Capstan_SA-1128 Manual for SA1014.pdf

1141 Reco Avenue

St. Louis, MO 63126

(314) 965-3339 www.schoellhorn-albrecht.com

TECHNICAL MANUAL

SA1214

Electric Capstan

Model: SA1214

Revision 0

January 13, 2025 Job No.: SA-1128

Serial No.: 28705

PO: 24-011-24-C01

Sold to:

3MC Mobile & Mechanical Repair, LLC.

PO Box 366

Hillard, FL 32046

January 13, 2025

Tammy Fox 3MC Mobile & Mechanical Repair, LLC.

PO Box 366 Hillard, FL 32046

RE: Job No. SA-1128

SA1214

Purchase Order 24-011-24-C01

Dear Tammy Fox:

Please find enclosed two (2) copies each of the PARTS / OPERATION / MAINTENANCE MANUALS covering the SCHOELLHORN-ALBRECHT 10 HP SA1214 Electric Capstan shipped to you 1-14-25.

Please call if you have any questions. We appreciate your business and look forward to doing business with you again in the future.

Best regards, Jeff Beckmann

SCHOELLHORN-ALBRECHT MACHINE CO., INC.

Enclosures: Two (2) manuals

INDEX

Model SA1214 Capstan

Serial Number: 28705 Job Number: SA-1128

Purchase Order: 24-011-24-C01

DESCRIPTION PAGE

Purpose of the Manual

General Safety Instructions

Foot Switch

Design / Operating Characteristics

Capstan Drive Parts List Detail

Capstan Drive Parts List

Scheduling Reducer Maintenance

Bearing and Seal Inspection

Reducer Parts Replacement

Gear Replacement

Bearing and Seal Replacement

Shim and Gasket Replacement

Equipment Storage Procedures

Trouble Shooting

Gearbox Installation, Operation and Lubrication Instructions

Major Component Data

Schoellhorn-Albrecht Capstan Warranty

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 1

PURPOSE OF THE MANUAL

This manual has been compiled by the Manufacturer to provide information on the safe transport, handling, installation, maintenance and repair of capstans.

Failure to adhere to the information provided here may result in risk to personal health and safety as well as damage to equipment.

This documentation must be stored by a person with the correct authority and must always be made available for consultation by equipment operators. A copy of the user's manual must be kept close to the working area of the capstan.

This manual reflects the state of the art at the time of shipping of the capstan. The Manufacturer reserves the right to modify, supplement and improve the manual without the present publication being considered inadequate.

Sections of the manual and important specifications are highlighted by symbols whose meanings are given below.

! DANGER

This symbol indicates situations of serious danger which, if ignored, may result in serious risks to the health and safety of personnel.

! WARNING

This symbol indicates the need to adopt specific precautions to avoid risks to the health and safety of personnel and possible economic damages.

! IMPORTANT

This symbol indicates important and technical information.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 2

GENERAL SAFETY INSTRUCTIONS

THE CAPSTAN SHALL NOT BE USED FOR LIFTING LOADS OR MOVING

PERSONS.

READ MANUAL CAREFULLY BEFORE START, USE OR PERFORMING

MAINTENANCE ON THE CAPSTAN.

This manual is a guide for the correct and safe use of the capstan and for its maintenance.

Carefully read and keep this manual in good condition and near the capstan in order to be available. Any questions regarding the manual or capstan should be directed to Schoellhorn-Albrecht Machine Co., Inc.

For any kind of technical assistance please contact Schoellhorn-Albrecht Machine Co., Inc. or an official dealer of Schoellhorn-Albrecht Machine Co., Inc.

Schoellhorn-Albrecht Machine Co., Inc. cannot know of, or provide all the procedures by which capstan operations or repairs may be conducted and the hazards and/or results of each method. If operation or maintenance procedures not specifically recommended by the manufacturer are conducted, it must be ensured that product safety is not endangered by the actions taken. If unsure of an operation or maintenance procedure step, personnel should place the product in a safe condition and contact supervisors and/or the factory for technical assistance.

1. Only qualified personnel may operate the capstan;

2. The capstan operator must read the instructions and familiarize himself with the product before operation;

3. Only authorized dealers and qualified mechanics may adjust or repair the capstan;

4. Before performing any maintenance or inspection of the capstan, ensure that it is not under load and that the power supply is switched off and disconnected;

5. Check controls for proper operation before using the capstan;

6. Do not operate without testing;

7. Do not operate capstan in a damaged condition;

8. Do not operate capstans that have not been properly maintained or equipped;

9. Do not attach the capstan to an unsafe foundation. All bolts and foundations for capstan attachment should have a higher load carrying capacity than the bollard rating of the capstan;

10. Do not operate capstan with any personnel near the line of force or capable of coming into contact with moving parts;

11. Ease the slack out of the wire/rope when starting a pull. Do not jerk the load;

12. Periodically check the tightness of all fasteners and tighten if necessary. Replace any damaged fasteners found;

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 3

13. Place the capstan in a proper position and secure all points with the correct size bolts properly tightened;

14. Check oil level and fill up if necessary;

15. Ensure that all personnel and spectators are clear of the load and capstan;

16. Avoid shock loads on the capstan, inch the load into engagement before applying full power;

17. Swinging loads will significantly increase the capstans load and must be avoided;

18. Never try to move wires/ropes under tension;

19. Check wire/rope integrity for broken strands or kinks which may cause problems with safe operation;

20. Check safety device operation;

21. Make sure that working conditions conform to capstan features;

22. Never pull loads exceeding maximum safe working load (W.L.L.);

23. Beware of snatch loads on the capstan. Any sudden loading can cause excessive acceleration forces on the capstan system, resulting excessive wear or even compete failure.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 4

USING THE CAPSTAN

Rope Safety

STRETCH IS DANGEROUS! Stretch in a rope can cause the rope to snap out of your hand with extreme force and could cause a serious injury by pulling your hand or body into the capstan. Stretch in the rope can cause the load to "break free" with considerable force and jump in an unpredictable and dangerous manner. All rope will stretch. A long rope will stretch more than a short rope. The more the pull the more a rope will stretch.

Use care when releasing tension on the rope. The line can recoil and pull your hand into the capstan or cause a severe rope burn. A rope can part and snap back causing injury or even death.

Operating Instructions It is the operators' responsibility to understand all aspects of the operation of the capstan.

Operators must be physically capable and mentally alert. They must have good hearing, vision and depth perception. The operator must make sure all conditions are safe for operations. If the operator feels that anything is unsafe, or even questionable, do not proceed until properly evaluated or corrected.

It is standard for our capstans to be provided without controls. A capstan normally uses a foot pedal controller or a pushbutton station with momentary “dead man” switches. The foot pedal allows the operator to use both hands to handle the rope while controlling the capstan. A second person operates the pushbutton station when it is the means of control. The below operating instruction is based on the use of a foot pedal control that automatically returns to its neutral position when released.

!DANGER

• Never wrap the line around your hand, arm, foot or leg, and always be prepared to release the line. Stand a safe distance (at least 4 feet) away from the capstan.

• Stand to side of the pull line to prevent injury in case it breaks. Always wear protective equipment: hard hat, safety glasses and safety shoes.

• Stay clear of the rotating capstan.

• Moving pull lines can entangle. Do not touch the moving line. Serious injury could result.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 5

WARNING

USE OF FOOT CONTROLS ON MACHINERY LACKING EFFECTIVE POINT OF

OPERATION SAFEGUARDS CAN CAUSE SERIOUS INJURY TO THE OPERATOR.

Foot controls should only be used where “Point of Operation” and “Pinch Point” guarding devices have been properly installed and are utilized so that it is IMPOSSIBLE for the operator’s hands or fingers to remain within the point of operation during the machine cycle.

IT IS THE RESPONSIBILITY OF THE USER to determine the suitability of a foot control for the user's intended use and to determine that the foot control chosen by the user and wiring up and installation of same will comply with all federal, state and local safety and health regulations and codes.

Due to the unlimited variety of business equipment, instruments, machines and vehicles on which our foot switches are used, the thousands of standards, and customers’ varying interpretations of the standards covering these applications, it is impossible for SCHOELLHORN-ALBRECHT personnel to be experts on standards and requirements for all these products. We can advise you what is available in our foot switch line and you can examine models to see what meets your needs. We believe our customers’ engineering departments should be the qualified experts in their own product field and know what specifications or details they may require in a foot switch for their equipment. If one of our stock models meets their needs, they can specify it, or possibly ask for modification of a stock model if that is required.

SHOULD YOU HAVE ANY QUESTIONS OR IF ANY OF THE ABOVE WARNING IS

UNCLEAR, PLEASE CALL SCHOELLHORN-ALBRECHT MACHINE COMPANY,

314-965-3339 or (fax) 314-965-3341.

READ INSTRUCTIONS

DEFINITIONS:

POINT OF OPERATION—The point or area of the machine or equipment where the work piece or material is actually positioned and work is being performed during any process such as cutting, shearing, punching, forming, welding, riveting, assembling, etc.

PINCH POINT—Any point at which it is possible for a portion of the body to be caught and injured between moving machine or equipment or work piece parts.

HEAVY DUTY FOOT SWITCH

1. READ WARNING STATEMENT.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 6

2. When wiring up this device make sure POWER IS OFF AND LINES ARE DEAD.

3. When wiring up this device with flexible cord an UNDERWRITERS LABORATORIES LISTED liquid tight connector MUST BE provided. Use appropriate pipe thread sealant at assembly to seal connector threads. When threading into the conduit opening, CARE must be taken to tighten the threaded joint sufficiently to prevent loosening but should NOT BE FORCED. The conduit threads should be kept clean; free from dirt and foreign materials that would hinder proper installation.

4. TO CHANGE ADJUSTMENT of the operation point of an interior switch, depress the treadle to the point where you want the switch to operate. With the treadle depressed to the desired operating point, turn the adjusting screw until the switch snaps.

Turn clockwise to lower the operating point and counter clockwise to raise it.

Apply Loctite Corporation Threadlocker Adhesive #290 (or equivalent) penetrating low-viscosity anaerobic liquid adhesive to adjusting screw J after changing adjustment.

Avoid applying an excessive amount of the liquid adhesive to prevent migration.

Remove excess liquid adhesive by wiping.

5. Tighten the cover screws such that an effective seal is obtained with the gasket.

6. CLEANLINESS must be observed during installation and in use.

On a REGULAR BASIS, inspect foot switch frequently to guard against wear, damage, unlawful alterations or removal of guards, or for unusual enclosure deterioration and the like. Inspect the entire length of the connecting cord (r wiring system) from where it enters the foot switch to the equipment it’s wired up to for wear, loose strain relief connections and the like. DO NOT OPERATE the foot switch if any of the above is observed or if the nameplate or warning label has been obscured or removed.

It is IMPERATIVE that inspection authorities and users exercise more than ordinary care with regard to installation and maintenance and that this information sheet be made available to the end user, operators, maintenance personnel and others responsible for the proper installation and safe operation of this foot switch.

ADDITIONAL COPIES of this information sheet and warning labels are available upon request.

H - Spring Bracket Screw

F - Spring Bracket

G - Projection

D - Actuator Spring

E - Projection

I - Lock Washer

J - Adjusting Screw (0.050 Hex Key Size)

B - Switch Pivot Rod C - Hooks

A - Actuator

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 7

Fitting the rope The rope will wrap best on the capstan if the rope is angled about 5° away from the pull line.

This will allow the line to walk down the side of the capstan and push the previous wraps to the side.

Place three or more side-by-side wraps of the pull line around the capstan in the direction of rotation. Do not wrap more than one layer of pull line on the capstan.

"Paying in"

• Start the capstan operation by pressing down on the appropriate controller (foot pedal, pushbutton, etc.).

• Remove any slack or excess pull line before increasing the capstans speed (proportional control only).

• Attend the line coming off the capstan to avoid any tangles, and keep some tension on the line so that the capstan grips the pull line.

To stop the capstan

• Release the appropriate controller (foot pedal, pushbutton, etc.) in order to allow the unit to return to the neutral or “OFF” position.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 8

DESIGN / OPERATING CHARACTERISTICS

CAPSTAN

Serial Number: 28705

Job Number: SA-1128

Purchase Order: 24-011-24-C01

MODEL SA1214

This unit is a deck mounted Capstan. It is of watertight construction, with a cast steel 12” Single barrel. Its power train consists of a Single speed Reversing motor driving a helical reduced right angle worm drive, incorporating double tapered roller bearings for axial and radial load control.

All gears, bearings, and components operate in a continuous oil bath and are housed in a heavy duty ductile iron gearbox.

The prime mover on this capstan is a crane and hoist duty NEMA design “D”, 30-minute duty cycle, 10 HP Electric motor. The motor is wired for 3-phase, 60 hertz, and 208-230/460 VAC, and is designed for weatherproof operation.

APPROXIMATE OPERATING CHARACTERISTICS

10 HP

26 fpm line speed

11,800 lbs. running line pull 31,300 lbs. starting line pull

35,000 lbs. static (bollard) line pull

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 9

CAPSTAN DRIVE PARTS LIST DETAIL

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 10

Capstan Drive Parts List Number Component Required Part Number S-A Part No.

1 ea. Housing 010 80-007-026 1 ea. Motor Adapter 020 80-007-127 1 ea. Cover 030 80-007-137 1 ea. Internal Cap 040 80-007-129 1 ea. Output Shaft 050 80-007-126 1 ea. Worm Gear 060 80-007-140 1 ea. Worm Shaft 070 80-007-141 1 ea. Helical Gear 080 80-007-132 1 ea. Hi-Speed Shaft & Pinion 090 80-007-120 1 ea. Cover Gasket 100 80-007-130 1 ea. Internal Cap Gasket 110 80-007-131 2 ea. Spacer 120 80-007-128 1 ea. Worm Gear Key 130 80-007-123 1 ea. Input Key 135 80-007-142 1 ea. Ball Bearing 140 80-007-121 2 ea. Hi-Speed Cup 150 80-007-124 2 ea. Hi-Speed Cone 160 80-007-125 1 ea. Lo-Speed Cone 170 80-007-135 1 ea. Lo-Speed Cup 180 80-007-136 1 ea. Lo-Speed Cup 190 80-007-133 1 ea. Lo-Speed Cone 200 80-007-134 2 ea. Hi-Speed Seal 210 80-007-122 2 ea. Lo-Speed Seal 220 80-007-240 1 ea. Grease Fitting 230 80-007-160 1 ea. Grease Fitting 235 80-007-165 1 ea. Breather Filter 240 80-030-275 2 ea. Steel Pipe Plug 250 80-007-171 1 ea. Filler Plug with Air Vent 255 80-007-172 10 ea. Lockwasher 260 80-007-067 10 ea. Hex Head Cap Screw 270 80-007-166 8 ea. Hex Head Cap Screw 280 80-007-167 8 ea. Lockwasher 290 80-007-068 1 ea. Support Washer 300 80-007-138 1 ea. Retaining Ring 310 80-007-139 2 lbs. Synthetic Lithium Complex 320 80-007-069 4 gal. Oil 330 86-000-004 1 ea. Locktite 340 1 ea. Cross Section Assembly 345 1 ea. Barrel, 12" C1012 1 ea. Lid 82-080-301 3 ea. Lid Screw 1 ea. Output Key

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 11

SCHEDULING REDUCER MAINTENANCE

ITEM PAGE

End of First Week of Operation

End of First Month of Operation

Subsequent Scheduling

Changing Oil

Grease-Lubricated Parts

Outer Seal Area

Checking Reducer Loads

Inspecting Reducer Surroundings

Reducer Parts Replacement

Gear Replacement

Bearing and Seal Replacement

Shim and Gasket Replacement

Equipment Storage Procedures

Trouble Shooting A. Excessive Gear Wear B. Broken Gear Teeth or Keys; Opened Keyways C. Bent or Broken Shafts D. Excessive Temperature E. Bearing Failures F. Bearing Noise G. Leakage H. Improper Gear Contact I. Failure of High-Speed Shaft, Motor Shaft, or Key J. Inability to Start Drive

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 12

SCHEDULING REDUCER MAINTENANCE

Depending on the numbers and types of speed reducers in a plant, and the type of plant, mainte-nance schedules may vary from simple to complex. Every maintenance program should include a schedule that insures regular attention to the reducers. The following schedule generally fulfills the basic needs. More severe applications like extremes of weather, temperature, dirt, or humidity, call for more frequent attention.

End of First Week of Operation ___________________________________________________________________

Check the reducer mounting. Tighten hold-down bolts for reducer, motor and outboard bearings.

Also, check external reducer housing bolts and tightness. Examine oil fill, level, and drain plugs for leakage, and tighten if needed.

If the power transmission system involving the reducer includes connecting belt or chain drives, check them for proper alignment and tension. Consult Schoellhorn-Albrecht’s literature for maintenance recommendations. Be sure that belt and chain guards contact no moving parts.

Internal parts of the reducer usually need no inspection at this point, because they are factory installed and aligned. (Internal-component inspection procedures follow later).

Check the reducer oil level, adding oil if necessary to bring the lubricant to the proper level.

However, if the oil level is higher than the recommended level, check a sample for water con-tamination. If there is water in the oil, remove the water and examine all seal contacts.

End of First Month of Operation __________________________________________________________________

If no problem was discovered in the first week’s inspection, drain and flush the oil from the housing at the end of the first month. Inspect the oil for excessive amounts of metal particles.

They could indicate that gears or bearings are loaded abnormally. Also, check a lubricant sample for water and other contaminants, and check all seals.

Inspect connecting drives for proper alignment and tension, and check couplings for the correct alignment. Tighten foundation bolts and reducer housing bolts if needed. See that the oil has been maintained at the proper level and that the lubricant is correct for the application. Inspect and service grease fittings and replace broken or damaged fittings.

Subsequent Scheduling ______________________________________________________________________________

There are some periodic procedures to follow after the first month of operation. Time spans between them depend on the application. In any event, include these periodic steps in plant maintenance schedules:

Changing Oil __________________________________________________________________________________________

Generally, oil changes may be made about every 6 months or after 2500 hours of running, whichever is first. If necessary, change lubricant type to suit seasonal changes. Follow Schoellhorn-Albrecht’s lubricant recommendations.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 13

Grease-Lubricated Parts ____________________________________________________________________________

At least every six months, apply fresh grease to grease-lubricated bearings and seals. Regrease with recommended type and amount as specified by Schoellhorn-Albrecht.

Outer Seal Area _______________________________________________________________________________________

Reducers may develop excessive seepage around seal openings. A slight amount is usually of no concern, because a little oil lubricates the seal lip and prevents wear. However, if seepage be-comes progressively worse, inspect the seals and the shaft surfaces in the seal contact area, and replace faulty parts immediately. If the shaft area is nicked, scored, or corroded so severely that it cannot be repaired by polishing, and shaft replacement is impractical, you may be able to re-store the surface by adding a sleeve. Such devices are available through Schoellhorn-Albrecht and many bearing and power transmission distributors.

Checking Reducer Loads ___________________________________________________________________________

Sometimes an application changes, thus increasing the reducer load. Increased loads may also result from malfunctioning of some other drive-system component. Periodically check the drive load with an ammeter or other device to be sure that the unit is within its capacity. Check over-load protection equipment to be sure it works. Make necessary adjustments or repairs to driven machinery to eliminate overload.

Inspecting Reducer Surroundings _________________________________________________________________

Some applications are in dirty or dusty environments. If so, keep reducer housing surfaces clean so that heat can dissipate into the atmosphere.

Dust, lint, or other materials can easily accumulate in housing corners, acting as insulators and lowering the reducer’s thermal capacity. Insure that fan openings are free of material build-up that would prevent air flow to housing surfaces.

If you have more than one reducer, keep a history chart for each. Such a chart tells the mainte-nance staff at least the name of the reducer manufacturer, serial number, date of the installation, last service date, repairs or modifications on the unit or the driven machine, and in-plant location.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 14

BEARING AND SEAL INSPECTION

Gears in any type of reducer must be supported and aligned properly to function properly. The housing and bearings must maintain correct alignment. The bearings support the shafts, and the housing provides a rigid mounting for the bearings.

Schoellhorn-Albrecht selects bearings sufficient for the reducer ratings when the reducer is properly selected, installed, and maintained. Usually, such bearings are precise rolling-element bearings that require some attention to insure proper operation. Bearing neglect can shorten reducer life drastically.

Abnormal gear wear sometimes results from misalignment of bearings which otherwise appear to be in good condition. When a gear or bearing fails, check to insure that the bearings are properly installed, fitted and aligned.

Maintenance personnel should acquaint themselves with the locations and types of bearings in speed reducers. They should study the reducer parts drawing by Schoellhorn-Albrecht or other data so that they can perform inspection and maintenance procedures effectively.

Flaking of bearing parts, though hard to see with the bearing in place, often shows itself in the form of metal particles in the reducer oil. If the gear teeth show no abnormal wear, the presence of such particles means that you should inspect the bearings for flaking. Replace faulty bearings immediately.

Noise often accompanies bearing overheat. However, it may not occur immediately in a hot bearing. The most common cause of bearing overheat is inadequate or improper lubrication. If you find a bearing running hot, shut down the reducer at once. Check the lubricant for contami-nation as well as for correct oil type. Drain and replace contaminated lubricant immediately.

Check reducers with forced-lubrication systems or external oil coolers to insure that all lubricant lines are clear.

When replacing bearings, follow the recommendations of Schoellhorn-Albrecht or the manu-facturer or supplier of the replacement bearings. Local bearing distributors are good sources of advice on bearing maintenance and replacement.

Shaft seals must retain the lubricant and keep the gears and bearings running in a clean environ-ment. When a seal fails, the reducer lubricant can be lost or contaminated, or both. The result:

early failure of gears or bearings. Frequent seal inspection (look for signs of oil leakage around shaft openings) will usually spot potential trouble areas. The cost of new seals is low, con-sidering their importance to the reducer’s life. If you question the integrity of any seal, replace it.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 15

REDUCER PARTS REPLACEMENT

Speed reducer components can wear enough normally that they must be replaced. Maintenance personnel with a good understanding of reducer construction should replace parts. Schoellhorn- Albrecht’s representative or distributor can provide advice on reducer repair; and we can factory-rebuild speed reducers.

Every reducer comes with a nameplate, usually on the housing. It usually includes a serial number which tells Schoellhorn-Albrecht when the unit was built, special features, ratio, and capacity. Be sure to include the serial number in reducer maintenance records and give it to Schoellhorn-Albrecht if we are to rebuild the reducer or furnish replacement parts. Don't remove or paint over a reducer nameplate.

Gear Replacement ____________________________________________________________________________________

In order to insure proper wear it is Schoellhorn-Albrecht's standard practice to replace both gears in sets of mating gears. Follow any published instructions that Schoellhorn-Albrecht provides to insure proper gear disassembly and assembly.

Bearing and Seal Replacement _____________________________________________________________________

Use only those bearings or seals specified by Schoellhorn-Albrecht, and install them in accor-dance with recommended mounting procedures. Many bearings are dimensionally interchange-able, but drastically different in capacity. When installing tapered roller bearings or angular-contact bearings, pay attention to bearing preload. Your local bearing distributor can provide such information and advice.

Most replacement bearings come in oil-impregnated paper. Don't remove it until it is time to in-stall the bearing. There are many ways to heat bearings to the correct temperature for installation on the shaft. Whatever method you use, be sure to have a solid working surface to support all components during installation.

Inspect new seals to be sure that shaft contact areas are undamaged and concentric. Mount the seals carefully to avoid damage to the lip portions, and see that the contact area on the shaft is free of ridges or other irregularities. When replacing a shaft seal, follow these suggestions to help insure leak-free operation and long life:

1. Wrap the shaft with light shim stock or heavy paper to protect the seal lip from damage by a rough shaft or a sharp edge of a keyway.

2. Use a sealant between the seal OD and the bore into which the seal is installed. Also, be sure that the seal bore is free of burrs, nicks, and scratches.

3. Be sure that the seal is not cocked in its seat. The outer face of the seal should be flush with the surface of the part into which it mounts.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 16

Shim and Gasket Replacement ____________________________________________________________________

Shims or gaskets are often used to align speed reducer gears or to provide proper bearing clearances. Shims can be made up or ordered from Schoellhorn-Albrecht. Install them only as needed and in the correct locations between the reducer housing and bearing retainers or end caps. Shims are inexpensive. Always replace damaged ones.

Gaskets that retain lubricants are rarely reusable once the reducer is disassembled. In replacing gaskets, clean off the machined surfaces where the new gasket will seat. Also, inspect housing bolt holes to be sure that they are clean and free of dirt and old gasket material.

Equipment Storage Procedures ____________________________________________________________________

• During any storage period the equipment must be protected from moisture, dust, dirt and other corrosive environments.

• The capstans shall be rotated, for a minimum of ten minutes, each month and a dated signed (by a designated qualified person) log of such action, be maintained for the warranty period.

• Also monthly, the lubricating oil shall be inspected for correct level, contamination and moisture, if either is found the unit shall be drained and refilled, prior to running.

• The lubricating oil shall be drained and refilled before the unit is put into operation.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 17

TROUBLE SHOOTING

The trouble-shooting guide that follows will handle the more commonly encountered problems in speed reducer maintenance. If you need more information, consult Schoellhorn-Albrecht.

A. Excessive Gear Wear

Possible Causes Potential Solutions

1. Continuous or frequent overload. Actual load on reducer can be determined from torque load calculations. Or, actual input horsepower to the reducer can be determined with these equations:

Single-phase motors:

HP = (0.49*)(VOLTS)(AMPS)

Three-phase motors:

HP = (0.64*)(1.732)(VOLTS)(AMPS)

* 0.49 and 0.64 are constants approximating motor efficiency and power factor.

1. Compare actual reducer load with reducer nameplate rating. Check the service factor.

If service factored load exceeds reducer mechanical rating, reduce load, if possible, or replace the reducer with a larger unit.

2. Jam-ups in driven machinery. 2. Locate and eliminate jam-ups.

3. Excessively high acceleration or deceleration.

3. Control acceleration or deceleration with soft-start motors, torque-limiting couplings, or inertia-controlling devices.

4. Low oil level or improper oil type or grade. 4. Be sure that the lubricant is correct for the reducer and that the reducer is filled to the right level.

5. Defective bearing, improperly installed, aligned, or adjusted bearings; or wrong bearing for application.

5. Inspect all bearings for excessive wear or discoloration due to heat, and insure that proper type and size bearings are used, and that, if needed, bearings are preloaded properly. If in doubt, consult Schoellhorn- Albrecht or your bearing distributor.

B. Broken Gear Teeth or Keys; Opened Keyways Possible Causes Potential Solutions

1. Frequent overload. 1. See A.1., above.

2. Jam-ups. 2. See A.2., above.

3. Severe acceleration or deceleration. 3. See A.3., above.

C. Bent or Broken Shafts

Possible Causes Potential Solutions

1. Excessive overhung load. 1. Reduce overhung load.

2. Jam-ups. 2. See A.2., above.

3. Sever acceleration or deceleration, or high-inertia starts or stops.

3. See A.3., above.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 18

4. Shaft misalignment. 4. Check for shaft misalignment and correct if necessary.

D. Excessive Temperature (more than 200ºF)

Possible Causes Potential Solutions

1. Overload 1. See A.1., above.

2. Insufficient thermal capacity. 2. Provide for external cooling of reducer, or replace with fan-cooled unit or larger unit.

3. Tight or defective bearings. 3. See A.5., above.

4. Excessive ambient temperature. 4. Provide for ventilation of unit or external oil cooling.

5. Improper oil or oil level, or old or contami-nated oil.

5. See A.4., above.

E. Bearing Failures

1. Improper adjustment. 1. Adjust bearings to proper preload. Consult local bearing distributor or Schoellhorn- Albrecht.

2. Lack of lubrication, improper lubrication, old or contaminated lubricant.

2. See A.3., above.

3. Excessive overhung load. 3. See C.1., above.

F. Bearing Noise

Possible Causes Potential Solutions

1. Defective bearing. 1. Inspect and replace bearings.

2. Improper bearing adjustment. 2. Adjust bearing endplay. Consult Schoellhorn-

Albrecht or bearing distributor, if necessary.

3. Wrong or insufficient lubricant. 3. Insure that enough oil of the right type and grade is used. Lubricate grease fittings with recommended type and amount.

G. Leakage Possible Causes Potential Solutions

1. Damaged or worn seal or improper seal installation.

1. See “Bearing and Seal Replacement.”

2. Imperfections in shaft surface (like nicks, scratches, or corrosive pitting).

2. Reposition seal away from imperfection, if possible; remove imperfection (lap with emery cloth), install sleeve on shaft, or replace shaft.

3. Insufficient venting. 3. Insure that vent plugs are properly installed and free of obstructions.

4. Imperfection in seal mounting bore. 4. Clean up bore; install sealant between seal OD and mounting bore.

5. Excessive operating temperature, causing brittle seals.

5. Isolate reducer from extreme temperature, use fan cooling, or install high-temperature seals.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 19

6. Abrasive or corrosive atmosphere. 6. Use double seals or severe-duty seals; isolate reducer seal area from environment.

7. Pumping from vent due to wrong location of vent plug, high oil level, or improper reducer mounting.

7. Obtain Schoellhorn-Albrecht’s recommendation for proper vent location and oil level relative to reducer mounting.

H. Improper Gear Contact

1. Improper adjustment of low-speed gear (off center).

1. Readjust low-speed bearings to center gear.

2. Excessive bearing endplay. 2. Readjust bearings to eliminate endplay.

I. Failure of High-Speed Shaft, Motor Shaft, or Key (motorized reducers)

Possible Causes Potential Solutions

1. Motor shaft not concentric with motor register.

1. Check concentricity of motor shaft. Check with motor manufacturer for concentricity tolerance.

Replace motor, if necessary.

2. Motor not seated against motor adapter.

2. Check with feeler gage to insure that motor face is tight against reducer motor adapter. Check for burrs or nicks in mating flanges.

3. Reducer input shaft bore (hollow shaft type) not concentric with motor adapter register.

3. Check concentricity. It should be within

0.001 in. TIR. Replace input shaft or motor adapter, if necessary.

4. Motor shaft bottoming in reducer input bore.

4. Insure that bore is deep enough to accept shaft without bottoming. Shorten motor shaft, if necessary.

J. Inability to Start Drive

1. Improper lubricant (high viscosity, especially at low temperature).

1. Consult Schoellhorn-Albrecht for oil recommendation.

2. Insufficient torque at output shaft to overcome inertia load.

2. Check reducer efficiency. Be sure that enough torque is available at the output shaft after re-ducer losses. Increase motor size as necessary within reducer’s input horsepower rating limitation.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 20

GEARBOX INSTALLATION, OPERATION AND LUBRICATION INSTRUCTIONS

PROPER SELECTION

The selection of the appropriate speed reducer for a given application requires that all factors af-fecting the operation of the unit be given careful consideration. Service factors must be applied to catalog ratings depending on the type of prime mover used, severity of the application and duration of daily service. If you have any questions relative to the selection section of the appropriate catalog, contact Schoellhorn-Albrecht.

PROPER ALIGNMENT

1. The various drive members (motor, speed reducer, couplings, sprockets, sheaves, gears, etc.)

should be aligned as accurately as possible to guard against unusual stresses and overloads imposed by misalignment.

2. If a prime mover shaft is to be directly connected to the high speed (input) shaft, or if the slow speed (output) shaft is to be directly connected to the driven shaft, flexible couplings should be used. It should be remembered that even flexible couplings have limited ability to accommodate misalignment. Care must be taken at installation to insure that shaft alignments are within the limits recommended by the coupling manufacturer. Use of a rigid coupling to connect speed reducer shafts to other drive components is not recommended as it is almost impossible to obtain exact alignment between two shafts.

3. A common base plate supporting the motor and reducer will help preserve the original alignment between reducer and motor shafts. If a structural steel base is used, the plate should be at least equal in thickness to the diameter of the bolts used to fasten the speed reducer to the base plate.

Also, for sufficient rigidity, the design in general including angle or channel members should be substantial enough to prevent flexing under vibration. After the first week or two of operation all of the bolts and nuts used to fasten the reducer and motor, pedestal, etc., to the base plate should be re tightened. Vibration tends to loosen the nuts even if tight initially. Doweling the motor and speed reducer to the base plate will help insure that alignment is maintained.

LUBRICANT

1. FACTORY FILLING Our speed reducers are filled to the proper level prior to shipment with the appropriate grade of oil for operation in an industrial environment. The oil level should be checked prior to operation, using the oil level plug provided for that purpose.

2. AMBIENT TEMPERATURE If ambient temperatures are abnormally low or high, the type of lubricant installed at the factory may be unsuitable. See the chart in this bulletin for extreme temperature lubricant recommendations.

3. INITIAL OIL CHANGE The oil in a new speed reducer should be drained (using the drain plug provided) at the end of 250 hours of operation. (Thirty days for 8 hour per day service, 15 days for 16 hour service, 10 days for 24 hour service).

4. OIL CHANGING When changing oil for any reason, it should be remembered that oils of various types may not be compatible. Therefore, when changing to a different oil, it is recom-mended that the housing be completely drained and thoroughly flushed with a light flushing oil prior to refilling with the appropriate lubricant. Under normal conditions, after the initial change, the oil should be changed after every 2500 hours of operation, or every six months, whichever occurs first. Under severe conditions (rapid temperature changes, moist, dirty or corrosive environment) it may be necessary to change oil at intervals of one to three months. Periodic examination of oil samples taken from the unit will help establish the appropriate interval. If a speed reducer is to stand idle for an extended period of time, (such as when used as a spare) it is recommended that the unit be filled completely with oil to protect interior parts from rust and corrosion due to condensation inside the housing. Be sure to drain the oil to the proper level before placing the speed reducer into service.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 21

5. WP (EXTREME PRESSURE) OILS Extreme pressure gear oils are generally recommended for use in planetary speed reducers. EP oils may also be used in helical gear speed reducers such as concentric shaft, shaft mount, and parallel shaft (700-800-900) type units if no backstop device is used. CAUTION: When a backstop is installed in a speed reducer, EP oils should not be in-stalled. To assure proper operation of a backstop, non-EP gear oil of the proper viscosity as shown on the chart contained in this bulletin is mandatory.

6. GREASE FITTINGS Some reducers are equipped with grease fittings to lubricate bearings not adequately lubricated by the oil splash. These fittings should periodically be pressure lubricated with a short fiber grease with a work penetration of 310 to 340 at 77ºF and an ASTM drop point of 250ºF minimum.

7. OIL TEMPERATURE Speed reducers in normal operation can generate temperatures up to 200ºF depending on the type of reducer and the severity of the application (loading, duration of service, ambient temperatures). Excessive oil temperatures may be the result of one or more of the following factors:

A. OVERLOADS An overload, due to the original selection of a unit too small for the ap-plication, or increasing loads on the speed reducer to a point where its rating is exceeded after it has been in service for a period of time. Always check the speed reducer rating when increasing driven loads or increasing the horsepower rating of the motor or other prime mover.

B. OVERFILLING OR UNDERFILLING If a speed reducer is overfilled with oil, the energy used in churning the excessive oil can result in overheating. If this occurs, shut down the drive, remove the oil level plug and allow oil to drain until oil ceases to drain from the level hole, reinstall the oil level plug, and restart the drive. If the speed reducer is underfilled, the resultant friction can cause overheating. If this occurs, fill the speed reducer to the oil level plug hole.

C. INADEQUATE COOLING In order to dissipate internally generated heat, the speed reducer must be installed in such a way that air can circulate freely. Tightly confined areas (inside cabinets, etc.) should be avoided. If this is not possible, forced air cooling by means of a separate blower or a fan integral to the speed reducer should be used.

8. OIL RETENTION

A. VENT PLUGS To prevent loss of oil during shipment, Schoellhorn-Albrecht speed reducers are shipped with a brass pin in the vent hole in the filler and vent plug. This pin must be removed before the reducer is put into operation. Failure to remove the brass pin can result in pressure build up which can pump oil through the seals. If the speed reducer is installed in an atmosphere containing exceptional amounts of moisture or dust, a shielded or hooded vent plug should be used.

B. OIL SEALS Although Schoellhorn-Albrecht uses high quality oil seals and precision ground shafts to provide a superior seal contact surface, it’s possible that circumstances beyond Schoellhorn-Albrecht’s control can cause oil seal leakage (defective seal, damage during shipment or installation, etc.). When replacing a shaft oil seal, using the following suggestions will help to insure leak-free operation and long seal life.

1) When installing a new seal, wrap the shaft in the keyway area with light shim stock or adhesive tape to protect the seal lip from being damaged by a rough shaft or cut by the sharp edge of the keyway.

2) A sealant should be used between the OD of the seal and the ID of the bore into which the seal is installed. The seal bore should also be free of any burrs, nicks, or scratches.

3) Be sure that the seal is not cocked in the seal bore. The outer face of the seal should be flush with the surface into which it is mounted.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 22

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 23

LUBRICANTS For special applications that involve severe ambient temperature extremes or seasonal oil requirement use Mobil SHC 629.

WORM GEAR REDUCERS

Ambient Temperature -30ºF to 15ºF 16ºF to 50ºF 51ºF to 110ºF 111ºF to 165ºF Max. Operating Temp. 150ºF 185ºF 200ºF 200ºF Viscosity @ 100ºF, SUS 1919 to 2346 2837 to 3467 4171 to 5098 Compounded with: 3% to 10% fatty or synthetic fatty oils or mild EP additives AGMA Lubricant No. #7 Compound #8 Compound #8A Compound Cities Service Co. CITGO EP Comp 68 CITGO Cyl. Oil 400-S CITGO Cyl. Oil 680-7 CITGO Cyl. Oil 680-7 Fiske Bros. Refining APG-80 Lubriplate CP GearOil 7 Lubriplate CP GearOil 8 Lubriplate CP GearOil 8A Gulf Oil Corp. SL-460 E.P. Transgear EP 460 Transgear EP 680 Transgear EP 800 Keystone Div. KSL-365 KSL-366 K-600 K-620 Mobil Oil Corp. SHC 629 Mobil 600W Mobil 600W Super Mobil Extra Hecia Super Shell Oil Corp. Omala 68 Omala 460 Omala 680 Omala 800 Sun Oil Corp. Sunep 1050 Sunep 1110 Sunep 1150 Sunoco Gear Oil 8 AC Texaco, Inc. Meropa 68 Vanguard Cyl. Oil 460 Honor Cyl. Oil 680 650T Cyl. Oil 1000 American Lub., Inc. SHC 90W AGMA #7 Gear Oil AGMA #8 Gear Oil AGMA #8 Gear Oil Chevron NL Gear Comp 100 NL Gear Comp. 460 NL Gear Comp. 680 NL Gear Comp. 1500

PLANETARY GEAR REDUCERS, PARALLEL SHAFT REDUCERS (700-800-900)

Ambient Temperature -30ºF to 15ºF 16ºF to 50ºF 51ºF to 110ºF 111ºF to 165ºF Max. Operating Temp. 150ºF 185ºF 200ºF 200ºF Viscosity @ 100ºF, SUS 284 to 347 417 to 510 626 to 765 AGMA Lubricant No. #2 EP #3 EP #4 EP Cities Service Co. CITGO A/W Hydr Oil 32 CITGO EP Comp. #68 CITGO EP Comp. #100 CITGO EP Comp. #150 Fiske Bros. Refining Lubriplate APG 75 Lubriplate APG-80 Lubriplate APG 80 Lubriplate APG 90 Gulf Oil Corp. SL-460 E.P. EP Lubricant HD 68 EP Lubricant HD 100 EP Lubricant HD 150 Keystone Div. KSL-365 KLC-543 KLC-432 KLC-432 Mobil Oil Corp. Mobil Universal ATF Mobilgear 626 Mobilgear 627 Mobilgear 629 Shell Oil Corp. Donax TD Omala 68 Omala 100 Omala 150 Sun Oil Corp. Sunvis 921 Sunep 1050 Sunep 1060 Sunep 1060 Texaco, Inc. Meropa 68 Meropa 68 Meropa 150 Meropa 150 American Lub., Inc. SHC 90W Ind. Gear Oil 90-210 Ind. Gear Oil 90-210 Chevron NL Gear Comp. 68 NL Gear Comp. 100 NL Gear Comp. 150

HELICAL HOLLOW SHAFT

Ambient Temperature -30ºF to 15ºF 16ºF to 50ºF 51ºF to 110ºF 111ºF to 165ºF Max. Operating Temp. 150ºF 185ºF 200ºF 200ºF Viscosity @ 100ºF, SUS 284 to 347 417 to 510 626 to 765 AGMA Lubricant No. #2 #3 #4 Cities Service Co. A/W 32 Hydr. Oil Pacemaker #68 Pacemaker #100 Pacemaker #150 Fiske Bros. Refining Lubriplate Non-Det #10 Lubriplate Non-Det #20 Lubriplate Non-Det #30 Lubriplate STM 90 Gulf Oil Corp. ATF Dextron II Harmony 68 Harmony 100 Harmony 150 or 1500 Keystone Div. KSL-365 KLC-543 KLC-432 KLC-432 Mobil Oil Corp. Mobil Universal ATF Mobil DTE heavy med. Mobil DET heavy Mobil DTE extra heavy Shell Oil Corp. Donax TG Turbo 68 Turbo 100 Turbo 150 Sun Oil Corp. Sunvis 921 Suvis 931 Suvis 951 Sunvis 975 Texaco, Inc. Regal R&O 32 Regal R&O 68 Regal R&O 100 Regal R&O 150 American Lub., Inc. 160 R&O Hyd. Oil 300 R&O Hyd. Oil 600 R&O Hyd. Oil 1000 R&O Hyd. Oil Chevron GST Oil 32 GST Oil 68 GST Oil 100 AW Mach. Oil 150

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 24

MAJOR COMPONENT DATA

SCHOELLHORN ALBRECHT CAPSTAN

January 13, 2025

Customer: 3MC Mobile & Mechanical Repair, LLC.

Capstan Type: SA1214 Capstan Serial Number: 28705

Job Number: SA-1128 Purchase Order No. 24-011-24-C01

GEARBOX DATA

Type: Helical Worm Reducer Manufacturer: Schoellhorn-Albrecht

MOTOR DATA

Manufacturer: Schoellhorn-Albrecht Marine Duty Serial Number: Z2409111187 Product Number: 09N344Y261G1

Type: Sq. Cage Max. Ambient: 40°C PH: 3 HZ: 60 Frame: 254TC

Z HP: 10 ENCL: TENV Service: 1.0

RPM: 1,125 Style: Sq. Cage Insulation System: F Volts: 230/460 Amps: 31/15.5 Time Rating: 30

BRAKE DATA

Manufacturer: Schoellhorn-Albrecht Serial No: 2577927010-0001

Type: Holding Number: 108706200GQF Torque (ft-lb): 75 Insulation System: N/A Volts: 208-230/460 HZ: 60

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 25

MOTOR INSTALLATION AND CARE

This Schoellhorn-Albrecht product has been precision manufactured with high quality materials.

With proper installation and maintenance, it will deliver years of trouble-free service.

Check motor carefully to be sure it has not been damaged in shipment. Connect motor to line of proper specification as stamped on motor nameplate; check voltage, frequency, phase etc.

Connection diagram will be found in terminal box or on nameplate except 3-lead polyphase and 2-lead single phase that do not require a diagram.

Provide suitable overload protection based on full load ampere rating shown on nameplate, as recommended by control manufacturer.

Protect wiring circuit with proper size fuses selected according to local code requirements.

The bearings in ball bearing motors have been especially selected according to our policy of precision manufacture. To avoid bearing damage, coupling, pulleys, etc., SHOULD NOT BE DRIVEN ON MOTOR SHAFT. A light press fit or light tap fit is recommended.

MOTOR REDUCERS APPLICATION

Hollow shaft motor reducers SHOULD NOT be forced or pounded onto the driven shaft.

Never rigidly restrain the torque reaction end of the torque arm. Ball-rod and spring-rod mount units must be installed per instructions furnished with the motor reducer. Pulleys or sprockets should be mounted on output shaft as close as practical to the housing. Belt or chain drives should be properly aligned and tensioned. Overly tight belts or chains cause destructive wear and vibration. If the unit is to be direct connected, shim under the motor feet, if necessary, to get true alignment of driving and driven shaft. Foot, face, and flange mounted units must be securely bolted to flat and rigid bases.

It is important that the driven load does not impose a greater torque on the output shaft than the rated output torque of the motor reducer. High inertia loads that are stopped quickly by a braking action on the rotor shaft, or the self-locking characteristics of the higher ratios of worm units can impose a reverse torque many times the capacity of the motor reducer.

Schoellhorn~Albrecht SA1214 Operation / Maintenance Manual 26

FLUID SHAFT MOTORS AND FLUID SHAFT MOTOR REDUCERS

GENERAL: This unit has a fluid coupling mounted between the motor and the output shaft or gear unit to obtain special starting characteristics. The fluid coupling has been filled to normal oil level at the factory for operating in ambient temperature above minus 10ºF. The oil level should be maintained and the coupling will require no attention under normal operating conditions.

Check oil level every three months with unit cool. In case a coupling develops a leak at the shaft seal, the equipment should be stopped and the cause of the leak determined and necessary repairs made.

FLUID COUPLING OIL

AMB. TEMP.

°F

FACTORY

FILLED

MOBIL OIL SHELL

OIL

CHEVRON TEXACO

–10°F and above SAE 10W Straight Mineral Oil

Mobil Fluid 350…