Wesmar Vortex Model V2-34 Thruster.pdf

Thrusters P/N V2-36

Installation & Maintenance Manual

V2-36

WESMAR

WESMAR

Bow Thruster

Installation & Maintenance Manual

May 2012

14120 NE 200th Street, Box 7201 Woodinville, WA 98072-4001 USA

T: (425) 481-2296 / F: (425) 486-0909 Email: cjones@wesmar.com Email: bsentz@wesmar.com

Web: www.wesmar.com

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Equipment Location

Bow Thruster Tunnel Location

1. Locate the tunnel as far forward in the bow and as close to the bottom of the keel as pos-sible for best thruster performance.

Note: Consult a Naval Architect for the best location.

2. Position the thruster tube at least the same distance below the waterline as the tube’s inside diameter.

3. Hull fairings may reduce the drag caused by the thruster while under way. Contact your boat yard or naval architect for assistance in placing an effective fairing.

4. If protective rods are installed they should be placed longitudinally. See page 12 for ex-amples.

5. The installation of the tunnel must be per-formed by a installer qualified to work on vessel’s hull material (fiberglass, aluminum, steel and wood).

Note: A thruster tunnel located too close to the waterline may cause air ingestion reducing thruster performance.

Thruster Location V2-36

1. Thruster must be mounted in the center of the tunnel. No part of the thruster is to be ex-posed outside of the tunnel.

2. The thruster can be mounted at any angle between horizontal and vertical. Any other mounting location voids all warranties.

3. Position thruster with the fill plug (located on the flange) on the upper side to avoid oil leak-age. Also, the oil reservoir should be located where it is convenient and accesible.

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Installation of the Thruster

When you receive your WESMAR thruster, please confirm the items you received matches the packing list. A standard system contains the following items.

• Combined steel tunnel ring and stainless steel thruster drive unit assembly.

• Steel bearing retaining collar.

• Stainless Kaplan style propellors (right & left) with two cotter pins.

• Castle propeller nuts and two keys.

• Four quarts of SAE 90 wt gear oil and two

1/4” NPT x 45 degree elbow fittings.

• Disassembled shaft centering jigs and four spacer blocks with nuts and bolts.

• Zincs and spar kit.

1. On the tunnel ring (Held to the V2-36 drive leg with 8 bolts), you will find the oil and air vent holes plugged. In the lube package, you will find the ¼” NPT x 45 ° pipe thread fit-tings to be fit after welding is complete. The NPT fittings must run 90 degrees away from the thruster shaft centerline axis.

2. The diameter of the supplied tunnel ring is 9.5”. Cut a 9.7” diameter hole in the thruster tube tube to fit the tunnel ring. Avoid gaps be-tween the thruster tunnel ring and the thruster tube. This will prevent misalignment and al-low for sufficient welding space.

3. WESMAR supplies a lifting eyebolt that will screw into the thruster input shaft. This will be used to help position the thruster for weld-ing and offer support means.

4. With props on, shim to center up the drive leg for welding by positioning the shaft in the centerline of the tunnel.

5. The top of the tunnel ring must be 0.08” above the existing tunnel, and 2.1” perpen-dicular to the tunnel length. There should be 7.35” for V2-24 and 8.35” for the V2-26 from the bottom of the thruster to the tunnel wall.

Use a jack on the bottom of the thruster to

Kaplan Propeller

Castle Nut and Cotter Pin

Bearing Collar

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easily raise and lower the system.

6. Tack–weld several spots on the outside tunnel ring to the inside of the tube.

7. Remove the bolts holding the drive leg to the tunnel ring (9/16” - 18 bolts, 4 of which will be in an enclosed bag. The remaining 4 will be holding the drive leg to the runnel ring). Slowly lower the thruster drive leg and remove it from the tunnel completely. This is to protect the oil seals, O-rings and snap rings from the heat generated by the welding.

8. Now weld the tunnel ring on the outside and inside of existing tube and let cool.

9. Prior to fitting the drive leg back in tunnel ring, fill drive with 4 quarts of 90 weight gear oil from the top of the input shaft through the upper bearing. Fill until full this will take some time.

10. Grease the O-rings on the drive leg and slide thruster back into the tunnel ring Check oil and air vent holes. Make sure that the bear-ing retaining collar is in place as you do this.

The thruster will not operate correctly if this collar is not installed.

11. Drop 2 of the 8 bolts through the tunnel ring to help align the thruster.

12. Insert the remaining bolts and tighten one at a time diagonally to 72-80 ft. lbs. torque.

13. Tape snap ring groove on input shaft (Wesmar recommends using clear tape). This will allow easy installing of the two oil seals, which must be placed back-to-back. Replace the steel/alu-minum seal retaining plate.

14. Put on the 2 props using the shaft keys and castle nuts. The prop can go on either side of the output shaft. Pin the castle nuts through the hole in the shafts.

Tunnel Ring Top Side

Tunnel Ring Bottom Side

Eye Bolt Lift

Tunnel Ring on Thruster

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15. Two support spars with zincs for the gear housing ears are included. Theses must be welded to the inside of the thruster tunnel.

Bolt the spars to the thruster ear using the supplied ½” x 13” bolts. Hand tighten the bolts.

Use a ½” center punch to mark out center holes on the support spars.

Remove the bolts and drill 17/31” holes in the support spar.

Reassemble and torque all the bolts to 72-80

ft. lbs. torque. Check the zinc bolts for tight-ness. Zinc size is 3” x 3” x ½”.

16. The thruster should be installed with the props. Turn the thruster output shafts by hand to ensure the props clear the tunnel. Minimum clearance between tunnel and thruster props is .25”.

17. Gear Oil Reservoir – WESMAR supplies a gear oil header tank. This allows air to circu-late out of the thruster while keepping pres-sure on the drive leg. This reservoir should be installed a minimum of four feet above the drive leg to maintain pressure.

After double-checking all welding, bolts are secured, props clear the tunnel, zincs are mounted and secured, and the thruster is now ready for operation.

V2-36 Assembly

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System Operation and Maintenance

Operation Time

WESMAR bow thrusters are hard working, powerful units. There are two types of duties for these thrusters, intermittent and continuous. The WESMAR V2-24/26 thruster is designed for intermittent and continuous duties. The system cannot operate for more than ten minutes at peak power or eight hours at 68% power, the continuous rating, within a 24 hr period.

Cautions:

• Do not reverse the rotation of the shaft at full RPM. Reduce speed before reversing the direction of the thruster. Failure to do so may significantly reduce the thruster’s operational life.

• Gear oil temperature should not exceed 150 degrees fahrenheit.

Maintenance

WESMAR thrusters are low maintenance sys-tems that require infrequent, routine servicing. When looking over your thruster, check the following.

• Examine the oil level in the gear oil reservoir.

• Maintain a fluid level in the oil reservoir of half to three quarters full. Any drop below this could indicate a leak in the system that must be repaired immediately. Check the fol-lowing components:

1. The gear fill hole located by the flange for a leak

2. The oil seal at input and output shaft, especially at the input shaft.

3. The propeller nut on the end of the pro-peller shaft for electrolysis corrosion. Do

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this every time the vessel is hauled out.

Nut should be secured to output shaft with cotter pin.

4. Check propellers for damage. If damage is present, props can be removed without hauling the vessel out of the water. Please consult a commercial diver for this kind of work.

Specifications

Input Spped 2600 RPM Gear Ratio 3:1

Blades per Prop 4 Output Spped 867 RPM

The WESMAR V2-36 thruster has a 3:1 gear reduction ratio with a 250 –350 horsepower @ 2600 RPM input outside of the steel tube. This unique de-sign allows easy installation and repair. Our engineers designed the system to meet the requirements of ABS for thrusters and dynamic positioning systems. Our parts were selected from well-known manufacturers maximizing our bow thruster performance and dura-bility while reducing the total cost for WESMAR and our customers.

The following are the specifications of each component that follow the ABS guide for thrusters and dynamic position systems.

1. The spiral bevel gears, made by Arrow Gear Company, are 8620 alloy steel with carbu-rized and hardened teeth which are lapped to AGMA quality number 9. This set of gears is strongly recommended by the manufacture as it is designed for heavy-duty usage. WES- MAR engineers designed the gear set based on bevel rating per AGMA 2003-A86 which gave service factors for bending and pitting 5% above the 2.35 required by ABS.

2. Timken tapered roller bearings are calculated based on 9000 hrs. of heavy duty service.

3. The material of the input and output shafts is 17-4 PH stainless steel.

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4. Right and left 4-blade Kaplan propellers are chosen because they have high strength, ex-cellent resistance to bending and flexing, and are ideal for installations involving high rpm or power.

Replacement Parts List

P/N 61.09018.0 Brass prop nut (2 ea.per unit) P/N 94.50006.0 Cotter pin (2 ea.per unit) P/N 95.02684.0 Bearing cup P/N 95.02685.0 Bearing cone P/N 95.00054.0 Oil seal P/N 83.02362.0 O-ring 2-362 P/N 83.02269.0 O-ring 2-269

For parts not listed please consult with WES- MAR for recommendations.

Tunnel Specifications

V2-36 Steel:

38”OD x 37” ID or 96.52 cm OD x 93.98 cm ID

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LUBRICATORS/DISPENSERS:

RESERVOIR - NO FLOW CONTROL

LUBE DEVICES’ gravity feed reservoirs without flow control are ideal for use as make-up or replenish-ing reservoirs. They can be installed in most cases to serve both as an oil cup to maintain oil level, and as an oil gage to provide a full 360° visual check of fluid level and condition. All reservoirs feature self-closing snap lid filler caps, vented on the vertical plane to minimize the possibility of dust and dirt from entering the reservoir through the vent. Reservoirs can be disassembled for occasional cleaning. Filters are available - see Bulletin F357-7 and Gravity Feed Full Flow Control is available - see Bulletin F279-1.

STANDARD MATERIALS:

• Aluminum construction

• Buna N seals

• Break resistant, colorless, transparent acrylic Borosilicate glass for fluid compatibility and thermal shock

MODIFICATIONS AVAILABLE MADE TO ORDER - CONSULT OUR FACTORY.

(MINIMUM ORDER MAY BE REQUIRED)

OPERATING CONDITIONS:

• Acrylic up to 160°F (71.1°C).

• Glass up to 250°F (121.1°C).

• Ratings are at atmospheric pressure

Lube Devices, Inc.

1864 Nagle Ave, Po Box 1810

Manitowoc WI 54221 Phone: 920-682-6877

Fax: 920-7210

Reservoir - No Flow Control

Bulletin F357-1

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Fairing Examples:

Protective Rod Examples:

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Flexible Coupling Alignment

The provided shaft couplings have two setscrews in them each. One of these is aligned with the bore key-way. This setscrew must be tightened down against the key of the given shaft. Align the coupler halves such that both shafts have setscrews set against their respective keys and that the coupler halves firmly together about the hytrel insert. If a setscrew cannot be driven into its appropriate shaft key then the shaft and coupler alignments must be adjusted to correct this.

Note: all setscrews must be tightened down prior to thruster operation

Figure A: Improper shaft alignment prevents proper setting of setscrew against shaft key

Figure B: Shaft re-aligned to facilitate proper setting of setscrew against shaft key

LUBE DEVICES

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For hard copy manuals replace this page with drawing number 91.10058.0 printed on “B” sized paper

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WESMAR/WESTERN MARINE ELECTRONICS AND SUBSIDIARIES

TERMS AND CONDITIONS OF SALES

Following are the terms and conditions of all purchase orders accepted by and all sales made by WESTERN MARINE ELEC- TRONICS COMPANIES: (Hereafter called “SELLER”.)

1. ACCEPTANCE: Purchase orders are subject to SELLER’s acceptance at Woodinville, Washington.

2. PAYMENT TERMS: The purchase price shall be paid by the BUYER to SELLER as set forth on the purchase order.

Delinquent payments shall bear interest at the rate of up to 18 percent per annum.

3. DELIVERY: Delivery shall be FOB SELLER’s plant in Woodinville, Washington, and BUYER shall pay all costs of transportation and shall assume all risks of loss.

4. SHIPMENT: In the absence of explicit instructions as to routing and method of shipment, SELLER may use its discretion as to both, and may forward by express or parcel post when packages are small. Parcel post shipment will be insured at BUYER’s expense unless otherwise specified. SELLER assumes no responsibility for placing valuation upon shipment unless specifically requested to do so by BUYER.

5. INSTALLATION AND FIELD START-UP: Quotations for installations and field start-up do not include SELLER’s travel and associated expenses, which BUYER shall pay. Further, such quotations anticipate that the work to be performed by SELL- ER will be during normal working hours. If at BUYER’s request or with BUYER’s consent, overtime is applied to this work, the expenses thereof shall be charged to BUYER.

6. WARRANTY AND DISCLAIMER: PARAGRAPH 6a APPLIES EXCLUSIVELY TO ALL PURCHASES FOR NONPER- SONAL, FAMILY OR HOUSEHOLD PURPOSES; PARAGRAPH 6b APPLIES EXCLUSIVELY TO ALL PURCHASES

FOR PERSONAL, FAMILY OR HOUSEHOLD PURPOSES.

6a. COMMERCIAL WARRANTY, DISCLAIMER, AND REMEDIES. SELLER WARRANTS TITLE, MATERI-

ALS, AND WORKMANSHIP OR EQUIPMENT, EXCEPT COMPONENTS MANUFACTURED BY OTHERS FOR

WHICH SELLER ASSIGNS, AS PERMITTED, THE ORIGINAL MANUFACTURER’S WARRANTY. SELLER’S WARRANTY PERIOD FOR ALL APPLICABLE EXPRESS OR IMPLIED WARRANTIES SHALL BE ONE (1) YEAR AFTER DATE OF SHIPMENT TO THE ORIGINAL BUYER, OR NINETY (90) DAYS AFTER INSTALLA- TION IF THE INSTALLATION DOES NOT OCCUR WITHIN ONE (1) YEAR AFTER DATE OF SHIPMENT TO

THE ORIGINAL BUYER.

NONCONFORMING EQUIPMENT REPORTED TO SELLER DURING THE APPLICABLE WARRANTY PERIOD

AND RETURNED TO SELLER AT BUYER’S EXPENSE AND RISK SHALL BE REPAIRED, OR REPLACED AT SELLER’S OPTION. IF SELLER IS UNABLE OR UNWILLING TO REPAIR OR REPLACE SUCH REPORTED

AND RETURNED NONCONFORMING EQUIPMENT WITHIN A REASONABLE TIME, THEN BUYER SHALL

BE ENTITLED TO A REFUND OF THE PURCHASE PRICE OF THE EQUIPMENT AS BUYER’S SOLE REM- EDY. THIS PARAGRAPH SETS FORTH BUYER’S EXCLUSIVE REMEDIES FOR NONCONFORMING GOODS.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING DESIGN, COURSE OF DEALING, MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

6b. CONSUMER LIMITED WARRANTY, DISCLAIMER, AND REMEDIES. SELLER WARRANTS TITLE, MA-

TERIALS, AND WORKMANSHIP ON EQUIPMENT, EXCEPT COMPONENTS MANUFACTURED BY OTHERS

FOR WHICH SELLER ASSIGNS, AS PERMITTED, THE ORIGINAL MANUFACTURER’S WARRANTY. SELL- ER’S WARRANTY PERIOD FOR ALL APPLICABLE EXPRESS OR IMPLIED WARRANTIES SHALL BE ONE

(1) YEAR AFTER DATE OF SHIPMENT TO THE ORIGINAL BUYER, OR NINETY (90) DAYS AFTER INSTAL- LATION IF THE INSTALLATION DOES NOT OCCUR WITHIN ONE (1) YEAR AFTER DATE OF SHIPMENT TO

THE ORIGINAL BUYER.

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NONCONFORMING EQUIPMENT REPORTED TO SELLER DURING THE APPLICABLE WARRANTY PERIOD

AND RETURNED TO SELLER AT BUYER’S EXPENSE AND RISK SHALL BE REPAIRED OR REPLACED AT SELLER’S OPTION. IF SELLER IS UNABLE OR UNWILLING TO REPAIR OR REPLACE SUCH REPORTED

AND RETURNED NONCONFORMING EQUIPMENT WITHIN A REASONABLE TIME, THEN BUYER SHALL

BE ENTITLED TO A REFUND OF THE PURCHASE PRICE OF THE EQUIPMENT AS BUYER’S SOLE REMEDY.

THIS PARAGRAPH SETS FORTH BUYER’S EXCLUSIVE REMEDIES FOR NONCONFORMING GOODS.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING DESIGN, COURSE OF DEALING, MERCHANTABILITY, AND FITNESS FOR A PARTICULAR PURPOSE.

7. LIMITATION OF SELLER’S LIABILITY: SELLER shall not be liable on any claim for loss of use, revenue, or profit, for injury, or for any other incidental or consequential damages, regardless of the basis for BUYER’S claim(s), including, but not limited to, the law of contract, warranty, or tort. In no case shall SELLER’S liability on any claim(s) exceed the amount paid to SELLER for the purchased goods.

8. SPECIAL TOOLING: In the event that SELLER manufactures special tools dies, or equipment for any particular work, such special tools, dies, or equipment shall remain the exclusive property of SELLER, unless a specific agreement in writing is made otherwise.

9. SPECIAL DOCUMENTATION: The quoted prices include one operations manual with each system. The price for additional special documentation required in conjunction with BUYER’s purchase order shall be in accord with SELLER’s then existing price list and shall be paid by BUYER.

10. TAXES: All sales and use taxes applicable hereto shall be paid by BUYER.

11. EXCUSABLE DELAYS OR LOSSES: SELLER shall not be liable for any damages resulting from delay or losses which are caused by or due to labor dispute, strike, shortage of labor, fuel, materials, supplies, power, transportation, fire, flood, riot, or any other cause, accident, or casualty beyond SELLER’s control.

12. VENUE AND JURISDICTION: The venue of all suits shall be laid in King County, Washington unless SELLER, at its op-tion, commence any suit in the county and state of BUYER’s residence. By this purchase, BUYER has transacted business in the State of Washington and submits to the personal jurisdiction thereof.

13. GOVERNING LAW: This transaction shall be constituted in accordance with and be subject to the laws of the State of Washington.

14. ATTORNEY’S FEES: BUYER shall be liable to SELLER for SELLER’S legal fees and related costs in the event of a default by BUYER.

BUYER SIGNATURE TITLE DATE