HEADQUARTERS DD-5111V User manual

1
TM 55-1945-205-24-3-3
TECHNICAL MANUAL
UNIT, DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE MANUAL
FOR
MODULAR CAUSEWAY SYSTEM (MCS)
WARPING TUG (WT) MARINE GEAR
DD-5111V
NSN 2040-01-505-2033
This manual supersedes TM 55-1945-205-24-3 dated 29 August 1997, including all changes.
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
30 AUGUST 2003

TM 55-1945-205-24-3-3
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C.30 AUGUST 2003
TECHNICAL MANUAL
UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
FOR
MODULAR CAUSEWAY SYSTEM (MCS)
WARPING TUG (WT) MARINE GEAR
DD-5111V
NSN 2040-01-505-2033
This manual supersedes TM 55-1945-205-24-3 dated 29 August 1997, including all changes.
TABLE OF CONTENTS
WP Sequence No.
WARNING SUMMARY
HOW TO USE THIS MANUAL
General Information .............................................................................................................. 0001 00
CHAPTER 1 - DESCRIPTION AND THEORY OF OPERATION
Description and Data, Equipment Characteristics, Capabilities and Features ...................... 0002 00
Description and Data, Location and Description of Major Components .............................. 0003 00
Description and Data, Equipment Data ................................................................................. 0004 00
Theory of Operation .............................................................................................................. 0005 00
CHAPTER 2 - UNIT, DIRECT SUPPORT AND GENERAL SUPPORT
TROUBLESHOOTING PROCEDURES
Troubleshooting Procedures Index ........................................................................................ 0006 00
Clutch Will Not Engage In Engage/Backflush Directions .................................................... 0007 00
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment
Technical Publications), through the Internet, on the Army Electronic Product Support (AEPS) website.
The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on
“ACCESS REQUEST FORM”. The DA Form 2028 is located in the ONLINE FORMS PROCESSING
section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to
respond quicker to your comments and better manage the DA Form 2028 program. You may also mail,
fax or email your letter or DA Form 2028 direct to: AMSTA-LC-CI / TECH PUBS, TACOM-RI, 1 Rock
Island Arsenal, Rock Island, IL 61299-7630. The email address is T[email protected].mil.
The fax number is DSN 793-0726 or Commercial [phone].
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TM 55-1945-205-24-3-3
TABLE OF CONTENTS (CONT’D) WP Sequence No.
CHAPTER 2 - UNIT, DIRECT SUPPORT AND GENERAL SUPPORT
TROUBLESHOOTING PROCEDURES (CONT’D)
Excessive Noise and/or Vibration ......................................................................................... 0008 00
No Neutral ............................................................................................................................. 0009 00
Harsh Gear Engagement ........................................................................................................ 0010 00
No Output Power ................................................................................................................... 0011 00
Electronic Control Valve Malfunction .................................................................................. 0012 00
CHAPTER 3 - UNIT, DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE INSTRUCTIONS
Service Upon Receipt............................................................................................................. 0013 00
Preventive Maintenance Checks and Services (PMCS) Procedures, Introduction ............... 0014 00
Preventive Maintenance Checks and Services (PMCS) and Lubrication Procedures ........... 0015 00
Servicing ................................................................................................................................ 0016 00
Breather, Replacement .......................................................................................................... 0017 00
Removal and Installation ....................................................................................................... 0018 00
Manifold Assembly, Replacement ........................................................................................ 0019 00
Rebuild .................................................................................................................................. 0020 00
Filter Screen, Removal, Cleaning, Inspection and Installation ............................................. 0021 00
Oil Cooler, Cleaning and Inspection ..................................................................................... 0022 00
Oil Cooler, Replacement ....................................................................................................... 0023 00
Oil Cooler Lines, Replacement ............................................................................................. 0024 00
Oil Pump, Replacement ......................................................................................................... 0025 00
Pump Drive Adaptor, Replacement ....................................................................................... 0026 00
Electronic Control Valve, Removal and Installation ............................................................. 0027 00
Electronic Control Valve Solenoid, Replacement ................................................................. 0028 00
Electronic Control Valve, Repair .......................................................................................... 0029 00
Mount, Replacement .............................................................................................................. 0030 00
Output Flange, Replacement ................................................................................................. 0031 00
Output Seal, Replacement ..................................................................................................... 0032 00
Torsional Coupling, Replacement ......................................................................................... 0033 00
Preparation for Storage or Shipment ..................................................................................... 0034 00
Torque Limits Work Package ................................................................................................ 0035 00
CHAPTER 4 - SUPPORTING INFORMATION
References ............................................................................................................................. 0036 00
Maintenance Allocation Chart (MAC), Introduction ............................................................ 0037 00
Maintenance Allocation Chart (MAC) .................................................................................. 0038 00
Expendable and Durable Items List (EDIL) .......................................................................... 0039 00
Tool Identification List (TIL) ................................................................................................ 0040 00
INDEX
Alphabetical........................................................................................................................INDEX - 1
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TM 55-1945-205-24-3-3
HOW TO USE THIS MANUAL
This manual contains certain features to improve the convenience of using this manual and increase the user’s
efficiency. These features include:
a. Accessing Information
Information is accessed by referring to the Table of Contents, located in the front of this manual, or by looking in the
Alphabetical Index, located in the back of this manual.
b. Illustrations
Various methods are used to locate and repair components. Locator illustrations in Controls and Indicator tables,
PMCS tables, exploded views and cut-away diagrams make the information in the manual easier to understand
and follow.
c. Using This Manual
When using this manual, read and understand the entire maintenance action before performing the task. Also, read
and understand all warnings, cautions and notes as well as general safety precautions that apply to the task to be
performed. The warning summary will inform personnel of hazards associated with the equipment to be worked on.
However, the summary is not all inclusive and personnel should be aware at all times of hazardous conditions that
may arise.
Prior to starting the procedures in this manual, the initial setup requirements are located directly above each
procedure. The information is given to ensure all materials, expendables, tools and any other equipment necessary are
readily available for use. The initial setup will be accomplished prior to starting the actual steps of each
maintenance procedure.
Locating Major Components
Obtain the manual for the system to be worked on. Open to the Table of Contents located in the front of this manual.
Find Chapter 1, Description and Theory of Operation. Under the chapter title you will find the work package titled
Location and Description of Major Components. Turn to the work package indicated. This work package will give a
brief description of the major components, and show an illustration of what the component looks like and its location.
The Alphabetical Index, located in the back of this manual, contains an alphabetical list of all sections of this manual.
Location and Description of Major Components is found in section L. The work package is found on the right side of
the title where the Location and Description of Major Components is located. Turn to the work package indicated to
find the description and location of each component.
Troubleshooting Procedures
The Table of Contents or Alphabetical Index may be used to locate sections within this manual. To locate a particular
troubleshooting procedure, open the manual to the Table of Contents located in the front of this manual. Find
Chapter 2, Troubleshooting Procedures. Under this section, find a work package titled Troubleshooting Index. Turn to
the work package indicated, which lists all of the troubleshooting procedures. Look down the list until you find the
appropriate work package for the problem you are trying to solve. To the right side of the procedure will be a work
package number. Turn to the work package indicated and follow the steps to complete the troubleshooting procedure.
The procedures list the malfunction, symptom and the corrective action. The corrective action will indicate which
maintenance procedure to go to for the repair of the symptom or what level of maintenance is capable of repair of
the problem. Follow the procedures indicated to complete the task. At the top of the task you will have a section
called INITIAL SETUP. There are five basic headings listed under INITIAL SETUP.
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TM 55-1945-205-24-3-3
Test Equipment: Lists all test equipment (standard or special) required to troubleshoot, test and inspect the
equipment covered in this manual. The test equipment is identified with an item number and work package
number from the Tool Identification List located in Chapter 4, Supporting Information.
Tools: Lists all tools (standard or special) required to perform the task. Tools are identified with an item number
and work package number from the Tool Identification List located in Chapter 4, Supporting Information.
Personnel Required: Lists all personnel necessary to perform the task.
Equipment Condition: Notes the conditions that must exist before starting the task. The equipment condition
will also include any prerequisite maintenance tasks to be performed with reference to the work package number
or to the TM number.
References: Includes any other manuals necessary to complete the task. When there are no references listed, all
steps necessary to complete the task are contained within this manual. A listing of reference materials is
contained in the work package References in Chapter 4, Supporting Information.
Maintenance Instructions
To locate a maintenance procedure, open the manual to the Table of Contents located in the front of this manual. Find
Chapter 3, Maintenance Instructions. Look down the list and find the maintenance procedure to be accomplished. On
the right side of the maintenance procedure will be a work package number. Turn to the work package indicated.
Before beginning the maintenance task, look through the procedure to familiarize yourself with the entire
maintenance procedure. At the top of the task you will have a section called INITIAL SETUP. There are five basic
headings listed under INITIAL SETUP.
Tools: Lists all tools (standard or special) required to perform the task. Tools are identified with an item number
and work package number from the Tool Identification List located in Chapter 4, Supporting Information.
Materials/Parts: Lists all parts or materials necessary to perform the task. Expendable and durables are
identified with an item number from the applicable work package located in Chapter 4, Supporting Information.
Personnel Required: Lists all personnel necessary to perform the task.
References: Includes any other manuals necessary to complete the task. When there are no references listed, all
steps necessary to complete the task are contained within this manual. A listing of reference materials is
contained in the work package References in Chapter 4, Supporting Information.
Equipment Condition: Notes the conditions that must exist before starting the task. The equipment condition
will also include any prerequisite maintenance tasks to be performed with reference to the work package number
or to the TM number.
Test Equipment: Lists all test equipment (standard or special) required to troubleshoot, test and inspect the
equipment covered in this manual. The test equipment is identified with an item number and work package
number from the Tool Identification List located in Chapter 4, Supporting Information.
Repair Parts and Special Tools List
Refer to TM 55-1945-205-24P-3 when requisitioning parts, special tools and equipment.
Identify the mandatory repair parts required to perform this task listed at the top of the work package in the INITIAL
SETUP. Using the part number provided, refer to the part number index work package in TM 55-1945-205-24P-3.
Look up the part number in the part number column and identify the figure and item number where the part is located.
Turn to the figure and locate the item number listed. Verify that the item is correct.
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TM 55-1945-205-24-3-3
0001001
0001 00
UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
WARPING TUG
MARINE GEAR
GENERAL INFORMATION
SCOPE
This manual contains descriptions and maintenance instructions for Unit, Direct Support and General Support
maintenance levels for the Warping Tug (WT) marine gear, model number DD-15111V.
Type of Manual: Unit, Direct Support and General Support Maintenance Manual.
MAINTENANCE FORMS, RECORDS AND REPORTS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM
738-750, Functional Users Manual for The Army Maintenance Management System (TAMMS); and AR 700-138,
Army Logistics Readiness and Sustainability.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
If any component in your system 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 or performance.
Put it on an SF 368 Product Quality Deficiency Report. Mail it to the address specified in DA PAM 738-750, or as
specified by the contracting activity. We will send you a reply.
CORROSION PREVENTION AND CONTROL (CPC)
CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported
so that the problem can be corrected and improvements can be made to prevent the problem in future items.
While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such
as rubber and plastic. Unusual cracking, softening, swelling or breaking of the materials may be a corrosion problem.
If a corrosion problem is identified, it can be reported using an SF 368, Product Quality Deficiency Report. Use of
key words such as “corrosion”, “rust”, “deterioration” or “cracking”, will ensure that the information is identified as a
CPC problem. The form should be submitted to the address specified in DA PAM 738-750, Functional Users Manual
for The Army Maintenance Management System (TAMMS).
OZONE DEPLETING SUBSTANCES (ODS)
The continued use of ODS has been prohibited by Executive Order 12856 of 3 August 1993.
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE
The procedures for destruction of Army materiel to prevent enemy use are contained in TM 750-244-6.
PREPARATION FOR STORAGE AND SHIPMENT REFERENCE
Reference WP 0034 00 for preparing marine gear for storage or shipment.

TM 55-1945-205-24-3-3
CHAPTER 1
DESCRIPTION AND THEORY OF OPERATION
FOR
MODULAR CAUSEWAY SYSTEM (MCS)
WARPING TUG (WT) MARINE GEAR

TM 55-1945-205-24-3-3
0002 00 1/2 blank
0002 00
UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
WARPING TUG
MARINE GEAR
DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES
Marine Gear
The marine gear provides the capability to reverse the directional rotation of the other drive train components making
it possible to backflush the pump-jet. It is mounted directly to the flywheel housing of the diesel engine. The gear is
equipped with an integral hydraulic system consisting of a pump, shifting valve and internal hydraulic cylinders. The
pump utilizes the gear lubricating oil to operate hydraulic cylinders which shifts the gears to the backflush, neutral or
engaged configurations. The shifting valve is solenoid actuated from a toggle control switch in the operators cab. In
addition to powering the shifting cylinders, the pump also circulates case oil through an oil cooler that is plumbed
into the engine raw water cooling system.

TM 55-1945-205-24-3-3
0003001
0003 00
UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
WARPING TUG
MARINE GEAR
DESCRIPTION AND DATA
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
The marine gear is attached directly to the flywheel housing of the engine and to the drive shaft at the output flange.
There are two marine gears: one for the starboard engine and one for the port engine. The marine gear weighs
approximately 561 lb dry weight. The marine gear consists of five major subassemblies: the main housing group, the
forward clutch group, the reverse clutch group, the input group and the output group.
DESCRIPTION OF MAIN HOUSING GROUP
The main housing group consists of the main housing assembly, the manifold assembly, oil pump assembly, bearing
carrier and electronic control valve assembly.
Main Housing Assembly
The main housing assembly is a high quality casting with integral mounting pads that support the marine gear on the
engine bed rails. The housing contains the following: gears, shafting and forward bearings for the drive components.
The flywheel housing adaptor is cast as an integral part of the assembly. The electronic control valve is positioned on
top of the main housing assembly.

TM 55-1945-205-24-3-3
0003002
0003 00
Manifold Assembly
The manifold assembly provides oil passages and a mounting pad for the oil pump, as well as the Power
Takeoff (PTO).
Oil Pump Assembly
The oil pump assembly is externally mounted. The pump is located at the rear of the marine gear, behind the rear
clutch assembly. The oil pump supplies oil for several functions to include: electronic control valve, clutch
engagement, clutch cooling and bearing and gear lubrication.
MANIFOLD
ASSEMBLY
ELECTRONIC CONTROL
VALVE ASSEMBLY
OIL PUMP
MAIN HOUSING
MAIN HOUSING
OIL PUMP
ELECTRONIC CONTROL
VALVE ASSEMBLY

TM 55-1945-205-24-3-3
0003003
0003 00
Bearing Carrier
The bearing carrier is mounted between the main housing assembly and manifold assembly. The bearing carrier
locates the rear bearing cones of all power transmitting shafts. The bearing carrier is aligned with the front housing.
DESCRIPTION OF ELECTRONIC CONTROL VALVE ASSEMBLY
A three position (forward, neutral and reverse) rotary type electronic control valve is externally mounted on top of the
gear, over the forward clutch, and is hydraulically operated. The valve assembly consists of the main regulator valve
body and the electronic control valve group of parts. The main regulator valve consists of a piston and two springs.
The electronic control valve includes the valve body, cover, cover gasket, shift lever, detent assembly plate and
valve spool.
DESCRIPTION OF FORWARD AND REVERSE CLUTCH GROUPS
Both groups consist of: a clutch shaft with two horizontally drilled passages, which are intersected by cross drilled
holes, providing oil for cooling of the clutch and lubrication of moving parts, as well as clutch engagement. A clutch
pack located within the clutch housing gear, supporting power flow and a clutch housing gear with internal teeth that
engage the external teeth of the metal clutch plates and back plate. Cross drilled holes in the clutch housing permit
cooling and lubrication oil to return to the sump.
OIL PUMP
TORSIONAL
COUPLING
MAIN
HOUSING
BEARING
CARRIER
MANIFOLD ASSEMBLY
ELECTRONIC CONTROL
VALVE ASSEMBLY

TM 55-1945-205-24-3-3
0003004
0003 00
A dump valve in the clutch gear housing provides oil pressure relief when the clutch is engaged.
DESCRIPTION OF INPUT GROUP
The input group transfers power from the engine flywheel to the marine gear. The marine gear may employ two
different input groups; torsional coupling or rubber block system. The rubber block system consists of the driving
ring, drive spider and rubber blocks. The type of input group used is determined through a series of tests conducted
by the manufacturer. The input gear shaft-transfers rotational power from the engine to the input gear which transfers
rotational power to the forward or reverse clutch.
CLUTCH GEAR
CLUTCH SHAFT
TORSIONAL COUPLING
RUBBER BLOCKS
DRIVE RING
DRIVE SPIDER

TM 55-1945-205-24-3-3
0003 00 5/6 blank
0003 00
DESCRIPTION OF OUTPUT GROUP
The output group of parts consists of an output gear that provides rotational power to the output shaft. The output
shaft receives rotational power from the output gear and provides rotational power to the drive shaft assembly. The
output flange provides for the installation of a six bolt companion flange.
OUTPUT SHAFT
OUTPUT GEAR
OUTPUT FLANGE