REPLACEMENT OF ANTENNA LIFT WINCHES

Note:

For optimal operation of the system it is highly suggested to replace both antenna lift winches and wire ropes at the same time. By accomplishing this it will allow better operation for lifting the antenna.

PROCEDURE SUMMARY

1. Procedures for removing the inner and middle sections of the ladders from the antenna enclosure need to be accomplished prior to antenna lift winch replacement.

2. Procedures for removing the antenna roof panels needs to be accomplished prior to antenna lift winch replacement.

3. Procedures for raising the antenna needs to be accomplished prior to antenna winch replacement.

4. Procedures for installing the antenna safety props needs to be accomplished prior to antenna winch replacement.

5. Remove old wire cable from antenna winches.6. Remove old antenna winch replacement. Install new antenna winch.7. Install new wire cable.

SAFETY SUMMARY

WARNING:

FAILURE TO FOLLOW PROPER INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH AND EQUIPMENT DAMAGE.

WARNING:

WHEN THE ANTENNA AND LIFTING FRAMES ARE IN THE RAISED POSITION, DO NOT ENTER THE AREA BELOW UNLESS THE WIEGHT OF THE INSTALLATION IS SUPPORTED BY CORRECTLY INSTALLED SAFETY PROPS.

WARNING:

OPERATION OF THE ANTENNA LIFT SHOULD ONLY BE CARRIED OUT BY QUALIFIED PERSONNEL.

WARNING:

EACH ROOF PANESL WEIGHS 124LBS EACH. PROPER LFITING TECHNICQUES MUST BE OSBERVED OR PERSONAL INJURY MAY RESULT.

WARNING:

WHEN THE ANTENNA AND LIFTING FRAMES ARE IN THE RAISED POSITION, DO NOT ENTER THE AREA BELOW THE ANTENNA STRUCTURE UNLESS IT IS SUPPORTED BY PROPERLY INSTALLED SAFETY PROPS.

WARNING:

DO NOT ATTEMPT TO DISENGAGE THE CENTER FRAME LOCKING PINS IF THERE IS SLACK IN ANY OF THE WIRE ROPE RUNS.

WARNING:

IF THE UPPER FRAME WIRE ROPE HAS SLACK, UNDER NO CIRCUMSTANCES HSOULD THE UPPER FRAME LOCKS BE DISENGAGED. WIND THE WINCH CLOKCWISE TO RE-TENSION THE WIRE ROPES.

WARNING:

USE LADDERS WHEN PERFORMING WORK ON THE ANTENNA STRUCTURE. DO NOT CLIMB ON THE FRAME AT ANY TIME.

WARNING:

WHEN RAISING THE ANTENNA KEEP ALL PARTS OF THE BODY CLEAR OF THE LFITING FRAMES. MOVING PARTS POSE A CRUSH HAZARD THAT MAY RESULT IN PERSONAL INJURY.

WARNING:

VERIFY THE LOCKING PINS ARE FULLY ENGAGED PRIOR TO INSTALLING ANTENNA SAFETY PROPS WITHIN THE ANTENNA ENCLOSURE AREA. FAILURE TO OBSERVE THIS PROCEDURE MAY RESULT IN SERVERE PERSONAL INJURY OR DEATH.

CAUTION:

OPERATION OF THE LIFTING MECHANSIM IS A TWO-PERSON OPERATION. BOTH WINCHES MUST BE OPERATED IN UNISON TO PREVENT BINDING THAT MAY RESULT IN EQUIPMENT DAMAGE.

1. Remove the inner and middle sections of the ladders from the antenna enclosure. See TO 31R4-2TRN48-21, Section 2, Chapter 1, Page 34 (pg. 74).

2. Remove the antenna roof panels prior to antenna lifting procedures. See TO 31R4-2TRN48-21, Section 2, Chapter 1, Page 36 (pg. 76).

WARNING:EACH ROOF PANELS WEIGHS 124LBS EACH. PROPER LIFTING TECHNIQUES MUST BE OBSERVED OR PERSONAL INJURY MAY RESULT.

3. Raise the antenna using the procedures stated in TO 31R4-2TRN48-21, Section 2, Chapter 1, Page 37 thru Page 43 (pg. 77-83).

WARNING:

WHEN THE ANTENNA AND LIFTING FRAMES ARE IN THE RAISED POSITION, DO NOT ENTER THE AREA BELOW THE ANTENNA STRUCRE UNLESS IT IS SUPPORTED BY PROPERLY INSTALLED SAFETY PROPS.

WARNING: USE LADDERS WHEN PERFORMING WORK ON THE ANTENNA STRUCTURE. DO NOT CLIMB ON THE FRAME AT ANY TIME.

WARNING:WHEN RAISING THE ANTENNA KEEP ALL PARTS OF THE BODY CLEAR OF THE LIFTING FRAMES. MOVING PARTS POSE A CRUST HASZARD THAT MAY RESULT IN PERSONAL INJURY.

CAUTION:OPERATION OF THE LIFTING MECHANISM IS A TWO-PERSON OPERATION. BOTH WINCHES MUST BE OPEARTED IN UNISON TO PREVENT BINDING THAT MAY RESULT IN EQUIPMENT DAMAGE.

Note:Check all locking pins (inner/outer) are disengaged prior to lifting the antenna.

Note:Pay attention to the antenna lift mechanism rollers while raising/lowering the antenna. Ensure that they are moving smoothing up/down and touching the track during operations.

Note:Pay attention to the changes in the antenna winch pressure while raising/lowering the antenna lift. If the antenna lift becomes increasing difficult to lift, stop winding and check the position of the antenna lift. When this happens winding is not occurring in unison.

4. Antenna must be raised to SECOND line height marker in order to place the antenna safety props.

WARNING:VERIFY THE LOCKING PINS ARE FULLY ENGAGED PRIOR TO INSTALLING ANTENNA SAFETY PROPS WITHIN THE ANTENNA ENCLOSURE AREA. FAILURE TO OBSERVE THIS PROCEDURE MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH.

a. Install antenna safety props prior to antenna lift winch replacement. TO 31R4-2TRN48-21, Section 5, Chapter 4, Page 2 (pg. 383).

b. Install antenna safety props on opposite corners of antenna cage. Ensure the base plate of the antenna safety prop is facing towards the corner.

c. Release locking pins (inner/outer) and lower antenna onto the support beams. Ensure wire rope has slack and the antenna frame is resting on the antenna props.

5. Removing Wire Cables from Antenna Winch.

WARNING:

ALWAYS USE LEATHER GLOVES WHILE HANDLING THE WIRE CABLE TO PREVENT HAND INJURY FROM FRAYED WIRES.

WARNING:

USE LADDERS WHEN PERFORMING WORK ON THE ANTENNA STRUCTURE. DO NOT CLIMB ON THE FRAME.

WARNING:

HOLD ON TO WIRE ROPE TO MAINTAIN TENSIONS AT ALL TIMES WHEN UNCOILING. THIS WILL PREVENT WIRE ROPE FROM SNAPPING BACK AND CAUSING PERSONAL HARM.

a. Using a 3mm hex-wrench, unfasten the hex-head screws securing the cover for the antenna winch assembly (nine driver side, seven passenger side). (See figure 5-1 for passenger and driver antenna winch assembly locations).

b. Use a 19mm wrench to remove the bolts from the antenna frame bracket. Hold tension on the wire rope while uncoiling the cable through the antenna lift pulley system.

c. Loosen the two 4mm screws on the antenna lift winch assembly. Continue to pull wire cable through antenna lift winch wheel until wire cable is removed.

Figure 5-1

6. Removing the antenna winch assembly.NOTE:

Prior to removing the antenna winch assembly the wire cable must be removed.

Passenger Side Driver Side

a. Remove the front snap ring using the 180 degree snap ring pliers (Figure 6-1).

Figure 6-1(F

b. Remove the back snap ring using the 180 degree snap ring pliers (Figure 6-2).

Figure 6-2c. Remove the retaining pin from the antenna winch input shaft and remove the two washers on

the front and back of the antenna winch (Figure 6-3).

Figure 6-3d. Remove the four 5mm hex screws on the antenna winch drive and remove the antenna winch

drive from the casing (Figure 6-4).

Figure 6-4e. Remove the antenna winch wheel from casing (Figure 6-5).

Figure 6-5f. Remove the four 17mm bolts that secure the antenna winch housing using a 17mm socket

wrench with a 10 inch extension (Figure 6-6).

Figure 6-6g. On the new antenna winch assembly accomplish steps a thru e and then secure the new

antenna winch housing using the four 17mm bolts and the 17mm socket wrench with a 10 inch extension.

Note:The retaining pin will only fit in one direction. The flat side of the pin is towards the front of the antenna winch wheel housing.

h. Ensure the antenna winch wheel is properly greased before installing inside housing. Place the antenna winch wheel back inside the antenna winch housing with the greased side towards the front of the housing and install the retaining pin (Figure 6-7).

Figure 6-7i. Install the back and front washer and then secure the back and front snap rings using the 180

degrees snap ring pliers (Figure 6-8).

Figure 6-8

Caution:

Do not over torque or use too much pressure while removing and replacing the antenna winch drum handle guide. There are two brake discs in the antenna winch gear. If the antenna winch gear is over tightened the brakes with not have room to expand while antenna is being raised and lowered and will cause damage to the antenna winch gear assembly.

7. Remove the antenna winch handle drum guide.a. Using a 17mm socket wrench remove the nut on the antenna winch handle drum guide

from the old antenna winch gear (Figure 7-1).

Figure 7-1b. Remove the antenna handle guide and repeat step 7a to remove the nut from the new

antenna winch gear (Figure 7-2).

Figure 7-2Note:

BACK FRONT

Over tighten the nut could cause damage to the antenna winch gear assembly.

c. Secure the antenna handle drum guide using the 17mm nut and washer. Hand-tighten the nut onto the handle drum guide (clockwise) and once tighten back off one-quarter turn (counter clockwise). There needs to be a gap between both brake disc and the gear.

Note:See Figure 7-3 for approximate spacing needed for the antenna winch gear brakes.

Figure 7-38. Using a 5mm Allen wrench reinstall the new antenna gear winch onto gear housing (Figure 8-1).

Figure 8-1

WARNING:

ALWAYS USE LEATHER GLOVES WHILE HANDLING THE WIRE CABLE TO PREVENT HAND INJURY FROM FRAYED WIRES.

WARNING:

USE LADDERS WHEN PERFORMING WORK ON THE ANTENNA STRUCTURE. DO NOT CLIMB ON THE FRAME.

WARNING:

HOLD ON TO WIRE ROPE TO MAINTAIN TENSIONS AT ALL TIMES WHEN UNCOILING. THIS WILL PREVENT WIRE ROPE FROM SNAPPING BACK AND CAUSING PERSONAL HARM.

9. Install the new wire cable.a. Thread the wire cable through both holes of the sub frame securing bracket (non-

threaded end first). Figure 9-1 shows direction of the wire cable through the pulley system.

Figure 9-1

b. Align the wire cable flush with the bottom of the hole (Figure 9-2).

Figure 9-1c. Using a 4mm Allen wrench secure the wire cable in place by tightening the two screws.d. Secure wire cable to shelter sub frame bracket to the upper hole of the frame. Place the

nut on threaded cable approximately 1.5 inches from the bottom of the frame. Then place the washer to the top of the bracket hole and then place the wire cable onto the top of the sub frame bracket.

e. Using a 19mm socket wrench secure the wire cable at the bottom of the sub frame bracket with a washer and nut. Ensure both nuts are tightened on both sides of the wire cable (Figure 9-2).

f. Attach winch handle to antenna winch.Note:

While winding the wire cable ensure that the wire cable is evenly distributed. The wire cable needs to lay side by side and not intertwined while winding. If the wire cable is not even distributed while winding this could cause binding of the wire cable make it hard to raise and lower the antenna.

g. Apply tension onto the wire cable and start slowly winding the cable around the wire drum. Ensure the wire cable is wound tightly against itself. Use a flat head screwdriver if needed to ensure it is winding correctly.

h. Turn antenna winch handle slowly clockwise while a second person keeps tension on the wire cable and guides the wire cable through the antenna lift system.

i. Continue to turn antenna winch handle slowly until there is slight tension on the line.j. Adjust using the adjustment/locking nut so that the left hand and right hand cables are

equal (Figure 9-3).

Figure 9-3Note:

There should be a minimum of a quarter inch of tread exposed between the end of the cable assembly threaded bar and the adjustment/locking nut.

k. Raise the antenna frame by six inches then lower. If binding takes place, then adjust using the adjustment/locking nut. Repeat until frame raises and lowers smoothly.

l. Lock cable assembly using the jam nut.

10. Replace the antenna winch assembly cover plates.a. Using a 3mm hex-wrench, fasten the hex-head screws securing the cover for the

antenna winch assembly (nine driver side, seven passenger side). (See figure 5-1 for passenger and driver antenna winch assembly locations).

Figure 5-1

11. Return system to normal configuration.

Passenger Side Driver Side