Manufacturer Operating and Maintenance Manual for the Specific Capstan Unit.pdf

INSTRUCTION MANUAL

CAPSTAN-WINDLASS

POWER UNIT

MODEL X-1623

Serial Nos. 23089 & 23090

For Shallow Draft Hopper Dredge

Philadelphia Corps of Engineers Contract No. DACW61-77-C-0158

NETECo. S.O. 7570 - J-7658, J-7661 - J-7662

NEW ENGLAND TRAWLER EQUIPMENT CO.

291 Eastern Ave.

Chelsea, Massachusetts 02150

NEW ENGLAND TRAWLER EQUIPMENT Co.

• NE MACHINERY SHOCK TESTING EQUIPMENT

291 EASTERN AVENUE

CHELSEA, MASSACHUSETTS 02150

TEL. 6 I 7-884-4354

INDUSTRIAL MACHINERY

IMPORTANT NOTICE

THIS INSTRUCTION MANUAL CONTAINS INFORMATION

VITAL TO THE SAFETY AND PERFORMANCE OF THE

EQUIPMENT DESCRIBED HEREIN. IT IS IMPERATIVE

THAT PERSONNEL RESPONSIBLE FOR OPERATION AND

MAINTENANCE BE THOROUGHLY FAMILIAR WITH THE

CONTENTS OF THIS MANUAL.

FAILURE TO DO SO MAY RESULT IN IMPROPER OPERATION

AND/OR MAINTENANCE WHICH WILL DAMAGE THE EQUIPMENT

AND VOID OUR WARRANTEE.

Date Manuals Shipped ---- Customer

Purchase Order No.

SAFETY PRECAUTIONS

The following are general safety steps. These should be understood and followed at all times:

a. All circuits not known to be dead must be considered alive at all times.

b. Do not wear loose clothing when working with rotating machines.

c. Do not use metal tools or objects when working near electricity.

d. Be certain you are not grounded when using test meters or making adjustments.

e. Shut off power before making any connections.

f. Whe·n using a meter, select a range higher than ex pected.

g. Do not use test equipment known to be in poor condi tion.

RESUSCITATION

A high voltage is required to operate deck machinery.

Those working with the motor and control(s) should know modern methods of resuscitation. Such informa tion may be obtained from the Bureau of Medicine and Surgery.

C

GENERAL

CAPSTAN-WINDLASS

MODEL X-1623

The general arrangement and parts list of the capstan-windlass is shown on Dwg. R-1247S~ which is included in this manual.

There are two units, one port and one starboard, driven from a single electro-hydraulic power package located below deck.

Each capstan-windlass consists of a 24" diameter cast steel head mounted above the chain wildcat and keyed to a vertical shaft. The wildcat is bronze bushed to turn freely on a spud extension of the deck plate, and is driven by an axial sliding dog contained in a driving head keyed to the shaft between the capstan head and the wildcat. Th~ dog is actuated by a bronze cam located in the cover of the capstan head.

The main shaft is driven by an internal gear housed below deck with two spur pinions. Each pinion in turn is keyed to the output shaft of a planetary reducer which is driven by a high speed, ~xial piston type, hydraulic motor.

The wildcat is fitted with a band brake which can be operated by handwheel through a bevel gear stand on deck. Tension on the band is applied through a pair of nested coil springs and the ears of the band are fitted with a pair of hydraulic cylinders which can be used to oppose the spring force and release the brake in an emergency. This procedure is discussed in a later section of this manual.

RATING

Both units are capable of si~ultaneousiv liftina /a 3,500# anchor from 60 fathoms depth with 1-9/16" stud-· link chain at an average speed of 30 FPM. With the full scope of chain (180 fathoms) suspended off the bottom one unit at a time can be operated to hoist the anchor with an overall average speed of 30 FPM.

Speed will automatically increase as the anchor comes up and the load decreases.

POWER UNIT

The central power unit consists of a double ended, 40 H.P., 1800 RPM, electric motor close coupled to two 6 cubic inch displacement variable stroke pumps. Each pump has a built-in phg._rge pump and ~ex:...vo cQn_tx.oJ._ri_th_horseo.ower_ limiter_ ._Lcut-o.ff_

1 pressure set at 3,000 p.s.i.}. The latter will override the 1 manual control and slow the pumps down as the load increases, I :to P:event overloading the electric motor. The two pump contro~s are interconnected so that, whenever the port and starboard \ capstans are used simultaneously, their total load demand will will not--=eMOeell 4 O _H, ··11 '

POWER UNIT (CONTINUED)

MODEL x-·1623

Pumps and motor are mounted on a reservoir unit with charge pump suction filters and gages, all pre-piped at the factory.

Mounted on each pump is a push-pull control cable for pump stroke control. This cable is to be connected to the control stand on deck. A separate magnetic motor starter is furnished for installation below deck and connection to the pushbutton on the aforementioned control stand. Following is a list of pertinent drawings included in this manual:

Rivett GP 8957 - Power Unit Technical Controls Dwg. 7712 - 40 H.P. Starter NETECo. Dwg. B-12481 - Remote Control Stand

Refer also to special sections on the hydraulic pump, motor and other components.

REMOTE ANCHOR DROP

Provision is made for remotely dropping the anchor in increments of approximately 10 fathoms. The windlass must be left with the wildcat and the chain sto ed. The brake should e set sot at t e in icator ro Pt. is lined up with the spring seat (Pt. 40) as shown on the Assembly Dwg. R-12475.1

( The drop is initiated by a pushbutton on the pilot house console, one for the port and one for the starboard unit. When pressed the button energizes a pair of relays (see Technical Controls Dwg. 7714) which starts a DC hydraulic power pack and opens a solenoid valve connected to the brake cylinders on the unit selected.

Refer to NETECo. Drawings C-12478 and C-12482. The pressure generated by the power unit is directed to the brake cylinders to force the brake band open allowing the anchor to drop:

To prevent the anchor from running away, a regulating device is built into the system. Referring to Assembly Dwg. R-12457, a small gear pump (Pt. 49) is driven by the wildcat through a roller chain (Pt. 9) and a worm gear reducer (Pt. 51) used in this case as a speed up drive. This pump draws oil from a separate reservoir shown on NETECo. Dwg. C-12483. As shown on the brake s~stem diagram, Dwg. C-12478, the delivery of the pump is directed through an adjustable restrictor valve and back to tank·.·. The pressure built up in forcing the oil through this restriction is fed to the opposite end of the brake cylinders tending to set the brake.

The faster the wildcat turns the greater this pressure becomes th~s \applying more force to the brake and slowing down the wildcat limiting the speed of pay out. Maximum speeds can be varied by adjusting the restrictor valve. Also driven by the wi]d::at through the roller chain and worm gear unit is a cam type limit switch (Pt. 67). This switch is wired into the DC power circuit (Technical Controls Dwg. 7714) and can be adjusted to r

MODEL X-1623

REMOTE ANCHOR DROP (CONTINUED)

shut down the pump, through allowing the springs to set the wildcat brake, at intervals up to 10 fathoms. Another incremental pay out of anchor and chain can then be accomplished by again depressing the button in the pilot house.

NORMAL OPERATION

Before starting the power unit, be sure both control handles are in the neutral position. Then press the start button.

To operate the Capstan: Engage the wildcat brake and disengag~ the wildcat driving dog by turning the operating knob as far as possible in the counter-clockwise direction. Be sure the detent drops into position. This knob has a hole in the side to accommodate a 1/2" rod, if necessary, to assist in operating the clutch. It may be necessary to jog the windlass in the reverse direction to take any tension off the driving lug. With the driving dog disengaged, the capstan can be operated in either direction.

To oeerate the Wildcat: Engage the wildcat brake, and then the driving dog. Turn the clutch knob in the clockwise direction as far as possible (180° from the disengaged position). When fully engaged, the hole in the side of the operating knob will line up with the engaged nameplate. It may be necessary to jog the windlass to allow the drive dog to fall between the driven lugs.

Release the wildcat brake, and the windlass is ready to operate.

When dropping the anchor, release the brake slowly and maintain a controlled lowering speed. Do not release the brake completely and let the chain run free. This can be a very dangerous situation.

Whenever the windlass is not going to be used for a time, shut down the power unit. Leaving it running will only generate unnecessary heat in the oil.

INSTALLATION

Each capstan-windlass is an integral unit which can be lowered onto a prepared 51" diameter foundation ring parallel to the deck with a clearance hole through the deck of approximately 42" diameter. It should then be bolted in place with twelve 1-1/4" diameter ASTM-A354 Grade BC (125,000 PSI tensile strength) bolts. The brake stand is separate and should be installed as shown on the drawing at the same level as the deck plate and secured with four 5/8" bolts.

INSTALLATION {CONTINUED}

MODEL X-1623

The power unit should be bolted to a foundation below the fore castle deck and centrally located between the two capstan windlasses. Two main hydraulic lines of at least 1" inside diameter, and good for 3,000 p.s.i. operating pressure, are to be installed from the l" split flange pump ports to each of the windlass units. There the two main lines split and connect the two motors on each windlass in parallel. I The motors are also provided with l" SAE split flange ports. Make certain the hydraulic motors are connected so as to run in the same direction of rotation. Connect the motor drain ports to the connection provided in the hydraulic reservoir.

In connecting the electric motor to its starter, be certain the motor is rotating in the direction indicated by the arrow on the pumps. Jog it very quickly, and then interchange two motor leads, if necessary, to reverse rotation.

High pressure hose and fittings can be used throughout. If not, short hoses are recommended at the power unit and at each motor. In addition, the piping should be prepared in accordance with the enclosed recommendations.

Before starting, fill the reservoir to the prescribed level with a mineral based fluid from Dynapower's recommended list.

During and after initial running, check the level, and add, as necessary.

LUBRICATION

The internal gear drive and the two planetary reducers run in a common oil bath. A fill pipe, with a threaded cap is provided in the deck plate. Fill to the level pluq on the case with a_qood grade of EP-90 gear oil. After the initial run, re-check the oil level and add, if necessary. The oil should be changed once a year.

Two drain plugs are provided in the bottom of the main gear case and one in each of the planetary units.

A Type "A".transmission oil with a viscosity of approximately 110 at 130° F will give the maximum performance in this unit.

Heavier viscosity oils will decrease the maximum differential pressure available across the motor.

Three grease fittings are provided in the deck plate under the brake rim of the wildcat, two under the lower rim of the capstan head, and one in the bronze cam on top of the head. In addition, grease fittings are provided in the brake nut, pin, thrust washer, sliding joint, universals, brake stand and upper bearing of the small worm gear reducer.

C 0

LUBRICATION (CONTINUED)

CAPSTAN-WINDLASS

MODEL X-1623

All fittings should be greased weekly, when in regular use, with a water repellant grease, such as Lubriplate's Marine Lube "A".

MAINTENANCE

No special maintenance other than the prescribed lubrication and painting, when necessary, is required on the windlass units. The principal maintenance procedure on the power unit is to regularly check the charge pump suction filters, which are equipped with dirt indicators. These should be changed during and/or immediately after the initial running period and whenever a change is indicated. Check all hydraulic lines periodically for any sign of leaks, and correct same immediately.

AUTOMATIC DROP SETUP AND ADJUSTMENTS

( 1. Hydraulic Pressure Adjustment

When the brake is set up for use of the automatic, remote anchor drop by aligning the end of the indicator rod (Pc. 42} with the spring seat (Pc. 40), the spring assembly should have been com pressed 1 inch. This equates to a spring force of 5,730 lbs.

To overcome this force and release the brake will require about 585 psi at the cylinders. The relief valve at the D.C. pump should be set to relieve at 650 psi. Refer to Dwg. R-12475.

Any appreciable increase in spring pressure will necessitate a corresponding increase in the discharge pressure of the D.C.

pump. The load rating of the spring-set is 5,730 lbs./inch of compression.

To check the D.C. pump discha:rge pressure, remove the discharge hose and install a suitable pressure gage. WARNING: Be certain the opening from which the hose is removed is plugged before activating the D.C. electrical system. Failure to plug this connection could result in an oil spill when the system is activated.

To adjust the discharge pressure from the D.C.pump, remove the top cover. The relief valve is mounted under the cover. After loosening the lock nut, turn the adjusting screw clockwise to increase pressure. CAUTION: This pressure should be enough to relieve the spring,-,pressure. Excessive pressure will necessitate a higher pressure from the wildcat driven pump to slow down the chain.

2. System Startup

Before running trials on the remote control drop system, it is imperative that all air be bled from the system. To do this, activate the system and loosen a fitting at each cylinder. Run the system until no more air is present. Failure to remove all air will result in sluggish operation and slow response.

WARNING: Continually watch the oil level in the small reservoir.

As the lines fill, considerable oil will be removed from the reservoir.

C

Adjustments

AUTOMATIC DROP SETUP AND ADJUSTMENTS

(Continued)

After all air is bled from the system, activate one side at a time and observe the rate of fall. The speed can be increased by opening the restrictor valve (Pc. 3 on Dwg. C-12478) and decreased by closing the restrictor valve. The adjustments to the restrictor valve should be made in small increments until the desired speed is obtained.

Relief valve (Pc. 4 on Dwg. C-12478) should be set at 1,000 psi. This valve has nothing to do with the control of the anchor. It is a safety device to prevent damage to the system from over-pressure.

FLUSHING THE SYSTEM

Pipework installed between the power pack and the machinery must be flushed after the system is com-pleted and before starting up the pump. This is done to remove any foreign matter left during the installa tion and to leave the inner surface of the pipe coated with a film of fluid. It is recommended that a separate pump, filter and fluid be used in the flushing cycle.

However, the system hydraulic fluid and the system pump may be used provided exacting procedures have been been followed in the preparation and joining of the pipe throughout the system and that the oil in the reser-voir is pre-filtered and/or the pump has a micron suc-tion filter (not just a strainer). If the above con ditions cannot be met, a separate pump, filter and flushing fluid must be used.

The knowledge that a subsequent flushing operation is to be performed is no justification for permitting any contamination to occur during assembly of the piping system. •

It is important that control valves and motors are by passed for this flushing operation, otherwise particles from downstream could damage internal parts or block small pilot passages. Circulate the fluid throughout all parts of the system at the maximum possible rate for a period of 1/2 hour or more, depending on the extent of the piping. The flow of flushing oil in the piping should be reversed for 15 minutes in those sections of the system which will carry oil flow in both directions. Constantly check the filters and change the elements whenever the dirt alarm so indicates, and always at the conclusion of the flushing operation.

Remove the bypasses one at a time, and carefully make up the permanent connections to the valves and motors.

Never leave any hydraulic connection open longer than necessary. Install temporary plugs or reconnect the piping whenever it is necessary to leave the job even for a few minutes. The system should then be ready for start-up.

A. ROTATION CHECK

DYNAPOWER PUMP

SYSTEM START UP PROCEDURE

Make a careful comparison of the direction of rotation of your power source .with reference to the direction of rotation shown by the arrow on the Dynapower charge pump cover. It is absolutely essential that direction of rotatio'n of power source be the same as that shown by the arrow on the charge pump cover.

CAUTION

No matter whether your power source is diesel, gasoline, steam or electric; no matter if its direction is clockwise or counterclockwise-if the direction of your power source rotation is not the same as the direction shown on the charge pump cover plate-DO NOT PROCEED WITH THE INSTALLATION-IF YOU DO, DAMAGE TO

THE SYSTEM WILL OCCUR.

B. COUPLING FIT

Your couplings on both pump and motor must be of a snug, slip fit

C on the shafts. Mounting flanges must be concentric. They also must be at right angles to both the drive shaft and the output shaft. Check for concentricity and angle tolerance. When you use semiflexible couplings, maintain tolerances normally required by the type connection you employ, If you make a direct coupling from the power shaft to the pump shaft, you must use a dial indi cator. In this case, tolerances must be within 0.001 in. total indicator run-out. Do not proceed with installatio~ until comply ing with s~ated coupling fit tole·rances.

C. MOUNTING

After the above conditions have been met, mount the pump. First, grease the coupling with non-corrosive grease, then bolt the pump to its mounting flange. Follow the same procedure for mounting the motor, greasing the coupling and then bolting the motor to its mounting flange.

D. USE GOOD HYDRAULIC PRACTICES

Be sure the interior of reservoir, connections and fittings are perfectly clean.

E. BEFORE OPERATION

Be sure all lines and connections are set up according to your system layout.

1 pr·. (2) l:

Part No.

Bl2470-3/ 4 .

SFT20

894240 894193 894025 KlO 800009

311SZZ

EG80CK

BJX

EG80

50D25621 BJPl D13758004

TRS-55

CAPSTAN-WINDLASS

MODEL X-1623

SPARE PARTS LIST

Name

Brake linings with rivets Ball bearings for hand brake gear box "O" ring kit for hydraulic motor Seal kit for hydraulic motor Seal kit for hydraulic pump (1 case) Filter elements "O" ring kit for low pressure relief valve (1 set) electric motor bearings Set Electric contacts for motor starter Pushbutton contact . hlocks Coil for contactor Pushbutton boots Pushbutton operator Bulbs (4 sets) fuses

ELECTRIC MOTOR DATA

40 H.P.

1800 RPM

CAPSTAN-WINDLASS

MODEL X-1623

460 volt, 3 phase, 60 hertz Vent. Enclosure Continuous Duty BBB Insulation Frame 326U Foot mounted Double end hydraulic pump mount Type FOOO IEEE-45 Marine Specifications