S9241-BM-MMA-010 rev 10.pdf

TECHNICAL MANUAL

FOR

PROPULSION

REDUCTION GEAR

SUPERSEDURE NOTICE: THIS MANUAL SUPERSEDES S9241-BM-MMA-010,

DATED 30 NOV 2018, AND ALL CHANGES THERETO.

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; ADMINISTRATIVE/OPERATIONAL USE; 6 APRIL 2004. OTHER U.S. REQUESTS

FOR THIS DOCUMENT SHALL BE REFERRED TO NSWC PHILADELPHIA, CODE 314.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE

ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC 2751, ET SEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979 (TITLE 50, U.S.C., APP 2401 ET SEQ.), AS AMENDED. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH THE

PROVISIONS OF DOD DIRECTIVE 5230.25.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS

OR RECONSTRUCTION OF THIS DOCUMENT.

S9241-BM-MMA-010

REVISION 10

TITLE-1 / (ii Blank)@@FIpgtype@@TITLE@@!FIpgtype@@ @@FIpgtype@@TITLE@@!FIpgtype@@

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

* 0910LP0008640* 29 OCT 2021

TITLE-2

@@FIpgtype@@BLANK@@!FIpgtype@@

RECORD OF REVISIONS

REV NO. DATE TITLE AND/OR BRIEF DESCRIPTION/PREPARING ACTIVITY

1 CH A 1 JAN 2005 INCORPORATE SCD-70030 (MA-612) WHICH INSTALLS A SPLIT

SEAL ON THE OUTPUT DRIVE SHAFTS FOR THE ATTACHED

CPP AND LUBE OIL PUMPS.

2 18 JUL 2006 INCORPORATED ECP 241-01-C043, C044 AND C046, MISCELLA-

NEOUS CLASS II CHANGES. POC FOR THIS CHANGE IS

SUPSHIP BATH MAINE, N62786 CODE 240.

3 29 APR 2009 INCORPORATED ECP 241-01-C047 (CLASS II CHANGES). POC

FOR THIS REVISION IS SUPSHIP BATH MAINE, N62786 CODE

240.

4 23 NOV 2009 INCORPORATED ECP 241-01-C048 (MISCELLANEOUS CLASS I

CHANGES) AND ECP 241-01-C049 (MRG LUBE OIL SEALS). POC

FOR THIS REVISION IS SUPSHIP BATH MAINE, N62786 CODE

240.

5 15 OCT 2013 INCORPORATED ISEA ADVISORY (017-13) TO IMPROVE THE

ABILITY TO LOCKOUT THE SSS CLUTCH WHEN CLUTCH

ROLL BACK IS ENCOUNTERED.

6 18 NOV 2016 INCORPORATE CHANGES TO SCD-70030 (MA-612). SPECIFI-

CALLY, THE MANUFACTURER AND PART NUMBER OF THE

SPLIT SEAL HAS CHANGED. TO INCORPORATE TMDER

N64498-16-JC06 TO REQUEST APPROVAL OF PERMANENT

BEARING ALARM SET POINT CHANGES VIA MAJOR DEPAR-

TURE FROM SPECIFICATION (DFS).

CHANGED INFORMATION INCLUDES THE FOLLOWING:

PARAGRAPHS:2-4.2, 3-8.4, 6-1.2.12, 6-2.4.5, 6-2.4.6and7-4.

FIGURES:6-25.and6-26A.

TABLES: 7-31.and7-49.

7 1 JUN 2017 INCORPORATED HYBRID ELECTRIC DRIVE (HED) REFERENCE

INFORMATION IN CHAPTER 1; INCORPORATED UPDATE TO

TABLE 1-9.

CHANGED INFORMATION INCLUDES THE FOLLOWING:

PARAGRAPH:1-5.4

TABLE: 1-9.

8 11 JUN 2018 INCORPORATED TMDER N60550-18-BD01 TO CORRECT THE

P/N FOR ITEM IN FIGURE 7-39-5 & 7-40-5.

INCORPORATED TMDER N50054-18-0010 TO CHANGE STATE-

MENT IN PARAGRAPH 6-2.16.1.1 & 6-2.16.3.1 TO REPRESENT

THE ACCURATE STATEMENT.

CHANGED INFORMATION INCLUDES THE FOLLOWING:

PARAGRAPHS:6-2.16.1.1and6-2.16.3.1 TABLES: 7-40.and7-41.

9 30 NOV 2018 INCORPORATED TMDER N55262-18-RC01 TO ADD CAUTION TO

PREVENT SERIOUS DAMAGE TO THE TURBINE CLUTCH. THE

FOLLOWING WAS CHANGED.

PARAGRAPH:6-2.16.1.3.2

10 29 OCT 2021 INCORPORATED TMDER N67562-20-CS00 TO ADD CAUTION TO

PREVENT SERIOUS DAMAGE TO THE TURBINE CLUTCH. THE

FOLLOWING WAS CHANGED.

TABLE: 6-4.

S9241-BM-MMA-010

FOR OPTIMAL VIEWING OF THIS TECHNICAL MANUAL, THE PAGE LAYOUT IN ADOBE ACROBAT

READER SHOULD BE SINGLE PAGE. CONTINUOUS PAGE DISPLAY CAN CAUSE PROBLEMS WITH

LINK REFERENCES AND THE BOOKMARKS.

FOREWORD

This technical manual provides description, operation, maintenance, troubleshooting, repair, parts list and installation information for the General Electric Company Model MDT151A Main Reduction Gear. This techni-cal manual is intended for use by personnel operating and maintaining the equipment described herein.

Chapter 1- General Information, Safety Precautions, and Main Reduction Gear Security Requirements

Chapter 2- Operation

Chapter 3- Functional Description

Chapter 4- Scheduled Maintenance

Chapter 5- Troubleshooting

Chapter 6- Corrective Maintenance

Chapter 7- Parts Lists

Chapter 8- Installation

Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for maximum practical use and evaluation of NAVSEA technical manuals. All errors, omis-sions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be forwarded to:

COMMANDER, CODE 310 TMDERs, NAVSURFWARCENDIV NSDSA, 4363 MISSILE WAY, BLDG 1389, PORT HUENEME CA 93043-4307, on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER), NAVSEA form 4160/1. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom. One copy of NAVSEA form 4160/1 is included at the end of each tech-nical manual 8-1/2 x 11 inches or larger. Copies of NAVSEA Form 4160/1 may be requisitioned from the Naval Systems Data Support Activity Code 310 at the above address. Users are encouraged to transmit deficiency sub-mittals via the web site located at:

https://mercury.tdmis.navy.mil/def_external/pubsearch.cfm i / (ii Blank)

FOREWORD-2

TABLE OF CONTENTS

Chapter/Paragraph Page

1 GENERAL INFORMATION, SAFETY PRECAUTIONS, AND MAIN

REDUCTION GEAR SECURITY REQUIREMENTS. . . . . . . . . . . . . . . 1-1

1-1. SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1.1 Main Reduction Gear Security Requirements. . . . . . . . . . . . . . . . . . . 1-1

1-2. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3. EQUIPMENT DESCRIPTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-3.1 Equipment Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-3.2 Equipment Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-3.3 Component Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-4. EQUIPMENT DEVIATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1-5. OPTIONAL EQUIPMENT (FUTURE INSTALLATION). . . . . . . . . . . . . . . . . 1-37 1-5.1 Racer Turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 1-5.2 Franco Tosi Reversing System. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 1-5.3 Gear Casing Revisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 1-5.4 Hybrid Electric Drive (HED). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

1-6. ADDITIONAL REDUCTION GEAR DATA. . . . . . . . . . . . . . . . . . . . . . . . 1-37

1-7. APPLICABLE SHIP AND MACHINERY ALTERATIONS . . . . . . . . . . . . . . . 1-90

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2. CONTROLS AND INDICATORS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-3. OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-3.1 Turning Gear and Shaft Lock Operation. . . . . . . . . . . . . . . . . . . . . . 2-1 2-3.2 Turbine Clutch Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-3.2.2 Clutch Position Indicator. . . . . . . . . . . . . . . . . . . . . . . . 2-15 2-3.3 Turbine Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2-3.4 Lubricating Oil Pump Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2-3.5 Hydraulic Pump Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 2-3.6 Dehumidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 2-3.7 Reduction Gear Operation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2-4. OPERATOR’S MAINTENANCE INSTRUCTIONS AND SCHEDULES. . . . . . . . 2-31

2-4.1 In Port Operator Maintenance.. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 2-4.2 At Sea Operator Maintenance.. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

3 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 iii

TABLE OF CONTENTS - Continued

3-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2. GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-3. GEAR CASING AND COVERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-3.1 Casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-3.2 Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. ROTATING ELEMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-4.2 High Speed Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-4.2.1 Input Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-4.2.2 Turbine Brake Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-4.2.3 Turbine Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-4.2.3.1 Operating Principles. . . . . . . . . . . . . . . . . . . 3-7 3-4.2.3.2 Details of Construction. . . . . . . . . . . . . . . . . . 3-13 3-4.2.3.3 Details of Operation. . . . . . . . . . . . . . . . . . . 3-16

3-4.2.4 First Reduction Pinion.. . . . . . . . . . . . . . . . . . . . . . . . . 3-22 3-4.3 Intermediate Speed Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-4.3.1 First Reduction Gear.. . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 3-4.3.2 Flexible Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 3-4.3.3 Quill Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 3-4.3.4 Second Reduction Pinion. . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-4.4 Low Speed Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-5. BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 3-5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 3-5.2 Journal Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-5.2.1 Pressure Groove Bearings.. . . . . . . . . . . . . . . . . . . . . . . 3-29 3-5.2.2 Elliptical Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 3-5.2.3 Three-Lobe Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 3-5.2.4 Journal Bearing Caps. . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 3-5.2.5 Positioning Thrust Bearings.. . . . . . . . . . . . . . . . . . . . . . 3-31

3-6. TURBINE BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 3-6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 3-6.2 Brake Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 3-6.3 Brake Caliper Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 3-6.4 Brake Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 3-6.5 Brake Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-6.5.1 Air Pressure Regulator. . . . . . . . . . . . . . . . . . . . . . . . . 3-36 3-6.5.2 Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 3-6.5.3 Hydraulic Booster. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 3-6.5.4 Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3-7. TURNING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 3-7.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 iv

3-7.2 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 3-7.3 Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 3-7.4 First Reduction Worm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 3-7.5 First Reduction Gear and Second Reduction Worm. . . . . . . . . . . . . . . . 3-41 3-7.6 Second Reduction Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 3-7.7 Engagement Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 3-7.8 Shaft Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 3-7.9 Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 3-7.10 Bearings and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-8. PUMP DRIVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 3-8.1 Quill Pump Drive Disconnect.. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 3-8.2 Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 3-8.3 Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 3-8.4 Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3-9. REVOLUTION COUNTER TRANSMITTER AND TACHOMETER SIGNAL

GENERATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3-9.1 Drive Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 3-9.2 Revolution Counter Transmitter.. . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 3-9.3 Tachometer Signal Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3-10. LUBRICATING OIL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 3-10.1 Lubricating Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3-10.1.1 Pump Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 3-10.1.1.1 Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

3-10.1.2 Mechanical Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 3-10.2 Lubricating Oil Distribution System. . . . . . . . . . . . . . . . . . . . . . . . 3-55 3-10.3 Lubricating Oil Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3-10.3.1 Input Shaft Seals.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 3-10.3.2 Low Speed Shaft Oil Deflector. . . . . . . . . . . . . . . . . . . . . 3-64

3-11. RESISTANCE TEMPERATURE DETECTOR SYSTEM. . . . . . . . . . . . . . . . . 3-64 3-11.1 RTD Installation in Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 3-11.2 RTD Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

3-12. DEHUMIDIFIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 3-12.1 Operating Principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 3-12.2 Details of Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 3-12.3 Controls.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3-12.3.1 Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3-13. ISOLATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 3-13.1 Operating Principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 3-13.2 Details of Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

3-14. CASING SNUBBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 v

4 SCHEDULED MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.1 Planned Maintenance System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1.1.1 PMS Documentation.. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.1.2 Use of Documentation.. . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2. MAINTENANCE PLAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-3. MAINTENANCE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-3.1 Daily Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3.1.2 Lubricating Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . 4-4 4-3.1.2.1 Mechanical Seal Inspection. . . . . . . . . . . . . . . 4-4 4-3.1.2.2 Inlet Strainer Inspection. . . . . . . . . . . . . . . . . 4-4 4-3.1.2.3 General Observations. . . . . . . . . . . . . . . . . . . 4-4

4-3.1.3 Clutch Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4-3.1.4 Turning Gear Inspection. . . . . . . . . . . . . . . . . . . . . . . . 4-5 4-3.1.5 Oil Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4-3.1.6 Sight Flow Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4-3.1.7 Reduction Gear Lubricating Oil Quality. . . . . . . . . . . . . . . . 4-5

4-3.2 Semi-Annual Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4-3.2.1 Lubricating Oil and Hydraulic Pump Coupling Lubrication. . . . . 4-5 4-3.2.2 Lubricating Oil Pump Alignment Check. . . . . . . . . . . . . . . . 4-6 4-3.2.3 Turning Gear Coupling Lubrication. . . . . . . . . . . . . . . . . . 4-6 4-3.2.4 Turning Gear Motor Bearing Lubrication. . . . . . . . . . . . . . . 4-6 4-3.2.5 Brake Assembly Inspection. . . . . . . . . . . . . . . . . . . . . . . 4-7 4-3.2.6 Reduction Gear Tooth Visual Inspection. . . . . . . . . . . . . . . . 4-9 4-3.2.7 Oil Spray Nozzles Inspection. . . . . . . . . . . . . . . . . . . . . . 4-9

4-3.3 18-Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4-3.3.1 Snubbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4-3.3.2 Isolators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4-3.3.3 Dehumidifier Performance Testing. . . . . . . . . . . . . . . . . . . 4-10

4-3.3.3.1 Disassembly and Inspection of Dehumidifier. . . . . . 4-10 4-3.3.3.2 Temperature Measurement. . . . . . . . . . . . . . . . 4-11 4-3.3.3.3 Moisture Balance. . . . . . . . . . . . . . . . . . . . . 4-12 4-3.3.3.4 Moisture Removal. . . . . . . . . . . . . . . . . . . . 4-13 4-3.3.3.5 Airflow Measurement.. . . . . . . . . . . . . . . . . . 4-13

4-3.3.4 Clutch Oil Rotary Seal Inspection. . . . . . . . . . . . . . . . . . . 4-13 4-3.3.5 Positioning Thrust Bearing Measurement. . . . . . . . . . . . . . . 4-14 4-3.3.6 Reduction Gear Running Tooth Contact Inspection. . . . . . . . . . 4-18

4-3.4 80-Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 4-3.4.1 Turning Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 4-3.4.2 Turbine Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4-3.4.2.1 Examination of Primary and Secondary Pawls. . . . . 4-23 4-3.4.2.2 Examination of Thrust Ring. . . . . . . . . . . . . . . 4-25 4-3.4.2.3 Clutch Assembly. . . . . . . . . . . . . . . . . . . . . 4-25 4-3.4.2.4 Examination of Thrust Bearing. . . . . . . . . . . . . 4-25 vi

4-3.4.2.5 Lockout Procedure. . . . . . . . . . . . . . . . . . . . 4-27 4-3.4.3 Turbine Clutch Status Switch Shoe Inspection. . . . . . . . . . . . 4-27 4-3.4.4 Lubricating Oil and Hydraulic Pump Drives. . . . . . . . . . . . . 4-27 4-3.4.5 Input Shaft Seal Internal Inspection. . . . . . . . . . . . . . . . . . 4-27 4-3.4.6 Lubricating Oil Pump Internal Inspection. . . . . . . . . . . . . . . 4-28 4-3.4.7 Revolution Counter Transmitter Drive. . . . . . . . . . . . . . . . . 4-28

4-3.4.7.1 Gear Inspection. . . . . . . . . . . . . . . . . . . . . . 4-28 4-3.4.7.2 Drive Quill. . . . . . . . . . . . . . . . . . . . . . . . 4-28 4-3.4.7.3 Coupling Inspection.. . . . . . . . . . . . . . . . . . . 4-28

4-3.4.8 Intermediate Flexible Coupling Inspection.. . . . . . . . . . . . . . 4-28

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

SECTION I ADJUSTMENT AND ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

SECTION II REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

6-2. PROCEDURE FOR COMPONENT REPAIR. . . . . . . . . . . . . . . . . . . . . . . 6-51 6-2.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 6-2.2 Turning Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

6-2.2.1 Preparation for Removal and Disassembly.. . . . . . . . . . . . . . 6-52 6-2.2.2 Removal of Turning Gear. . . . . . . . . . . . . . . . . . . . . . . . 6-52 6-2.2.3 Disassembly of Turning Gear. . . . . . . . . . . . . . . . . . . . . . 6-81

6-2.2.3.1 Removal of First Reduction Worm (Turning Gear Removal Not Required). . . . . . . . . . . . . . . 6-81

6-2.2.3.2 Removal of First Reduction Worm Gear (Turning Gear Removal Not Required). . . . . . . . . . . . 6-81

6-2.2.3.3 Removal of Second Reduction Worm (Turning Gear Removal Not Required). . . . . . . . . . . . . . . 6-81

6-2.2.3.4 Removal of Second Reduction Worm Gear. . . . . . . 6-82 6-2.2.4 Internal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82

6-2.2.4.1 First Reduction Mesh. . . . . . . . . . . . . . . . . . . 6-82 6-2.2.4.2 Second Reduction Mesh (Removal and Disassembly of the Turning Gear Required). . . . . . . . . . . . 6-83 6-2.2.4.3 Adjustment of Bearing. . . . . . . . . . . . . . . . . . 6-84

6-2.2.5 Disassembly of Engaging and Signal Device. . . . . . . . . . . . . 6-85 6-2.2.6 Replacement of Limit Switch.. . . . . . . . . . . . . . . . . . . . . 6-85

6.2.2.7 Repair of Shaft Lock End Plate Assembly.. . . . . . . . . . . . . . 6-85 6-2.2.8 Assembly of Turning Gear. . . . . . . . . . . . . . . . . . . . . . . 6-85

6-2.3 Turning Gear Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 6-2.3.1 Preparation For Removal. . . . . . . . . . . . . . . . . . . . . . . . 6-86 vii

6-2.3.2 Removal of Turning Gear Motor. . . . . . . . . . . . . . . . . . . . 6-87 6-2.3.3 Disassembly of Turning Gear Motor. . . . . . . . . . . . . . . . . . 6-88 6-2.3.4 Replacement of Turning Gear Motor Bearing. . . . . . . . . . . . . 6-88 6-2.3.5 Assembly of Turning Gear Motor. . . . . . . . . . . . . . . . . . . 6-93 6-2.3.6 Installation of Turning Gear Motor. . . . . . . . . . . . . . . . . . . 6-93

6-2.4 Lubricating Oil and Hydraulic Pump Drives. . . . . . . . . . . . . . . . . . . 6-94 6-2.4.1 Removal and Disassembly of Pump Drives. . . . . . . . . . . . . . 6-94

6-2.4.1.1 Preparation for Removal of Pump Drives.. . . . . . . 6-94 6-2.4.1.2 Removal of Pump Drive. . . . . . . . . . . . . . . . . 6-95 6-2.4.1.3 Disassembly of Pump Drive. . . . . . . . . . . . . . . 6-99 6-2.4.1.4 Removal of Gear Train. . . . . . . . . . . . . . . . . . 6-100

6-2.4.2 Replacement of Bearing and Rotor. . . . . . . . . . . . . . . . . . . 6-100 6-2.4.3 Internal Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100 6-2.4.4 Assembly of Pump Drive. . . . . . . . . . . . . . . . . . . . . . . . 6-100 6-2.4.5 Replacement of Oil Seal (Continuous Spring Design Installed by

ECP 241-01-C035 or C049). . . . . . . . . . . . . . . . . . . . . 6-101 6-2.4.6 Replacement of Oil Seal (Split Seal Design Installed by ECP

241-01-C038, C044, or SCD-70030 (MA-612). . . . . . . . . . 6-101 6-2.5 Revolution Counter Transmitter Drive. . . . . . . . . . . . . . . . . . . . . . . 6-103

6-2.5.1 Removal of Revolution Counter Transmitter Drive. . . . . . . . . . 6-103 6-2.5.2 Disassembly of Revolution Counter Transmitter Drive. . . . . . . . 6-103 6-2.5.3 Assembly and Installation of Revolution Counter Transmitter

Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103 6-2.5.4 Coupling Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104

6-2.6 Revolution Counter Transmitter.. . . . . . . . . . . . . . . . . . . . . . . . . . 6-104 6-2.6.1 Disassembly of Revolution Counter Transmitter. . . . . . . . . . . 6-104 6-2.6.2 Repair of Revolution Counter Transmitter. . . . . . . . . . . . . . . 6-104

6-2.6.2.1 Replacement of Worm Shaft Assembly. . . . . . . . . 6-104 6-2.6.2.2 Replacement of Counter Components. . . . . . . . . . 6-105 6-2.6.2.3 Replacement of Flanged Mount Assembly. . . . . . . 6-111

6-2.6.3 Assembly of Revolution Counter Transmitter. . . . . . . . . . . . . 6-111 6-2.7 Lubricating Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112

6-2.7.1 Removal of Lubricating Oil Pump. . . . . . . . . . . . . . . . . . . 6-112 6-2.7.2 Disassembly of Lubricating Oil Pump. . . . . . . . . . . . . . . . . 6-113 6-2.7.3 Inspection of Lubricating Oil Pump. . . . . . . . . . . . . . . . . . 6-118 6-2.7.4 Cleaning and Lubrication of Lubricating Oil Pump.. . . . . . . . . 6-118 6-2.7.5 Assembly of Lubricating Oil Pump. . . . . . . . . . . . . . . . . . 6-118 6-2.7.6 Installation of Lubricating Oil Pump.. . . . . . . . . . . . . . . . . 6-120 6-2.7.7 Alignment of Lubricating Oil Pump. . . . . . . . . . . . . . . . . . 6-120 6-2.7.8 Venting Lubricating Oil Pump. . . . . . . . . . . . . . . . . . . . . 6-120 6-2.7.9 Start-Up of Lubricating Oil Pump. . . . . . . . . . . . . . . . . . . 6-121

6-2.8 Dehumidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121 6-2.8.1 Disassembly of Dehumidifier. . . . . . . . . . . . . . . . . . . . . . 6-121 6-2.8.2 Assembly of Dehumidifier. . . . . . . . . . . . . . . . . . . . . . . 6-124

6-2.8.2.1 Post Assembly Inspection of Dehumidifier. . . . . . . 6-124 6-2.8.3 Removal of Dehumidifier. . . . . . . . . . . . . . . . . . . . . . . . 6-124 viii

6-2.8.4 Installation of Dehumidifier. . . . . . . . . . . . . . . . . . . . . . . 6-125 6-2.9 Sight Flow Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125

6-2.9.1 Removal of Sight Flow Indicators. . . . . . . . . . . . . . . . . . . 6-125 6-2.9.2 Disassembly of Sight Flow Indicators. . . . . . . . . . . . . . . . . 6-125 6-2.9.3 Assembly of Sight Flow Indicators. . . . . . . . . . . . . . . . . . 6-125

6-2.10 Turbine Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126 6-2.10.1 Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126

6-2.10.1.1 Disassembly of Solenoid Valve. . . . . . . . . . . . . 6-126 6-2.10.1.2 Cleaning of Solenoid Valve. . . . . . . . . . . . . . . 6-131 6-2.10.1.3 Inspection of Solenoid Valve.. . . . . . . . . . . . . . 6-131 6-2.10.1.4 Assembly of Solenoid Valve. . . . . . . . . . . . . . . 6-131

6-2.10.2 Pressure Regulating Valve. . . . . . . . . . . . . . . . . . . . . . . 6-132 6-2.10.2.1 Disassembly of Pressure Regulating Valve. . . . . . . 6-132 6-2.10.2.2 Cleaning Pressure Regulating Valve. . . . . . . . . . . 6-134 6-2.10.2.3 Inspection of Pressure Regulating Valve. . . . . . . . 6-134 6-2.10.2.4 Assembly of Pressure Regulating Valve.. . . . . . . . 6-134

6-2.10.3 Air/Oil Booster.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134 6-2.10.3.1 Removal of Air/Oil Booster. . . . . . . . . . . . . . . 6-134 6-2.10.3.2 Disassembly of Air/Oil Booster. . . . . . . . . . . . . 6-134 6-2.10.3.3 Inspection of Air/Oil Booster. . . . . . . . . . . . . . 6-135 6-2.10.3.4 Assembly of Air/Oil Booster. . . . . . . . . . . . . . . 6-135 6-2.10.3.5 Installation of Air/Oil Booster. . . . . . . . . . . . . . 6-135

6-2.10.4 Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135 6-2.10.5 Brake Caliper Assembly.. . . . . . . . . . . . . . . . . . . . . . . . 6-135

6-2.10.5.1 Removal of Brake Housing and Caliper Assemblies. . 6-139 6-2.10.5.2 Removal of Caliper Assemblies. . . . . . . . . . . . . 6-139 6-2.10.5.3 Disassembly of Brake Caliper. . . . . . . . . . . . . . 6-139 6-2.10.5.4 Cleaning of Brake Housing Assembly.. . . . . . . . . 6-140 6-2.10.5.5 Inspection and Repair of Turbine Brake Caliper. . . . 6-140 6-2.10.5.6 Assembly of Turbine Brake Caliper. . . . . . . . . . . 6-141 6-2.10.5.7 Installation of Caliper Assemblies. . . . . . . . . . . . 6-147 6-2.10.5.8 Installation of Brake Housing and Caliper

Assemblies. . . . . . . . . . . . . . . . . . . . . . . 6-147 6-2.10.6 Inspection and Repair of Brake Disc.. . . . . . . . . . . . . . . . . 6-147 6-2.10.7 System Charging.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-148 6-2.10.8 System Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149

6-2.11 Seals and Deflectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149 6-2.11.1 Input Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149

6-2.11.1.1 Removal of Input Shaft Seal. . . . . . . . . . . . . . . 6-149 6-2.11.1.2 Inspection of Input Shaft Seal. . . . . . . . . . . . . . 6-152 6-2.11.1.3 Assembly of Input Shaft Seal. . . . . . . . . . . . . . 6-155

6-2.11.2 Clutch Oil Rotary Seal. . . . . . . . . . . . . . . . . . . . . . . . . 6-159 6-2.11.3 Replacement of Low Speed Shaft Oil Deflector.. . . . . . . . . . . 6-160

6-2.12 Gear Case Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-167 6-2.12.1 Removal of Gear Case Cover.. . . . . . . . . . . . . . . . . . . . . 6-167 6-2.12.2 Replacement of Gear Case Cover. . . . . . . . . . . . . . . . . . . 6-168 ix

6-2.12.2A Clutch Lockout Cover Status Indicator Switch Assembly. . . . . . 6-168 6-2.12.3 Inspection and Replacement of Acoustic Tile. . . . . . . . . . . . . 6-168

6-2.12.3.1 Acoustic Tile Surface Damage.. . . . . . . . . . . . . 6-168 6-2.12.3.2 Acoustic Tile Application. . . . . . . . . . . . . . . . 6-173

6-2.13 Journal Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-174 6-2.13.1 High Speed and Intermediate Speed Rotor Bearings. . . . . . . . . 6-174

6-2.13.1.1 Removal of HS Input Shaft and Pinion Bearing. . . . 6-174 6-2.13.1.2 Removal of Upper Intermediate Speed Rotor

Bearing. . . . . . . . . . . . . . . . . . . . . . . . . 6-228 6-2.13.1.3 Removal of Lower Intermediate Speed Rotor

Bearing. . . . . . . . . . . . . . . . . . . . . . . . . 6-229 6-2.13.1.4 Installation of HS and Intermediate Speed Rotor

Bearing. . . . . . . . . . . . . . . . . . . . . . . . . 6-230 6-2.13.2 Low Speed Gear Bearings. . . . . . . . . . . . . . . . . . . . . . . 6-231

6-2.13.2.1 Removal of LS Gear Bearing. . . . . . . . . . . . . . 6-231 6-2.13.2.2 Installation of LS Gear Bearing. . . . . . . . . . . . . 6-232

6-2.13.3 Inspection of Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . 6-234 6-2.13.4 Replacement of Bearing.. . . . . . . . . . . . . . . . . . . . . . . . 6-236

6-2.14 Positioning Thrust Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-237 6-2.14.1 Adjustment of Positioning Thrust Bearing.. . . . . . . . . . . . . . 6-237 6-2.14.2 Inspection of Positioning Thrust Bearing Components. . . . . . . . 6-241 6-2.14.3 Replacement of Thrust Shoes. . . . . . . . . . . . . . . . . . . . . . 6-241 6-2.14.4 Refit Filler Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-242

6-2.15 Replacement of Bearing RTD.. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-244 6-2.16 Rotating Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-244

6-2.16.1 High Speed Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6-244 6-2.16.1.1 Removal of High Speed Assembly. . . . . . . . . . . 6-244 6-2.16.1.2 Removal of Auxiliary Drives. . . . . . . . . . . . . . 6-244 6-2.16.1.3 Turbine Clutch Status Switch. . . . . . . . . . . . . . 6-247 6-2.16.1.4 Removal of Turbine Clutch. . . . . . . . . . . . . . . 6-252 6-2.16.1.5 Installation of Turbine Clutch. . . . . . . . . . . . . . 6-255 6-2.16.1.6 Removal of HS Pinion. . . . . . . . . . . . . . . . . . 6-258 6-2.16.1.7 Installation of HS Pinion. . . . . . . . . . . . . . . . . 6-259 6-2.16.1.8 Removal of Input Shaft.. . . . . . . . . . . . . . . . . 6-263 6-2.16.1.9 Removal of Brake Disc.. . . . . . . . . . . . . . . . . 6-263 6-2.16.1.10 Installation of Input Shaft. . . . . . . . . . . . . . . . 6-263 6-2.16.1.11 Input Shaft Positioning for Coupling Power

Turbine. . . . . . . . . . . . . . . . . . . . . . . . . 6-263 6-2.16.2 Intermediate Speed Assemblies. . . . . . . . . . . . . . . . . . . . . 6-265

6-2.16.2.1 Removal of Intermediate Speed Assemblies. . . . . . 6-265 6-2.16.2.2 Removal of Upper Intermediate Speed Assembly. . . 6-265

6.2.16.2.3. Removal of Lower Intermediate Speed Assembly. . . 6-265 6-2.16.2.4 Installation of Intermediate Speed Rotor. . . . . . . . 6-266 6-2.16.2.5 Adjusting the Intermediate Speed Rotor Length and the Axial Backlash. . . . . . . . . . . . . . . . . . 6-266 x

6-2.16.2.6 Gear Rotor Positioning for Thrust Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . 6-268

6-2.16.3 Intermediate Flexible Couplings. . . . . . . . . . . . . . . . . . . . 6-269 6-2.16.3.1 Removal of Intermediate Speed Assembly. . . . . . . 6-269 6-2.16.3.2 Disassembly of Flexible Coupling. . . . . . . . . . . . 6-269 6-2.16.3.3 Inspection of Flexible Coupling. . . . . . . . . . . . . 6-271 6-2.16.3.4 Replacement of Flexible Coupling. . . . . . . . . . . 6-271 6-2.16.3.5 Assembly of Flexible Coupling. . . . . . . . . . . . . 6-273 6-2.16.3.6 Gear Rotor Axial Positioning for Diaphragm

Coupling Replacement.. . . . . . . . . . . . . . . . 6-274 6-2.16.4 Low Speed Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-275

6-2.16.4.1 Removal of Low Speed Gear. . . . . . . . . . . . . . 6-275 6-2.16.4.2 Installation of Low Speed Gear. . . . . . . . . . . . . 6-276 6-2.16.4.3 Low Speed Gear Axial Positioning. . . . . . . . . . . 6-276

6-2.17 Acceptable Bolt Torque Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . 6-276

6-3. SECURITY LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-278

7 PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2. USE OF PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-2.1 Figure and Index Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-2.2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-2.3 Quantity.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-2.4 Commercial and Government Entity (CAGE) Code. . . . . . . . . . . . . . . 7-1 7-2.5 Manufacturer’s Part Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3. LIST OF MAJOR COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-4. PARTS LISTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

SECTION I REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1.1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1.2. PACKAGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1.3. SHIPPING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1.4. INSTALLATION MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1.5. SUPPORT SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SECTION II PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 xi

8-2.1. POST RECEIPT SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8-2.1.1 Unloading The Reduction Gear Shipset. . . . . . . . . . . . . . . . . . . . . 8-5 8-2.1.2 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-2.1.2.1 Receipt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8-2.1.2.1.1 Shipment Accountability. . . . . . . . . . . . 8-6 8-2.1.2.1.2 Damage Report. . . . . . . . . . . . . . . . . 8-6 8-2.1.2.1.3 Storage Instructions.. . . . . . . . . . . . . . 8-7 8-2.1.2.1.4 Storage Monitoring. . . . . . . . . . . . . . . 8-9 8-2.1.2.1.5 End of Storage Period. . . . . . . . . . . . . 8-10 8-2.1.2.1.6 Installation Period Instructions.. . . . . . . . 8-11 8-2.1.2.1.7 Rotation of Gearing During Storage. . . . . 8-11

8-2.1.2.2 Removal of Shipping Locks. . . . . . . . . . . . . . . . . . . 8-12 8-2.1.3 Initial Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8-2.1.3.1 Dehumidifier Temporary Installation. . . . . . . . . . . . . . . 8-16 8-2.1.3.2 Sight Flow Indicator Assembly. . . . . . . . . . . . . . . . . . 8-16 8-2.1.3.3 Lubricating Oil Pressure Gage Assembly. . . . . . . . . . . . 8-17 8-2.1.3.4 Hydraulic Pump Coupling and Guard Assembly. . . . . . . . 8-17

8-2.1.4 Dehumidifier Initial Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 8-2.1.4.1 Current Phasing Test. . . . . . . . . . . . . . . . . . . . . . . 8-17 8-2.1.4.2 Checking Airflow. . . . . . . . . . . . . . . . . . . . . . . . . 8-17

8-2.1.5 Brake System Initial Servicing.. . . . . . . . . . . . . . . . . . . . . . . . . 8-18 8-2.1.6 Lube Oil Pump Initial Servicing.. . . . . . . . . . . . . . . . . . . . . . . . 8-18 8-2.1.7 Repacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8-2.2. ASSEMBLY OF REDUCTION GEAR ONTO SUBBASE IN ASSEMBLY

BUILDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

8-2.2.1 Subbase Fabrication and Machining. . . . . . . . . . . . . . . . . . . . . . . 8-19 8-2.2.1.1 Second Reduction Gear Flange to Lineshaft Assembly.. . . . 8-19

8-3.2 Vertical Isolator Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 8-2.2.3 Preparation For Shipboard Installation. . . . . . . . . . . . . . . . . . . . . 8-47

8-2.3. MISCELLANEOUS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

8-2.4. RIGGING AND HOISTING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . 8-47

8-2.5. WATERBORNE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47 8-2.5.1 Propulsion Shaft Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48 8-2.5.2 Horizontal Isolator Installation.. . . . . . . . . . . . . . . . . . . . . . . . . 8-51 8-2.5.3 Horizontal Isolator Thermal Preset. . . . . . . . . . . . . . . . . . . . . . . 8-51 8-2.5.4 Vertical Isolator Thermal Presets. . . . . . . . . . . . . . . . . . . . . . . . 8-52 8-2.5.5 Setting Low Speed Gear Axial Position.. . . . . . . . . . . . . . . . . . . . 8-52 8-2.5.6 Verify Propulsion Shaft Alignment. . . . . . . . . . . . . . . . . . . . . . . 8-54 8-2.5.7 Final Isolator Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54 8-2.5.8 Casing Snubber Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61

8-2.5.8.1 Striker Plates.. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61 8-2.5.8.2 Round Snubbers. . . . . . . . . . . . . . . . . . . . . . . . . . 8-61 8-2.5.8.3 Rectangular Snubbers. . . . . . . . . . . . . . . . . . . . . . . 8-63 xii

8-2.5.8.4 Square Snubbers. . . . . . . . . . . . . . . . . . . . . . . . . . 8-65 8-6.9 Final Foundation Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67 8-2.5.10 18-Month Maintenance Check. . . . . . . . . . . . . . . . . . . . . . . . . . 8-68

8-2.6. PIPING AND MECHANICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . 8-69 8-2.6.1 Security Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75

8-2.7. ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91

8-2.8. RECOMMENDED PRESERVATIVE REMOVAL PROCEDURES. . . . . . . . . . . 8-91

8-2.8.1 Exposed Surface Cleaning Procedures. . . . . . . . . . . . . . . . . . . . . 8-91 8-2.8.2 Oil Flushing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92

SECTION III CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-109

8-3.1. PRESTART INSPECTIONS AND PROCEDURES. . . . . . . . . . . . . . . . . . . . 8-109

8-3.2. INITIAL START AND PRELIMINARY TESTS. . . . . . . . . . . . . . . . . . . . . . 8-109

8-3.3. INSTALLATION VERIFICATION TEST.. . . . . . . . . . . . . . . . . . . . . . . . . 8-110 xiii

LIST OF TABLES

Table Title Page

1-1. Reference Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-2. Gear Data, Full Power Mode (Two Turbines) (Units in Inches Except as Noted) . . . 1-17

1-3. Gear Data, Cruise Mode (Single Turbine) (Units in Inches Except as Noted) . . . . . 1-18

1-4. Bearing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

1-5. Torsional Vibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

1-6. Auxiliary Drive Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1-7. Gear Material List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1-8. List of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

1-9. Alterations Approved for the Main Propulsion Reduction Gear . . . . . . . . . . . . . 1-90

2-1. Reduction Gear Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2. Reduction Gear Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

3-1. List of Rotating Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-2. Intermediate Speed Assembly Drive Functions . . . . . . . . . . . . . . . . . . . . . . 3-25

3-3. Bearing Applications and Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-4. Dehumidifier Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

3-5. Dehumidifier Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

4-1. Maintenance Plan Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2. Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5-1. Reduction Gear Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2. Babbitted Journal Bearing Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3. Turning Gear Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-4. Revolution Counter Transmitter Drive and Tachometer Signal Generator Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-5. Lubricating Oil and Hydraulic Pump Drive Assemblies Troubleshooting . . . . . . . . 5-7

5-6. Revolution Counter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-7. Turbine Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-8. Air/Oil Booster Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 xiv

LIST OF TABLES - Continued

5-9. Pressure Regulator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-10. Actuating Valve Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-11. Flexible Coupling Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-12. Thrust Bearing Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-13. Lubricating Oil Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-14. Turbine Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-15. Dehumidifier Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

6-1. Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2. Equipment Not Provided with Gear Sets . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-3. Adjustment and Alignment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-4. Pressure Switch Set Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-5. Dykem Kit Material List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6-6. Coarse Corrections for Initial Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

6-7. Fine Corrections for Measured Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

6-8. Torque Split vs Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

6-9. Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

6-10. Turning Gear Bearing Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84

6-11. Lubricating Oil Pump Diametrical Clearances . . . . . . . . . . . . . . . . . . . . . . 6-118

6-12. Surface Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-173

6-13. Free Spread Bearing Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236

6-14. Special Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-276

6-15. Lubricating Oil and CPP Hydraulic Pump Coupling Torque Table . . . . . . . . . . . 6-277

6-16. Miscellaneous Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-278

6-17. MRG Bearing Alarm Set Point Data Table - Port. . . . . . . . . . . . . . . . . . . . . 6-281

6-18 MRG Bearing Alarm Set Point Data Table - Starboard. . . . . . . . . . . . . . . . . . 6-283

7-1. List of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 xv

7-2. Reduction Gear Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-3. Inspection Cover Assembly (Port) Parts List . . . . . . . . . . . . . . . . . . . . . . . 7-29

7-3A. Inspection Cover Assembly (Starboard) Parts List . . . . . . . . . . . . . . . . . . . . 7-29

7-4. Extension Shaft and First Reduction Pinion Assembly Parts List . . . . . . . . . . . . 7-35

7-5. First Reduction Pinion Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-39

7-6. Clutch Position Indicator Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

7-7. First Reduction Gear and Second Reduction Pinion Parts List . . . . . . . . . . . . . 7-45

7-8. Intermediate Flexible Coupling Assembly Parts List . . . . . . . . . . . . . . . . . . . 7-51

7-9. Geared Intermediate Flexible Coupling Assembly Parts List. . . . . . . . . . . . . . . 7-53

7-10. Second Reduction Gear Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . 7-54

7-11. Pressure Groove Bearing 8.50 x 4.00 Extension Shaft Parts List . . . . . . . . . . . . 7-57

7-12. Elliptical Bearing 10.00 x 5.50 First Reduction Pinion Parts List . . . . . . . . . . . . 7-61

7-13. Elliptical Bearing 12.00 x 5.50 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-65

7-14. Elliptical Bearing 12.00 x 12.00 Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-69

7-15. Three-Lobe Bearing 24.00 x 20.00 Second Reduction Gear Parts List . . . . . . . . . 7-73

7-16. Positioning Thrust Bearing Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77

7-17. Turbine Brake Assembly Parts List (Original Equipment) . . . . . . . . . . . . . . . . 7-81

7-17A. Retrofit Turbine Brake Assembly Parts List (With MACHALT 241-69001 (ECP-500) Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91

7-18. Brake Caliper Assembly Parts List (Original Equipment) . . . . . . . . . . . . . . . . 7-92

7-18A. Retrofit Brake Caliper Assembly Parts List (With MACHALT 241-69001 (ECP-500) Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97

7-19. Brake Control Assembly and Oil Seal Drain Parts List . . . . . . . . . . . . . . . . . 7-97

7-20. Cover Assemblies Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101

7-21. Gage and Valve Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103

7-22. Test Gage Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105

7-23. Air/Oil Booster Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106

7-24. Pressure Reducing Valve Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . 7-109 xvi

7-25. Solenoid Valve Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-111

7-26. Turning Gear Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115

7-27. Engaging and Signal Device Assembly Parts List . . . . . . . . . . . . . . . . . . . . 7-126

7-28. Turning Gear Motor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-128

7-29. Hydraulic Pump Drive Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-133

7-30. Lubricating Oil and Hydraulic Pump Drive Coupling Assemblies Parts List . . . . . . 7-135

7-31. Lubricating Oil and Hydraulic Pump Drive Assemblies Parts List . . . . . . . . . . . 7-139

7-32. Lubricating Oil Pump Attaching Hardware Parts List . . . . . . . . . . . . . . . . . . 7-143

7-33. Revolution Counter Transmitter Drive Assembly Parts List . . . . . . . . . . . . . . . 7-145

7-34. Revolution Counter Transmitter Assembly Parts List . . . . . . . . . . . . . . . . . . . 7-149

7-35. Lubricating Oil Pump Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-155

7-36. Lubricating Oil Pump Mechanical Seal Parts List . . . . . . . . . . . . . . . . . . . . 7-157

7-37. Lubricating Oil Piping Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-158

7-37A. Lubricating Oil Piping Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-171

7-38. Piping Gage Assembly Parts List. . . . .