Title:

Installation Procedure, Deck Machinery

Doc. No.:
Rev No:
Date:

DM06001
05
08.07.10

Installation Procedure, Deck Machinery

08.07. 10
09.10.07
13.11.06
13.09.06
18.05.06
12.05.06
Date

05
04
03
02
01
0
Rev

Pusnes TM deck machinery

Tables added in 5.2.3 and 5.2.4

Chapter 5.3 Added, Logo Changed
Figure 1.3 And Appendix Added
Alignment Of Gear Case (EW)
Generally Updated
Initial Issue
Remarks

KH
ThB
ThB
ThB
ThB
ThB
Prep.

SEl

TS
JHP
TS
Check

KH
TS
KH
KH
Appr.

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Title:

Installation Procedure, Deck Machinery

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Table of contents:

1 INSTALLATION PROCEDURE FOR DECK MACHINERY ...........................3

1.1 General.................................................................................................................3
1.2 Deck Machinery, General information for installation........................................3
2 ANCHOR- MOORING WINCH.............................................................................6
2.1 Alignment of Anchor and Mooring Winch..........................................................6
3.0 WINCH BAND BRAKE........................................................................................7
3.1 Adjustment to Brake Drum..................................................................................7
3.3 Brake Band Support.............................................................................................7
4 CABLE LIFTER UNIT (CU) ..................................................................................8
4.1 Alignment of Cable Lifter Unit............................................................................8
5 WINCH AND CABLE LIFTER UNIT COMBINATION....................................8
5.1 Alignment of Windlass ........................................................................................8
5.2 Angular deviation.................................................................................................9
5.3 Engagement of Claw Couplings ........................................................................12
6 TIGHTENING TORQUE AND FINAL CHECK ...............................................13
7 ENDSTOPPERS .....................................................................................................13
8 HYDRAULIC PIPING...........................................................................................14
9 ELECTRIC INSTALLATIONS............................................................................14
10 APPENDIX............................................................................................................14
10.1 Record Sheet Winch ........................................................................................15
10.2 Record Sheet Windlass ....................................................................................16
10.3 Gear Contact Record Sheet I/II........................................................................17
10.4 Gear Contact Record Sheet II/II ......................................................................18

Pusnes TM deck machinery

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Title:

Installation Procedure, Deck Machinery

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1 Installation procedure for Deck Machinery

1.1 General
1.1.1 Purpose of this Document
This document covers the installation procedure for winches and cable lifter units of
Aker Kvrner Pusnes AS Deck Machinery. This document combined with Working
(Certified) drawings for actual project give instructions, guidelines and how to
prepare and erect foundations, and also specifies how to install the actual units.
1.1.2 Referenced Documents
Ref.
1
2
3

Title/ Description
General Information, Deck Machinery
Working (Certified) Drawings for the actual project
Instruction for Lifting, Handling and Transportation, Deck Machinery
IMPORTANT!
This installation procedure together with the Working (Certified) drawings
of each unit holds the guidelines and tolerances necessary for a safe
installation of hydraulic and electric driven deck machinery.
However, this procedure can be superseded by other procedures, which
ensure the integrity of the below instructions.

1.2 Deck Machinery, General information for installation

1.2.1
1.2.2

1.2.3

1.2.4

1.2.5

The anchor/ mooring winches and cable lifter unit (CU) can be installed on
deck with an inclination of maximum 5 in any direction.
The winch and CU foundations have to be welded to the deck structure
keeping the top level of the foundation within a flatness tolerance of +/- 5,0
mm in any direction. Check by means of a levelling telescope, laser level,
alignment plate or a piano wire. An accurate top level on foundation regarding
flatness would reduce the alignment process, especially for the steel liners.
The top of steel liners and/ or plastic compound should be within flatness
tolerance of +/- 1,0 mm.
Steel liners should be made in one part, this to avoid/ limit crevice corrosion
between several plate layers. Steel liners are required for all CUs as plastic
compound will crack and crumble away due to heavy vibrations when
dropping the anchor.
Before lifting the winches and CU units onboard, check that the borehole
pattern of all units and foundations are within the tolerance of +/- 1,5mm, see
fig.1.
Check also that the centrelines for the holes in length and transverse direction
are perpendicular to each other.
Place the winches and CU units on the foundations resting on their adjustment
screws. Allowance for liner thickness is to be taken into consideration, in

Pusnes TM deck machinery

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Title:

Installation Procedure, Deck Machinery

)
1.2.6

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general a maximum thickness of 30mm.

Note!
The thickness of the liner compounds to be in accordance with makers
recommendation.
When positioned on the foundation, check that the foundation bolts slip easily
through the bolt holes.

Fig 1.1 Geometrical tolerances for foundations

Given geometrical tolerances are applicable for foundation top level with belonging
hole patterns for Winch and Cable lifter Unit, combined/ or not.
1.2.7

Gear contacts between pinions and wheels for all gear types to be kept at a
minimum of 80% over the gear tooth length.
1.2.8 For electric driven winches special conditions needs to be considered;
Adjust height of gearbox in motor end with jack bolt on motor side
(see fig. 1.2).
Adjust jack bolt opposite from motor to 0.2 - 0.3mm clearance.
Tighten foundation bolt opposite side of motor until the jack bolt with
clearance is pressed against foundation.
Tighten foundation bolt on motor side finger tight (~2Nm).
Check the gear tooth contact. It should be minimum 80 % tooth surface
contact (Use blueprint).
If gear contact is less than 80 % adjust again with larger or smaller clearance
on jack bolt opposite of motor.
On the rest of the gearboxes, start with the final clearance from previous
winch and adjust to get required gear contact.
After pouring and hardening of chock fast, tighten securing nuts as usual.
Make sure required gear contact is achieved.
(Record data in enclosed Gear Contact Record Sheet II/II).

Pusnes TM deck machinery

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Fig 1.2 Alignment of Gear Case, Electrical driven winches.

For electric driven winches special conditions due to weight of motor needs to be
considered, see1.2.8

Fig 1.3 Gear tooth contact.

Specified requirements given in 1.2.7 and 1.2.8 are applicable for both open gears
(Cable Lifter Unit) and closed gears (Hydraulic and Electrical Winches).

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Fig 2. Flatness requirements for foundation

2 Anchor- Mooring Winch

2.1 Alignment of Anchor and Mooring Winch
Following has to be taken into consideration when aligning these units:
2.2

Adjust the jacking bolts on the gear case and the outermost bearing bracket to
correspond with the thickness of the liner compound/ steel liners to be used.
For two or three drum winches check that the centre-bearing brackets are
hanging loose.
2.3
When the main shaft is resting properly in both the gear case and the
outermost bearing bracket, i.e. in 6 oclock position, tighten the foundation
bolts in the gear case slightly. For electric driven winches special conditions
needs to be considered, see details 1.2.8.
2.4
Check that the couplings will operate properly.
2.5
It is essential that the bearing bushings are parallel to the main shaft. There are
several methods to check this:
2.5.1 If no access from outside, remove the top cover of the split bearing and check
the gap each side is equal by using a feeler gauge. Tolerance: +/- 0.1 mm.
2.5.2 Use a feeler gauge to check the axial clearance between the bearing bracket
and the distance ring to be equal all way around the shaft within a tolerance of
+/- 0.1 mm.
2.5.3 When finished, tighten the foundation bolts slightly and set back the top cover
of bearing housing.

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Installation Procedure, Deck Machinery

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Fig 3. Radial clearing shaft/ bearing

2.6

2.7

2.8

2.9
2.10

Position the centre-bearing bracket(s).

As the bearing bracket is hanging loose turn the jacking bolts clockwise until
the lower part of the bearing reaches the main shaft. This to be checked by
positioning a dial gauge at the outermost bearing bracket. When the pointer
shows a reaction, the bearing bracket is in position.
For positioning of dial gauge, see fig.1.1.
As for the outermost bearing bracket it is essential that the bearing bushing is
parallel to the main shaft. If no access from outside remove the top cover of
the bearing housing and check the gap on each side and both ends of bearing.
Tolerance: +/-0,1 mm.
Then tighten the foundation bolts slightly and reinstall the top cover.
Gear contacts between pinions and wheels for all gear types to be kept at a
minimum of 80% over the gear tooth length. This to be checked with blue
paint or lead thread. For electric driven winches, see 1.2.8.
If adjustment is necessary to obtain specified gear contact, repetition of above
alignment procedure to given requirements is obtained.
Coupling/ Clutches supported by the bearing bracket(s) to be adjusted to
operate fully engaged/ completely free. When in correct position holes for the
locking pin has to be drilled, one in engaged position and one in completely
free position. Diameter holes, 14mm.

3.0 Winch band brake

3.1 Adjustment to Brake Drum
Place the brake support in accordance with the foundation and
check/do following:
3.1.1 The brake fits properly around the brake drum.
3.1.2 The brake is vertically correct and in centre of machined
brake drum.
3.1.3 Tighten brake.
3.2 Fastening Brake Anchor
3.2.1 Tack weld the brake anchor to the foundation.
3.2.2 Check that the brake is in correct position according to
above criterias. When placement is satisfactory,
complete the welding.
3.2.3 Check the alignment.

Fig 4.1 Brake Anchor

3.3 Brake Band Support

3.3.1 When the brake is fully applied, check the gap between
brake band and supporting bolt(s).
Gap = 1-2mm (min-max), adjust if necessary.
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Fig 4.2 Brake Band Support

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Installation Procedure, Deck Machinery

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4 Cable Lifter Unit (CU)

4.1 Alignment of Cable Lifter Unit
The cable lifter unit should be aligned separately. Following has
to be taken into consideration when aligning this unit:
4.2
4.3
4.4

4.5

4.6

Position the cable lifter unit on its four jack bolts. Adjust the height to
compensate for the thickness of the steel liners, refer to 1.2.3.
Check that the position of the chain pipe is in accordance with the
specification given on the installation drawing for the unit.
Driving shaft and driving shaft bearings:
The driving shaft has to rest in the bearings at about 6 oclock position and to
be parallel with the inside of the bearing bushings.
This to be checked by using a feeler gauge directly into the bearings and
checking the gap to be equals both sides.
Remove top cover of bearing housings to check the gap if no access from
outside is possible.
Tolerance: +/- 0,1 mm.
Driving shaft equipped with a mooring drum:
Start with adjusting the jack bolts to compensate for liner thickness.
Adjust the jack bolts clockwise until the shaft is resting at the 6 oclock
position in the bearing bracket. In correct position, the shaft shall rest with
equal spacing in all three bearings.
This to be checked by using a feeler gauge in the two bearings on cable lifter
unit. Remove top cover of bearing housings to check the gap if no access from
outside is possible.
Tolerance: +/- 0,1 mm.
Gear contact between the main wheel and pinion to be checked with blue
paints or lead thread.

5 Winch and Cable lifter unit combination

5.1 Alignment of Windlass
The cable lifter driving shaft and the anchor winch main shaft are to be aligned as
follows:
5.1.1

Start with aligning the cable lifter unit and continue with the anchor winch, see
section 4, 2 and 3 for instructions.
5.1.2 The horizontal offset tolerance between the two shafts is +/- 0.1 mm.
5.1.3 The main shaft of anchor winch should preferably be 0,2 - 0,3 mm higher than
the driving shaft of the cable lifter unit. This due to the fact that the windlass
driving shaft will be lifted up and come into contact with the upper part of the
bearing when the cable lifter is under tension.
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Title:

Installation Procedure, Deck Machinery

5.1.4

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Above demands can be checked by using a dial gauge. Check points, four
positions 3-6-9 and12 oclock around the outside of the two couplings.

Fig 5. Vertical offset, Winch and cable lifter combination

Note!
Excepted are cable lifter units of CUO type (driving shaft placed at the
opposite side). For these units the shafts to be in line.

5.2 Angular deviation

5.2.1 The angular deviation between the Winch main shaft and the driving shaft of
the Cable Lifter Unit is to be kept within a tolerance of 0,1 degrees.

Fig 6. Angular deviation between CU and Winch (horizontal and vertical)

5.2.2 There are several methods to check this:

5.2.3 With use of a feeler gauge.
Measure gap between the shaft ends of the shafts/couplings.
Guideline for the checking:
0,1 degrees deviation make 0,175 mm over 100 mm.
Measure the diameter (D mm) for shaft or coupling and use this formula to
calculate the maximum gap or use the table below:
0,175
D = Gap in mm.
100

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Title:

Installation Procedure, Deck Machinery

Shaft /
Coupling
diameter
(mm)
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250

GAP
(mm)
0,175
0,193
0,210
0,228
0,245
0,263
0,280
0,298
0,315
0,339
0,350
0,368
0,385
0,403
0,420
0,438

Shaft /
Coupling
diameter
(mm)
260
270
280
290
300
310
320
330
340
350
360
370
380
390
400
410

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GAP
(mm)
0,455
0,473
0,490
0,508
0,525
0,543
0,560
0,578
0,595
0,613
0,630
0,648
0,665
0,683
0,700
0,718

Shaft /
Coupling
diameter
(mm)
420
430
440
450
460
470
480
490
500
510
520
530
540
550
560
570

GAP
(mm)
0,735
0,753
0,770
0,788
0,805
0,823
0,840
0,858
0,875
0,893
0,910
0,928
0,945
0,963
0,980
0,998

5.2.4 An alternative is to place a ruler on one of the couplings and measure the gap
between ruler and shaft at two points with a distance of l .
To obtain certain accuracy, l should be at least 200mm.
Max allowable deviation to be calculated for a distance l by using the below
formulae or the table values:
0,175
l = Deviation in mm.
100

l
(mm)

Deviation
(mm)

200
210
220
230
240
250
260
270
280
290
300

0,350
0,368
0,385
0,403
0,420
0,438
0,455
0,473
0,490
0,508
0,525

Pusnes TM deck machinery

(mm)

Deviation
(mm)

(mm)

Deviation
(mm)

310
320
330
340
350
360
370
380
390
400

0,543
0,560
0,578
0,595
0,613
0,630
0,648
0,665
0,683
0,700

410
420
430
440
450
460
470
480
490
500

0,718
0,735
0,753
0,770
0,788
0,805
0,823
0,840
0,858
0,875

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5.2.5 With use of a dial gauge.

Attach a dial gauge to the cable lifter driving shaft, see fig. 7. By measuring
the offset on the winch driving shaft at two points with
distance l (min 100 mm ) , alignment and angular deviation is given.
Instructions:
Rotate the cable lifter driving shaft and measure the offset on the main shaft of
the winch.
Allowable offset, vertical, v pos .1 : +0,2-0,3mm (12 and 6 oclock)
Allowable offset, horizontal, h pos.1 : 0,1mm (3 and 9 oclock)
Move the measuring point ( l ) to Pos 2 figure 7.
0,175
l (12 and 6 oclock)
100
0,175
l (3 and 9 oclock)
: h pos .1
100

Allowable offset vertical, v pos .2 : v pos.1

Allowable offset horizontal, h pos.2

Fig 7. Alignment of windlass with use of dial gauge

5.2.6 When dial gauge is placed on claw coupling, use a wedge lock to avoid radial
movement between claw coupling and shaft, see fig.8.
To avoid damage on shaft and claw coupling, use a wedge lock made of brass
or copper.

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Fig 8. Radial locking of claw coupling

5.2.7 Use of two dial gauges at pos1. and pos.2 simultaneously would simplify the
aligning process.
5.3 Engagement of Claw Couplings
5.3.1

Inaccuracy in alignment of main shaft and driving shaft would lead to a radial
force acting on one claw face, instead of the desired torque transmission (force
equally distributed on two claw faces). If the radial force acting on only one
claw face it could result in overload and severe damage of claw face, shaft and
bearing bushings.

5.3.2

Control claw contact with a feeler gauge or marking colour. Turn driving shaft
(CU) in pull in direction to obtain pressure against contact face (area of
engagement) on claw coupling (main shaft on the anchor winch). Measure and
note gap at A and B.
5.3.3 Since there is two possible ways of engagement of claw couplings in each
rotating direction, rotate the driving shafts (CU) 180 degrees, and make new
engagement. Repeat procedure in 5.3.2.
5.3.4 If there have been gaps more than 0,8 mm between the claw couplings contact
areas in 5.3.2 and 5.3.3 improve the coaxial alignment between the shafts and
repeat procedure in 5.3.

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6 Tightening torque and final check

The winches and cable lifter units are now ready for moulding the liner compound
(winches) or making the final steel liners (cable lifter units).

)
6.1

6.2

6.3
6.4

Note!
All hydraulic pipe connections to be made after the compound is properly
hardened and the foundation bolts tightened to the specified torque.
When moulding, make sure that the jack bolts are not fastened in the liner
compound. This can be done by covering or greasing the treaded part of the
jack bolt in the moulding area.
After the liner compound is completely hardened and/or the steel liners are
finished, loosen the jack bolts slightly so the entire weight rests on the
foundation.
The foundation bolts shall be tightened according to specified torque, see
specification in the Working (Certified) Drawings.
As a final check of the alignment, all winches have to be run for 15 minutes in
each direction at varying speed, with the bearing temperature monitored.
After running the test of the Cable Lifter Unit:
Control/ adjust brake band support according to point 3.3.

7 Endstoppers
7.1.1

7.1.2

Endstoppers should be fitted in accordance to the Working (Certified)

Arrangement Drawings. Different arrangements can be used. Pusnes
recommend one of the alternatives shown in fig.9.
The endstoppers should be fitted with a clearance to the thrust edge. The
clearance must be wide enough to allow welding all around. Make wedges for
each endstopper to fit clearance. One edge being chamfered to leave room for
welding. Weld endstoppers to the foundation, drive the wedge home and tack
weld together.

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Fig 9. Alternative arrangement of endstoppers

Note!
1. Bolt, wedges, steel- or compound liners and endstoppers: Yards supply.
2. The fastening bolts may be mounted with head up or down.

8 Hydraulic Piping
Pipe dimensions and arrangement should be according to Working (Certified)
drawing: Pipe Diagram.
For further information see Pusnes instructions for hydraulic pipe installations.

9 Electric Installations
For installation of control columns, electric connections etc., refer to electric drawings
and instructions included in the Working (Certified) drawings.

10 Appendix

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10.1 Record Sheet Winch

10.2 Record Sheet Windlass

10.3 Gear Contact Record Sheet I/II

10.4 Gear Contact Record Sheet II/II