CG_TECH_PUB_7348A.pdf

Table of Contents

PART I. INTRODUCTION

SECTION 1 FOREWORD

SECTION 2 CAUTIONS AND WARNINGS

2.1 CAUTION:

2.2 GENERAL NOTE:

2.3 WARNING:

2.4 IMPORTANT GENERAL LUBRICATION NOTES:

PART II. START UP / POWER UP & SHUT DOWN / POWER DOWN

SECTION 1 START UP / POWER UP

1.1 Pre Start-up Lubrication Inspection - Boat Hoist System

1.2 START UP: NORMAL

1.3 POWER UP: IF POWER IS OFF

SECTION 2 SHUT DOWN / POWER DOWN

2.1 Shut Down:

2.2 Power Down:

2.3 Unknown Power Outage:

SECTION 3 WIRE ROPE MAINTENANCE

3.1 Wire Rope Removal (Hoist Drums)

3.2 Wire Rope Re-Spooling

3.3 Re-Spooling Trouble Shooting

3.4 Wire Rope Inspection

PART III. BOAT RETRIEVAL HOIST SYSTEM

SECTION 1 DESCRIPTION AND GENERAL DATA

SECTION 2 BOAT RETRIEVAL HOIST OPERATION

2.1 Pre Start-up Lubrication Inspection - Boat Retrieval Hoist

2.2 Startup ( Reference Paragraph 1.2 Start Up and 1.3 Power Up)

2.3 Emergency Stops:

2.4 Basic Operation:

2.5 Hoist Operation:

2.6 Trolley Operations:

2.7 Positioner Operations:

2.8 Positioner Alignment:

SECTION 3 MAINTENANCE - BOAT RETRIEVAL HOIST

3.1 Forward

3.2 Cautions and Warnings

3.3 Boat Retrieval Hoist Limit Switches

3.4 Positioner Slide Areas – Cleaning

SECTION 4 LUBRICATION - BOAT RETRIEVAL HOIST

4.1 IMPORTANT GENERAL LUBRICATION NOTES

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4.2 Hoist Gear Reducer

4.3 Travel Gear Reducer

4.4 Positioner Screw and Gear Reducers

4.5 Gear Rack

4.6 Hoist Pillow Blocks & Bearing Covers

4.7 Travel Pillow Blocks & Bearing Covers

4.8 Trolley Wheels

SECTION 5 ILLUSTRATIONS - BOAT RETRIEVAL HOIST

5.1 D2-402-0013 BOAT RETRIEVAL BRIDGE CRANE

5.2 D2-402-0015 TRUSS AND HOISTS ASM, BRHS

5.3 C2-402-0009 HOIST, AFT STBD, BRHS

5.4 C2-402-0011 HOIST, AFT PORT, BRHS

5.5 D2-413-0013 BAND BRAKE, AFT STBD

5.6 D2-413-0019 BAND BRAKE, AFT PORT

5.7 D2-413-0018 BAND BRAKE, FORE STBD

5.8 D2-413-0020 BAND BRAKE FORE PORT

5.9 C2-402-0012 TRAVEL ASSEMBLY, BRHS

SECTION 6 COMPONENTS - BOAT RETRIEVAL HOIST

6.1 Hoist Gear Reducers

6.2 Travel Gear Reducers

6.3 Positioner Screw Jacks

6.4 Pneumatic Valves

6.5 Gemco Rotary Limit Switch

6.6 Limit Switch, Side Rotary SPDT

6.7 Filter

6.8 Separator

6.9 Hoist And Travel Motors

PART IV. CARRIAGE WINCH

SECTION 1 DESCRIPTION AND GENERAL DATA

1.1 Carriage Winches:

1.2 Data:

1.3 Description:

SECTION 2 OPERATION - CARRIAGE WINCH

2.1 Pre Start-up Lubrication Inspection – Carriage Winch

2.2 Emergency stops:

2.3 Basic Operation:

2.4 Limit Switches:

SECTION 3 MAINTENANCE - CARRIAGE WINCH

3.1 Carriage Winch Slide Tubes – Cleaning

SECTION 4 LUBRICATION - CARRIAGE WINCH

4.1 Carriage Gear Reducer

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4.2 Drum Bushings

4.3 Drum Shaft Bearings

4.4 Brake Ballscrew Actuator

4.5 Linkage Bushings And Cylinder Rod Seal

SECTION 5 TROUBLESHOOTING - CARRIAGE WINCH

SECTION 6 ILLUSTRATIONS - CARRIAGE WINCH

6.1 D2-402-0020 CARRIAGE WINCH ASSEMBLY

6.2 D2-413-0021 CARRIAGE WINCH BRAKE ASSEMBLY

SECTION 7 COMPONENTS - CARRIAGE WINCH

7.1 Carriage Winch Reducer

7.2 Brake Actuator

7.3 Clutch

7.4 Carriage Winch Motors

PART V. CENTERLINE WINCH

SECTION 1 DESCRIPTION AND GENERAL DATA

1.1 Centerline Winch:

1.2 Data:

1.3 Description:

SECTION 2 OPERATION - CENTERLINE WINCH

2.1 Pre Start-up Lubrication Inspection – Centerline Winch

2.2 Emergency Stops:

2.3 Basic Operation:

2.4 Gypsy Head Operation:

2.5 Return to Normal Operation:

SECTION 3 LUBRICATION - CENTERLINE WINCH

3.1 Hoist Gear Reducer

3.2 Drum Bushings

3.3 Clutch Jaw Key Slots

3.4 Clutch Jaw Shoe

3.5 Clutch Ballscrew Actuator

3.6 Brake Ballscrew Actuator

3.7 Drum Bearing

3.8 Linkage Bushings And Cylinder Rod Seal

SECTION 4 TROUBLESHOOTING - CENTERLINE WINCH

SECTION 5 ILLUSTRATIONS - CENTERLINE WINCH

5.1 D2-402-0014 CENTERLINE WINCH ASSEMBLY

5.2 C2-413-0016 BRAKE SUB ASSEMBLY

5.3 C2-419-0010 CLUTCH SYSTEM SUB ASSEMBLY

5.4 B2-419-0009 CLUTCH LINKAGE ASSEMBLY

SECTION 6 COMPONENTS - CENTERLINE WINCH

6.1 Centerline Winch Reducer

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6.2 Brake Actuator

6.3 Clutch Actuator

6.4 Centerline Winch Motors

PART VI. ELECTRICAL

SECTION 1 ELECTRICAL - TEST / INSPECTION

1.1 Operator Station And Control Panels

1.2 Motor Lubrication – All

SECTION 2 ELECTRICAL - DRAWINGS

2.1 Rockwell’s Schematic Numbering

2.2 Cabinet Layouts

2.3 Electrical Schematics

2.4 Transformer

2.5 Total Harmonic Distortion (THD)

SECTION 3 ELECTRICAL - LITERATURE

3.1 General Information

3.2 PowerFlex 700 Drives

3.3 PowerFlex 700H & 700S Drives

3.4 Communication Modules

3.5 1336 Drive Supplements

3.6 ControlNet Information

3.7 ControlLogix System

3.8 Flex I/O Information

3.9 Miscellaneous Items

PART VII. APPENDIX

SECTION 1 BOAT RETRIEVAL SYSTEM

1.1 INSTALLATION

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PART I. INTRODUCTION

SECTION 1 FOREWORD

The manner that any piece of machinery is taken care of and operated determines the measure of its satisfactory performance, useful life and freedom of repairs. A Superior- Lidgerwood-Mundy (S-L-M) product is a piece of quality machinery designed and constructed to give the ultimate in trustworthy service at the lowest possible cost.

Optimum performance is within reach of all S-L-M equipment users that give appropriate attention to the importance of lubrication, clean parts, timely adjustments, replacements, and careful operation. The following sections represent the condensed operation, maintenance, of the specific S-L-M product.

The following sections represent the details of correct operation, maintenance, repair of the specific S-L-M product, and all items manufactured by others incorporated in this product. Also included are the lists of the parts and recommended spare parts.

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SECTION 2 CAUTIONS AND WARNINGS

2.1 CAUTION:

Read and understand this technical manual completely before you begin to operate the derrick winch.

2.1.1 Read and understand this manual completely before you begin to operate the equipment.

2.1.2 Approach any machine, and each situation of the new operation, with respect and a safety first attitude.

2.1.3 All information, illustrations, and technical characteristics contained in this manual are based on the most current product information available at the time of this publication.

2.1.4 The right to alter, or change any specification, or methods at any time are reserved.

2.1.5 Obligation for any personal injury or property damage incurred by the use of this manual in effecting maintenance, operation, or repair of your S-L-M unit is not assumed by Superior-Lidgerwood-Mundy Corp.

2.1.6 Anyone using a procedure not recommended by S-L-M, should first completely satisfy themselves that their personal security and the integrity of the machine will not be at risk for the method selected.

2.2 GENERAL NOTE:

Appropriate operation and maintenance are factors in the reduction of expensive equipment repair and lost time. This manual contains suggested procedures for operation, general inspection, and security cautions that should be employed to maintain the machine in correct operation. When using this manual, keep in mind all the variables the mechanic or operator will find on the site; that is why a general rule applies here:

Approach your machine, and each situation of the new operation, with respect and a safety first attitude.

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All information, illustrations, and technical characteristics contained in this manual are based on the most current product information available at the time of this publications approval.

The rights to alter or change any specification or methods at any time are reserved.

Obligation for any personal injury or property damage incurred by the use of this manual in effecting maintenance, operation, or repair of your S-L-M unit is not assumed by Superior-Lidgerwood-Mundy Corp.

Anyone using a procedure not recommended by S-L-M should first completely satisfy themselves that their personal security and the integrity of the machine will not be at risk for the method selected.

2.3 WARNING:

A sudden change of the load could harm the hoist. This could result in machinery damage or personal injury. Use extreme caution when any load is being moved or handled by the equipment.

Failure to observe any of the following limitations could result in serious structural or mechanical failures, or accidents.

2.3.1 All ratings only apply to machines as originally manufactured and equipped, but includes machines in that repairs or replacements have been made in accordance with the original specification. S-L-M has no responsibility for machines or components in which replacements have been made, or that are operated after damage has occurred which has not been repaired and equipment that has not been properly maintained.

2.3.2 Do not exceed the rating of the machine. See rated duty page 5.

2.3.3 Check the daily condition of the machine. See pages 5, and 6.

2.3.4 Keep the equipment clean; grime will cause problems in the future.

Inspection and maintenance is easier on equipment that is kept clean, saving time and assuring a proper inspection.

2.3.5 Do not start the winch before lubricating the necessary parts as required;

examine the winch and fluid levels and determine if fluid is needed.

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2.4 IMPORTANT GENERAL LUBRICATION NOTES:

2.4.1 Synthetic lubricants shall not be mixed with other lubricants.

2.4.2 Always wipe excess lubricant from components and areas.

2.4.3 The lubrication frequency is only a guide. The user shall develop a schedule.

2.4.4 Lubricants listed may substituted with an “or equal”, but must be an equal.

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PART II. START UP / POWER UP & SHUT DOWN /

POWER DOWN

SECTION 1 START UP / POWER UP

1.1 Pre Start-up Lubrication Inspection - Boat Hoist System

Do not start the Boat Hoist System before lubricating the necessary parts as required;

examine the Boat Hoist System and fluid levels and determine if fluid is needed.

1.1.1 See Part III, Section 4 for lubrication of the Boat Retrieval Hoist equipment.

1.1.2 See Part IV, Section 4 for lubrication of the Carriage Winch.

1.1.3 See Part V, Section 3 for lubrication of the Centerline Winch.

1.2 START UP: NORMAL

The equipment should remain powered up, unless it has been powered down for maintenance or due to a loss of power and it is best to follow the power down procedure if a known loss of power is to occur.

With all the drive cabinets powered up, for operation, the one item is to pull out all of the E-STOP push-pull buttons on the face of the drive cabinets below deck; the equipment is then available for operation from the Operators Stations.

1.3 POWER UP: IF POWER IS OFF.

Should the power be off the start up is as follows:

1.3.1 Check that all maintenance of the equipment has been performed.

1.3.2 Check the ships breakers, in the main power panel, both the Hoist and Centerline Winch breakers shall be ON.

1.3.3 In the Drive Room, below deck, all E-STOPS depressed.

i) Power up the Main, Number 1, RGU Panel, always wait until the read-out screen has stabilized, approx. 15 seconds.

ii) Power up the Stbd Hoist, Number 2, Drive Panel and wait 15 sec.

iii) Power up the Carriage Winch, Number 3, Drive Panel and wait 15 seconds.

iv) Power up the Port Hoist, Number 4, Drive Panel and wait 15 sec.

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v) Power up the Centerline Winch, Number 5, Drive Panel and wait the 15 seconds. Pull out the below deck E-STOP buttons and the equipment should be ready to operate from the Operators Stations above deck..

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SECTION 2 SHUT DOWN / POWER DOWN

2.1 Shut Down:

Normal SHUTDOWN is accomplished by, first pushing the STOP buttons on the OPERATORS STATIONS (all operators’ stations). Then, below deck, pushing the E- STOPS on all four of the drive cabinets, shut down is then complete. Leaving the cabinets powered up maintains the heat in the cabinets and the Heaters in the equipment operating, keeping the moisture out of the equipment and cabinets.

Note: SHUT DOWN is the standard method to leave this equipment non-operational, this allows the heaters to maintain condensation protection.

2.2 Power Down:

To Power Down the equipment for maintenance, and always Power Down for maintenance, or for a known power outage; with all the E-STOPS depressed, start at cabinet 5 and pull the handle, at the right upper side of the door, down, this is will power down this cabinet. Wait until the readout screen goes blank, approximately 15 seconds.

Next Power down the cabinet 4 in the same manner, waiting the 15 seconds and continue thru the remaining cabinets in the same manner in the reverse order 5 thru 1.

The circuit breakers, in the ships power panel, may then be switched to OFF.

Note: When the maintenance or power outage is complete, then re-set the circuit breakers to ON, the equipment Cabinets shall be Powered Up.

2.3 Unknown Power Outage:

When an unknown outage has occurred shut down the cabinets as soon as possible and when the outage has been rectified Power Up the cabinets, see paragraph 1.3 POWER-

UP.

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SECTION 3 WIRE ROPE MAINTENANCE

Reference Wire Rope Installation – B2-402-0022 Reference Carriage Winch Wire Rope Lengths – B2-502-0009 12/13 Reference Carriage Winch Wire Rope Spooling – B2-502-0009 13/13

3.1 Wire Rope Removal (Hoist Drums)

Removing wire rope, wind each drum down, in Maintenance Mode and correct drum selected. Spool down to last wrap and slowly continue down until rope clamps on both ends of the drum are accessible and stop, depress e-stop. Mark the rope end position, beyond the clamps, loosen the rope clamps and remove both ropes. Do Not operate the drums with out rope on the drum, operation shall move the switch beyond its setting.

3.2 Wire Rope Re-Spooling

To re-spool the rope onto the drums, install the rope, one at a time, thru the hole in the flange and thru the rope clamps to the mark beyond the clamp. Tighten the nuts on the two clamps, the clamp legs should be approximately 1/16 inch from contacting the drum flange. Install the second rope in the same manner. The crew shall guide the rope onto the drum, while the operator, with care and undivided attention, spool the drum inward until the limit switch stops the drum.

3.2.1 Should the hook not be level, the ropes need to be un-spooled and one rope, at the clamps, be moved in, or out, the amount the hook was uneven and retighten the clamps nuts and recheck for level.

3.3 Re-Spooling Trouble Shooting

If the drum will not operate in the up position with the rope off, the limit switch has gone beyond the setting. To proceed, a temporary jumper wire must be installed in the limit relay, in the drive cabinet. Remove the jumper wire when completed spooling rope, but before proceeding to the next drum.

3.4 Wire Rope Inspection

All wire rope which has broken wires, deformed strands, variation in diameter or any change from its normal appearance, shall be considered for replacement. It a is always better to replace a rope when in doubt of its condition or its ability to perform the required task. The cost of replacement is insignificant when considered in terms of injuries and the cost of down time.

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Wire rope inspection includes examination of basic items such as:

1) Diameter reduction 2) Rope lay damage

3) External ware 4) Internal ware

5) Peening 6) Scrubbing

7) Corrosion 8) Broken wires

Wire rope sections may break without any visible warning. Sections where this occurs are usually found at end terminations, or other semi operational areas. This is due to the “working” that takes place at those areas. The core may fail thereby allowing adjacent strand nicking, when this happens, valley breaks are likely to appear and the rope should be replaced.

With proper preventative maintenance diligently preformed rope life may be prolonged.

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PART III. BOAT RETRIEVAL HOIST SYSTEM

SECTION 1 DESCRIPTION AND GENERAL DATA

The Boat Retrieval Hoist System consists of two independent bridge cranes, one port, and one starboard. Each crane consists of one trolley, four electric powered wire rope hoists, two travel units (one forward, one aft), and two positioners. The cranes are mounted on two parallel transverse monorails (one forward and one aft). The system accommodates the NSC’s stern launch area, with stowage for 2 boats (either 2 Long Range Interceptors (LRI’s), 2 Short Range Prosecutors (SRP’s), or one of each), one port and one starboard boat stowage cradle.

The port crane can lift and move an LRI or SRP from the ship’s centerline to its port stowed position and back to centerline, and the starboard crane can lift and move an LRI or SRP from the ship’s centerline to its starboard position and back to centerline.

Nominal rated safe working load of each crane: 30,000 lb.

Maximum lift: 25 ft.

Hoist Speed: 28 fpm.

Travel Speed: 23 fpm.

Each trolley consists of a pair of fore and aft I-beams connected by two crossbeams.

Two travel motors are attached to each trolley for moving the trolleys from centerline to their respective port or starboard positions.

Each hoist has one hook with two part line stored on drums which are driven by a motor and quadruple reduction, parallel shaft gear reducer. Each hook is designed to lift one quarter (25%) of the nominal safe working load of the bridge crane. Control braking is provided through regenerative motor braking, and will; 1) stop and hold the load when controls are released and 2) limit the lowering speed. Both a primary and secondary holding brake is provided. The primary holding brake is the motor brake which is spring set/electrically released and holds a minimum 125% of the rated load.

The secondary holding brake is the drum band brake which operates directly on the wire rope drum. It is spring set/pneumatically released and is designed to hold 150% of the rated load. Both holding brakes will set automatically in the event of a power failure.

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The aft hoists are located at fixed positions at the aft end of each trolley.

The forward hoists are located on a movable truss section, which is moved by means of two screw positioners located at the forward end of each trolley. Each screw positioner is operated by an electric brake motor. The positioners move the truss and forward hoists to either a forward locked position used for retrieval of the LRI, or an aft locked position used for retrieval of the SRP.

A watertight control station is provided for each crane. They are designated Port Crane Operator’s Station and the Starboard Crane Operator’s Station. Each operators station includes a START pushbutton, emergency STOP pushbutton, white POWER ON indication light, TROLLEY joystick, HOIST joystick, SRP POSITION button, LRI POSITION button, HOIST DRIVE SELECT for FWD-BOTH-AFT, and MAINT MODE SELECT for PORT-NORMAL-STBD. The control cabinets containing the electrical drives and equipment are mounted below deck. These control cabinets are designated the Main RGU (Regenerative Unit), Port Crane Drive Cabinet, Starboard Crane Drive Cabinet and Master Cabinet. There is also an isolation transformer which the incoming power supply enters and out to the proper cabinet.

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SECTION 2 BOAT RETRIEVAL HOIST OPERATION

2.1 Pre Start-up Lubrication Inspection - Boat Retrieval Hoist Do not start the hoists before lubricating the necessary parts as required; examine the hoists and fluid levels and determine if fluid is needed. See Part III, Section 4 for lubrication of the Boat Retrieval Hoist equipment.

2.2 Startup ( Reference Paragraph 1.2 Start Up and 1.3 Power Up) Start the hoist system by first checking that maintenance has been performed and that everyone and everything is clear of the crane area. Check the ships electrical load center that the circuit breakers for the Crane and Winches are in the ON position.

2.3 Emergency Stops:

Maintained emergency stop pushbuttons are located on each drive cabinet below deck.

The emergency stop pushbuttons may be pressed at any time necessary, and if a equipment is running this will set all brakes and disable all drives. The E-STOP pushbuttons only affect the particular unit they are connected to. For example, the Port Crane Operator E-STOP only stops the Port Crane. Interlocking across both operator stations is unnecessary, since the controls only allow one crane or the Carriage Winches to run at a time. The controls will then inhibit restarting until the crane has come completely to a safe stop.

Note: All Emergency Stop pushbuttons, on the below deck drive cabinets, or for a particular unit must be returned to the “out” position, for any operations to occur.

The Operators Stations are equipped with a “STOP” button that operates as the E-stop.

This STOP button also is the normal shut down button a completion of operation, push the STOP when that units operation is completed, this will allow one of the other units Operators Station to have control.

The START button shall be pushed to start one of the units, Port Crane, Stbd Crane or Carriage Winches, the white light shall illuminate when that station is in control. If the light for the station being asked to operate does not illuminate another station has not had the STOP button pushed to relinquish control.

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2.4 Basic Operation:

During normal operations, the Maintenance Mode Selector Switch shall be set to NORMAL, and the Hoist Mode Selector Switch set to “BOTH”. When the START pushbutton, on either Operator Station, is pressed, that station shall then be activated.

The Operator Station on which the START pushbutton is pressed will become the “owner” of the control; this means that the other Operator Stations will be disabled until the first has had its STOP button depressed. As the system starts up, should it determine that everything is ready to run, the white POWER ON pilot light will illuminate. If the system determines that there is a fault, the POWER ON pilot light will flash, and troubleshooting measures may need to be performed and the problem resolved.

Note: When a change in selection for operation the START button must be depressed to resume operation. If the START button is not pushed the drives will not reset and the previous operation command shall be maintained.

2.5 Hoist Operation:

2.5.1 Normal Operation:

Note: The air system requires pressure to release the band brakes, to allow the hoists to operate. (90 PSI minimum)

Note: To level the hooks it is easiest to lower them to the cradle deck, do not touch the deck, but then equal each hook, by operating single drums.

For normal operation the MAINT MODE SELECT, three position selector switch shall be in NORMAL position and the HOIST DRIVE SELECT, three position selector switch, shall be in the BOTH position. With the selectors set as listed all four (4) hoists shall be synchronized, lifting and lowering at the same speed.

2.5.2 Leveling a Boat:

The two (2) aft hoists, or the two forward hoists may be selected to level the boat, to operate the two (2) aft hoists, place the HOIST DRIVE SELECT in the “AFT” position (press the START button) and the two aft hoists will operate together, synchronized, raise, lower and stop. To operate the two (2) forward hoists, place the HOIST DRIVE SELECT in the ‘FWD’ position (press the START button) and the two forward hoists shall operate together, synchronized. Switching the HOIST DRIVE SELECT, back to BOTH position (press the START button) and all four hoists shall again operate together.

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Each Hoist Drum may be operated individually, ie; the Fwd Port Hoist, select from MAINT MODE SELECT switch to “PORT” and from the HOIST DRIVE SELECT switch to “FWD”, press START and only the Fwd Port Hoist will operate.

To raise or lower the hoists, in any of the selected modes of operation, the HOIST joystick lever shall be moved to the UP, raise or DOWN, lower position. The hoists receive a speed reference signal based on how far the joystick lever has been moved to the UP or DOWN direction, there is a slight delay in starting and stopping the drives, “ramping up and ramping down”.

With the joystick in the neutral, center position, the hoist stop, the motor brakes set and the hoist drum brakes set. There is a timing sequence in the stopping (also raising and lowering) operation, the drives hold the load position until the brakes sequence on and hold the load. Should there be an electrical or drive failure the brakes set ASAP.

2.5.3 Limit Switches:

The hoists have geared rotary limit switches, each hoist drum has a four switch limit.

The upper limit has been set at the factory. The upper limit switch is a safety switch and should not trip in normal operations; it is set to protect the machinery from damaging itself and is the Park position for the empty hooks. During normal operations where the hoists are operating together, the limit switches are interlocked by the control. In this case, whichever limit switch trips first will stop all of the operating hoists.

2.5.4 System Operation:

When a hoisting or lower motion is requested, the control system first checks the motors to verify they are capable of producing torque to lift the load. Once this is verified, the control will hold the load then release both the motor and drum brakes, and begin moving the load. When a move is complete, the drive will stop holding the load, set the motor brake and the drum brake remains released for several seconds, should another operation be required. If the time period elapses with no further movement, the drum brake will also be set. An emergency stop or fault, at any time, will immediately set both brakes. The torque proving and brake release functions are interlocked between hoists, depending on the number of hoists operating.

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2.5.5 Hoists home position:

When the Hoists hooks are disconnected from the boat and trolley in the cradle position, the hooks shall be raised until the limits stop the raising of the hooks. This is the Home position for each hoist and shall level the Forward hooks to each other and the Aft hook to each other. This is also the park position for the hooks during ship movement. The hooks may be secured to a boat in the cradle in lieu of the previous sentence.

2.5.6 Maintenance:

When the MAINT MODE SELECT switch is moved from the NORMAL position to either PORT or STBD the hoists go into the maintenance mode. In this mode the SRP and LRI limit switches are not used for stopping the hoist, but if tripped will force the hoist into a slowdown mode. In this mode, the hoists are allowed to travel at a very slow speed until the upper limit switch has been tripped.

Maintenance mode also allows a single hoist to be run. For example, to run the forward port hoist, the MAINT MODE SELECT switch must be placed in the PORT position and the HOIST DRIVE SELECT selector switch must be placed in the FWD position and the START button pushed. To return to the normal operation, MAINT MODE SELECT to NORMAL and the HOIST DRIVE SELECT to BOTH and depress the START ready to operate.

2.6 Trolley Operations:

To move the trolley, the joystick lever must be moved up towards PORT or towards STBD position. The trolley receives a speed reference signal based on how far the joystick lever has been moved in the selected direction. The position of the joystick lever controls the speed at which the trolley moves the further from neutral the faster the unit travels (Max speed 27 FPM).

The trolley will move in the appropriate direction until it is either at the Center, over the boat retrieval well, or it arrives at the Park position, over the boat cradle, the Park position has a limit switch and is the home position. The trolley operation shall automatically slow when it is 6 to 8 inches from the Center or Park position, the system must make the stop on its own, do not stop the unit with the joystick, unless there is a problem.

The trolleys have motor brakes on both the forward and aft motors, which set when the trolley has stopped and the joystick lever is returned to the neutral position.

At the Park position the limit switch references the home position and readjusts the trolley drives, keeping them in alignment.

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CAUTION: The Trolley’s shall not be moved when the LRI or other high boat is in the cradle stowage position. The boat shall be lifted free of the cradle prior to moving the Trolley.

Note: Should there be a power down while the Trolley is not at it home position and then the power restarted, the Trolley must be returned to home and it will move at the reduced slow speed until it trips the limit and stops to reset the drive.

2.6.1 Trolley Adjustment:

Should the Trolley come out of alignment (the Fwd, or Aft drive, ahead of the other) re-adjustment may be made by holding the START button depressed and operating with the JOYSTICK, the following is what takes place: Both motors operate at reduced speed, but in opposite directions, the Fwd motor moves in the normal direction that the Joystick is commanding and the Aft opposite. Carefully, as the operator must observe for the correct movement, square up the unit, release the START button and push the START normally and release, the unit should be ready to operate.

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2.7 Positioner Operations:

The hooks shall be not connected to a boat and should be in the raised position to operate the Positioner. The Positioner location is controlled by the, LRI Position and SRP Position, (lengths of the boat), illuminated pushbuttons. The pushbutton corresponding to the current position, LRI (Fwd) or SRP (Aft), will illuminate. To change the Positioner location, (there shall not be a boat connected to the lifting hooks) either the LRI Position or SRP Position pushbutton must be pressed and held, with no other motions active, the Positioner will begin moving to the selected location.

The light on the current position pushbutton will turn off and the light for the destination location will begin to flash, the button may then be released. The Positioner will continue to move until it reaches the designated position and the Positioners will stop. The light for the final position will illuminate steady.

The forward (LRI) position is the home position and has a factory set limit and readjusts the Positioner drives, this aligns the Positioners.

The Positioner may be stopped to accommodate any length boat, within the Positioner movement range and the boat does not exceed the weight limit of the system, align the boats aft lifting eyes with the aft hooks. Then move the Positioner to align the forward hooks and depressing the STOP button when the forward hooks are aligned with the boats forward lifting eyes. With the boat in position directly under the hooks and hooks secure to the lifting eyes the boat may be lifted.

CAUTION: The Boat being lifted shall be verified that it may be lifted in the manner required for this Hoist system and the Boat attaching points are not to close to the boat centerline, or the Hoists will induce excessive side load into the boat hull when raised and the boat shall be damaged, also the Hoist System may be damaged!

CAUTION: The Positioner shall not be moved while the hooks are attached to a boat, or when a LRI, or higher type boat, is in the cradle stowage position. The Positioner shall not be moved, the Boat or Hoist System shall be damaged.

CAUTION: The hooks shall be centered on the boat, fore and aft direction, attachment points. The hooks shall not lift at a fore and aft angle, but shall lift straight up, or damage may occur!

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2.8 Positioner Alignment:

Should the Positioner become misaligned, (one side forward or aft, of the other) if the Positioner is misaligned they shall not operate, adjustment may be made by holding the START button depressed and operate with the LRI/SRP BUTTONS, either button, the following is what takes place: Both motors operate at a reduced speed, but in opposite directions, The TRUSS section must be observed as the direction is random, and only move a minimum amount. If the attempted direction was incorrect push the opposite direction button, to align the TRUSS. When corrected release the START button and push the START normally and release, the unit should be ready to operate.

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SECTION 3 MAINTENANCE - BOAT RETRIEVAL HOIST

3.1 Forward

The manner that any piece of machinery is taken care of and operated determines the measure of its satisfactory performance, useful life and freedom of repairs. A Superior-Lidgerwood-Mundy product is a piece of quality machinery designed and constructed to give the ultimate in trustworthy service at the lowest possible cost.

Optimum performance is within reach of all S-L-M equipment users that give appropriate attention to the importance of lubrication, clean parts, timely adjustments, replacements, and careful operation.

The following sections represent the details of correct operation, maintenance, repair of the specific S-L-M product, and all items manufactured by others incorporated in this product. Also included are the lists of the parts and recommended spare parts.

3.2 Cautions and Warnings

3.2.1 Caution:

Read and understand this technical manual completely before you begin to operate the derrick winch.

3.2.2 General Note:

Appropriate operation and maintenance are factors in the reduction of expensive equipment repair and lost time. This manual contains suggested procedures for operation, general inspection, and security cautions that should be employed to maintain the machine in correct operation. When using this manual, keep in mind all the variables the mechanic or operator will find on the site; that is why a general rule applies here:

Approach your machine, and each situation of the new operation, with respect and a safety first attitude.

All information, illustrations, and technical characteristics contained in this manual are based on the most current product information available at the time of this publications approval.

The rights to alter or change any specification or methods at any time are reserved.

Obligation for any personal injury or property damage incurred by the use of this manual in effecting maintenance, operation, or repair of your S-L-M unit is not assumed by Superior-Lidgerwood-Mundy Corp.

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Anyone using a procedure not recommended by S-L-M should first completely satisfy themselves that their personal security and the integrity of the machine will not be at risk for the method selected.

3.2.3 WARNING:

A sudden change of the load could harm the hoist. This could result in machinery damage or personal injury. Use extreme caution when any load is being moved or handled by the equipment.

Failure to observe any of the following limitations could result in serious structural or mechanical failures, or accidents.

i) All ratings only apply to machines as originally manufactured and equipped, but includes machines in that repairs or replacements have been made in accordance with the original specification. S-L-M has no responsibility for machines or components in which replacements have been made, or that are operated after damage has occurred which has not been repaired and equipment that has not been properly maintained.

ii) Do not exceed the rating of the machine. See rated duty page 5.

iii) Check the daily condition of the machine. See pages 5, and 6.

iv) Keep the equipment clean; grime will cause problems in the future.

Inspection and maintenance is easier on equipment that is kept clean, saving time and assuring a proper inspection.

3.3 Boat Retrieval Hoist Limit Switches

Reference Bridge Crane Hook Limit Setting – D2-402-0013 3/5

Limit switch adjustment in maintenance mode to re-establish home position.

3.3.1 Aft Hoist Drums

Limit switch adjustment is located within the box with the drive chain rotating it from the drum. Remove the limit switch cover which is held on with four socket head cap screws. The wire connections under the cover, feeding the limit switches are live 120 volts. There are (4) cams on a vertical shaft, with the top operating the upper limit switch. The other 3 cams are not used and must be left loose and free of rotation. There are four holes in the bottom cam, each hole has a set screw, one for each cam. The cam adjustment set screws require a 1/16” Allen wrench, the set screws are located at four different depths. The upper limit cam will be the furthest up the assembly. The upper

NSC 1, 2, 3, 4 Superior-Lidgerwood-Mundy Corporation Page 24 of 60 limit cam adjustment is sensitive. With the hook close to the position, (slightly below the upper limit), loosen the upper screw, rotate the cam with a small screw driver, lock the set screw. Lower the hook, raise the hook, (if the hook does not stop, the operator must stop the hoist prior to rope socket hitting the drum. If the hook position is not correct, repeat the process for adjusting. Assure the 3 lower cams are loose and remain free for rotation, prior to replacing the cover. Proceed to the opposite Aft drum and repeat the above process.

3.3.2 Forward Hoist Drum

The limit switches are positioned higher into the assembly, and more difficult to access, but the same home position setting procedures as the aft hoist drum apply.

3.4 Positioner Slide Areas – Cleaning

3.4.1 Hoist Postioners

The slide area on the top of the beams shall be cleaned with a scrub brush, soap and water every 6 months.

3.4.2 Hoist Positioner Beams

The Hoist beams for the Positioner slide area shall be polished with a good auto wax once every year, after cleaning.

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SECTION 4 LUBRICATION - BOAT RETRIEVAL HOIST

Reference Lubrication chart – B2-415-0014

4.1 IMPORTANT GENERAL LUBRICATION NOTES.

4.1.1 Synthetic lubricants shall not be mixed with other lubricants.

4.1.2 Always wipe excess lubricant from components and areas.

4.1.3 The lubrication frequency is only a guide. The user shall develop a schedule.

4.1.4 Lubricants listed may substituted with an “or equal”, but must be an equal.

4.2 Hoist Gear Reducer

4.2.1 Gear Oil Type

Number of Locations: 1 each Hoist, 4 per unit Recommended Lubricant: MOBILGEAR SHC 220 Viscosity: ISO VG 220 Application Method: Oil Bath

4.2.2 Gear Oil Level

i) Oil should be visible within the indication range on the sight gauge.

ii) Replenish as necessary.

iii) Frequency – Weekly

4.2.3 Gear Oil Sample

i) Clean area around drain plug.

ii) Loosen drain plug and fill sample bottle with oil.

iii) Tighten drain plug.

iv) Allow sample to settle for 10 minutes.

v) Inspect sample for water and sediment; if sample is contaminated, renew oil to proper level.*

vi) Frequency – Every 6 Months

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4.2.4 Gear Oil Change

i) Clean area around drain plug.

ii) Remove drain plug and drain oil, into a container.

iii) Replace and tighten drain plug.

iv) Replenish 4.5 gallons/ to middle of sight gauge.

v) Frequency – Every 3 Years, or when sample fails sample inspection*

4.3 Travel Gear Reducer

4.3.1 Gear Oil Type

Number of Locations: 1 each Travel Unit, 2 per Hoist System Recommended Lubricant: MOBILGEAR SHC 220 Viscosity: ISO VG 220 Application Method: Oil Bath

4.3.2 Gear Oil Level

i) Oil should be visible within the indication range in the level plug.

ii) Replenish as necessary.

iii) Frequency – Every 3 Months

4.3.3 Gear Oil Sample

i) Clean area around drain plug.

ii) Loosen drain plug and fill sample bottle with oil.

iii) Tighten drain plug.

iv) Allow sample to settle for 10 minutes.

v) Inspect sample for water and sediment; if sample is contaminated, renew oil to proper level.*

vi) Frequency – Every 6 Months

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4.3.4 Gear Oil Change

i) Clean area around drain plug.

ii) Remove drain plug and drain oil into a container.

iii) Replace and tighten drain plug.

iv) Replenish system; 7 quarts

v) Frequency – Every 3 Years, or when sample* fails inspection

4.4 Positioner Screw and Gear Reducers

4.4.1 Grease Type

Number of Locations: 1 each Positioner Drive Recommended Lubricant: MOBILGEAR SHC 460 Viscosity: NLGI Grade 1.5 Application Method: Grease Gun and hand Frequency: 6-months

4.4.2 Grease Procedure – Gear Reducer

Each reducer unit is furnished grease fitting and a pipe plug on opposite sides of the housing. After removing the pipe plug, pump 3 to 4 strokes of the grease gun into the unit. Run the unit through the travel of the lead screw to distribute the grease within the unit. Re-install pipe plug.

4.4.3 Grease Procedure – Positioner Lead Screw

Remove boots by loosening clamps at each end of boots, pull boots away from ends.

Wipe screw dry with a rag by hand, Apply grease the full length of the screw. Reinstall the boots prior to operating, with the clamps on each end of the boot, operate the Positioner full SRI to LRI and return.

4.5 Gear Rack

4.5.1 Grease Type

Number of Locations: 2 (1 Forward, 1 Aft) Recommended Lubricant: AMSOIL GFW Grade: NLGI Grade 1.5 Application Method: Aerosol Spray Frequency – 6-months

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4.5.2 Grease Procedure

Lubricate as necessary to ensure adequate coverage.

4.6 Hoist Pillow Blocks & Bearing Covers

4.6.1 Grease Type

Number of Locations: 1 each Hoist Drum, 4 per hoist system Recommended Lubricant: MOBILITH SHC 460 Grade: NLGI Grade 1.5 Application Method: Grease Gun Frequency – 6-months

4.6.2 Grease Procedure

Lubricate as necessary to ensure adequate coverage 5 to 6 strokes of hand grease gun.

4.7 Travel Pillow Blocks & Bearing Covers

4.7.1 Grease Type

Number of Locations: 1 each Travel Unit Recommended Lubricant: MOBILITH SHC 460 Grade: NLGI Grade 1.5 Application Method: Grease Gun Frequency – 6-months

4.7.2 Grease Procedure

4 to 5 strokes of hand grease gun ensure adequate coverage.

4.8 Trolley Wheels

4.8.1 Grease Type

Number of Locations: 16 Recommended Lubricant: MOBILITH SHC 460 Grade: NLGI Grade 1.5 Application Method: Brush on lightly

4.8.2 Grease Procedure

Lubricate as necessary to ensure adequate coverage.

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Troubleshoot - BOAT RETRIEVAL HOIST This section provides basic troubleshooting information. Determinations of specific causes to problems are best identified by thorough inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common hoist, trolley, and winch problems, probable causes and solutions.

PROBLEM PROBABLE

CAUSE

SOLUTION

Hoist will not operate.

1. Drives not powered.

2. No power to drives.

1. Power up Drives see start-up instructions.

2. Check circuit breakers in ships electrical panel.

Load continues to move when hoist is stopped.

Drive faulty. Drive system shall be checked out and adjust (Rockwell).

Motor runs hot or makes excessive noise during operation.

1. Motor bearing need lubrication.

2. Motor bearings failing.

1. Lubricate bearings, see motor lubrication.

2. Replace motor bearing.

Hoist runs slow. Drum brake dragging.

Adjust band brake.

Brake fails to release. 1. Motor brake not operating.

2. Drum brake solenoid valve coil faulty.

1. Check power to brake.

2. Check & Replace solenoid coil, as necessary.

All hoists will lower but not raise.

Loss of ships air pressure.

Restore ships air.

One hoist will lower but not raise.

Solenoid coil may have failed.

Check & Replace solenoid coil.

Total crane system will not operate.

Power to electric drive panels shut down.

May have been power loss, restart panels.

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PROBLEM PROBABLE

CAUSE

SOLUTION

Hoist motor brakes do not release.

Brake fuses blown (indicator light’s red).

Replace fuses.

Hoist drum will not turn.

Electrical drive tripped.

Reset drives.

Travel will not move. 1. Brake fuses blown (indicator light’s red).

2. Electrical Drive tripped.

1. Replace fuses.

2. Reset drives.

Trolley travel slow from center to park position.

There has been a power loss, power is now operating.

The trolley drive has lost its’ known position and the trolley must be moved at slow speed back to the home position (park location).

One hoist or one travel will not operate. Motor tries to drive, will not.

1. Fault on drive cabinet screen ‘F’.

2. Motor brake not operating.

1. Shut down drive & clear (press red button).

2. Check brake voltage, check brake operation.

Screen will not clear,

1. above fault.

No or low voltage to encoder.

Check at encoder plug, between terminals No. 1 & 6 for 12 V. no volt short in electrical wire. Low volt check at drive cabinet.

Gear reducers warm to touch.

Low lubricating gear oil.

1. Check for leak and repair.

2. Check & add correct oil to full zone.

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SECTION 5 ILLUSTRATIONS - BOAT RETRIEVAL HOIST

5.1 D2-402-0013 BOAT RETRIEVAL BRIDGE CRANE

5.2 D2-402-0015 TRUSS AND HOISTS ASM, BRHS

5.3 C2-402-0009 HOIST, AFT STBD, BRHS

5.4 C2-402-0011 HOIST, AFT PORT, BRHS

5.5 D2-413-0013 BAND BRAKE, AFT STBD

5.6 D2-413-0019 BAND BRAKE, AFT PORT

5.7 D2-413-0018 BAND BRAKE, FORE STBD

5.8 D2-413-0020 BAND BRAKE FORE PORT

5.9 C2-402-0012 TRAVEL ASSEMBLY, BRHS

SECTION 6 COMPONENTS - BOAT RETRIEVAL HOIST

6.1 Hoist Gear Reducers

6.2 Travel Gear Reducers

6.3 Positioner Screw Jacks

6.4 Pneumatic Valves

6.5 Gemco Rotary Limit Switch

6.6 Limit Switch, Side Rotary SPDT

6.7 Filter

6.8 Separator

6.9 Hoist And Travel Motors

6.9.1 Installation, Operation, and Maintenance

6.9.2 Encoder

6.9.3 Brake

6.9.4 Positioner Motor 3/4 HP

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6.9.5 Hoist Motor 7.5 HP

6.9.6 Travel Motor 7.5 HP

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PART IV. CARRIAGE WINCH

1.1 Carriage Winches:

There are two (2) Carriage Winches, one (1) port unit and one (1) Starboard unit. Each winch is a rope on and rope off configuration, the top rope pulls the carriage up the boatwell and the lower rope pulls the carriage down the boatwell. The Carriage winches are mounted in an alcove at the forward end of the boat well.

1.2 Data:

The rated line pull and speed are of each is;

Line pull 8,000 pounds (at all speeds 0 to 55 FPM) Line speed 0 through 55 FPM (at rated load)

1.3 Description:

Each Winch is powered by a 15 HP motor, to a parallel shaft gear reducer that drives the drum which is grooved and handles the ¾ inch wire rope. The drum has a band brake, which is designed for 150% of the rated line pull; the brake flange is constructed of 316 stainless steel to prevent most corrosion. The drum brake is spring set electric released. There is a clutch on the drum shaft that is air set, with the air supplied from the ship through a solenoid valve to a rotary union on the drum shaft.

The drum shaft is drilled and tapped for the rotary union and a fitting for the clutch.

There is an encoder on the drum end, opposite the clutch end, the encoder feed information to the electric drive for speed and position of the carriages.

There is a tensioning sheave, one each side of the boatwell, at the lower end of the boatwell, the lower wire rope from the appropriate drum enters the lower side of the sheave assembly thru the sheave and connected to the carriage. This sheave is to maintain tension on the wire ropes when the boat strikes the net.

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SECTION 2 OPERATION - CARRIAGE WINCH

2.1 Pre Start-up Lubrication Inspection – Carriage Winch

Do not start the winch before lubricating the necessary parts as required; examine the winch and fluid levels and determine if fluid is needed. See Part III, Section 4 for lubrication of the Carriage Winch.

2.2 Emergency stops:

The drive cabinet has an emergency stop push button on the face of the cabinet. The E- Stop may be depressed at any time necessary and will shut down both winches and set the brakes. To reset this E-stop the button shall be pulled out (this is a latching button) and the system will be active, the operator at the Operators Station, shall be required to restart operations, joystick to neutral and then pushing the START button to restart operations.

The Operators Station is equipped with a STOP button this serves as the E-STOP from that location. The START button, on the Operators Station, shall be pressed to restart the winch operation. This STOP button is also for the normal shut down for the winches.

Note: All Emergency Stop push-pull buttons, on the below deck drive cabinets shall be returned to the “out” position for operations to occur.

2.3 Basic Operation:

To start operation (the below deck equipment running and the E-Stop out) the Operators Station START button is required to be pushed; the white POWER ON light will be illuminated. Should the POWER ON light be flashing there is a fault in the system and trouble shooting shall be preformed.

The OPERATION SELECT switch has two positions MANUAL and START, each time the selector switch is changed the START button shall be pushed, this resets the system.

The Joystick control is the means of MANUAL operation, the further the lever is moved from the center position the faster the carriages move. The lever moved up move the carriages OUT, down the boatwell. To move fwd, IN, the lever is the down direction. STOP is the center, neutral, position of the lever.

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Note: The main drive controls (below deck) only allow the operation of one of the two Hoists, or the Carriage Winches at a time.

1. With the carriages in the full…