TM-55-1905-217-34 Landing Craft Mechanized; Steel; DED; Overait Length 74 Feet Mod 1 Marl VIII Navy Design LCM-8 Manual

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TM-55-1905-217-34

DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
WARNING DANGEROUS CHEMICALS
LANDING CRAFT, MECHANIZED, STEEL, DED OVERALL LENGTH 74 FEET, MOD 1, MARK VIII, NAVY DESIGN LCM-8
LANDING CRAFT, MECHANIZED, STEEL, DED OVERALL LENGTH 74 FEET, MOD 1, MARK VIII, NAVY DESIGN LCM-8
SERIOUS INJURY OR DEATH
WARNING ASPHYXIATION DANGER
LANDING CRAFT, MECHANIZED, STEEL, DED OVERALL LENGTH 74 FEET, MOD 1, MARK VIII, NAVY DESIGN LCM-8
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS-Continued
LIST OF ILLUSTRATIONS-Continued
CHAPTER 1 Introduction
Figure 1-1. Landing craft, mechanized, diesel, design LCM (8) Mod-1-hull nos. 8540 through 8560 and 8580 through 8618.
Section II. DESCRIPTION AND DATA
Table 1-1. Engine Repair and Replacement Standards
Table 1-1. Engine Repair and Replacement Standards
Table 1-1. Engine Repair and Replacement Standards
Table 1-1. Engine Repair and Replacement Standards
Table 1-2. Standard Bolt and Nut Torque Specifications
Table 1-3. Special Bolt and Nut Torque Specifications
Table 1-4. Stud Torque and Height Specifications
Figure 1-3. Wiring diagram-hull no. 8520 thru 8539.
CHAPTER 2 DIRECT SUPPORT AND GENERAL SUPPORT
Table 2-1. Special Tools and Equipment (Continued)
Section II. TROUBLESHOOTING
Table 2-2. Troubleshooting
Transmission and Transfer Gear
Alternator
Section III. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS AND ASSEMBLIES
Propulsion Units
CHAPTER 3 REPAIR OF ENGINE AND TRANSMISSION
Figure 3-3 illustrates the fuel metering from no load to full load by rotation of the plunger in the bushing
Figure 3-3. Fuel metering from no load to full load.
Figure 3-4. Phase of fuel injector operation through vertical travel of plunger.
Operation
Figure 3-5. Checking fuel injector rack for freeness
Figure 3-6. Fuel injector in testing and popping fixture, installation.
Valve holding pressure test
Figure 3-7. Fuel injector high pressure test.
Figure 3-8. Fuel injector follower stop pin, removal.
Figure 3-9. Defective fuel injector plungers.
Figure 3-10. Setting comparator stroke counter.
Figure 3-11. Injector follower, spring and plunger, removal and installation.
Figure 3-12. Installing fuel injector in comparator.
Figure 3-13. Fuel injector filter, removal and installation.
Figure 3-14. Injector rack, gear, spray tip and valve assembly components, removal and installation.
Figure 3-15. Removing spray tip from fuel injector nut.
Figure 3-16. Reaming fuel injector spray tip.
Figure 3-17. Cleaning fuel injector spray tip orifices.
Figure 3-18. Cleaning fuel injector nut spray tip seat.
Figure 3-19. Fuel injector sealing surfaces which may require lapping
Figure 3-20. Lapping edge of hole in fuel injector valve seat
Reassembly
Figure 3-21. Installing fuel injector follower stop pin.
Figure 3-22. Checking fuel injector spray tip concentricity.
Figure 3-23. Reaming seat of injector tube in cylinder head
Inspection and Repair
Reassembly
Figure 3-25. Governor and throttle controls, disassembly and reassembly.
Governor control housing
Cleaning and Inspection
Figure 3-26. Governor-assembled.
Expansion Tank (Fresh Water)
Figure 3-27. Fresh water expansion tank, removal and installation.
Figure 3-28. Fresh water pump, exploded view.
Fresh Water Pump
Figure 3-29. Raw water pump-exploded view.
Keel Cooler Heat Exchanger
Blower Assembly
Disassembly
Figure 3-31. Blower, disassembly and reassembly.
Cleaning and Inspection
Reassembly
Figure 3-32. Proper shim location for correct rotor lobe clearance
Reassembly-cont.
Figure 3-33. Chart of minimum clearances for blower
Figure 3-34. Installing rotor gears on shaft for preliminary check of clearance.
Reassembly-cont.
Figure 3-35. Blower and Drive Assembly with accessories attached to blower.
Transmission Control Valve
Figure 3-36. Transmission control valve, exploded view.
Figure 3-37. Removing shutoff valve oil seal from control housing
Figure 3-38. Installing shutoff valve oil seal in control valve housing.
Transmission Oil Pump
Figure 3-39. Transmission oil pump, disassembly and reassembly
Cleaning, Inspection and Repair
Figure 3-40. Oil pump porting and rotors including bleed holes.
Power Take-Off Assembly
Disassembly
Figure 3-43. Power take-off clutch, disassembly and reassembly
Section II. ENGINE COMPONENTS AND TRANSMISSION
Figure 3-44. Injector control tube and cylinder head mounting nuts and bolts, removal and installation.
Figure 3-45. Cylinder head and valves, disassembly and reassembly.
Figure 3.46. Injector control tube assembly, disassembly and reassembly
Figure 3-47. Checking bottom face of cylinder head.
Figure 3-49, Correct installation of water nozzles in cylinder head
Reassembly
Figure 3-50. Rocker arm and shaft, removal and installation.
Figure 3-51. Rocker arms, cam followers, and push rods, disassembly and reassembly
Figure 3-52. Cam follower and guide, removal and installation.
Figure 3-53. Cam roller wear and clearance diagram
Figure 3-54. Cam follower, roller, and pin, removal and installation.
Exhaust Valves
Figure 3-55. Valve seat insert, removal.
Figure 3-56. Relationship between exhaust valve, insert, and cylinder head.
Idler Gear Assembly and Hole Spacer
Figure 3-57. Idler gear assembly, cross section view
Idler Gear Assembly and Hole Spacer-cont.
Figure 3-58. Idler gear hole spacer, removal and installation.
Idler Gear Assembly and Hole Spacer-cont.
Figure 3-59. Idler gear assembly, disassembly and reassembly.
Figure 3-60. Pressing hub out of bearing
Idler gear bearing and spacer, cross-section view
Figure 3-63. Location of notches in idler gear
Figure 3-65. Plates for bearing test fixture.
Checking Bearing Preload
Figure 3-66. Checking pre-load of idler gear bearing
Installation
Engine Timing
Figure 3-67. Gear train and timing marks- left-hand rotation engines.
Figure 3-68. Gear train and timing marks- right-hand rotation engines.
Checking Engine Timing
Oil Pan
Oil Pump
Figure 3-70. Oil pump, removal, disassembly, reassembly, and installation.
Disassembly
Figure 3-71. Oil pump drive shaft and gear assembly
Figure 3-72. Piston, connecting rod and cylinder sleeve, removal, disassembly, reassembly, and installation
Disassembly
Figure 3-73. Reaming piston pin bushings in connecting rod.
Figure 3-73. Reaming piston pin bushings in connecting rod.
Fitting Piston Rings
Cylinder Liners
Figure 3-76. High and low pressure contact areas on cylinder liner
Figure 3-77. Cylinder liner measurement diagram.
Inspection of New Cylinder Liner
Figure 3-78. Cylinder liner mounting in block
Figure 3-79. Installing piston and connecting rod assembly in cylinder liner.
Figure 3-80. Crankshaft pulley, removal.
Figure 3-81. Power transfer gear assembly (HM marine).
Figure 3-82. Transfer gear housing and flywheel housing, removal and installation.
Figure 3-83. Removing lock nut from power driven shaft.
Installation
Figure 3-84. Main bearing cap, removal.
Figure 3-85. Rear main bearing thrust washer and mounting.
Figure 3-86. Main bearing upper shell, removal (except rear main) crankshaft in place.
Figure 3-87. Rear main bearing upper shell, removal -crankshaft in place.
Installation (Crankshaft in Place).
Transmission and Flywheel
Figure 3-88. Torquematic marine gear and flywheel assembly, cross-section view.
Disassembly
Figure 3-89. Reverse gear assembly, cross-section view.
Figure 3-90. Removing retaining ring from reverse gear housing.
Figure 3-91. Removing oil seal rings from reverse gear drive shaft.
Figure 3-92. Flywheel and forward clutch, cross-section view.
Flywheel and Forward Clutch
Reassembly
Reassembly-cont.
Reverse Gear
Reverse Gear-cont.
Figure 3-93. Installing reverse clutch plate and drive plate assembly into reverse rear housing.
Reverse Gear-cont.
Figure 3-94. Installing reverse planetary gear assembly and sun gear on reverse gear drive shaft .
Crankshaft Front Cover
Figure 3-95. Crankshaft front cover, removal and installation.
Figure 3-96. Crankshaft front cover bolt tightening sequence .
Crankshaft
Figure 3-97. Crankshaft, disassembly and reassembly.
Camshaft and Balance Shaft
Figure 3.98. Balance weight cover, removal and installation and bolt tightening sequence.
Figure 3-99. Loosening nut on camshaft or balance shaft.
Figure 3-100. Camshaft and balance shaft, exploded view.
Camshaft and Balance Shaft-cont.
Camshaft and Balance Shaft-cont.
Cylinder Block
Figure 3-101. Cylinder block, disassembly and reassembly.
CHAPTER 4 REPAIR OF CONTROL SYSTEMS
Figure 4-1. Alternator-exploded view, (Hulls 8500-8519 and 8520-8539).
CHAPTER 4 REPAIR OF CONTROL SYSTEMS-cont.
CHAPTER 4 REPAIR OF CONTROL SYSTEMS-cont.
Figure 4-2. Alternator, exploded view (hulls 8540-8560 and 8580-8618).
Figure 4-2. Alternator, exploded view (hulls 8540-8560 and 8580-8618).
Cleaning, Inspection, Repair and Testing
Figure 4-4. Stator, rotor and brush test points, Hulls 8500-8519 and 8520-8539.
Figure 4-5. Rectifier diode test points (hulls 8500-8519 and 8520-8539).
Figure 4-6. Alternator stator testing (hulls 8540-8560 and 8580-8618).
Figure 4-7. Diode testing (hulls 8540-8560 and 8580-8618).
Reassembly of Rotor and Front Housing Assembly (Hulls 8500-8519 and 8520-8539).
Reassembly of Rotor and Front Housing Assembly (Hulls 8540-8560 and 8580-8618).
Electric Starter Motor
Figure 4-8. Starter motor-cross-section view.
Figure 4-9. Motor drive housing-exploded view
Figure 4-10. Middle bearing assembly-exploded view.
Figure 4-11. Commutator end bearing assembly-cross-section view.
Figure 4-12. Frame and field assembly-cross-section view.
Inspection and Repair
Field coils
Section II. HYDRAULIC STARTING SYSTEM
Figure 4-13. Hydraulic starting system reservoirs (hulls 8500-8519 and 8520-8539).
Figure 4-14. Hydraulic starting system reservoir (hulls 8540-8560 and 8560-8618).
Figure 4-15. Hydraulic oil reservoir, removal, disassembly, reassembly, and installation.
Hydraulic Starting Motor
Figure 4-16. Hydraulic starting motor-cross section view.
Hydraulic Starter Pump
Figure 4-17. Starting system hydraulic pump-disassembly and reassembly.
Figure 4-18. Pump pressure relief piston assembly, cross-section view.
Figure 4-19.. Installing pressure relief piston backup ring, seat ring, and washer, with tool J 7192.
Accumulator
Figure 4-21. Accumulator, gage, and valve, removal and installation.
Figure 4-22. Accumulator, cross-section view.
Hydraulic Hand pump
Figure 4-23. Hand pump, cross-section view.
Section III. HYDRAULIC STEERING SYSTEM
Figure 4-24. Steering pump drive adapter assembly, removal, disassembly, reassembly, and installation.
Steering Cylinders
Figure 4-25. Steering cylinder, cross-section view.
Figure 4-26. Helm unit assembly.
Helm Control Unit
Figure 4-27. Helm unit control section and metering section, disassembly and reassembly.
Helm Control Unit-cont.
Figure 4-28. Helm unit column assembly, disassembly and reassembly.
Figure 4-30. Removing check valve seat, ball, and spring.
Reassembly
Figure 4-31. Drive and meter gear star.
Figure 4-32. Steering system relief valve, cross -section view.
Figure 4-33. Steering system flow control valve, cross-section view.
Figure 4-34. Steering system double over center value, cross-section view.
Figure 4-35. Steering system relief valve (hulls 8520-8560 and 8580-8618).
Figure 4-36. Steering system flow divider (hulls 8520-8560 and 8580-8618).
Figure 4-37. Steering system counter balance value (hulls 8520-8560 and 8580-8618).
Section IV. RAMP HOIST HYDRAULIC SYSTEM
Figure 4-38. Winch assembly, (hulls 8500-8519).
Gear reducer
Figure 4-39. Winch gear reducer (hulls 8500-8519).
Brake
Figure 4-40. Winch brake (hulls 8500-8519).
Winch Hulls 8520 thru 8560 and 8580 thru 8618.
Figure 4-41. Winch (hulls 8520-8560 and 8580-8618).
Figure 4-42. Winch final drive assembly (hulls 8520-8560 and 8580-8618),
Figure 4-43. Drum and winch base assembly (hulls 8520-8560 and 8580-8618), disassembly and reassembly.
Disassembly of primary drive assembly
Figure 4-44. Primary drive assembly (hulls 8520-8560 and 8580-8618), disassembly and reassembly.
Disassembly of drum bearings and seals
Figure 4-45. Final planet assembly (hulls 8520-8560 and 8580-8615), disassembly and
Inspection of primary drive assembly
Assemble winch
Assemble the final planet assembly
Figure 4-46. Winch alinement
Ramp Hoist Hydraulic Pump
Figure 4-47. Ramp hoist pump, exploded view
Reassembly
Ramp Hoist Control Valve
Figure 4-48. Ramp hoist control valve, disassembly and reassembly
Ramp Hoist Counterbalance Valves
Figure 4-49. Ramp hoist counterbalance valve, cross-section view
Figure 4-50. Ramp system relief valve (hulls 8500-8519), disassembly and reassembly
Ramp Hydraulic Check Valves
Figure 4-52. Ramp hydraulic check valve, cross-section view
Figure 4-53. Ramp hoist hand pump, cross-section view (hulls 8520-8560 and 8580-8618)
Figure 4-54. Ramp locking cylinder, cutaway view (hulls 8540-8560 and 8580-8618).
Cleaning, Inspection, and Repair
Figure 4-55. Ramp locking system two-way selector valve, exploded view (hulls 8540-8560 and 8580-8618).
CHAPTER 5 REPAIR OF PROPELLER, SHAFT, RAMP, AND HATCHES
Figure 5-2. Penning propeller on anvil
Figure 5-3. Badly damaged propeller on pitch block
Figure 5-4. Propeller on pitch block after straightening
Figure 5-5. Welding a replacement section to a propeller
Propeller Shaft Assembly
Figure 5-6. Stuffing box, removal and installation (hulls 8540-8560 and 8580-8618).
Figure 5-7. Anodes, removal and installation.
Rudder and Gudgeon Bearing
Figure 5-8. Rudder and bearing, removal and installation
Section II. HATCHES AND RAMP ASSEMBLY
CHAPTER 6 REPAIR OF COMMUNICATION AND
Figure 6-1. Radio set NA/SRC-32 (hulls 8540-8560 and 8580-8618).
Radio Set AN/SRC-32 (Hulls 8540-8560 and 8580-8619)
Figure 6-2. Radio set AN/VRC-46 (hulls 8540-8560 and 8580-8618).
Radio Set AN/VRC-46 (Hulls 8540-8560 and 8580-8619)
Figure 6-3. Radio set. AN/VRC-47 (hulls 8540-8560 and 8580-8618).
Radio Set AN/GRC-106 (Hulls 8540-8560 and 8580-8618)
Figure 6-4. Radio set AN/GRC-106 (hulls 8540-8560 and 8580-8618).
Remote Magnetic Heading System
Figure 6-5. Remote magnetic heading system (hulls 8540-8560 and 8580-8618).
Calibration
APPENDIX A REFERENCES
INDEX
Figure 1-2. Wiring diagram-hull no. 8500 thru 8519
Figure 1-4. Wiring diagram-hull nos. 8540-8560 and 8580-8618.
blank page
Distribution
TM-55-1905-217-34