S9582-AE-MMO-010_0_0.pdf

• UNCLASSIFIED

NAVSEA S9582-AE-MMO~·L?/()

VOLUME I

TECHNICAL MANUAL

FOR

T-ATF

TRACTION MACHINE

BUILT By

LAKE SHORE) INC.

IRON MOUNTAIN) MICHIGAN

(90") 77l..j-/foO

DEPARTMENT OF THE NAVY

NAVAL SEA SYSTEMS COMMAND

APRIL 1979

NAVSEA S9582-AE-MMO-~O/O

Title A i and ii 1-1 and 1-2 2-1 through 2-9 3-1 through 3-8 4-1 through 4-7 5-1 through 5-4 6-1 7-1 through 7-48 8-1 through 8-64 c

LIST OF EFFECTIVE PAGES

A

Issue

Original Original Original Original Original Original Original Original Original Original Original

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR:

TITLE OF MANUAL:

APPROVAL AUTHORITY:

CONTRACT OR

PURCHASE ORDER

NUMBER

N00024-78-C-2044

N00024-78-C-2300

REMARKS:

CERTIFICATION:

NAVSEA S9582-AE-MMO-:fIZ{FOIO

Installation, Operation, Maintenance and Repair Instructions with Parts List for T-ATF Traction Machine

Supervisor of Shipbuilding Conversion and Repair, USN Ninth Naval District P. O. Box 26 Sturgeon Bay, WI 54235 Ser. 1819 dtd. 25 June 1979 (Approval) Ser. 2131 dtd. 24 July 1979 (NAVSEA #)

NUMBER

OF

UNITS

DATE:

QUANTITY

OF

MANUALS

20 March 1980

It is hereby certified that the manuals to be provided under contract number N00024-78-C-2300 are exactly identical to NAVSEA S9582-AE MMO-020 approved by authority of approval data shown above.

R.F.Sendzik, Supervisor, Tech.Publ.

(Typed name and title)

Lake Shore, Inc.

(Contractor's name)

P.O.Box 809, Iron Mountain, MI 498q1 (Contractor's address)

NAVSEA S9582-AE-MMO~c?IO

TABLE OF CONTENTS

SECTION PAGE NO.

VOLUME I

I GENERAL INFORMATION ---------------------------- 1-1

1.1 Traction Drive -------------------------- 1-1

II DETAILED DESCRIPTION --------------------------- 2-1

2.1 Traction Drive -------------------------- 2-1

2.1.1 Traction Winch ----------------- 2-2

2.1.2 Transmission/Torque Converter -- 2-3

2.1.3 Cooling Oil Assembly ----------- 2-3

2.1.4 Engine Assembly ---------------- 2-4

2.1.5 Rope Transport Unit ------------ 2-4

2.1.6 Rope Fairleader Assembly ------- 2-5

2.1.7 Control Console -~----~--------- 2-5

III OPERATION -------------------------------------- 3-1

3.1 System Start-Up ------------------------- 3-1

3.2 Preoperation Procedures ----------------- 3-2

3.2.1 Control Console ---------------- 3-2

3.2.2 Rope Reeving ------------------- 3-2

3.3 Traction Drive Operation ---------------- 3-2

3.3.1 Payout ------------------------- 3-6

3.3.2 Inhaul ------------------------- 3-7

3.3.3 Emergency Stop ----------------- 3-7

3.4 Emergency Operation --------------------- 3-7

3.5 System Shutdown ------------------------- 3-7

IV MAINTENANCE ------------------------------------ 4-1

4.1 General Instructions -------------------- 4-1

4.2 Operator Inspection --------------------- 4-1

4.3 Mechanical Maintenance ------------------ 4-1

4.4 Preventive Maintenance ------------------ 4-1

4.4.1 Lubrication -------------------- 4-3

4.5 Component Maintenance ------------------- 4-3

4.5.1 Traction Drive ----------------- 4-3

4.5.2 Rope Transport Unit ------------ 4-3

4.5.3 Rope Fairleader ---------------- 4-4

4.5.4 Control Console ---------------- 4-4

4.6 Tightness of Bolts and Nuts ------------- 4-4

V TROUBLESHOOTING -------------------------------- 5-1

VI

5.1 General --------------------------------- 5-1

REPAIR PARTS ----------------------------------- 6-1

6.1 Repair Parts Ordering Information ------- 6-1

VII LAKE SHORE, INC. DRAWINGS ---------------------- 7-1

-i-

NAVSEA S9582-AE-MMO~ 0/0

TABLE OF CONTENTS (Continued)

PAGE NO.

VOLUME II

VIII MANUFACTURER'S INSERTS ----~-----------~--------- 8-1

NUMBER

1-1

4-1

5-1

7-1

8-1

NUMBER

3-1

3-2

3-3

3-4

4-1

4-2

4-3

LIST OF TABLES

TITLE PAGE NO.

Traction Drive Capabilities ----------------- 1-2

Equipment Standards ------------------------- 4-2

Troubleshooting Guide ----------------------- 5-2

List of Drawings ---------------------------- 7-1

List of Manufacturer's Inserts -------------- 8-1

LIST OF ILLUSTRATIONS

TITLE PAGE NO.

Control Console ----------------------------- 3-3

Rope Transport Unit Starter Panel ----------- 3-4

Engine Control Panel ------------------------ 3-5

Reeving Diagram ----------------------------- 3-6

Lubrication Data (Traction Winch) ----------- 4-5

Lubrication Data (Rope Transport Unit) ------ 4-6

Lubrication Data (Engine Assembly) ---------- 4-7

-ii-

NAVSEA S9582-AE-MMO-020

SECTION I

GENERAL INFORMATION

1 . 1 TRACTION DRIVE.

The traction drive used on the Navy model T-ATF ocean going tug consists of traction winch model TW-1520, the rope transport unit, the rope fairleader, and the control console. The main function of the traction drive is for towing, using a 6 - 15 inch circumference nylon rope. The traction drive is a twin drum, geared, mechanically driven, diesel powered winch fitted with two external brake bands. Operating functions of the trac tion drive are controlled from a remote control console and an engine control panel. The control console contains operator push-

• buttons, indicators, and operating levers. The engine control panel contains engine start and stop pushbuttons, throttle control

. and engine temperature and pressure gauges. The rope transport unit is a grooved, rubber-lined, electric motor-driven sheave used to guide and maintain tension in the tow rope between the rope locker and the traction drive. The rope transport unit is mounted overhead. The rope fairleader consists of a separate structure providing a rectangular opening welded to the main deck aft. Refer to Section II for detailed descriptions of the trac tion drive. Table 1-1 lists the capabilities of the traction drive.

1-1

• Table 1-1. Traction Drive Capabilities

Line Pull: 200,000 lbs. @ stall 175,000 lbs. @ 12 fpm 100,000 lbs. @ 39 fpm

40,000 lbs. @ 98 fpm

134 fpm light line speed @ INHAUL 370 fpm light line speed @ PAYOUT

Static braking capacity: 400,000 lbs.

Freewheeling: Transmission in neutral Air clutch disengaged

• . Torque converter clutch disengaged

1-2

2.1

NAVSEA S9582-AE-MMO-020

SECTION II

DETAILED DESCRIPTION

TRACTION DRIVE. (Refer to Dwg. No. 58264, Section VII.)

The traction drive is a Lake Shore, Inc., model TW-

1520 twin drum, geared, mechanically driven, diesel powered winch suitable for synthetic rope from 6 - 15 inch circumference. The major components of the traction drive are outlined and des cribed as follows:

l. Traction Winch·

a. Drum Brake Assembly

b. Slack End Tension System c . Air Clutch

d. Universal Joint

2. Transmission/Converter

3. Cooling Oil Assembly

4. Engine Assembly

a. Engine Control Panel

5. Rope Transport Unit

a. Rope Transport Unit Starter Panel

6. Rope Fairleader Assembly

7. Control Console

a. Rope Selector Control

b. Drum Brake ENGAGE/DISENGAGE

c. Slack End Cylinder CLAMP/RELEASE

d. Transport Cylinder CLAMP/RELEASE

e. Rope Tension Readout

f. Air Clutch ON/OFF

g. EMERGENCY STOP

h. Power ON Indicator Light

i. Air Pressure Gauge

2-1

2.1.1 j.

k.

NAVSEA S9582-AE-MMO-020

Rope Transport Pushbuttons

Controller INHAUL/PAYOUT

Traction Winch (Lake Shore Dwg. No. 321784). The traction winch is a twin drum, mechanically driven, geared winch used to haul in or payout rope. The traction winch gearing is totally enclosed with oil bath lubrication. Power is transmitted from the engine to a transmission/torque converter unit through a double U-joint drive shaft. The traction winch is equipped with two air/spring operated band brakes for line control. An air clutch is mounted to the winch for engagement control.

The traction winch operates in both the forward

(PAYOUT) and reverse (IlliiAUL) direction with movement selected and controlled from a remote control consDle. A three position, electrically operated valve controls winch movement.

2.1.1.1 DRUM BRAKE ASSEMBLY (Lake Shore Dwg. No. 321994).

The traction winch drums are equipped with two external band type brakes. The brakes are engaged and disengaged by the action of two air cylinders--one located at each brake. A brake valve at the control console supplies air to the air cylinders. When the brake valve is in the disengaged position, the air cylinders extend. The brake bands, being connected to the cylinders, relax away from the traction winch brake drums, .thus, releasing the brakes. When the brake valve is in the engaged position, air passes through the rope selector valve to the rod end of the air cylinders, causing them to retract. This draws the brake bands against the brake drums, thus, setting the brake.

An auxiliary mechanical braking ability is provided in the event system air pressure is lost. A compression spring, located in the main brake linkage and sustained by the air cylin der, will extend and set the brake band upon loss of air pressure.

The brake setting using the spring alone is 60,000 pounds.

2.1.l.2 SLACK END TENSION SYSTEM (Lake Shore Dwg. No. 321774).

The slack end tension system consists of a phenolic plastic pressure wheel activated by an air cylinder controlled by an air

2-2

NAVSEA S9582-AE-MMO-020

valve located at the control console. When the air cylinder ex tends, the pressure wheel clamps the rope to the traction winch rope drum maintaining tension in the slack end of the tow rope during inhaul. Retracting the air cylinder lifts the pressure wheel away from the rope during payout.

2.1.1.3 AIR CLUTCH. The traction winch is equipped with an

air clutch to engage and disengage the engine and transmission/ torque converter unit from the winch. The air clutch is con trolled from the control console by ON-OFF pushbutton switches.

The pushbuttons control a normally open, electrically operated air valve. The ON pushbutton provides the clutch with air, thus, keeping it engaged. Pressing the OFF pushbutton removes the air supply to the clutch allowing the internal springs to extend, lifting the floating plates away from the driving rings, thus, disengaging the clutch.

A mechanical means for engaging the air clutch is provided. Refer to Volume II, Manufacturer's Inserts for additional description of the air clutch.

2.1.1.4 UNIVERSAL JOINT. The double universal joint is a

Twin Disc Model J-170.T. Refer to Volume II, Manufacturer's Inserts for description.

2.1.2 Transmission / To'rgue Converter. . The torque

transmission/converter is a Twin Disc Model 4-MT-1623-l package.

This package is composed of a Twin Disc 4-M-1623 torque con verter and a Twin Disc TD-11-2805 forward-reverse transmission.

The torque converter and transmission operate from a single lever control located at the control console. Refer to Volume II, Manufacturer's Inserts for a description of the torque trans mission/converter.

2.1. 3 Cooling Oil As'sembly (Lake Shore Dwg. No. 321804).

The cooling oil assembly consists of three pumps, a reservoir, two salt water heat exchangers, filters and valves.

• Two pumps are driven off the diesel engine to direct filtered cooling and control oil for the transmission/torque

2-3

NAVSEA S9582-AE-MMO-020

converter. The third pump is belt driven off the diesel engine to provide necessary suction of oil from the transmission drain back to the reservoir.

All oil is directed through two shell and tube salt water heat exchangers for cooling prior to recycling through hydraulic circuit.

Refer to Lake Shore Dwg. No. 321804 for hydraulic schematic and Volume II, Manufacturer's Inserts for individual component descriptions.

2.1.4 Engine Assembly (Lake Shore Dwg. No. 322304). The

engine assembly consists of a Detroit Diesel (8V-7l) with a minimum flywheel horsepower of 353 @ 2300 rpm. Refer to Volume

II, Manufacturer's Inserts for a complete description of the engine assembly.

2.1.4.1 ENGINE CONTROL PANEL (Figure 3-3). Mounted directly

to the diesel engine assembly is a control panel for start-up, adjustment, and monitoring of the diesel engine. The panel con tains the necessary pushbuttons, temperature and pressure gauges, and throttle control to ensure proper operation of the engine.

Refer to Figure 3-3 for the description and operating ranges of the components contained within the control panel.

2.1.5 Rope Transport Unit (Lake Shore Dwg. Nos. 58484 &

321684). The rope transport unit consists of an electrically driven, grooved and rubber lined sheave and an air cylinder with a phenolic plastic wheel to maintain positive control of the tow rope between the rope locker and the traction winch. Four push button switches at the control console select rope transport operating mode for the drive motor of the sheave. In addition, a rope transport cylinder valve control activates the air cylin der. The air cylinder, when extended, causes a phenolic plastic pressure roller to clamp the tow rope into the groove of the rope transport unit sheave. The rope transport unit maintains 150

• pounds tension in the slack end of the tow rope during payout.

2-4

Refer to Volume II, Manufacturer's Inserts for individual compo nent descriptions.

2.1.5.1 ROPE TRANSPORT UNIT STARTER PANEL (Figure 3-2).

Mounted in the vicinity of the control console is the starter panel for the rope transport unit. Movement of the. throw lever in an upward direction energizes the circuits for the traction drive. Ships power of 440 volts, 60 hertz, 3 phase, enters at the rope transport unit starter panel. The panel contains trans formers to stepdown the voltage to 115 volts, 60 hertz, 3 phase, and, 24 volts D.C. Refer to Lake Shore Dwg. No. 61533 for electrical schematic.

2.1.6 Rope Fairleader Assembly (Lake Shore Dwg. Nos.

58584 & 321654). The rope fairleader consists of a separate structure providing a rectangular opening formed by two vertical rollers at the sides and one horizontal roller at the bottom.

The top of the fairleader opening consists of a flared plate.

The rope fair leader is welded to the main deck.

2.1. 7 Control Console (Figure 3-1 & Lake Shore Dwg. No.

322254). A control console is located away from the traction drive and provides operator controls and indicators. The follow ing paragraphs describe the controls and indicators located at the control console.

2.1.7.1 ROPE SELECTOR CONTROL. The rope selector control, located at the upper left corner of the control console panel, is a WABCO 2-HA-4PC No. 60324, four position, directional con trol and must be set to correspond to the size of rope used.

The position of the rope selector control directs the air pres sure through one of four regulators located within the console enclosure. The air travels from the regulator to the brake air cylinder at the winch, thus, limiting the braking ability mini mizing the possibility of rope failure. Refer to Lake Shore Dwg.

No. 322254 for regulator pressure settings and Volume II, Manu facturer's Inserts for additional information .

2-5

NAVSEA S9582-AE-MMO-020

2.1. 7.2 DRUM BRAKE-ENGAGE/DISENGAGE. The drum brake control located in the lower left corner of the control console panel is a WABCO 2-HA-2YFC No. 59340, two position, directional control.

Placing the lever in the ENGAGED position causes the drum brakes to set to a pressure regulated by rope selector control position.

Placing the lever in the disengaged position r~~eases the drum brakes. Refer to Volume II, Manufacturer's Inserts for addi tional information.

2.1.7.3 SLACK END CYLItIDER-CLAMP/RELEASE. The slack end

cylinder control located to the right of the rope selector control, is a WABCO 2-HA-2YPC No. 59340, two position, directional control.

With the lever in the CLAMP position, a phenolic plastic pressure wheel clamps the rope to the traction winch drum, maintaining tension in the slack end of the tow rope during inhaul. With the lever in the RELEASED position, the pressure wheel lifts away from the tow rope for payout. Refer to Volume II, Manufacturer's

Inserts for additional information.

2.1.7.4 TRANSPORT CYLINDER-CLAMP/RELEASE. The rope transport

cylinder control, located to the right of the drum brake ENGAGE/ DISENGAGE control, is a WABCO 2-HA-2YFC No. 59340, two position, directional control. Placing the lever in the CLAMP position causes a phenolic plastic pressure wheel to clamp the r9pe to the rubber-lined rope transport unit sheave. Placing the lever in the RELEASE position lifts the pressure wheel away from the rope for reeving.

Note

When the rope transport unit AUTO push button is depressed, the rope transport cylinder control is inoperative and the pressure wheel is in the clamp position.

Refer to Volume II, Manufacturer's Inserts for additional infor mation.

2.1.7.4 ROPE TENSION READOUT. The rope tension readout indi-

cator is located in the upper center of the control console panel. The rope tension readout maintains rope tension in pounds.

2-6

Three remote tension readout indicators are located elsewhere on the ship as follows:

Wheelhouse

First.Mate Stateroom

Officers Mess

Due to temperature changes, the tension readout meters may require readjustment to zero. Located next to the tension readout meter on the control console is a zero adjustment knob.

Note

Adjustment to zero shall be accomplished under no load conditions at the winch drums just prior to use.

Refer to Lake Shore Dwg. No. 322544 for the electri cal assembly and Volume II, Manufacturer's Inserts for individual component information.

2.1.7.5 AIR CLUTCH ON/OFF PUSHBUTTONS. The air clutch push-

buttons electrically control the supply of air to the clutch.

Pressing the ON pushbutton provides the clutch with air, thus, keeping it engaged. Pressing the OFF pushbutton removes air to the clutch, disengaging it. Once the clutch is disengaged and the brakes are released, the winch is in a freewheel condition.

2.1.7.6 EMERGENCY STOP. An EMERGENCY STOP pushbutton is

located to the right of the rope tension readout meter. This pushbutton provides the operator with a remote means of shutting down the engine through activation of a baffle removing engine air supply.

Note

A second EMERGENCY STOP pushbutton is located in the engine control panel.

2.1.7.7 POWER ON INDICATOR LIGHT. The power ON indicator

light, located directly below the EMERGENCY STOP pushbutton on the control console, comes on when the system is energized at the rope transport unit starter panel.

2-7

2.1. 7.8

NAVSEA S9582-AE-MMO-020

WARNING

This light must be ON before operating the traction drive.

AIR PRESSURE GAUGE. The air pressure gauge in the upper right corner cif the control. console' panel monitors ships air supply.

WARNING

Do not attempt' to operate the winch if the air supply reading is below 100 psi.

2.1.7.9 ROPE TRANSPORT PUSHBUTTONS. Four pushbuttons for the

control of the rope transport unit are located to the right of the air clutch ON/OFF pushbuttons. They are described as follows:

1. AUTO (Automatic). This pushbutton is functional only when the diesel engine is running, This is controlled by an engine oil pressure sensing switch. The with AUTO pushbutton de

,~ pressed, the rope transport unit will operate in the inhaul mode only.

2. INHAUL. This pushbutton activates the rope transport unit in the inhaul direction. This pushbutton is functional

.whether the diesel engine is running or not.

3. OFF. This pushbutton prevents the rope transport unit from operating in either direction. This pushbutton is functional whether the diesel engine is running or not.

4. PAYOUT. This pushbutton activates the rope trans-port unit in the payout direction. This pushbutton is function al whether the diesel engine is running or not.

2.1.7.10 CONTROLLER INHAUL/PAYOUT. The controller (ETCM-02), located in the lower right corner of the control console panel, is a three position, direction and speed, electric control. The

NEUTRAL position disengages the engine from the traction winch

• and allows the operator to freewheel the winch if the brakes are disengaged. Moving the handle to either the PAYOUT or INHAUL

2-8

NAVSEA S9582-AE-MMO-020

position activates the respective position. In each direction, a detent is provided at the minimum engagement position. Speed increases proportionally in either direction as lever departure from NEUTRAL is increased. A lockout is incorporated into the system to prevent detrimental effects· of a rapid transmission shift from PAYOUT to I!{[AUL or vice versa. Shifting can only take place after line speed drops below 76 fpm. If the system exceeds 350 fpm, the air clutch will disengage and the OVERSPEED light will come on. The light will remain on until speed drops below 350 fpm; however, the power train will not re-engage until line speed drops below 76 fpm. Refer to Volume II, Manufacturer's Inserts for a description of ETCM-02 controller .

2-9

3.1

1.

NAVSEA S9582-AE-MMO-020

SECTION III

OPERATION

SYSTEM START-UP.

To start the traction drive, proceed as follows:

WARNING

Prior to operating the traction drive, check that all components have been properly lubricated and visually inspected for damage, loose, or missing parts.

The salt water supply to heat exchangers for the cooling system must be on before start-up.

Check that all personnel are clear before operating the traction drive.

Turn ON salt water supply to heat exchangers for cooling the system.

2.

3-1).

3 .

4.

Check air pressure gauge at control console (Figure

Air pressure shall not be below 100 psi ..

Check engine fuel and hydraulic fluid levels.

Turn ON main circuit breaker (Figure 3-2) at rope transport unit starter panel. Ensure power on light control console is ON.

5. Disengage air clutch at control console by depress-ing air clutch OFF pushbutton.

6. Start diesel engine as follows (Figure 3-3):

a. Check and release EMERGENCY STOP and ENGINE STOP pushbuttons.

b. Check engine air pressure gauge. Pressure must be approximately 100 psi for start-up.

3-1

c. Push ENGINE START. Maintain until engine starts.

d. Adjust engine throttle speed to 750 rpm for warm-up. During warm-up monitor engine gauges to ensure proper pressures and temperatures. Refer to Figure 3-3 for normal operating ranges.

e. After engine warm-up is completed, adjust en-gine speed. With air clutch disengaged and converter engaged, the operating rpm shall be 2300 rpm.

3.2 PRE OPERATION PROCEDURES.

WARNING

The rope selector valve at the control con sole must be placed in the position correspond ing to the size of tow rope used. Failure to comply could result in rope breaking.

3.2.1 Control Console. The following must be accomplished

at the control console prior to operation. (Refer to Figure 3-1 for location of controls.)

1. Place rope selector valve in position corresponding to size of tow rope being used.

2. Move transport cylinder valve control to RELEASED position to swing pressure roller away from sheave.

3. Move slack end cylinder valve control to RELEASED position to lift pressure roller away from drum.

3.2.2 Rope Reeving. Reeve the rope in accordance with

Figure 3-4. After reeving has been completed, return transport cylinder and slack end cylinder valve controls to CLAMP.

3.3 TRACTION DRIVE' OPERATION.

Note

The speeds at which the traction drive will operate are proportional to the distance the control lever is moved from its center (NEUTRAL) position.

3-2

NAVSEA S9582-AE-MMO-020

BRAKE CAPACITY SE~ECTOR

CAUTION I POSITION ROPE SE~ECTOR VAL.UE

TO CORRESPONDING ROPE SIZE BeiNG usee

PRIOR TO OPERATION OP WINCH.

IS" & 12"'

I'" & 10"

9" & S-

7" & 6"

C I R C U M F E R E N C E

CLAMP

S C l.. Y A ~

C I K N e E E N R o

B A A K E

ENGAGE

ANO TOW

Figure 3-1.

poweR ON

Control Console

3-3

PAYOUT

t

NEUTRAL.·

t

INHAU~

WINCH CONTROL.

R P E

T R A N S P R T

U N I" T

CLAMP

T C A Y A l..

N I S N p 0 0 E R R T

AE~EASE

Figure 3-2. Rope Transport Unit Starter Panel

3-4

NAVSEA S9582-AE-MMO-020

EMERGENCY

STOP

ENGINE

WATER·TEMP.

CONVERTER

OIL·TEMP.

ENGINE

START

ENGINE

01 L·PRESSURE.

CONVERTER

01 L·PRESSURE

IN GEAR

ENGINE

STOP

ENGINE

AIR·PRESSURE

ENGINE TACHOMETER

ENGINE·FUEL

Figure 3-3. Engine Control Panel

3-5

NAVSEA S9582-AE-MMO-020

TO FAIRLEAOER

Figure 3-4. Reeving Diagram

3.3.1 P'ayout. To payout rope. proceed as follows:

1. Move slack end cylinder valve control to RELEASED position.

2. Engage air clutch by depressing ON pushbutton.

3. Place drum brake control lever in DISENGAGED posi-tion.

4. Depress rope transport AUTO pushbutton. '

5. Move control lever away from NEUTRAL toward PAYOUT position. The traction winch is now operating in PAYOUT mode.

3-6

NAVSEA S9582-AE-MMO-020

6. To stop PAYOUT, simultaneously move the control lever to NEUTRAL and drum brake control lever to ENGAGED. The traction winch will stop and the drum brake will set.

3.3.2 Inhaul. To inhaul rope, proceed as follows:

1. Move slack end cylinder valve control to ENGAGED position.

2. Engage air clutch by depressing ON pushbutton.

3. Place drum brake control lever in DISENGAGED posi-tion.

4. Depress rope transport AUTO pushbutton.

5. Move control lever away from NEUTRAL toward INHAUL position. The traction winch is now operating in INHAUL mode.

6. To stop INHAUL, simultaneously move the control lever to NEUTRAL and drum brake control lever to ENGAGED. The traction winch will stop and the drum brake will set .

3.3.3 Emergency Stop. Pressing the EMERGENCY STOP push-

button at the control panel will shut down the diesel engine.

However, control of the traction winch will be lost.

3.4 EMERGENCY OPERATION.

In the event that system air pressure is lost, the drum brake will spring set and the air clutch will disengage.

A jacking bolt is provided for releasing the drum brakes and screw bolts are provided at the air clutch for engagement. Refer to Volume II, Manufacturer's Inserts, for air clutch emergency engagement procedures.

3.5 SYSTEM SHUTDOWN.

To shutdown the system, proceed as follows:

1. Inhaul rope returning it to rope locker.

2. Depress air clutch DISENGAGE pushbutton at control console .

3.

panel.

Depress ENGINE STOP pushbutton at engine control

3-7

• 4. Turn off main circuit breaker at rope transport unit motor starter panel.

5. Shut off salt water supply to heat exchangers .

3-8

SECTION IV

MAINTENANCE

4.1 GE1"'ERAL INSTRUCTTONS.

Shipboard maintenance of the traction drive should include a regular program of periodic inspection and preventive maintenance. Inclusion of the traction drive in the Planned

Maintenance System is recommended.

Proper application of the lubricants as listed on the accompanying lubrication charts will extend the life of the traction machine. See Figures 4-1, 4-2 and 4-3 for lubrication data for the traction drive, diesel engine, and rope transport unit. Refer to Lake Shore Dwg. No. 58584 for lubrication data

4It for the rope fairleader. Refer to Volume II, Manufacturer's Inserts for lubrication data on component parts.

4.2 OPERATOR INSPECTION.

Before operating the traction drive, a visual in spection of all operating equipment should be made. Any abnormalities (loose parts, obstructions, oil leaks, etc.)

discovered should be corrected prior to operating traction drive.

4.3 MECHANICAL MAINTENANCE.

Acceptable standards of performance which will help the operator to detect substandard traction drive performance is contained in Table 4-1. This will give a basis of comparison for day-to-day operation.

4.4 PREVENTIVE MAINTENANCE.

WARNING

Positive measures must be taken to ensure that the traction drive is not operated while personnel are engaged in lubrication and maintenance operations.

4-1

NAVSEA S958Z-AE-MMO-OZO

Table 4.1. Equipment Standards

EQUIPMENT

General Information

Rope Drums

Sheave

Brakes

Pushbuttons and Switches

Motor

Control Panels

Diesel Engine

STANDARDS OF PERFORMANCE

Levers should move freely through full arc with no binding; equip ment should respond immediately.

Drums rotate freely without chatter or binding.

Rope rides in middle of sheave groove and does not ride up groove side. Sheave rotates freely with out chattering or wobbling.

Brakes engage and disengage freely, positively, and immediate ly in response to control lever.

These controles move freely without binding in mounting, and provide positive and immediate equipment response.

Motor operates with an even hum, and without vibration, overheat ing, or smoking.

Contactors operate smoothly with little arcing of the contacts.

Hydraulic fluid levels and temp eratures within recommended ranges.

4-Z

4It 4.4.1 Lubrication. Points to be lubricated, types of lubricant, and frequency are shown on Figure 4-1, 4-2 and 4-3, Lake Shore Dwg. No. 58584, and Volume II, Manufacturer's Inserts of this manual.

4.4.1.1 TRACTION DRIVE. Refer to Figures 4-1 and 4-2 for

lubrication data for the tractIon drive. Additional lubrication data is contained on Lake Shore Dwg. No. 58264 and Volume II, Manufacturer's Inserts contained in this manual.

4.4.1.2 ROPE TRANSPORT UNIT. Refer to Figure 4-3 for

lubrication data for the rope transport unit.

4.4.1.3 ROPE FAIRLEADER. Refer to Lake Shore Dwg. No. 58584

for lubrication data for the rope fairleader.

4.4.1.4 CONTROL CONSOLE. Refer to Volume II, Manufacturer's

Inserts for lubrication data for components of the control console .

4.5 COMPONENT MAINTENANCE.

4.5.1 Traction Drive. Component maintenance of the trac-

tion drive consists of the following. Refer to Volume II, Manufacturer's Inserts for detailed maintenance procedures for the following components.

1. Traction Winch

a. Air Clutch

b. Double U-Joint

2. Brake Band Assembly

a. Air Cylinders

3. Engine Assembly

a. Diesel Engine

b. Torque Converter/Transmission

4. Cooling Oil Assembly

a. Heat Exchangers

b. Control Valves

4.5.2 Rope Transport Unit. Component maintenance of the

rope transport unit consists of the electric motor, air

4-3

NAVSEA S9582-AE-MMO-020

cylinder, and sheave. Refer to Volume II, Manufacturer's Inserts for maintenance procedures for these components.

4.5.3 Rope Fairleader. The rope fairleader should seldom

require maintenance. Refer to Lake Shore Dwg. No. 58584 for information.

4.5.4 Control Console. Maintenance procedures for compo-

nents of the control console are contained in Volume II, Manufacturer's Inserts.

4.6 TIGHTNESS OF BOLTS AND NUTS. -- --- ----

On an annual basis, check all bolts, nuts, screws, and other fasteners for tightness, using torque wrenches where practical. Refer to appropriate assembly drawings for bolt torque values.

4-4

NAVSEA S9582-AE-MMO-020

----Qj 2 IN LINE

I , -. , . I .. ~TRUNNION PIN

d'-2 IN LlfIl.E

LUBRICATION

I I

I

DATA

UNE POINT OF TYPE QU~TITY REMARKS NO. LUBRICATION

I

BEARINGS €. PRESSURE ·26 ONCE A

BUSHINGS FITTINGS MONTH

GEAR FILL E 112 EVERY 6

CASE DRAIN GALLONS MONTHS'

I

I

,~FILL

SUGGESTED

LUBRICANT

MOBILUX

GREASE NO.2

MOBILGEAR

Figure 4-1. Lubrication Data (Traction Winch)

4-5

LINE

NO.

I

~ / ,I . ./ /---...:..---

CD

POINT OF

LUBRICATION

SHEAVE

BEARINGS

GEARS

ELECTRIC.

MOTOR

PRESSURE

WHEEL

NAVSEA S9582-AE-MMO-020

J \ 3

~ i-REMOVE ACCESS

PLATE TO SWAB

4 GEARS .

. LUBRICATION DATA -.-... -- - . --

TYPE QUANTITY REMARKS

SUGGESTED

LUBRICANT

PRESSURE

I

ONCE A MOBILU2<

FITTINGS MONTH GREASE NO,2

SWAB I ONCE A MOBIL-TAC E MONTH

FOR LUBRICATION SEE

MANUFACTURERS INSTRUCTIONS

PRESSURE

I

ONCE A MOBILUX

FITTINGS MONTH GREASE NO.2

Figure 4-2. Lubrication Data (Rope Transport Unit)

4-6

I-

LNE POINT OF

NO, LUBRICATION , ru'L TAIOII(

II.~I

" """"< CAlI (II Qu.A«fS ~.l

, OIl.-,ILTlIIt

. ....... '00 17CAu...QfiI'~.)

I T'WM)TTU CONTROl.

• HYOIiNJUC fAlol ..

I" CAU..OHI "'~.I

Figure 4-3.

NAVSEA S9582-AE-MMO-020

I ::::::===:;> ! i I

TRACTION WINCH DRIVE

LUBRICATION DATA

TYPE an: FREOUENCY

"1.1. , OAAiN , OAAIH ~lJI'" , WONTWS

'IUo' 0"04..1111 , r::HAHC. (liP'!' • IHlNTWS

(.:11.,. "LUD TO 0011..

'-IV .... INOIc.ATOlitI

........,. , . ItP\ACI AT I.4Ot au.

CHANOII

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1flU,. ,OQAIN , c.HAIIGl IVVtY I Io4ONTHS

(KIP "LUI) TO 04 ...

I..lVIlL SIGHT CAUCI

D

SUGGESTED

LUBRICATION

A.JTJA-.o-tn J-O tOIUIL AJILJ

"".-I..-J" .. / "'" coal CC;.5C."'. 18 0 .. -0 o.

SU""-IMIHT 1°"'" COOl eli-SAl It o ...

M:-"~"'''K ~c ~lllW 0" IIQU.<U.

WA, riA WITH AIOITln'1111 CH.UtGI: IVIJIY , IIfONf1ot$

CUOC 1 CIlIAS.

OCl,VAC •• UI, .... " URIIS Cl).SO

Lubrication Data (Engine Assembly)

4-7

ILL

RAIN

5.1 GENERAL.

NAVSEA S9582-AE-MMO-020

SECTION V

TROUBLESHOOTING

Troubleshooting the traction machine will generally be necessitated by noise, rough movement, uneven wear, or lack of proper response to the controls.

Most mechanical problems are a result of lack of lubrication or improper alignment of equipment. Refer to Section IV for the proper standards of performance and lubrica tion charts. The Lake Shore, Inc. drawings in Section IV list all of the parts that make up the traction machine. Volume II, Manufacturer's Inserts, contains data on all of the component parts including parts list, troubleshooting, alignment, and adjustment procedures.

Table 5-1 lists possible problems that may occur, the probable cause, and the recommended remedy for correction .

5-1

TROUBLE

Excessive noise or vibration.

Oil leaks.

Traction winch overheats.

Traction winch brakes will not set.

Traction winch brakes will not release.

NAVSEA S9582-AE-MMO-020

Table 5-1. Troubleshooting Guide

PROBABLE CAUSE

Foundation bolts loose.

Loose or broken parts.

Universal joint out of alignment.

Gasket covers loose.

Gaskets damaged.

Worn or damaged oil seals.

REMEDY

Tighten all bolts.

Repair or replace any broken parts.

See Volume II, Manufac turer's Inserts

Tighten covers.

Replace gaskets.

Replace seals.

Oil level too high. Drain to proper level.

Improper venting. Check and clean air

Lack of or im proper lubricant.

Excessive churning of oil. Oil level too high.

Improper venting.

Damaged bearing.

Faulty control at console.

Air regu1atcr out of adjustment or faulty at console.

vents .

Check level. Replenish when necessary.

Drain to proper oil level.

Check and clean air vents.

Inspect and replace as necessary.

Check control. Rep1ace/ repair as necessary.

Readjust/replace as necessary.

System air pressure Check system air pressure.

lost. Brake has spring set.

Faulty control at console.

5-2

Check control. Rep1ace/ repair as necessary.

NAVSEA S9582-AE-MMO-020

Table 5-1. Troubleshooting Guide (Continued)

TROUBLE

S:I.ack end roller will not set or release.

Rope trans port unit cylinder will not set or release.

Rope trans port unit motor will not run.

Air clutch malfunctions.

Transmis/ sian/torque converter malfunctions.

System overheats.

PROBABLE CAUSE REMEDY

System air pressure Check system air pressure.

lost.

Faulty control at console.

Check contr.ol. Replace/ repair as necessary .

. -. ----.-.. -- -- .- -... '-.. . 1- System air pressure ,Check system air pressure.

lost. '

Faulty control at 'Check control. Replace/ console. repair as necessary.

Starter panel not 'Turn on starter panel.

ON. .

Diesel engine not Start diesel engine.

running.

Faulty control at console .

Faulty motor.

Air control valve pushbutton faulty.

Various.

Various.

iCheck control. Replace/ irepair as necessary.

I iSee Volume II, Manufac- !turer's Inserts.

I i !Replace/repair as inecessary.

I

:See Volume II, Manufac- : turer 's Inserts.

;See Volume II, Manufac lturer's Inserts.

I

I

Salt water cooling Turn ON.

system not ON.

Faulty heat Replace/repair as exchanger. necessary .

5-3

NAVSEA S9582-AE-MMO-020

Table 5-1. Troubleshooting Guide (Continued)

TROUBLE

Diesel engine malfunctions.

PROBABLE CAUSE

Various.

REMEDY

See Volume II, Manufac turer's·Inserts.

Diesel engine Low system air Check system air pressure.

will not start. pressure.

EMERGENCY STOP/ Release STOP pushbuttons.

Traction winch will not INHAUL or

PAYOUT.

ENGINE STOP push-buttons depressed.

at engine control panel.

Converter / trans mission hydraulic clutch pressure lost.

Air clutch mal function.

Faulty control at console.

5-4

See Volume II, Manufac turer's Inserts.

See Volume II, Manufac turer's Inserts.

Check control. Replace/ repair as necessary .

6.1

NAVSEA S9582-AE-MMO-020

SECTION VI

REPAIR PARTS

REPAIR PARTS ORDERING INFORMATION.

To ensure the rapid execution of orders and correct shipment of parts, always give the following information:

1. Model and type of winch.

2. Serial number of winch.

3. Part number and description--reference should be made to Parts Drawings, Repair Parts Lists and Commercial Inserts which form a part of this book.

4. Number of parts required.

5. Method of shipment.

6. Technical manual number of this book.

7. Vessel identification.

Mail Information To:

Lake Shore, Inc.

Marine Parts P.O. Box 809

Iron Mountain, MI 49801

6-1

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