0202_A_Clutch_and_Brake_Inspections_rev_10-28.doc

USNS GRASP

( T-ARS 51 )

PROPULSION MACHINERY

SPEC. NO. N40442-12-R-4006

ITEM NO. 0202

CATEGORY "A"

10/28/2012 Clutch and Brake Inspections

Hulick

1.0 ABSTRACT

1.1 Perform Midterm inspections and overhaul of main engine brakes, clutches and pinions.

2.0 REFERENCES

2.1 Reduction Gear Tech manual. NAVSEA S9241-AJ-MMM-010 MAIN PROPULSION GEAR AND CLUTCHES

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity/Description

3.1.1 Location: Main Machinery Room (3-53-0), Quantity: FOUR (4) Drive Clutches Description: Eaton designed drive Clutches, Type 14VC1000.

3.1.2 Main Machinery Room; 1A and 1B Quill and Pinion Shaft for David Brown type 2R 84” Gearbox, Serial 11512604 including Eaton designed drive clutch, Type 14VC1000.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 ABS Surveyor.

4.2 Lubricants.

4.3 Clutch Assemblies; Friction shoes, torque bars, springs, rivets, bearings, sleeve, lock washers, air tubes.

4.4 Reduction gear bearings.

5.0 NOTES

5.1 All work specified in this item shall be in accomplished under the guidance and supervision of the Manufacturer’s Representative.

5.2 Tech manual instructions need to be followed, including the installation of the "come-home" or shipping bolts to support the assembly. If not, the quill shaft can drop and damage the oil seal on the shaft.

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

7.0 STATEMENT OF WORK:

7.1 Using technical manual section 4-3.4 INSPECT BRAKES AND CLUTCHES and CLUTCH AND PINION INSPECTION Table 6-6 provide all labor, rigging and materials to perform the complete disassembly and subsequent midterm inspection of Main Propulsion Engine brake, clutch and pinion inspections.

7.1.1 Temporarily open, drain and disassemble each clutch.

7.1.2 Temporarily remove Roto Seals. Dissemble bearing caps, remove spanner nuts, lock washers and bearings.

7.1.3 Clean all parts, and inspect parts for wear replace. Provide a condition survey of each. Inspect brake assemblies insure proper torque. Inspect bearing assemblies.

7.1.4 Disconnect the Starboard Main propulsion engines from the gear box shafting.

7.1.5 By removing upper section of gearbox, according to the manufacturer’s rep and technical manual remove pinion and quill shaft assemblies and bearings (removing all bearing caps and unsolder RDTs). This will require “tenting” this section of the machinery space to reduce possible contamination. This will also require the addition of at least 6 pad eyes to lift the housing and the pinion/quill assemblies without damaging other seals or bearings. All pad eyes to be tested prior to use in the presence of the MSC REP.

7.1.6 Draw out quill shaft from the pinion and transport to shop. Quill Shaft clutch bearing surface and Oil Sealing Surfaces will need to be flame sprayed or weld build up and machined to within the manufacturer’s tolerances. This work is to be done with the OEM reduction gear rep and the ABS surveyor. Once complete return to shop.

7.1.7 Remove existing pinion bearings and quill bearings for 1A MPDE and replace with new government furnished. This will require bluing of the new bearings and dressing in place to suit the shafting. Provide condition report of 1B MPDE shafting and bearings.

7.1.8 Clean and inspect gears and gear sump in the presence of the chief engineer, once the chief engineer has cleared to close the gearbox the cap must go on without stopping work.

7.1.9 Re-assemble pinion and quill assemblies, reduction gear and bearing casings with sealant in the presence of the chief engineer.

7.1.10 Flush the gear box oil in the presence of the chief engineer for no less than 36 hours with 2 micron filtration until the oil is contaminate free. The flushing rig and equipment used must be checked by the chief engineer and MSCREP to prove cleanliness.

7.1.11 Dissemble clutch elements, blast and paint.

7.1.12 Renew and balance the clutch assemblies to include; all air tubes, friction shoes, torque bars, springs, clutch bearing, sleeves, oil seals and lock nuts.

7.1.13 Replace all gaskets, soft parts including air line grommets, spanner washers and snap rings. Re-fill with OEM recommended oil.

7.1.14 Re-assemble and check alignment, re-torque in the presence of the OEM rep.

7.1.15 Reconnect propulsion engines to the gearbox.

7.2 Inspection/Test

7.2.1 Inspection: The Manufacturer’s Representatives shall accomplish all inspections.

7.2.2 The ABS Surveyor, the ship’s Chief Engineer and Port Engineer shall accomplish the final inspections, with Technical Representative’s in attendance. Contractor to coordinate with ABS scheduling of all inspections and testing.

7.2.3 Operational test the clutches after the overhaul and spin the gears using the turning gear while accomplishing a gearbox inspection. Operate all equipment during dock trials and sea trials. Ensure the tech rep is present during the dock trails and sea trials.

7.3 Painting and lagging: Paint all new & disturbed areas to match surrounding paint scheme.

7.4 Markings: Renew any missing tags, plates as necessary.

7.5 Manufacturer Representative: Provide the services of a recognized Technical Representative to oversee disassembly and repairs/testing and the procurement of repair parts (other than paragraph 4.0) as designated in this Work Item. BOTH the clutch and gear have separate technical representatives; there must be a rep for each side of the work.

Known Sources:

Eaton Corporation, Airflex Division, Cleveland, Ohio 44144 POC: Ed Luehring, (216) 634-8225 CMM Specialty Service POC: John Scanlon, 440-799-3235 Marine Systems Inc, Gear Department, Chesapeake, VA POC: Dennis Byrd 757.543.3000 Reduction Gear:

David Brown, 855 693 2432 , POC Marc Millgram

8.0 GENERAL REQUIREMENTS:

8.1 All work specified in this item shall be accomplished under the guidance and supervision of the Manufacturer’s Certified Field Service Engineers. The cost of these services shall be borne by the contractor.

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