Winches_Dragarm_Manual.pdf

Cold Weather Operation

Oils for use in cold weather should have viscosity not exceeding 7500 SSU at the minimum start-up temperature pour point of at least 20F -6.7C below start-up temperature is recommended Start-up procedures should allow for gradual warm-up until the oil reaches reasonably fluid state

The Use of Other Oils

Automatic Transmission Fluid ATF General experience here has been satisfactory however

ATE oils are sometimes too expensiv fr mal use in hydraul. systems

Diesel Fuel or Kerosene Coal Oil rietimes used as dilutants fo weather operations but are not recommended as they are not sufficiently refined proacL

Fire Resistant Fluids Of the several different types only the niU emulsion types may be used without changing to special seal packing gasket hose etc compositions Their use may materially reduce pump life Experience indicates that the use ot fluids can be disastrous unless certain precautions are followed DO NOT USE NY FE RESISTANT FLUIDS OR

NON-PETROLEUM OILS WITHOUT CONSULTING OUR TECHNICAL SERVICE DEPART

MENT

These suggestions are intended as guide only OBTAIN YCiR FINAL OIL RECOM

MENDATIONS FROM YOUR OIL SUPPLIER

recommended startup procedure for new or rebuilt pmp or motor

Before installing new or rebuilt pump or motor back off the main relief valve until the spring tension on the adjusting screw is relieved This will avoid the possibility of immediate damage to the replacement unit in the event that the relief valve setting had been increased beyond the recommended operating pressure

Before connecting any lines to the pump or motor fill all ports with clean oil to provide initial lubricatioa This is particularly important where the unit is located above the oil reservoir

After connecting the lines and mounting the replacement unit operate the pump or motor at least two minutes at zero pressure at lowest possible rpm During this break-in period the unit should run free and not develop an excessive amount of heat If the unit operates properly speed and pressure can then be increased to normal operating settings

Reset the main relief valve to its proper setting while the pump is running at maximum operating engine motor speed for the vehicle

ALWAYS USE AN ACCURATE GAUGE WHEN

ADJUSTING THE RELIEF VALVE PRESSURE SETTING

lubrication and oil recommendations

All parts with the exception of the outboard bearing are lubricated by the hydraulic oil in the circuit Particular atte ri must be paid to keep the oil in the system clean Whenever there is mp or motor failure here is reason to feet that metal particles may be in Th the nust be drained the ystem flushed clean and any fitter screens thocoivb- ioaned or replaced New oil shoui jpplied for the entire system Oil suitable and reurnmended for use in circuits invol imercials pumps and motors should meet the following specifications

Viscosity 50 SSU minimum operating temperature

7500 SSJaximum starting temperature

22 100F 37.8 generally

44 to 48 S.Su tj 210 989 generally

Approximate SSU at

Oil 100 210F

Grade 37.8C 98.9C

SAEU 150 43

SAE 2O 330

Viscosity Index 90 minimum

Aniline Point-t-i 75F 80C minimum

Recommended Additives Foam Depressant

Rust and Oxidon Inhibitors

Other Desirable Characteristics

Stability of physical and chemical characteristics

High demulsibility low emulsibility for sepa ration of water air and contaminants

Resistant to theformation of gums sludges acids tars and varnishes

High lubricity and film strength

General Recommendations good quality hydraulic oil with the characteristics listed above is essential to satisfact3ry performance and long life of any hydraulic system

Oil should be changed on regular schedules in accordance with the manufacturers recommendalions and the system periodically flushed

Oil temperature in reservoir .must not exceed 2000 F. 93.3 with maximum operating temperflure of 1800 82.20 recommended Higher temperatures will resut in rapid oil deterioration

Reservoir capacity should equat in gallons the pump output in gpm or the total gpm of all pumps where there is more than one in the system

Oil poured into the reservoir should pass through 100 mesh screen Pour only clean oil from clean containers unto the reservoir 100 mesh screen may be used in the suction line leading to the pump suction filter should be of sufficient size to handle twice the pump capacity It must be cleaned and checked regularly to avoid damage due to contaminatiru and cavitation

Normal Temperatures

18C to 100 37 8C Ambient

100 37.8C to 180 82.2C System

Be sure your oil is recommended for the temperatures you expect to encounter

DREDGE TECHNOLOGY CORPORATION

DRAGARM WINCHES

for

MEDIUM CLASS HOPPER DREDGE ESSAYONS1

for

U.S ARMY CORPS of ENGINEERS

FINAL APPROVED

Reference No

HSMC Job Nos C3662/3663/3664

G.E Req No 300-56187

IHC Order No 70.010

DTC Job No 3026F

Sunship Hull No 681

BIW Hull No 402

ACE Contract No DACW6I79C0159

Alteration

P/S No 681 -853C22

P.O No K-17600-N

CONTENTS

WINCH SYSTEM DESCRIPTION

Introduction

Assembly and Power

Frame Weldment

Electric Motors

Electric Brakes

Reduction Gears

Drums

Grease Pump

Pawl and Ratchet

Model and Serial Numbers

Auxiliary Hoist Motor

II EMERGENCY OPERATION

III DRAWINGS Number

Draghead Winch Assembly Port Side Starboard D-19786 Sheet and of

Rev.E

Gimbal Winch Assembly Port Side Starboard D-19784 Sheet and of

Rev.E

Trunnion Winch Assembly Port Side Starboard D-19785 Sheet and of

Rev.F

Clutch/Auxiliary Drive Assembly D-19212 Sheet of Rev

Hydraulic Schematic D-19778 Sheet of Rev

Draghead Drum Port Side D-19733 Sheet of Rev

Starboard D-19736 Sheet of Rev

Gimbal Drum Port Side D-19734 Sheet of Rev

Starboard D-19731 Sheet of Rev

Trunnion Drum Port Side Dl9732 Sheet of Rev

Starboard D-19735 Sheet of Rev

Draghead Skid Weldment Port Side D19742 Sheet of Rev

Starboard D-19739 Sheet of Rev

Gimbal Skid Weidment Port Side 019740 Sheet of Rev

Starboard 0-19737 Sheet of Rev

Trunnion Skid Weidment Port Side D-19741 Sheet and of

Rev.B

Starboard 0-19738 Sheet of Rev

CONTENTS continued

IV MAINTENANCE

REPAIRS

VI COMPONENT INFORMATION

Philadelphia Gear Corporation Speed Reducers

FMC Pillow Block Bearings

General Electric Motors

General Electric D.C Brakes

Gearmatic Rotoversal Drives

Solenoid OP Valve

Relief Valve

Flexible Hose

Grease Pumps

Coupling Motor-Gearbox

Pilot Devices Limit Switches

Slack Rope Sensorboxes Stromag Limit Switches Sensor Disc and

Teethcounter

VII SPARE PARTS

VIII MECHANICAL TROUBLE SHOOTING This pertains to Emergency Hoist with

Hydraulic Motor only

IX LUBRICANTS

INITIAL STORAGE

XI EXTENDED STORAGE

XII CONSUMABLE SUPPLIES LIST

INITIAL STORAGE

Should it become necessary to store these winches prior to installation certain precautions should be taken The following steps are recommended

Immediately fill the Philadelphia Gear Corporation reducers to their operating level with the proper grade of gear oil See the P.G service brochure in this manual The gear units should be rotated weekly to insure that an adequate coating of oil covers all gears and bearings Rotation can be accomplished by turning the input shaft after manually disconnecting the electric motor brake

The electric motor brushes should be lifted from the commutator The shafts should be rotated periodically

The motor space heater should be energized to prevent the entrance of moisture into the motor housing

All hydraulic lines should be filled with suitable grade of hydraulic fluid and capped

All lubrication fittings should be greased prior to storage rn rTi

EXTENDED STORAGE

Should it become necessary to store these winches for an extended amount of time certain precautions should be taken The following steps are recommended

Fill the gearbox to the top with Houghton Cosmoline 1102

Rotate each shaft at least two revolutions

Drain gearbox

Seal all openings

Store indoors in low humidity atmosphere

Inspect every six months by opening inspection covers and rotating the shaft

Ii

-c

WINCH SYSTEM DESCRIPTION

Introduction

The Six Dragarm Winches three on the port side three on the starboard side raise and lower the dragarms for storage on the upper deck One winch is positioned to raise the draghead while another carries the load of the gimbal joint third winch is used to move the trunnion elbow vertically and trunnion carriage laterally The winches are designed to raise the dragarm from the dredging depth to the breasted-in and stowed position in one continuous smooth operation when used in conjuction with the automatic dragarm controls The winches can also raise an extended dragarm from the extended dredging depth up to the breasted out position

Each winch is of single drum design complete with direct current electric motor direct current motor brake parallel shaft helical reduction gearbox and all items necessary for interfacing into the dredging system In addition an emergency hydraulic motor and clutch provide lifting power in the event of an electric motor failure The hydraulic drive system complete with two stage planetary reduction gear fail safe brake and jaw clutch is directly mounted on top of the main drive gearbox througha right angle spiral-bevel gear set manually engaged ratchet type pawl is provided on winch which when engaged will prohibit operating the winch in the lowering mode

Local operation of the winch in the raise mode is possible with pawl engaged

Winch System Description continued

Trunnion winches are provided with grease pumps for lubricating trunnion sliding pieces

Winches are provided with slack wire switches and also with tooth counters for dragarm position indicating and spindle switches for initiating certain winch stop commands

Operation of the winches can be controlled by

Automatic Dragarm Controller ADC

Dredge Control Officer on DCO Console Manually

Each winch manually from adjacent local controls

Assembly and Power

The Dragarm Winches are skid mounted units consisting of frame an electric motor and gearbox and drum assembly as described bel ow

Frame Weidment The fabricated steel skid provides rigid mounting surface for the winch components Components are bolted to this foundation

Electric Motors The totally enclosed unit cooled

General Electric motors power the winches through the gearbox input shaft The motor to gearbox couplings are made by Lovejoy

They are flexible with elastomeric cushions and mechanical stops

All motors are 135 H.P 850 nominal rpm 500 volt direct current 1750 rpm maximum speed and are provided with thermo stats and space heaters

Electric Brakes The General Electric D.C magnet operated brakes are of the spring set power released type providing fail safe operation All brakes are rated at 1000 ft.lbs

60 mi

Reduction Gears The winch reduction gears are Philadelphia

Gear Corporation parallel shaft marine duty reducers with

1.5 service factor The output shafts are configured for direct drum attachment and mounting of the outboard bearing The out board bearing is self-aligning spherical roller bearing The emergency hydraulic drive mounts directly to the top of the gear housing through right angle input shaft

Assembly and Power continued

Drums The winch drums are of fabricated steel construc tion keyed to the extended output shaft as shown on the assembly drawings The drum configuration accommodates the wire line on the grooved barrel in single layer Split clamps secure the dead end of the wire rope to the drum

Grease Pump The pump is Madison-Kipp Model MDB The pump is mounted only on the trunnion winches and is driven by chain off of the output shaft The pump only functions during k_the operation of the trunnion winches

Ratchet and Pawl As described.in the emergency hoist instructions this assembly is td be engaged before releasing the brake system When the proper procedure is followed this prevents the dragarm from dropping should an operator error occur limit switch keeps the electric motor from lowering while the pawl is engaged thereby preventing an overload to the motor

All electrical connections are made by shipyard

The model and serial numbers for each winch are listed below

Draghead Winch

Reducer Philadelphia Gear 2151 ratio

Model 3.2 MVBI-HP4

Serial 1/Port 128684

Starboard 128683

Electric Motor General Electric

Model 1/Port 5CD224PA8Z27A805

Starboard 5CDZ24PA827A803

Serial 1/Port HS-l-375-HS

Starboard HS-l-341-HS

Electric Brake General Electric

Model 5488A1O3ASG1

Hydraulic Motor Roto-Versal

Model 411-1231

Serial Port 411-2768

Starboard 411-2767

Gimbal Winch

Reducer Philadelphia Gear 201 .91 ratio

Model 3.OMVBI-HP4

Serial 1/Port 128686

Starboard 128685

Electric Motor General Electric

Model 1/Port 5CD224PA827A805

Starboard 5CD224PA827A804

Serial 1/Port HS-l-253-HS

Starboard HS-l-166HS

Electric Brake General Electric

Model 5488A1 O3ASG1

Hydraulic Motor Roto-Versal

Model 411-1231

Serial Port 411-2775

Starboard 4112774

Trunnion Winch

Reducer Philadelphia Gear 264.31 ratio

Model 4.OMVBI-HP4

Serial Port 128688

Starboard 128687

Electric Motor General Electric

Model Port 5CD224PA827A805

Starboard 5CD224PA827A804

Serial Port HS-l-417-FIS

Starboard HS-l-196-HS

Electric Brake General Electric

Model 5488-A1O3ASG1

Hydraulic Motor Roto-Versal

Model 411-l31

Serial Port 411-2781

Starboard 411-2898

Auxiliary Hoist Motor The hydraulic drive unit is Gearmatic

Model 4111231 with built in fail safe brake Serial numbers of

Gearmatic Roto-Versal Hydraulic Motors are as follows

4112777 Stbd Draghead Winch

4112776 Port Draghead Winch

4112778 Port Gimbal Winch

4112779 Stbd Gimbal Winch

4112782 Stbd Trunnion Winch

4112780 Port Trunnion Winch

411-2783 Centerwell Draghead Winch

4112784 Centerwell Gimbal Winch

4112766 Centerwell Trunnion Winch

Power transfer is made through manually operated jaw clutch The unit is idential for all winches The required torque for each winch is controlled by separate hydraulic relief valves which have been individaully preset See Dwg B-l9708 for relief setting

120 VAC hydraulic solenoid valve directs oil through the drive motor In the event of any hydraulic failure such as loss of pressure due to ruptured hose the brakes wfll set immediately and prevent the dragarm from dropping

Instruction for Emergency Hoist

In the event that an emergency hoist of dragarm is required due to the failure of electric power or remote control to one or more winches the following action must be taken prior to the initiation of the emergency hoist

Close shipside valves and stop pumps

Stop all winches

At each winch for the dragarm to be hoisted engage the locking pawl in the ratchet by removing the locking pin and releasing the pawl handle This allows the pawl to engage in the ratchet

NOTE With the pawl engaged lowering of the winch will be prevented by inhibiting the power to the local manual

COntrQl

Deflate trunnion seal and retract trunnion dogs

Auxiliary Hoist Motor continued

Instruction for Emergency Hoist continued

At the local winch control stations for the winchs requiring emergency power unlock the covers for the emergency brake release and also unlock the cover for the local/remote transfer switch

Note if more than one winch requires emergency power only one local/remote transfer switch cover need be unlocked inasmuch as if any one local/remote switch is turned to the local position at any local winch control station this will take preference of control away from the automatic or manual control at the dredge consoles for both dragarms

Switch the local/remote switch to the local at the local control station of choice

For each winch requiring emergency power

Unlock the clutch engagement levers on the hydraulic drive units by removing the padlock

Move the levers to the engage position while someone else gently jogs the emergency hydraulic motor hoist button on the local control panels until the jaw clutch hs aligned and is engaged by releasing the lever

NOTE Alignment can be observed through the window adjacent to the engagement lever

Once jaws are engaged replace and lock padlock to secure the lever in the engaged position

Disengage the electric motor brake by switching the emergency brake release switch at the local winch control stations to the off position

WARNING THE HYDRAULIC JAW CLUTCH MUST BE IN THE ENGAGED

POSITION AND THE PAWL ENGAGED IN THE RATCHET

PRIOR TO RELEASE OF THE ELECTRIC BRAKE

Assembly and PQwer LcQntinued

Auxiliary Hoist Motor continued

Instruction for Emergency Hoist continued

Hoist as required using the emergency hoist buttons in conjunction with local electric manual control for the remaining winches

WARNING While raising the dragarm using local manual and emergency hoist care should be taken by the emergency hoist personnel that the position and orientation of the dragarm be closely watched

II INSTRUCTIONS FOR EMERGENCY HOIST

In the event that an emergency hoist of dragarm is required due to the failure of electric power or remote control to one or more winches the following action must be taken prior to the initiation of the emergency ho st

Close shipside valves and stop pumps

Stop all winches

At each winch for the dragarm to be hoisted engage the locking pawl in the ratchet by removing the locking pin and releasing the pawl handle This allows the pawl to engage in the ratchet

NOTE With the pawl engagedlowering of the winch will be prevented by inhibiting the power to the local manual control

Deflate trunnion seal and retract trunnion dogs

At the local winch control stations for the winchs requiring emergency power unlock the covers for the emergency brake release and also unlock the cover for the local/remote transfer switch

Note if more than one winch requires emergency power only one local/remote transfer switch cover need be unlocked inasmuch-as if any one local/remote switch is turned to the local position at any local winch control station this will take preference of control away from the automatic or manual control at the dredge consoles for both draganns

JNSTRUCTIONS FOR EMERGENCY HOIST

Switch the local/remote switch to the local at the local control station of choice

For each winch requiring emergency power

Unlock the clutch engagement levers on the hydraulic drive units by removing the padlock

Move the levers to the engage position while someone else gently jogs the emergency hydraulic motor hoist button on the local control panels until the jaw clutch has aligned and is engaged by releasing the lever

NOTE Alignment can be observed through the window adjacent to the engagement lever

Once jaws are engaged replace and lock padlock to secure the lever in the engaged position

Disengage the electric motor brake by switching the emergency brake release switch at the local winch control stations to the off position

WARNING THE HYDRAULIC JAW CLUTCH MUST BE IN THE ENGAGED

POSITION AND THE PAWL ENGAGED IN THE RATCHET

PRIOR TO RELEASE OF THE ELECTRIC BRAKE

Hoist as required using the emergency hoist buttons in conjunction with local electric manual control for the remaining winches

WARNING While raising the dragann using local manual and emergency hdist care should be taken by the emergency hoist personnel that the position and orientation of the dragarin be closely watched

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..6

IV MAINTENANCE

The following recommendations are for average duty service See

The Component Information Section of this manual for more details

Item Interval

Philadelphia

Gear Reducers Check Oil Level Weekly Grease Bearings and Seals Monthly Change Oil Every 2500 Operat ing Hours

Outboard Bearing Check Grease Condition Monthly Flush and Regrease Yearly

Couplings Check Flexible Elements Every six months for abrasion and wear

Electric Motors Relubricate Bearings 1-1/2 years

Electric Brakes Check Condition of

Linings and Adjustment Every months

Foundation and

Component Bolts Check fo tightness Monthly

Wire Rope Check for wear Daily

Hydraulic Motor

Clutch Grease shifting yoke Monthly

Hydraulic Hoses and Fittings Check condition Weekly

Ratchet and Pawl Grease Monthly

Grease Pump Check grease level Daily

1Iii REPAIRS

ANY FIELD REPAIRS TO WINCHES OTHER THAN TO RESTORE BY

REPLACING PART ARE NOT AUTHORIZED BY THE EQUIPMENT

MANUFACTURERS BECAUSE OF THE UNAVAILABILITY OF CORRECT

PROCEDURES EQUIPMENT AND KNOWLEDGE OF MATERIALS INVOLVED

INDEX

Philadelphia Parallel Shaft Gear Drives

FMC Spherical Roller Bearings

G.E Direct Current Motors and Generators

Gearmatic Roto-Versal Parts and Instruction Manual

Racine Directional Controls Four-Way Valve 3/4 3000 PSI

Relief Valves

Aeroquip Hydraulic Hose

Kipp Model MDB Multi-Line Lubricator

Lovejoy Couplings

10 Pilot Devices

11 Slack Rope Sensorboxes Stromag Limit Switches Sensor Disc and Teethcounter

PHILADELPHIA

PARALLEL SHAFT GEAR DRIVES

14L

SERVICE MANUAL

PRODUCT OF THE PHILAOELPHIA GEAR CORPORATON

Philadelphia Gear Corporation King of Prussia Pennsylvania

FOREWORD The installation of most power transmission equip ment does not normally require the services of

Your Philadelphia Gear Corporation Speed Reducer factory engineer These services are not included in is high quality rugged machine designed in accord- the selling price of the equipment unless specifically ance with Standards of the American Gear Manufac-agreed upon in writing between the seller and pur turers Association to give long hours of trouble free chaser In applications requiring more complex ar service However certain precautions and procedures rangement of components consideration should be must be observed in handling installing and servicing given to the use of factory engineer for construction the unit in order to obtain optimum performance This supervision or check-out of the installation These manual contains general installation operating mainte- services are available from Philadelphia Gear by con nance and trouble-shooting instructions for your re-tacting the Service Department ducer Should questions arise that are not covered in this booklet additional information can be obtained The Sellers Warranty applies insofar as the unit is by contacting your local representative or the Service operated within the rating and service conditions for

ManagerReducer Divisionat the Philadelphia Gear which it was specifically sold

Corporation King of Prussia Pennsylvania Tele- The purchaser must prevent the existence of any phone 215-265-3000 TWX Number 10-660- destructive external conditions which might typically

3952 include vibratory loads due to critical speeds severe

All inquiries should be accompanied by the following shock loading mechanical or thermal overloads or information which can be optained from the unit name- other conditions concerning which the seller was not plate…