Enclosure 65 - TM-55-1905-223-24-2 - Main Reduction Gear (MRG).pdf

TM 55-1905-223-24-2

TECHNICAL MANUAL

UNIT, INTERMEDIATE DIRECT

SUPPORT

AND INTERMEDIATE GENERAL

SUPPORT

MAINTENANCE INSTRUCTIONS

MAIN REDUCTION GEAR

FOR

LANDING CRAFT UTILITY (LCU)

NSN 1905-01-154-1191

Approved for public release. Distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

17 JANUARY 1989

INTRODUCTION 1-1

UNIT MAINTENANCE 2-1

INSTRUCTIONS

INTERMEDIATE DIRECT SUPPORT

MAINTENANCE INSTRUCTIONS 3-1

INTERMEDIATE GENERAL SUPPORT

MAINTENANCE INSTRUCTION 4-1

APPENDIXES A-1

ALPHABETICAL INDEX-1

INDEX

This copy is a reprint which includes current pages from Changes 1 through 3.

C4

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

NO. 4 WASHINGTON, D.C., 28 February 1994

Unit, Intermediate Direct Support and Intermediate General Support Maintenance Instructions

MAIN REDUCTION GEAR

for

LANDING CRAFT UTILITY (LCU)

NSN 1905-01-154-1191

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

TM 55-1905-223-24-2, 17 January 1989, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages i and ii i and ii B-1 through B-9/(B-10 blank) B-1 through B-7/(B-8 blank)

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVAN

General, United States Army

Official: Chief of Staff

MILTON H. HAMILTON

Administrative Assistant to the

Secretary of the Army 06464

DISTRIBUTION:

To be distributed in accordance with DA Form 12-25-E, block no. 4801, requirements for TM 55-1905-223-24-2.

C3

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

NO. 3 WASHINGTON, D.C., 9 NOVEMBER 1992

Unit, Intermediate Direct Support and Intermediate General Support Maintenance Instructions

MAIN REDUCTION GEAR

FOR

LANDING CRAFT UTILITY (LCU)

(NSN 1905-01-154-1191)

Approved for public release; distribution is unlimited

TM 55-1905-223-24-2, 17 January 1989, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

C-1 and C-2 C-1 and C-2

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVAN

General, United States Army

Official: Chief of Staff

MILTON H. HAMILTON

Administrative Assistant to the

Secretary of the Army 02888

To be distributed in accordance with DA Form 12-25-E, block no. 4801, requirements for TM 55-1905-223-24-2.

C2

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

NO. 2 Washington, D.C., 30 September 1991

UNIT, INTERMEDIATE DIRECT SUPPORT AND INTERMEDIATE

GENERAL SUPPORT MAINTENANCE INSTRUCTIONS

MAIN REDUCTION GEAR

FOR LANDING CRAFT UTILITY (LCU)

(NSN 1905-01-154-1191)

Approved for public release; distribution is unlimited

TM 55-1905-223-24-2, 17 January 1989 is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

2-3 and 2-4 2-3 and 2-4 2-7 and 2-8 2-7 and 2-8

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVAN

General, United States Army Chief of Staff

Official:

PATRICIA P. HICKERSON

Brigadier General, United States Army The Adjutant General

To be distributed in accordance with DA Form 12-25E, (qty rqr bl no. 4801).

C1

CHANGE HEADQUARTERS,

DEPARTMENT OF THE ARMY

NO. 1 WASHINGTON, D.C., 11 August 1990

Unit, Intermediate Direct Support, and Intermediate General Support Maintenance Instructions

Main Reduction Gear for Landing Craft Utility, (LCU)

NSN 1905-01-154-1191

Approved for public release; distribution is unlimited.

TM 55-1905-223-24-2, 17 January 1989, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

2-23 and 2-24 2-23 and 2-24 2-37 and 2-38 2-37 and 2-38 3-3 and 3-4 3-3 and 3-4 3-11 and 3-12 3-11 and 3-12 3-15 and 3-16 3-15 and 3-16 4-3 and 4-4 4-3 and 4-4 4-15 and 4-16 4-15 and 4-16 B-5 through B-10 B-5 through B-9/B-10

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

CARL E. VUONO

General, United States Army Chief of Staff

Official:

WILLIAM J. MEEHAN, II

Brigadier General, United States

The Adjutant General

DISTRIBUTION:

To be distributed in accordance with DA Form 12-25E, Unit and Direct Support and General Support Maintenance

Requirements for Landing Craft, Utility, LUC-1466, Type III.

WARNING

MODIFICATION HAZARD

Unauthorized modifications, alterations or installations of or to this equipment are prohibited and are in violation of AR 750-10. Any such unauthorized modifications, alterations or installations could result in death, injury or damage to the equipment.

HIGH PRESSURE

HYDRAULIC SYSTEM HAZARDS

Hydraulic systems can cause serious injuries if high pressure lines or equipment fail.

Never work on hydraulic systems or equipment unless there is another person nearby who is familiar with the operation and hazards of the equipment, and who can give first aid. A second person should stand by controls to turn off hydraulic pumps in an emergency. When the technicians are aided by the operators, the operators must be warned about dangerous areas.

MOVING MACHINERY HAZARDS

Be very careful when operating or working near moving machinery.

Running engines, rotating shafts, and other moving machinery parts could cause personal injury or death.

ELECTRICAL HAZARDS

Whenever possible, the power supply to the equipment must be shut off before beginning work on the equipment. Do not be misled by the term "low voltage." Potentials as low as 50 volts may cause death under adverse conditions.

Be careful not to contact 115-Vac input connections when installing or operating this equipment.

Whenever the nature of the operation permits, keep one hand away from the equipment to reduce the hazard of current flowing through the body.

For Artificial Respiration, refer to FM 21-11.

a/(b blank)

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY

No. 55-1905-223-24-2 WASHINGTON, D.C., 17 January 1989

UNIT, INTERMEDIATE DIRECT SUPPORT, AND INTERMEDIATE GENERAL SUPPORT

MAINTENANCE INSTRUCTIONS

MAIN REDUCTION GEAR

For

Landing Craft Utility (LCU)

NSN 1905-01-154-1191

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve these procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to: Commander, US Army Aviation and Troop Command, ATTN:

AMSAT-I-MP, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. A reply will be furnished directly to you.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TABLE OF CONTENTS

PAGE

CHAPTER 1 INTRODUCTION ................................................................................................ 1-1 Section I General Information .............. ........................................................................ 1-1 Section II Equipment Description and Data ......................................................................... 1-3 Section III Principles of Operation ............................................ ........................................... 1-5

CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS....... ....................................................... 2-1 Section I Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment

(TMDE); and Support Equipment ................................. .................................... 2-1 Section II Service Upon Receipt ............................................ ............................................. 2-1 Section III Unit Preventive Maintenance Checks and Services (PMCS) ............................... 2-3 Section IV Unit Maintenance Troubleshooting Procedures ....................... ............................ 2-9 Section V Unit Maintenance Procedures ...................................... ....................................... 2-12 Section VI Preparation for Storage or Reshipment, and Return to Service ........ .................. 2-41

INTERMEDIATE DIRECT SUPPORT MAINTENANCE ....................................... 3-1

CHAPTER 3 INSTRUCTIONS

Section I Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment

(TMDE); and Support Equipment ................................. .................................... 3-1 Section II Service Upon Receipt ........................................... ............................................. 3-1 Section III Intermediate Direct Support Preventive Maintenance

Checks and Services (PMCS) .......................................................................... 3-2

Change 4 i

TABLE OF CONTENTS-Continued

Section IV Intermediate Direct Support Troubleshooting Procedures .............. ..................... 3-2 Section V Intermediate Direct Support Maintenance Procedures ................. ....................... 3-3 Section VI Preparation for Storage or Shipment .................................................................. 3-20

INTERMEDIATE GENERAL SUPPORT MAINTENANCE

CHAPTER 4 INSTRUCTIONS 4-1

Section I Repair Parts; Special Tools; Test, Measurement, and

Diagnostic Equipment (TMDE); and Support Equipment ............. ................... 4-1 Section II Service Upon Receipt ........................................... ............................................. 4-1 Section III Intermediate General Support Preventive

Maintenance Checks and Services (PMCS) ....................... ........................... 4-2 Section IV Intermediate General Support Troubleshooting Procedures ............ .................... 4-2 Section V Intermediate General Support Maintenance Procedures ............... ...................... 4-3 Section VI Preparation for Storage or Shipment.................................................................... 4-32

APPENDIX A REFERENCES.................................................................................................... A-1

APPENDIX B MAINTENANCE ALLOCATION CHART .............................................................. B-1

APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST............................ C-1

APPENDIX D TORQUE VALUES .............................................................................................. D-1

GLOSSARY ABBREVIATIONS AND DEFINITIONS ............................................................... Glossary 1

ALPHABETICAL INDEX ................................................................................................................. Index 1 ii

CHAPTER 1

INTRODUCTION

Page

Section I General Information ............................................................................................ 1-1

Section II Equipment Description and Data ........................................................................ 1-3

Section III Principles of Operation ................... ..................................................................... 1-5

Section I. GENERAL INFORMATION

1-1. Scope. The scope of this manual is as follows:

a. Type of Manual. Unit, intermediate direct support, and intermediate general support maintenance manual.

b. Name of Equipment. The equipment covered in this manual is the REINTJES WAV-850 Model Marine Reverse Reduction Gearbox. See FIGURE 1-1.

c. Purpose of Equipment. The two gearboxes (one per engine) transmit torque from the engines to the propeller shafts.

1-2. Maintenance Forms, Records, and Reports. Department of the Army forms and procedures used for equipment maintenance are prescribed by DA Pam 738-750, The Army Maintenance Management System.

1-3. Destruction of Army Materiel to Prevent Enemy Use. Refer to TM 750-244-3 for instructions covering the destruction of Army materiel to prevent enemy use.

1-4. Reporting Equipment Improvement Recommendations. If your equipment needs improvement, let us know.

Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design. Put it on an SF 368 (Quality Deficiency Report). Mail it to Commander, U. S. Army Troop Support Command, ATTN: AMSTR-QX, 4300 Goodfellow Blvd., St. Louis Missouri 63120-1798. We'll send you a reply.

1-5. Preparation for Storage or Shipment. Administrative storage of equipment issued to and used by Army activities will have preventive maintenance performed in accordance with the Preventive Maintenance Checks and Services (PMCS) charts before storing. When removing the equipment from administrative storage, the PMCS should be performed to assure operational readiness. Disassembly, and repacking of equipment for shipment or short term storage, are covered in paragraphs 2-22, 3-13, and 4-14.

1-1

FIGURE 1-1. WAV-850 Gearbox.

1-2

Section II. EQUIPMENT DESCRIPTION AND DATA

1-6. Description and Characteristics. The WAV-850 Model Marine Reverse Reduction Gearbox transmits torque from the engine to the propeller shaft. The unit is capable of providing either forward or reverse rotation to the shaft.

Speed reduction is the same in both directions, 4.941:1. The LCU 2000 Class watercraft is equipped with two gearboxes, one per engine, turning the propeller shafts in opposite (counter rotating) directions. Direction of rotation is shown on the equipment nameplate and cannot be changed except by factory modification. Therefore, units cannot be replaced without first making sure that the rotation of the new unit is the same as that of the unit to be removed.

1-7. Characteristics, Capabilities and Features. A very broad view of the reduction gear is as follows:

a. Characteristics

(1) Three-piece housing design provides for ease of maintenance in the craft.

(2) Self-lubricated by means of a shaft powered pump.

(3) Operation delay tanks soften shifting action to reduce shock to propulsion system components.

b. Capabilities and Features

(1) Uses the same lubricating oil as the engine.

(2) Rugged construction assures minimum breakdown.

(3) Lubricating oil drained by a sump pump common with the engine. Valve positioning permits draining either the engine or gearbox.

1-8. Location and Description of Major Components. FIGURE 1-1 shows the location of the lubricating oil pump (1), control valve (2), heat exchanger (3), input shaft (4), output shaft (5), and lubricating oil filter (6). Table 1-1 gives the specification data for the gearbox.

a. Controls. The gearbox is controlled from the bridge by a single lever which also controls engine speed.

Center position is NEUTRAL or STOP with the engine at idle speed. Movement of the control lever forward from the center or STOP position shifts the gearbox to the FORWARD or AHEAD mode. Engine speed increases proportionally to the degree of movement away from the center position. To reverse the gearbox to ASTERN, the lever is moved rearward until the desired speed is attained.

(1) The air-operated bridge controller moves a hydraulic actuator at the gearbox control valve, directing operating oil pressure to effect the proper operating mode, i.e. STOP, AHEAD, or ASTERN.

1-3

NOTE

The arrangement of the control is such that the gearbox cannot be engaged in either direction without first going through the NEUTRAL position with the engine at idle speed.

(2) The gearbox can be operated locally, if required, by turning the handle on the control valve either clockwise or counterclockwise from the center position.

b. Instrumentation and Alarms. An oil pressure gauge is located on top of the gearbox. Normal operating pressure is 260 to 280 psi. A low pressure alarm will sound if the pressure falls 5 to 10 psi. A temperature gauge is located just above the clutch packs where the higher oil temperature is generated. Normal operating temperature is 1750 to 1950F.

1-9. Equipment Data. Reference data for the reduction gear is given in Table 1-1. Also see the equipment data given in the operator's manual TM 55-1905-223-10.

Table 1-1. Gearbox Equipment Data

Characteristics Reference Data

Model WAV-850 Manufacturer REINTJES Weight 4472 lbs. dry-4582 lbs. wet Height 57 inches Width 49 inches Length 50 inches (including coupling) Oil Cooling Method Fresh water heat exchanger (25 gal. cap.)

Engine Speed Reduction 4.941:1 Oil Type Same as propulsion engine (10.6 gal. cap.)

Normal Operating Oil Pressure 260 to 280 psi (all modes of operation) Normal Operating Oil Temperature 175°-195°F

1-10. Safety, Care and Handling. Safety precautions must be observed at all times while performing maintenance.

General WARNINGS and first-aid data appear in the front of this manual. Review all safety information before starting any task. Carefully read through an entire maintenance procedure before performing any maintenance function. Make sure the task can be done safely. All WARNINGS, CAUTIONS, and NOTES are of great importance to your personal safety and the safety of the equipment.

1-4

Section III. PRINCIPLES OF OPERATION

Overview of marine reverse reduction gearbox. The Principles of Operation section will tell you basic information about how this reduction gear works.

1-11. General. Power is transmitted by disk clutches and pinion gears. The direction of rotation is changed with a counter (or intermediate) shaft arranged on the side. The reduction ratio is the same at AHEAD and ASTERN. The disk clutches are operated by oil pressure through the control valve, and do not need to be adjusted. See FIGURE 1-2.

a. Lubrication. Operating oil pressure is built up by the gear driven pump (4), as soon as the engine is started, and is controlled by a spring-loaded over-pressure valve. Overflow oil from this valve is used for lubrication, which allows operation in the STOP position as long as necessary without damage. The gearbox is equipped with a changeover-type (two-cartridge) oil filter so operation can continue if the cartridge in use becomes clogged. A fouled up (clogged) cartridge is indicated by a red pin popping up from its normally seated position on the top of the filter head.

Changeover from one cartridge to the other is accomplished by turning the handle on the filter board. Normal oil pressure is 260 to 280 psi, and can be adjusted if required by turning a set screw located on the oil control valve.

Operating oil is the same type as that used in the engine.

b. STOP Position. In the STOP position, the control valve diverts the oil through the non-return valve (11) directly to the sump. The annular pistons (4) are forced to their original position by return springs (2). Clutches are disengaged and the output shaft is stationary.

c. Counter Rotation (to Engine Rotation). The output shaft, and thus the propeller shaft, rotates in the direction opposite to that of the drive shaft. This is the normal condition, that is, the intermediate shaft is not employed.

(1) The oil pump (14) is driven by the input shaft (10) via the spur wheels (12 and 1). The pressure oil distributor (13) delivers the pressure oil through the bore in the drive shaft behind the piston (4).

(2) The piston (4) presses the inside and outside disks (5 and 6) together. Through the force locking of the disks, the carrier (3) and the pinion (8) are carried along, and the power is transmitted to output shaft (7) via the wheel (9).

d. Identical Rotation (to Engine Rotation). The oil pressure is supplied by the oil distributor (13) and the hollow intermediate shaft (15) behind the annular piston (4). The intermediate shaft clutches are engaged and the power is transmitted by the intermediate shaft pinion to the output gear (9). Thus, the output shaft, by engagement of the intermediate shaft, is reversed and engine and gearbox rotate in the same direction.

e. Direction of Rotation. The direction of rotation registered on the name plate indicates the direction of input rotation and the direction of output rotation as seen in the direction of travel. Since the two gearboxes counter rotate, you can see that one has the intermediate shaft clutches engaged while the other has the drive shaft clutches engaged in either drive mode.

1-5

FIGURE 1-2. Gearbox Assembly.

1-6

CHAPTER 2

UNIT MAINTENANCE INSTRUCTIONS

Page

Section I Repair Parts, Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support Equipment. ............................. 2-1

Section II Service Upon Receipt ........................................................................................ 2-1

Section III Unit Preventive Maintenance Checks and Services (PMCS) ............................... 2-3

Section IV Unit Maintenance Troubleshooting....................................................................... 2-9

Section V Unit Maintenance Procedures . ............................................................................ 2-12

Section VI Preparation for Storage or Shipment . ................................................................ 2-41

Section I. REPAIR PARTS, SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT

2-1. Common Tools and Equipment. For authorized common tools and equipment refer to the Modified Table of Organization and Equipment (MTOE) applicable to your organization.

2-2. Special Tools, TMDE, and Support Equipment. Special tools; test, measurement, and diagnostic equipment;

and support equipment requirements are listed and illustrated in the Repair Parts and Special Tools List (RPSTL), TM 55-1905-223-24P. These items are also listed in the Maintenance Allocation Chart (MAC), Appendix B of this manual.

2-3. Repair Parts. Repair parts are listed and illustrated in the Repair Parts and Special Tools List (RPSTL), TM 55- 1905-223-24P.

Section II. SERVICE UPON RECEIPT

2-4. Checking Unpacked Equipment.

a. Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report the damage in accordance with the instructions in DA Pam 738-750.

b. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies in accordance with the instructions in DA Pam 738-750.

2-1

c. Check to see whether the equipment has been modified.

2-5. Preliminary Servicing and Preparation for Installation, and Adjustment. Perform the following procedures to prepare the reduction gear for installation and operation.

Overview The steps for preliminary servicing of the reduction gear are very important. The steps will cover:

o Preparing the gearbox.

o Filling with oil.

o Checking oil level and checking for leaks.

WARNING

Acid may be extremely dangerous to personnel and machinery. Always provide a tank of strong soda water as a neutralizing agent.

NOTE

All bright parts on the outside of the gearbox (flange on the propeller side, drive shaft) are protected by an anti-corrosion agent. Connections (such as oil and water) that cannot be fitted until the unit has been installed are closed with plugs. Piping that could be damaged in shipment is packaged separately. Connections and pipes that must be modified (that is, renewed) in the course of installation must be acidified and cleaned before use. Adjustable units (pressure limiting valves and pressure controllers) have been set for the specified pressure before delivery.

a. Remove protective caps, plugs, inserts, wrappings, and tape. Inspect piping openings for damage. Wipe off dirt, grease, or protective films.

NOTE

The gearbox is supplied without an oil filling and is treated with an anti-corrosion treatment. It is not necessary to flush the anti-corrosion treatment from the gearbox before filling with oil. The treatment is oil soluble and will not affect any properties of the oil.

b. Fill gearbox with oil.

2-2

CAUTION

Never operate the gearbox with oil below the low level mark, or above the upper level mark. The oil level can be checked only when the propulsion engine is shut down.

(1) Fill gearbox with the same oil as used in the propulsion engine until the oil level reaches the upper dipstick mark. Reference LO 55-1905-223-12.

(2) Start the engine. Refer to TM 55-1905-223-10. Check for evidence of external leakage. Secure capscrews, fittings, and connections as necessary. Check oil dipstick and filler tube caps to see that they are tightened securely. After 5 to 10 minutes, shut the engine down and recheck the oil level.

Add oil as necessary to bring it up to the upper dipstick mark.

NOTE

A significant amount of oil will be required to bring the oil up to the proper level due to the initial filling of the piping system, oil cooler, and filter.

CAUTION

The first oil and filter cartridge change must be made after 100 hours of operation. Thereafter, strict adherence to the preventive maintenance schedule must be maintained. Failure to change the oil and cartridge at this time could cause severe damage to the gearbox and void the manufacturer's warranty. During the first 100 hours of operation particular attention must be paid to the fouling indicator on the oil filter (see PMCS, Item 4).

c. Check water flow rate. Refer to TM 55-1905-223-10.

Section III. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

2-6. Explanation of PMCS Table. PMCS is designed to keep the equipment in good working condition. This is accomplished by performing certain tests, inspections, and services. Table 2-1 lists items to be serviced and the procedures needed to accomplish the PMCS.

2-7. Column Headings. The "Interval" column tells you when to perform a check or service. If needed, PMCS may be performed more frequently than the indicated interval. The "Procedures" column tells you how to perform the required checks and services. If your equipment does not perform as required, see Table 2-2, Troubleshooting. Report any malfunctions or failures on DA Form 2404. In the Item Number column on DA Form 2404, record the appropriate Item Number from the PMCS table.

2-3

Table 2-1. Preventive Maintenance Checks and Services

Item Interval Items To Be No D W S A Inspected/Serviced Procedures

1 Oil level Before engine startup and engine shutdown, check oil level with the dipstick after oil has settled into the sump. Keep oil level as near the upper mark as possible.

2 Water pump operation Refer to TM 55-1905-223-10

3 Oil pressure With the engine running, check oil pressure at the oil pressure gauge on top of the gear box. Pressure should read 260 to 280 psi in all operational modes: neutral, ahead, and astern.

4 Gearbox Inspect the gearbox carefully. Look for; anything that appears to be damaged, leaking, broken, or out of the ordinary.

NOTE

An alarm sounding indicates the filter cartridge is fouled and must be cleaned

(PMCS 6).

Change 2 2-4

Table 2-1. Preventive Maintenance Checks and Services-CONT

D-Daily W-Weekly S-Semiannually A-Annually

Item Interval Items To Be No D W S A Inspected/Serviced Procedures 5 Operating temperatures The temperature gauge is located in the top cover of the gearbox.

Temperature should read 175°F (80°C) to 195°F (90.5°C).

Oil filters (See Note 1) Clean oil filter elements. (FIGURE 2-4)

CAUTION

Before removing the filter cartridge, be sure it is not the one in operation. High oil pressure could deplete the gearbox of oil and cause serious damage if the element in operation is loosened by mistake.

NOTE

Filter cartridges can be cleaned while the gearbox is in operation (if necessary) by cleaning the filter not in operation, then changing the position of the switchover lever and cleaning the other. The lever position points to the element in operation.

(1) Under normal circumstances, both filter cartridges will be cleaned at one time with the engine shut down.

2-5

D-Daily W-Weekly S-Semiannually A-Annually

Item Interval Items To Be No D W S A Inspected/Serviced Procedures 6 Oil filters-Continued

(2) Remove filter body bolts (4).

(3) Remove the filter cartridge (5) by turning counterclockwise.

WARNING

Spilled liquids create very hazardous decks and passageways. Slippery deck plates and walkways around operating machinery increase risk of injury from falls and moving machinery. Clean up spills right away.

(4) Remove elements and clean with solvent (Item 4, Appendix C). Inspect condition and, if necessary, replace.

(5) Dump out oil remaining in the canister. Clean canister with with solvent and inspect for damage to threads, etc.

(6) Place the cleaned element in the canister and fill with clean oil.

(7) Replace the canister onto the filter head by turning clockwise by hand until tight, then back off 1/4 to 1/3 turn. If the canister is not backed off as above, it will be very difficult to remove the next time removal is required.

2-6

D-Daily W-Weekly S-Semiannually A-Annually

Item Interval Items To Be No D W S A Inspected/Serviced Procedures 6 Oil filters-Continued (8) Replace filter body bolts (4).

(9) Repeat procedure for other filter element.

7 Exterior bolts Inspect all bolts and nuts. Replace any that are stripped or have rounded heads. Repair any stripped nut holes in the housing by installing helicoils. Check for tightness.

8 Mountings Inspect mountings for cracks. Repair as necessary by welding. Ensure that mounting bolts are in good condition and secure.

9 Oil (See Note 2 Change oil. The reduction gear is provided with a manually operated sump pump located at the right rear of the propulsion engine, mounted to the flywheel housing. The input side of the pump is connected to the engine and gearbox sumps. The output side of the pump is connected to the dirty lube oil tank. To change oil, proceed as follows:

WARNING

Spilled liquids create very hazardous decks and passageways.

Slippery deck plates and walkways around operating machinery increases risk of injury from falls and moving machinery. Clean up spills right away.

Change 2 2-7

D-Daily W-Weekly S-Semiannually A-Annually

Item Interval Items To Be No D W S A Inspected/Serviced Procedures

(1) Open valve (1) on the gearbox side of the sump pump and ensure that valve (2) on the engine side is closed. Turn the handle until all oil has been pumped from the gearbox.

Refer to Figure 2-2 (Detail).

(2) Close the sump pump valve on the gearbox side.

(3) Fill the gearbox to-the upper mark on the dipstick.

(4) Start the engine and check for leaks.

(5) Shut down engine; wait 5 minutes; recheck oil level. Add oil as required.

10 Oil filter element (See Note 2

Proceed as in PMCS Item 6, except discard oil elements and replace with new ones

11 Gearbox interior Remove the top covers from the gearbox. Inspect gears for galling, chipped or broken teeth, metal chips, irregular wear patterns, or anything else would indicate a problem in the gear clutch mechanism.

If any of these conditions is found, notify your supervisor immediately.

Internal repairs to the gearbox are the responsibility of general support personnel.

Notes: 1. To be performed weekly, whenever the fouling indicator pin pops up, indicating a fouled condition.

2. To be performed every 6 months or after 2000 hours operation, whichever comes first.

2-8

Section IV. UNIT MAINTENANCE TROUBLESHOOTING

2-8. Symptom Index. Both a symptom index and a troubleshooting table are provided. The symptom index will help you locate the information you need for troubleshooting.

Symptom Index

Troubleshooting Procedure

(Table 2-2)

CLUTCH

Not-disengaging Item 6 Not engaging (slipping) Item 5

EXPANSION TANK SIGHT GLASS

Contains oil Item 7

GEARBOX

Geartrain whine Item 8 Pressure too low or keeps changing Item 2 Temperature too high Item 1 Using/losing oil Item 3 Vibration Item 4

2-9. Other Symptoms. This manual cannot list every symptom that may show up, and it cannot list all the possible causes and corrective actions. If a symptom is not listed, or if it keeps up after you have performed the corrective actions, notify your supervisor.

2-10. Troubleshooting. Table 2-2 lists the common fault conditions that may be found during operation or maintenance of the equipment. Look for causes and do corrective actions in the order listed.

2-9

Table 2-2. Unit Maintenance Troubleshooting

Malfunction Test or Inspection

Corrective Action

1. Gearbox oil temperature exceeds 212°F (normal range is 175-195°F)

STEP 1. Check for cold oil.

Run gearbox up to operating level (see TM 55-1905-223-10).

STEP 2. Check for too much oil in gearbox.

Remove oil down to high mark on dipstick (PMCS, Item 1).

STEP 3. Check to see if oil cooler is fouled.

Clean or replace oil cooler (see para. 2-17).

STEP 4. Check to see if rate of flow through cooler is too low.

Set correct rate of water flow (see TM 55-1905-223-10).

STEP 5. Check to see if oil is unsuitable.

Check viscosity. Change oil if necessary (PMCS, Item 9).

STEP 6. Check to see if gearbox is overloaded.

Reduce engine speed (see Tm 55-1905-223-10).

STEP 7. Check to see if sensor is faulty.

Check sensor by replacement with a new one. Check rating, 2120F.

2. Operating pressure too low or keeps changing (normal range is 260-280 psi).

STEP 1. Check to see if oil level is low.

Top off oil; locate cause for loss of oil (PMCS, Item 1).

STEP 2. Check to see if operating pressure is low on account of normal wear.

Adjust operating pressure (see TM 55-1905-223-10).

STEP 3. Check to see if filter is blocked.

Clean filter (PMCS, Item 6).

STEP 4. Check for leaking seals or preformed packings on air side of control valve.

Change seals and packings (see para. 3-9).

STEP 5. Check to see if control valve is defective.

Replace control valve (see para. 2-20).

STEP 6. Check to see if control valve is not correctly positioned.

Adjust remote controls (see TM 55-1905-223-10).

2-10

Table 2-2. Unit Maintenance Troubleshooting-CONT

Malfunction Test or Inspection

Corrective Action

STEP 7. Check to see if suction line is leaking.

Replace suction line (see para. 2-17).

STEP 8. Check to see if suction line is blocked.

Clean suction line (see para. 2-17).

3. Using/losing oil.

STEP 1. Check piping system connections.

Secure connections. Replace connections or piping as necessary.

STEP 2. Check to see if oil drain screw will not seal.

Fit oil drain screw with new seal and secure.

STEP 3. Check inspection covers.

Clean mating surfaces with solvent (Item 4, Appendix C) and reseal.

4. Vibration.

STEP 1. Check for loose exterior plumbing connectors.

Secure connectors.

STEP 2. Check for loose mounting bolts.

Tighten. Torque to 350 ft-lb.

5. Clutch is slipping or not engaging.

STEP 1. Check for blocked filter.

Change filter cartridge (PMCS, Item 6).

STEP 2. Check pressure-limiting valve for normal wear, dirt, or blockage.

Adjust operating pressure (see TM 55-1905-223-10) or replace valve (para. 2-14).

6. Clutch does not disengage.

STEP 1. Check control valve.

Adjust neutral position, and check control system and operating pressure (see TM 55-1905-223-10).

STEP 2. Check to see if oil is unsuitable.

Check viscosity of oil. Change oil if necessary (PMCS, Item 9).

2-11

Table 2-2. Unit Maintenance Troubleshooting-CONT

Malfunction Test or Inspection

Corrective Action

7. Oil in expansion tank sight glass.

STEP 1. Check for leaks in tube bundle.

Replace oil cooler tube bundle (para. 2-17).

8. Geartrain whine.

STEP 1. Check to see if oil level is low.

Top off oil; locate cause for loss of oil (PMCS, Item 1).

STEP 2. Check for worn or chipped gears.

Intermediate general support maintenance is required. Notify your supervisor.

Section V. UNIT MAINTENANCE PROCEDURES

2-11. General. Unit level maintenance is limited to the external components of the gearbox such as: oil lines and fittings, pressure gauge, oil filter (and elements) operation, delay tanks, etc.

2-12. Understanding Principles of Operation. Refer to Chapter 1, Section III for a review of the principles of operation of the reduction gear.

2-12

MAINTENANCE OF MARINE REVERSE REDUCTION GEARBOX

2-13. Inspect Main Reduction Gear-Port and Starboard.

This task covers: a. Inspection/Service, b. Testing.

INITIAL SETUP

Materials/Parts Equipment Condition

Main reduction gear TM 55-1905-223-10: Engine Secured, WAV-850PT, WAV-850SB tagged "Out of Service, Do Not

Operate."

INSPECTION/SERVICE

Refer to PMCS, Table 2-1, for main reduction gear inspection procedures.

Testing of the main reduction gear consists of operational checks. Refer to paragraph 2-5.

2-13

2-14. Replace/Repair External Hardware. (FIGURE 2-1)

This task covers: a. Removal, b. Repair, c. Replacement.

INITIAL SETUP

Tools Equipment Condition

Deep well sockets, 1/2-inch drive, TM 55-1905-223-10, Engine Secured, 12 pr, 10 mm thru 27 mm, tagged "Out of Service, Do Not Operate."

5120-01-113-8078 Refer to the following paragraph in this

Allen wrenches 2 mm thru 9 mm, maintenance manual:

5120-01-087-3616 Gearbox drained (PMCS Item 9)

Combination wrench set, metric 10 mm thru 24 mm, 5120-01-046-4979

Pipe bender set, TBT-6/25

Materials/Parts General Safety Instructions

Pre-loaded valve P/N WAV850-A39A Wipe up spills.

Valve P/N WAV850-A28 Do not accidentally bend or kink tubes Pressure gauge P/N WAV850-A35 and hoses.

Buckets, Item 1, Appendix C Shop cloths, Item 6, Appendix C Warning tags, Item 12, Appendix C

2-14

REMOVAL

WARNING

Wipe up all spills immediately to prevent the possibility of personnel slipping and falling into surrounding equipment. The equipment area is very congested and any slip could cause serious injury or even death.

CAUTION

During removal and replacement, use two wrenches on all fittings, nuts, and other components used to couple tubes and hoses. Tubes and hoses may bend and kink unless a counter-torque is applied.

a. Remove the pipe (6) from the pipe union (5).

b. Remove the pipe union (5) from the operation delay tank (4).

c. Remove the bolt attaching the tank brace to the directional control valve.

d. Unscrew the double nipple (3) with the tank (4) and remove both from the pipe elbow (2).

e. Remove the double nipple (3) from the tank (4).

f. Remove the pipe elbow (2) and pipe union (1) from the pre-loaded valve (7).

g. Unscrew the coupling nut on the valve (7) from the pipe union (8). Remove the valve (7).

h. Remove the pipe (11) from the pipe union (12).

i. Remove the pipe union (12) from the operation delay tank (13).

j. Remove the tank (13) from the pre-loaded valve (10).

k. Unscrew the coupling nut on the valve (10) from the pipe union (9). Remove the valve.

l. Remove the mounting bracket from the upper casing assembly.

m. Disconnect the pipe (14) from the pipe union (20).

n. Remove sensor (28) from reducer (15).

o. Remove the reducer (15) from the pipe union (16).

2-15

p. Remove the union (16) from the pipe (17).

q. Remove the pipe (17) from the valve (18).

r. Remove the valve (18) from the pipe (19).

s. Remove the pipe (19) from the pipe union (20).

t. Remove the pipe union (20) from the pipe (21).

u. Remove the pipe (21) from the valve (22).

v. Remove the valve (22) from the pipe (23).

w. Remove screws (27) from retaining plate (25) and lift retaining plate from upper casing.

x. Remove pressure gauge (26) from retaining plate (25).

REPAIR

a. Inspect all unions, elbows, reducers, and other threaded parts for excess wear, thread damage, or other physical defects. Replace as required.

b. Check all parts with openings for clear, free fluid passage. Clean as required.

c. Inspect all pipes for kinks or bends that could result in a leak. Replace as required.

d. Check valves for sticking and plugging; replace if necessary.

(1) Pre-loaded valve (7 and 10).

(2) Valve (18 and 22).

e. Replace pressure gauge (26), if malfunctioning.

REPLACEMENT

CAUTION

Replacement pipes are received in straight lengths requiring maintenance personnel to bend to fit as necessary. Do not attempt the bending operation if proper bending equipment is not available.

a. Replace retaining plate (25) and pressure gauge (26) to upper casing; secure with two screws (27).

b. Replace the pipe union (23) onto the valve (22).

c. Replace the pipe (21) onto the valve (22).

2-16

d. Replace the pipe union (20) onto the pipe (21).

e. Install the pipe (19) onto the pipe union (20).

f. Install the valve (18) onto the pipe (19).

g. Replace the pipe (17) onto the valve (18).

h. Replace the pipe union (16) onto the pipe (17).

i. Replace sensor (28) onto reducer (15).

j. Replace the reducer (15) onto the pipe union (16).

k. Replace mounting bracket to upper casing assembly.

1. Replace the pipe (14) onto the pipe union (20).

m. Install the pre-loaded valve (10) onto the pipe union (9).

n. Install the pre-loaded valve (10) onto the operation delay tank (13).

o. Install the operation delay tank (13) onto the pipe union (12).

p. Replace the pipe (11) onto the pipe union (12).

q. Install the pre-loaded valve (7) onto the pipe union (8).

r. Replace the pipe union (1) and pipe elbow (2) onto the pre-loaded valve (7).

s. Replace the double nipple (3) onto the operation delay tank (4).

t. Install the operation delay tank (4) with the double nipple (3) onto the pipe elbow (2).

u. Attach tank bracket to directional control valve securing with bolt.

v. Replace the pipe union (5) onto the operation delay tank (4).

w. Replace the pipe (6) onto the pipe union (5).

x. Start the engine, check for leaks, and correct any troubles.

2-17

FIGURE 2-1. External Hardware.

2-18

2-15. Replace Nonmetallic Hose Assembly . (FIGURE 2-2)

This task covers: a Removal, b Replacement.

INITIAL SETUP

Tools Equipment Condition

Combination wrench set, TM 55-1905-223-10, Engine secured, metric; 10 mm thru 24 mm, tagged "Out of Service, Do Not Operate."

5120-01-046-4979 Refer to the following paragraph in this maintenance manual:

Gearbox drained (PMCS Item 9)

Materials/Parts Swing check valve P/N DOH435 General Safety Instructions Nonmetallic hose assembly

P/N DOH234-84 Wipe up spills.

Warning tags, Item 12, Appendix C

Do not accidentally bend or kink tubes and hoses.

REMOVAL

CAUTION

During removal and replacement, use two wrenches on all fittings, nuts, and other components used to couple tubes and hoses. Tubes and hoses may bend and kink unless a counter-torque is applied.

a. Remove the male elbow (6) from the bottom of the casing.

b. Remove the male elbow (6) from the female swivel of the hose assembly (7).

c. Disconnect the other female swivel of the hose from the male connector (3).

d. Remove the male connector from the swing check valve (4).

2-19

e. Remove the swing check valve from the 450 male pipe elbow (5).

f. Remove the 450 male pipe elbow.

REPLACEMENT

a. Replace the 450 male pipe elbow (5).

b. Replace the swing check valve (4) to the male pipe elbow (5).

c. Replace the male connector (3) to the swing check valve (4).

CAUTION

Install the hose assembly carefully to avoid twists or kinks that may impede the flow of oil.

d Replace one end (female swivel) of the hose assembly (7) to the male connector (3).

e Replace the male elbow (6) to the bottom of the casing and connect the remaining end of the hose assembly (7) to the male elbow (6).

f Refill the gearbox with oil (para. 2-5). Start the engine (TM 55-1905-223-10) and check for leaks. Correct any troubles.

2-20

FIGURE 2-2. Hose Assembly, Dirty Oil.

2-21

2-16. Repair Nonmetallic Hose Assembly. (FIGURE 2-2)

This task covers: a. Disassembly, b. Repair, c. Assembly.

INITIAL SETUP

Tools

Combination wrench set, metric, 10 mm thru 24 mm 5120-01-046-4979

Materials/Parts

Swing check valve P/N DOH435 Nonmetallic hose assembly

P/N DOH234-84

Warning tags, Item 12, Appendix C Solvent, Item 4, Appendix C

Equipment Condition

TM 55-1905-223-10, Engine Secured, tagged "Out of Service, Do Not Operate."

Refer to the following paragraph in this maintenance manual:

Gearbox drained (PMCS Item 9)

General Safety Instructions

Do not accidentally bend or kink tubes and hoses.

DISASSEMBLY

CAUTION

During disassembly and assembly, use two wrenches on all fittings, nuts, and other components used to couple tubes and hoses. Tubes and hoses may bend and kink unless a counter-torque is applied.

a. Disassembly of the nonmetallic hose assembly consists of removal of the components from the gearbox.

b. Refer to paragraph 2-15 for removal procedures.

REPAIR

a. Inspect the swing check valve (4) for proper operation and freedom from corrosion. Replace as required.

2-22

b. Inspect the nonmetallic hose assembly (7) for kinks, bends, leaks, or other evidence of physical damage. Replace as required.

c. Inspect all other parts for clear passages for fluid flow. Clean as required, using solvent, Item 4, Appendix C.

ASSEMBLY

CAUTION

During disassembly and assembly, use two wrenches on all fittings, nuts, and other components used to couple tubes and hoses. Tubes and hoses may bend and kink unless a counter-torque is applied.

a. Assembly of the nonmetallic hose assembly consists of replacement of the components to the gearbox.

b. Refer to paragraph 2-15 for replacement procedures.

2-23

2-17. Repair/Replace Fluid Transmission Cooler. (FIGURE 2-3)

This task covers: a, Removal, b. Disassembly, c. Repair, d. Assembly, e. Replacement.

INITIAL SETUP

Tools

Deep well sockets, 1/2-inch drive, 12 pt, 10 mm through 27 mm, 5120-01-113-8078

Combination wrench set, metric, 10 mm through 24 mm, 5120-01- 046-4979

Lifting sling P/N 3375958

Materials/Parts

Fluid cooler, transmission

P/N WAV850-A1

Gasket set P/N 45C109 Tube bundle P/N 45C105 Shop cloth, Item 6, Appendix C Paper towels, Item 7, Appendix C Solvent, Item 4, Appendix C Soft brush, Item 8, Appendix C Warning tags, Item 12, Appendix C

Equipment Condition

TM 55-1905-223-10, Engine Secured, tagged "Out of Service, Do Not Operate."

General Safety Instructions

Secure all oil cooler isolation valves.

REMOVAL

WARNING

Be prepared to catch water and oil as the connections are removed. Wipe up spills immediately to prevent injury to personnel.

a. Removal the attaching hardware and disconnect the input and output water connections (13) from the end of the cooler.

b. Remove the bolts (7) cover (6) gaskets (5) and disconnect the input and output oil lines from the top of the cooler.

Change 1 2-24

The oil cooler is very heavy. Make sure the proper lifting devices are used and that a lifting sling is securely attached to the cooler to prevent injury to personnel.

c. Attach a lifting sling to the cooler. Take up slack.

d. Remove two bolts (19) securing each of the two cooler mounting brackets (20) to the gearbox.

e. Loosen the input and output oil lines (1 and 2, FIGURE 2-2) for freedom of motion to remove oil cooler.

f. Swing the cooler away from the gearbox and lower to the deck.

DISASSEMBLY

a. Remove the eight nuts (22) from the studs (17).

b. Remove cover (15) and gasket (14).

c. Remove the open-end cover (16) and related gaskets (11, 12).

CAUTION

Make a scribe mark on the retainer only, not on the tube bundle surface. Scraping the tube walls may weaken the metal and lead to leakage.

d. Scribe a mark on the end of the retainer on the tube bundle (18).

e. Scribe a matching mark on the tube bundle casing (23).

NOTE

The scribe marks will aid in proper assembly.

f. Remove the six dome nuts (1) and six washers (27) from the stud (24).

g. Remove the eight hex bolts (2) and nuts (9).

h. Remove the cover (26).

i. Remove the rear support ring (25) and gaskets (3, 4).

j. Remove the plugs (10) and (21) from the casing (23).

2-25

k. Gently slide the tube bundle (18) out of the casing.

Overview Although the cooler may not look complicated, it is very important to the function of the reduction gear, and your inspection should be very thorough.

REPAIR

a. Inspect the tube surfaces for evidence of corrosion.

CAUTION

Do not use any rigid or hard material such as plastic or metal scrapers to clean the tubes.

b. Remove any tube surface corrosion by wiping with shop cloth or paper towels.

c. Inspect the tubes for obstructions. Clean and clear tubes using solvent and soft brush, or replace as required.

d. Inspect the interior of the casing for water mineral deposits or other corrosion. Clean, using solvent and soft brush, or replace as required.

e. Inspect all parts and orifices for freedom from obstruction and clear passage for fluid flow. Clean, using solvent and soft brush, or replace as required.

f. Inspect all threaded parts for wear, thread damage, or other physical defects. Replace as required.

NOTE

Perform the steps in this paragraph annually, regardless of any other maintenance requirements.

ASSEMBLY

a. Slide the tube bundle (18) into the casing (23), making sure the scribe marks on the bundle retainer and casing are lined up.

b. Replace the plugs (10 and 21) into the casing (23).

c. Replace the rear support ring (25) with gaskets (3, 4) installed.

d. Replace the cover (26).

2-26

e. Replace the hex bolt and nut (2, 9).

f. Replace the washers (27) and dome nuts (1) onto the studs (24).

g. Replace the open-end cover (16) with gaskets (11, 12) installed.

h. Replace the nuts (22) onto the studs (17).

i. Replace the covers (15) with gasket (14).

j. Replace the covers (6), end gaskets (5), and bolts (7) onto the flanges (8).

REPLACEMENT

a. Attach the lifting sling to the new cooler.

b. Position the cooler so the bracket holes line up with the mounting holes in the gearbox.

c. Install mounting bolts.

d. Remove lifting sling.

e. Connect oil and water lines. Secure oil lines on gearbox (13 and 14, FIGURE 2-2). Refill gearbox with oil, paragraph 2-5.

f. Open oil cooler isolation valve Refill expansion tank with water.

g. Turn water pump on, and check for leaks. Tighten connections as necessary until leak stops.

h. Start engine (TM 55-1905-223-10). Run for 5 minutes and check for oil leaks. Secure connections as necessary until leak stops.

i. Shut engine down and check gearbox oil level and add oil until oil is level with full mark.

NOTE

A significant amount of oil will be required to bring the oil up to the proper level due to the initial filling of the piping system, oil cooler, and filter.

2-27

FIGURE 2-3. Fluid Transmission Cooler.

2-28

2-18. Replace Double Changeover Filter. (FIGURE 2-4)

This task covers: a. Service, b. Removal, c. Replacement.

INITIAL SETUP

Tools

Deep well socket, 1/2-inch drive, 12 pt, 10 mm through 27 mm, 5120-01-113-8078

Combination wrench set, metric, 10 mm through 24 mm, 5120-01-046-4979

Materials/Parts

Double changeover filter P/N 3A4040

Cartridge P/N WAV850-A3 Warning tags, Item 12, Appendix C

Equipment Condition

TM 55-1905-223-10, Engine secured, tagged "Out of Service, Do Not Operate."

Refer to the following procedure in this…