched.
The exact amount of signal motion is related
to the amount of stretch through the calibration procedure, which ensures that each
0.005" of elongation will move the signal two
major screen divisions to the right. Once the
signal is positioned at a convenient screen
position prior to torquing the bolt, no further
instrument adjustments are permitted. Any
change in the fine range control would destroy
the calibration, any change in fine delay would
invalidate the signal's reference position, and
any change in gain indicates that some unacceptable change in the installation has
occurred. Just prior to applying torque, check
the tightness of the transducer installation
since loosening will cause a change in the
transducer's position relative to the flat bottomed hole's reflecting surface.
B-2.6.7.3 As torque is applied, the ultrasonic
signal will move smoothly to the right, indicating an elongation of the waterpath between
the transducer and the flat bottomed hole's
reflecting surface. When the desired stretch
has been achieved, tightening should be
halted. All in process measurements shall be
recorded on the chart provided as Figure B-5.
B-2.6.8 POST-INSTALLATION MEASUREMENTS
tion is required. To accomplish this, the difference in the lengths of each blade bolt and the
reference bolt are again measured, this time
with the blade bolt stretched but the reference
bolt in its original (unstretched) condition.
Accuracy is attained by measuring both bolts
side by side, underwater; this ensures that
they are under identical conditions of temperature and salinity.
B-2.6.8.2 Post-installation
measurements
are made by carrying the reference bolt underwater to the blade palm, where it will quickly
come to thermal equilibrium. The transducer
is first screwed into the reference bolt, then
the blade bolt, and the ZERO OFFSET is set
at a position for which both echoes are viewed
with no adjustments of any instrument settings.
The same echo feature chosen for baseline
measurements must be used for this measurement as well. As with the baseline measurements, the length of the blade bolt,
relative to the reference bolt, is determined by
the difference in their signal positions. Then,
subtracting the baseline difference from the
post-installation difference gives the blade bolt
elongation. These data are recorded in the
worksheet provided as Figure B-4.
B-2.7 MAINTENANCE
B-2.7.1 Maintenance is generally limited to a
freshwater rinse for all saltwater wetted and
sprayed components, other than the ultrasonic
instrument. Exterior surfaces and connectors
should be sprayed with a moisture displacing
anticorrosive spray prior to storage. The calibration standard should be thoroughly cleaned
and lubricated to prevent corrosion of the precision lead screw. Under normal use it is not
necessary to disassemble the transducer
assembly.
Should the transducer fail or
become damaged it is replaceable. Note that
in order to preserve high dimensional stability,
parts have been assembled with a thread
locking compound.
B-2.6.8.1 Once the bolts have all been

installed, a post-installation check on elonga-
B-13
S0600-AA-PRO-120
Figure B-4. Hex Socket Bolt Baseline and Post-Elongation Measurement Worksheet
Blade Bolt
Position
Bolt
serial #
Baseline
Measurement
(NOTE)
Post Installation
Measurement
(NOTE)
Bolt
Elongation
Final Hydraulic
Torquing
Pressure
Final
Installation
Torque
Reference Bolt
Blade 1/Bolt #1
Blade 1/Bolt #2
Blade 1/Bolt #3
Blade 1/Bolt #4
Blade 1/Bolt #5
Blade 1/Bolt #6
Blade 1/Bolt #7
Blade 1/Bolt #8
Reference Bolt
Blade 2/Bolt #1
Blade 2/Bolt #2
Blade 2/Bolt #3
Blade 2/Bolt #4
Blade 2/Bolt #5
Blade 2/Bolt #6
Blade 2/Bolt #7
Blade 2/Bolt #8
Reference Bolt
Blade 3/Bolt #1
Blade 3/Bolt #2
Blade 3/Bolt #3
Blade 3/Bolt #4
Blade 3/Bolt #5
Blade 3/Bolt #6
Blade 3/Bolt #7
Blade 3/Bolt #8
Reference Bolt
Blade 4/Bolt #1
Blade 4/Bolt #2
Blade 4/Bolt #3
Blade 4/Bolt #4
Blade 4/Bolt #5
Blade 4/Bolt #6
Blade 4/Bolt #7
Blade 4/Bolt #8
Reference Bolt
Blade 5/Bolt #1
Blade 5/Bolt #2
Blade 5/Bolt #3
Blade 5/Bolt #4
Blade 5/Bolt #5
Blade 5/Bolt #6
Blade 5/Bolt #7
Blade 5/Bolt #8
Note: Enter ZERO Offset (in microseconds, msec.) required to place the second interface echo at 2 screen divisions
B-14
Change 1
S0600-AA-PRO-120
NOTE:
Figure B-4, Hex Socket Bolt
baseline and Post-Elongation
Measurement Worksheet, is
also provided as a Windows
Office 97 EXCEL worksheet
(Elongation.xls) containing the
formulas required to calculate
bolt el ongation . Th is wo rksheet may be launched directly
from this CD-ROM or the file
may be copied to another computer directory for ease of use.
Change 1
B-14A
S0600-AA-PRO-120
B-14B
Change 1
S0600-AA-PRO-120
B-2.7.2 Replacement of the cleaning pads

used to clean the flat bottom of the bolt cavity
(3/8 inch flat bobs mounted on 3/8 inch round
stock) can be done using a hot melt glue gun.
ment procedures using an EPOCH II ultrasonic instrument and a 10 MHz transducer

provided by NAVSEA 00C. The ultrasonic
inspection requirement for blade bolts consists
of three measurements:
B-3. EPOCH II ADDENDUM

a) Baseline measurements which relate
the length of each bolt to the length of a
reference bolt. These measurements
are taken in the laboratory after bolts
have been cleaned and penetrant
inspected.
B-3.1 SCOPE
B-3.1.1 This section presents a detailed
description of DDG 51 and CG 47 (CG 66 and
higher) class ships bolt elongation measure-
Figure B-5. Hex Socket Bolt Elongation Measurement During Installation Worksheet
NDT File #:
J.O.N.:
Ship:
Work Center:
Date:
System: CRP Controller
Component: Blade
Job Description: Inspect Morgrip Bolt Elongation

Type of Inspection: Ultrasonic Inspection
DWG NO. NAVSEA 6698352
Inspection STD: S0600-AA-PRO-120
Acceptance STD: S0600-AA-PRO-120
Port:
Project (Ship):
Blade Serial Number:
Ultrasonic Instrument:
Calibration Standard:
Reference Bolt:
Transducer:
Bolt Serial #
and
Position in Hub
NDT Inspector:
Installed Screen
Position
Date:
Initial Screen
Position
Difference
(Screen div.)
Level II Examiner
Length Change
(Difference x 0.0025/div.)
Date:
B-15
S0600-AA-PRO-120
b) In-process measurements of elongation

taken during blade installation. These
measurements are used to control the
application of torque to the bolts.
c) Final stretch measurements taken after
all bolts are tightened, to confirm the
final stretch on each bolt. Under certain circumstances the initial stretch
achi eved on any one bol t may be
affected by tightening subsequent
bolts.
B-3.1.2 The principle of operation for each of
these measurements is the same as for conventional thickness gauging. For these measurements, the material being gauged is a
small amount of water that separates the tip of
an ultrasonic transducer from the bottom of a
flat-bottomed hole into which the ultrasonic
probe is inserted. The flat-bottomed hole is
part of the blade bolt design, and is intended
for conventional depth gauging with a depth
micrometer.
The ultrasonic probe is a
NAVSEA design that screws into the top of the
flat-bottomed hole, and places a 10 MHz
transducer element about 0.25 inches away
from the bottom of the hole (see Figure B-2).
As the bolt stretches, the length of the flat-bottomed hole increases, moving the flat bottom
away from the tip of the transducer (which is
stationary with respect to the top of the hole).
The ultrasonic instrument accurately measures the ultrasonic pulse's round-trip travel
time, and allows this time to be calibrated in
terms of distance, which is related to travel
time through the speed of sound. To ensure
accuracy throughout these measurements,
every effort is made to keep conditions of temperature and salinity (which affect the speed
of sound) the same for calibration and bolt
measurements. Also, to improve resolution,
the ultrasonic pulse is allowed to bounce back
and forth between the flat-bottomed hole and
the transducer element twice, effectively doubling any change in the waterpath length
between the transducer element and the bottom of the flat-bottomed hole.
B-16
B-3.2 INSTRUMENT CALIBRATION

B-3.2.1 The EPOCH II is calibrated to show
0.0025 inches per division. This makes each
small tickmark represent 0.0005 inches, and
full screen represents 0.025 inches. The calibration standard (see Figure B-3) used for
these measurements simulates the bolt hole's
flat bottom with the face of a piston that can be
raised or lowered precise amounts. The piston is driven by a 100 threads-per-inch (tpi)
precision lead screw (0.010" advance per revolution). During calibration the distance from
the transducer tip to the piston face is varied in
increments of 0.005" by turning the precision
lead screw one-half revolution at a time. For
calibration and baseline measurements, the
calibration standard must be at the same temperature and filled with the same water as the
reference bolt and all the blade bolts to eliminate sound velocity variations, between bolts,
due to temperature or salinity. To minimize
subsequent variations between these calibration settings and on-site instrument settings,
the water should be drawn from the harbor,
rather than using tap water.
B-3.2.2 Initial settings for the EPOCH II
should be as shown in Table B-1, using a 10
MHz transducer provided by NAVSEA 00C.
B-3.2.3 The calibration standard and the
rotatable base are assembled by placing the
standard in the base, ensuring the O-ring on
the calibration standard is lightly lubricated,
and that the slot in the base accepts the alignment dowel on head of the lead screw. A
small amount of seawater is then poured into
the calibration standard, and the transducer is
screwed into the calibration standard, ensuring that the face of the transducer is free of
bubbles. The precision lead screw should be
adjusted mid range, leaving about one quarter
inch of water between the transducer and the
face of the piston. Connect the cable to the
ultrasonic instrument and the transducer,
using a small amount of antiseize compound
to lubricate the underwater matable connector. The first objective is to identify the second
S0600-AA-PRO-120
interface echo (IFE) and adjust gain to bring

this echo to about 80% screen height. With
delay and zero offset set to zero, and range
set to 0.050"/div. the screen should show the
initial pulse and at least three IFE's. Adjust
gain to bring the second IFE to 80% screen
height.
B-3.2.4 In the remainder of the procedure it
is important that signal position be estimated
as accurately as possible; using the position of
the leading edge of the signal is not recommended. Many waveform features can be
used to track position, but the preferred feature is the peak of the first positive-going halfcycle of the waveform. The rf waveform typically shows a small negative-going peak followed by a large positive-going peak, a large
negative-going peak, and several much
smaller peaks (Figure B-6). With full wave
rectification all peaks appear positive, so the
peak that is generally used is the second peak
in the video display, even if the third peak (corresponding to the second negative-going
peak) is slightly larger (Figure B-7). In the

remainder of this discussion, the position of
the second IFE means the position of this
peak.
B-3.2.5 The next objective is to reduce the
range to 0.0025"/div. and position the second
IFE at 5 screen divisions. Note that because
the RANGE SELECT... display is limited to
three decimals, it will not be possible to actually display "0.0025 in / DIV" (it will read 0.002
or 0.003 in / DIV instead). Press the RANGE
button, then the UP ARROW until the second
IFE reaches the right edge of the screen. The
RANGE SELECT... display will read about
0.025 in / DIV at this point. Then press the
ZERO OFFSET button and the LEFT ARROW
until the second IFE is at the left edge of the
screen. Then press the RANGE button, and
the UP ARROW until the RANGE SELECT...
reads 0.002 in / DIV. Finally, press the ZERO
OFFSET button and use the LEFT or RIGHT
arrows to position the second IFE at 5 screen
divisions.
Table B-1. EPOCH II Initial Settings

Reject: 0%
Range 0.050 in / DIV
Velocity: 0.0300 in/s.*
XCR- 15.0 MHz ON
Thickness: 0.000
Pulser HIGH, 50W
Zero: 0.000 s.
FULL WAVE
Delay: 0.000 in.
PULSE-ECHO MODE
Angle: 0.0
* The published speed of sound in seawater is about 0.06 inches/microsecond, or about twice the recommended
set-up value. This discrepancy arises because the procedure calls for using the second interface echo, which
means that travel time for the ultrasonic pulse is twice as long as it would be for the first interface echo.
B-17
S0600-AA-PRO-120
200
180
Signal Amplitude
160
140
120
100
80
60
40
20
0
Time
Figure B-6. rf Ultrasonic Signal
100
90
Signal Amplitude
80
70
60
50
40
30
20
10
0
Time
Figure B-7. Full Wave Rectified Signal
B-3.2.6 The next objective is to calibrate the

screen to give two screen divisions per 0.005".
The calibration standard allows the waterpath
below the transducer to be accurately
changed in increments of 0.005", since indexing marks allow the 100 tpi precision lead
screw to be rotated one-half revolution within
a fraction of a degree. Once the second interface echo has been set to 5 screen divisions,
the lead screw will be adjusted to add and
subtract 0.010" to the waterpath, and the
B-18
instrument will be adjusted to produce a

change of 4 screen divisions up (to the ninth
division), and 4 screen divisions down (to the
first division), making one division correspond
to 0.0025" change in waterpath length. Starting with the second IFE at 5 screen divisions,
rotate the base of the calibration standard
clockwise one full revolution, adding 0.010" to
the waterpath. The second IFE will move to
the right as this is done. Press the RANGE
button and use the LEFT or RIGHT arrows to
S0600-AA-PRO-120
position the echo at 9 screen divisions. Then,

turn the base of the calibration standard two
full revolutions counterclockwise to reduce the
waterpath by 0.020" (this is 0.010" less than
the initial waterpath length). Press the ZERO
OFFSET button and use the arrows to position
the signal at 1 screen division. Repeatedly
lengthen the waterpath by 0.020" (two rotations clockwise) and use RANGE to position
the signal at 9 screen divisions, then shorten
the waterpath by 0.020" (two rotations counterclockwise) and use ZERO OFFSET to position the signal at 1 screen division. Repeat
these adjustments until the signal is properly
positioned for both waterpaths without further
adjustments to the instrument. Make the final
adjustments being extremely careful that the
transducer is firmly seated.
the reference bolt. The difference between

these two relative lengths is the amount the
blade bolt has stretched. The first step in this
process is to establish the position of the reference bolt's second IFE signal. In the following
discussion, it is assumed that the same cable
and transducer is used for the reference bolt
and the blade bolts, both before and after
installation, since the physical lengths of the
transducer and cable both contribute to the
absolute echo arrival time.
B-3.2.7 Accuracy can be checked at this

point by using the gate. Set GATE START to
0.0000 inches. Press GATE WIDTH and then
the RIGHT ARROW until the gate reaches
exactly 10 screen divisions.
The GATE
WIDTH display should read 0.0250 within
0.0001 inches. The full screen width represents exactly 0.025" by virtue of the calibration
procedure, but the gate width calculated by
the instrument depends on sound velocity,
which can vary slightly with temperature and
salinity. Presuming that the screen calibration
has been performed extremely accurately, the
VELOCITY may be adjusted slightly to make
the full screen GATE WIDTH display 0.0250
inches. No further changes should be made
to the RANGE or VELOCITY values for the
remainder of the baseline measurement process.
B-3.3.1.3 Pour a small amount of seawater

into the reference bolt, and screw the transducer in securely. Ensure that the shape of
the waveform is reasonable (small negative
peak, followed by a large positive and a large
negative peak, then several smaller peaks). If
the waveform is not as "clean" as expected,
there may be loose material in the hole, or
small bubbles adhered to the face of the transducer: eliminate these conditions.
B-3.3 BASELINE MEASUREMENTS

B-3.3.1 REFERENCE
MENTS
BOLT
MEASURE-
B-3.3.1.1 The purpose of baseline measurements is to document the initial (unstretched)

length of each bolt relative to a well identified
reference bolt. Later, when all of the blade
bolts have been installed, their new
(stretched) lengths will again be compared to
B-3.3.1.2 For this, and all subsequent blade

bolt measurements, cleanliness is a critical
issue. Any small piece of material in the measurement hole will affect the measurement by
its thickness; the goal of 0.0005" accuracy
will not tolerate any such loose material at all.
B-3.3.1.4 Position the second IFE at 2

screen divisions using ZERO OFFSET, with
DELAY=0.000.
Record the zero offset
required to achieve this screen position.
B-3.3.2 BLADE BOLT BASELINE MEASUREMENTS
B-3.3.2.1 After ensuring that each blade bolt
is well cleaned, pour a small amount of seawater into the flat-bottomed hole. Insert the
transducer and screw it in securely. Position
the second IFE at 2 screen divisions, check
that DELAY is 0.000, and record the ZERO
OFFSET required. If the blade bolt is shorter
than the reference bolt, less ZERO OFFSET
will be required, and the relative length will be
recorded as a negative number. These data
are recorded on the chart provided as Figure
B-4. The calculation of length is:
B-19
S0600-AA-PRO-120
Relative blade bolt length =

((Reference bolt offset - Blade bolt offset) *
Velocity) / 2
be very minor (less than 1% variation in velocity is expected).

CAUTION
EXAMPLE:
Reference bolt offset = 17.875 microseconds
Blade bolt offset = 16.975 microseconds
Velocity = 0.0300 inches/microsecond
Relative blade bolt length = -((17.875 16.975) * 0.0300) / 2 = -0.0135 inches
(The blade bolt is 13.5 thousandths of an inch
shorter than the reference bolt).
B-3.3.2.2 Save each bolt signal in memory.
Note bolts with unusual waveforms. Assuming that the flat-bottomed hole has been properly cleaned, an unusual waveform is the
result of the geometry of the hole bottom, and
can be expected to recur during all measurements on that bolt.
B-3.3.2.3 Print out each bolt waveform for
comparison with the signal obtained during inprocess and final measurements.
B-3.4 IN-PROCESS MEASUREMENTS
B-3.4.1 INITIAL CALIBRATION
B-3.4.1.1 The instrument calibration should
be checked on-site to account for minor variations in the speed of sound. To accomplish
this, immerse the calibration standard in local
seawater until thermally stabilized, then
recover it full of seawater. Install the calibration standard in its base and make minor
adjustments to RANGE and ZERO OFFSET
as required to achieve a calibrated screen.
Finally, set the gate to full screen width and
adjust VELOCITY to produce a GATE WIDTH
of 0.0250 inches. These adjustments should
B-20
In order to protect the precision

lead screw threads from corrosion, a waterproof cap is supplied with the calibration
standard. Before lowering the
standard into the local seawater, this cap must be installed,
and before removing the cap,
topside, excess seawater must
be wiped off the standard. In
placing the standard in its rotatable base, an O-ring seal is
formed to protect the lead
screw from seawater spill-over.
B-3.4.2 SITE CONSIDERATIONS
B-3.4.2.1 The ultrasonic instrument should
be set up in a location which allows direct
communication with the hydraulic tool operator. As each bolt is tightened the ultrasonic
inspector will monitor the stretch, and call for
torquing to stop when the appropriate stretch
has been attained.
B-3.4.2.2 Cables should be routed from the
ultrasonic instrument to the dive site in such a
way as to prevent damage to the cables. Care
should be taken to prevent the cables from
being pinched or cut, and to prevent personnel
from tripping on the cables. Chafing protection must be provided where the cable might
abrade as it passes over the side, or through
windows or doorways. Cables should be
coiled using either a figure-of-eight pattern or
the "over/under" technique to prevent kinks
from forming. A small amount of metal-based
antiseize compound should be applied to the
underwater end of the cable before passing it
over the side.
B-3.4.2.3 Active radar and large diesel
engines near the ultrasonic instrument may
S0600-AA-PRO-120
affect the ultrasonic signal. At the present

time there is no effective remedy, and no procedural changes are permitted without
NAVSEA approval. If the source of intense
noise on the ultrasonic display cannot be
located and shut down, measurements must
be delayed until the ultrasonic signal appears
normal.
B-3.4.3 MEASUREMENTS DURING TIGHTENING
B-3.4.3.1 Before hydraulic tightening, bolts
have been hand tightened to capture hydrolube in the bolt hole, but the bolts have not
been measurably stretched. For DDG-51
class, tightening should result in 0.006 to
0.008 inches stretch for bolt holes 1,2,3,4,6,7,
and 0.007 to 0.008 inches for bolt holes 5 and
8. The ultrasonic inspector should keep the
hydraulic pump operator advised of stretch,
and tightening should be halted when stretch
is about 0.0075 inches. For CG66 and higher
all bolts should be stretched 0.005 to 0.007
inches and during tightening aim for 0.0065
inches.
B-3.4.3.2 The ultrasonic inspector must control the flow of work. Once the transducer is
installed in each bolt, the hydraulic pump
operator must wait until the signal has been
positioned (DELAY and GAIN) and data
logged. The ultrasonic operator then calls for
hydraulic power to be applied ("Start torquing").
When the target stretch (typically
0.0075") is reached, the ultrasonic operator
halts the torquing ("Whoa!"). The divers must
leave the transducer in place until data is
logged, the waveform is stored, and the ultrasonic operator calls for the transducer to be
moved.
B-3.4.3.3 The diver will install the transducer,
with the hex key already in place, but the
cable disconnected. The hydraulic tool will
then be slipped over the transducer carrier
and onto the hex key. At this point the cable is
connected. Divers should be advised that
they should never strain the cable itself, only
the connector bodies.
B-3.4.3.4 Before hydraulic power is applied,

the second IFE is placed at 2 screen divisions,
and the quality of the signal is checked. If it is
not "clean" the diver should be instructed to
disconnect, unscrew the transducer, and
pump it in the hole to get rid of foreign material. Without disconnecting the cable, the
diver should slightly loosen, then retighten the
transducer, and the inspector should verify
that the signal returns to exactly the same
position on the display; this verifies that the
transducer is properly seated with its feet resting on the bolt's reference surface. Proceed
with measurements only when a clean and
stable signal is obtained.
B-3.4.3.5 With the signal at 2 screen divisions, call for hydraulic power, and observe
the signal move to the right as the bolt is
stretched.
B-3.4.3.6 During tightening the signal should
move smoothly as the bolt is stretched. Any
abrupt jumps in signal position may indicate
improper lubrication or improper placement of
the torque tool's reaction foot. These conditions should be corrected to ensure that the
proper stretch is achieved. Any significant
change in the signal's shape during tightening
indicates improper installation, typically a
loose transducer. These conditions must be
corrected before reliable measurements can
be taken. If necessary, back the bolt out to a
low level of stretch (to ensure captured hydrolube is not lost) and retighten once the transducer installation has been corrected. Record
the in-process measurements in the chart provided as Figure B-5.
B-3.5 FINAL LENGTH MEASUREMENTS
B-3.5.1 After all bolts have been installed,
verify the final stretch by repeating measurements relative to the reference bolt. To ensure
that all bolts are at the same temperature and
salinity, the reference bolt is lowered to the
hub, and the ZERO OFFSET required to place
the signal at 0, 2, and 10 screen divisions is
recorded. The calibration check during in-process measurements is sufficient for this
B-21
S0600-AA-PRO-120
phase, unless there have been significant

changes in the water (this could happen in
areas with a strong tidal flow). Should there
be any question, repeat the in-process calibration procedure before measuring final lengths.
B-3.5.2 Each bolt is checked by inserting the
transducer, positioning the signal at 2 screen
divisions, checking the quality of the signal,
and recording the ZERO OFFSET. The relative bolt length is calculated as described
above. The change in relative bolt length
between this measurement and the baseline
measurement indicates stretch, and should
correspond with the in-process stretch measurement. Slight variations can be expected
due to inherent measurement error (approximately 0.0005"), and bolt interactions. Any
significant differences must be resolved as
large changes in stretch may indicate an
unsatisfactory installation. Record these data
in the chart provided as Figure B-4.
B-22
B-3.5.3 Recording and Reporting. All records

associated with an underwater CPP blade
change will be maintained by NAVSEA
00C54.
B-3.6 PERSONNEL QUALIFICATION AND
B-3.6.1 Personnel performing bolt elongation
measurements inaccordance with this procedure shall be certified in accordance with
NAVSEA Technical Publication 271 (latest
revision) as an Ultrasonic Inspector (Level II,
or Level II Limited) or Examiner (Level III).
B-3.6.2 Competence and familiarity with the
procedure and system hardware may be
acquired by repeated measurements on a set
of unstressed bolts. The normal variations of
approximately + 0.0005 inch. Readings more
than 0.001 inch from the mean indicated
S0600-AA-PRO-120
B-23
SO600-AA-PRO-120
C-1
SO600-AA-PRO-120
C-3
SO600-AA-PRO-120
C-5
SO600-AA-PRO-120
C-7
SO600-AA-PRO-120
C-9
S0600-AA-PRO-120
D-1
SO600-AA-PRO-120
D-3
SO600-AA-PRO-120
D-5
S0600-AA-PRO-120
F-1
S0600-AA-PRO-120
F-3
S0600-AA-PRO-120
F-5
S0600-AA-PRO-120
F-7
S0600-AA-PRO-120
F-9
S0600-AA-PRO-120
G-1
S0600-AA-PRO-120
G-3
S0600-AA-PRO-120
G-5
S0600-AA-PRO-120
G-7
S0600-AA-PRO-120
H-1
S0600-AA-PRO-120
H-3
S0600-AA-PRO-120
H-5
S0600-AA-PRO-120
I-1
S0600-AA-PRO-120
B-24

Navsea s0600 Aa Pro 120

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Navsea s0600 Aa Pro 120

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S0600-AA-PRO-120

UNDERWATER SHIP HUSBANDRY MANUAL

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

LIST OF EFFECTIVE PAGES

B-10 through B-13 . . . . . . . . . . . . . . . . . . . . O

* O in this column indicates an original page.

TITLE AND/OR BRIEF DESCRIPTION**

Incorporate warning blade bolt installation

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

CONTROLLABLE PITCH PROPELLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

SECTION 2 FFG 7 BLADE REMOVAL, RETRIEVAL, AND REPLACEMENT PROCEDURE

PROCEDURE SYNOPSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

RIG SHIPS HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9

ROTATE BLADE TO BE REMOVED INTO THE 12 O'CLOCK POSITION . . . . . 12-11

REMOVE MORGRIP BLADE BOLT CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11

REMOVE MORGRIP BLADE BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12

BLADE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16

BLADE PORT AND BLADE INSPECTION AND PREPARATION. . . . . . . . . . . . 12-20

BLADE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23

MORGRIP BOLT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

MEASURE INSTALLED BOLT LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30

BOLT CAP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30

TEST THE CPP AND PRAIRIE AIR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . 12-31

FINAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31

FFG 7 CLASS REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33

DD 963, DDG 993, AND CG 47 CLASS REPAIR PROCEDURE . . . . . . . . . . . . 12-33

DDG 51, CG 47 (CG 66 AND ABOVE), AND MODIFIED EARLIER

SECTION 4 FFG 7 CLASS WATERBORNE BLADE PORT HUB SEAL REPAIR

SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35

REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35

SECTION 5 DD 963, AND CG 47 BLADE REMOVAL, RETRIEVAL, AND REPLACEMENT

PROCEDURE SYNOPSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-45

SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46

RIG SHIPS HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-49

ROTATE BLADE TO BE REMOVED INTO THE 12 O'CLOCK POSITION . . . . . 12-49

REMOVE MORGRIP BLADE BOLT CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-50

REMOVE MORGRIP BLADE BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-51

BLADE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-55

BLADE PORT AND BLADE INSPECTION AND PREPARATION. . . . . . . . . . . . 12-59

BLADE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-62

MORGRIP BOLT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-67

MEASURE INSTALLED BOLT LENGTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-69

BOLT CAP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-70

TEST THE CPP AND PRAIRIE AIR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . 12-70

FINAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-70

SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-73

REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-73

SECTION 7 DDG 51 "FLEET" TYPE BLADE REMOVAL, RETRIEVAL, AND REPLACEMENT

PROCEDURE SYNOPSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-83

SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-84

RIG SHIPS HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-87

ROTATE BLADE TO BE REMOVED INTO THE 12 OCLOCK POSITION. . . . . 12-87

REMOVE BLADE BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-88

BLADE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-91

BLADE PORT AND BLADE INSPECTION AND PREPARATION. . . . . . . . . . . . 12-99

BLADE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-99

BLADE BOLT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-105

MEASURE INSTALLED BOLT LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-108

REMOVE THREE-POINT LIFTING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 12-109

BOLT NYLON PLUG AND SCREW INSTALLATION . . . . . . . . . . . . . . . . . . . . 12-109

TEST THE CPP AND PRAIRIE AIR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . 12-109

FINAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-109

TUTORIAL DISCUSSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1