4. MAINTENANCE MANUAL - opcois.com FFL_66/FFD_4... · FREE FALL LIFE BOAT DAVIT & WINCH DWG NO....

MAINTENANCE MANUAL FREE FALL LIFE BOAT DAVIT & WINCH

DWG NO. FD0000-990000-4000 1/15

4. MAINTENANCE MANUAL

4.1 INTRODUCTION

The maintenance program has been developed by ORIENTAL in accordance with

supplier’s own maintenance program for each component. Conforming to this

maintenance program will ensure long-time trouble-free operation and eliminate

unexpected occurrences.

4.2 DESCRIPTION OF MAINTENANCE ACTIONS

The maintenance program contain the following actions:

- Lubrication - Inspection

- Overhaul - Replace

Lubrication : Lub.

Lubrication is identified with following:

� Apply grease to grease nipples.

� Apply grease or oil onto surfaces due to friction or corrosion.

� Refill or change oil to system or component.

Inspection : Insp.

Inspection is identified with the following:

� Check component for any damage.

� Check for correct function of each component.

� Check for any unfamiliar noise from each component.

� Check for any abnormal vibration from rotating components.

� Check for correct oil quantity.

� Check paint condition on all components.

� Check for leaks.

� Check for corrosion.

� Check main fall wire for wear.


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Overhaul : Ovhl.

Overhaul is identified with the following :

� Remove the component from the unit.

� Disassemble the component and inspection each part.

� Repair if necessary :

- Bearings.

- O-rings

- Hydraulic valves fittings and hoses.

- All bolts, nuts and washers.

� Clean all components before mounting assembly.

� Replace or components if required, before mounting assembly.

� Repair damaged painted areas.

Replace : R

Replace is identified with the following:

� Remove original component and exchange with a new component

4.3 GENERAL CAUTION

(1) WINCH � Carry out the periodical inspection on each brake lining, if possible once 6

months, and replace those which are extremely worn with new ones.

� In case of the hoisting/lowering operation being stopped, muti-disc hydro-

brake acts automatically to prevent the boat from dropping by its own weight.

It is necessary that this system is inspected once every years.

� The engagement of gears should be of free detected from the noise.

Listen to the noise from the operation. When opening the casing cover to

change the oil and inspect the gear, remove the cover carefully to avoid dust

of foreign matter from entering.


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(2) WIRE CLAMPER The end of boat fall wire clearly fixed into wire clamper by proper torque.


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4.4 LUBRICATION To preserve the service life of this system and effective operation, it is important to

execute properly. That is Comprehend hoisting winch, davit arm hinge pin, sheave pin,

cylinder pin and etc which is required greasing or inspection periodically according to

lubrication oil chart. [table-1]

Greasing (see Fig-16)

Greasing point required for each component is provided grease nipple PT 1/8 greasing

periodically for each component to be follow up according to lubrication oil chart.

[table-1]

Gear oil (see Fig-16)

Replace the gear oil of the hoisting winch at list once one year. Check periodically oil

quantity. If discoloration by mixing moisture, water and etc, remove oil through the drain

plug. Fill gear oil up to oil gauge center line.


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Greasing Point


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4.5 INSPECTION & REPLACEMENT OF BOAT FALL WIRE

The most important element of this system is the life of wire rope. Breakage of rope will

result in disastrous accident, and due care should be taken during maintenance and

inspection.

(1) Judgment of the life

It is extremely difficult to judge the wire rope internal state from the outside.

Indeed, necessity of replacement is determined by means of the outside state.

Representative factors related to judgment are described below :

a. Worn rope

Rope worn to 7 % of the original diameter

b. Deformation

Return of twist or kink(in particular, kink) causes permanent damage.

If deformation appears corrected, the damage point becomes a weak point

where the strength drops to one half, Any kink, if occurring during operation,

should be corrected while sopping the operation tentatively. Resume

operation after correction.

c. Corrosion

Check if simple red rusting exists or any corrosion has occurred or there is

any possibility of internal corrosion.

(2) Protection of wire rope

Application of grease may prove effective to prolong the effective life of the rope.

It has been proved that the greased rope shows the life at least two to three

times longer than the greased rope. Generally, the greased rope is asphalt-

based with composition oil superior in pressure and weather resistances used as

adhesive.

(3) Checking for abnormality in join and termination.

Check the join for any protruding, dislodging inserted terminal wire or for any

displaced clip.

(4) Replacement of boat fall wire.

From the inspection as per above procedure, replace with new one when

necessary due to wear or not later than five years whichever is earlier.


DWG NO. FD0000-990000-4000 8/15

4.6 INSPECTION FOR MOTOR

The quality of maintenance gives a large influence to the life of motor.

1) Planning of inspection and maintenance

a) Since an emergency motor to absorb moisture during a long rest, and insulation

resistance is lowered, it needs daily attention but does not need overhaul inspection

by disassembly so often.

b) A motor continuously used for pump or fan needs disassembly for cleaning and

inspection.

c) Preserve the records of daily inspection, monthly inspection and overhaul for

future reference.

2) Daily inspection

a) Listen to sound.

Listen to the sound of every part of motor using a stethoscope bar, magnetic sound,

sound of mechanical friction or sound of abnormal bearing can be perceived.

b) Pay attention to smell.

When the motor gets overloaded due to disturbed ventilation, a special bad-smell of

burnt varnish makes you perceive a trouble.

c) Judgment from appearance

Check for all leakage, disturbance in the ventilation, etc.

d) Because it is dangerous to check the temperature of bearing, frame, etc.

By touching use a temperature measuring device such as an alcohol thermometer.

3) Monthly inspection

a) Measurement of insulation resistance

Check whether the insulation resistance is a specified value or higher.

b)Surface panting

If the surface painting comes off, rust takes place rapidly. Repair it immediately


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when the painting has come off.

4) Inspection and cleaning at disassembly

a) Bearing

Remove dirt and rust on bearing and its housing

b) Coil and insulation

Check for the looseness of binding strings for coils and the adgesion of dust.

Repair or clean if any.

c) Other parts

Clean off dirt.

Well-keeping of coil and insulation

1) When coil gets moisture.

In addition to at a specified time in the maintenance schedule, measure the

insulation resistance of the coil in such a case that it has absorbed moisture

during transportation, stage or rest. If the measured value is lower than the

following value, dry the coil without foil.

High voltage 1 minute value by 1000 V megger at 40 degree rated

voltage[kV] + 1[MQ]

Low voltage 1 minute value by 500 V megger at 40 degree 1[MQ]

Space heater 1 minute value (before charge) by 500 V megger at normal

temperature 1[MQ]

Dry the coil by either of the following methods until the recovery of insulation

resistance is confirmed.

a) Dry it in a drying furnace at a temperature not exceeding 90 °c

b) Cover the motor with canvas or a similar cover having a vent hole at the top,


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and dry it by blowing in hot air or by placing a heater device or a lamp in the

cover. In that case, it is necessary to control the temperature at 90°c max, so

as to avoid local heating.

2) In case of soiled coil

When the coil is soiled or the insulation resistance cannot recover by drying,

clean it as follows:

a) Wipe off dust on coil, wash it with detergent and hot water or low pressure

steam, thereafter rinse it with clean water.

b) If the dirt cannot be removed thoroughly with detergent, wash it by chloride.

At that time, take care not to be poisoned.

c) Dry the coil in either of the methods mentioned on above(1).

d) If possible, apply high quality varnish by brushing, spraying or dipping

when the coil is dried up and still warm.

e) Before starting, check the insulation resistance without fail.


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4.7 PERIODIC INSPECTION CHECK LIST OF FREE FALL DAVIT

INSPECTION CHECK LIST OF FREE FALL DAVIT

NO

INSEPCTION PART INSEPCTION PART

OPERATION WEEKLY MONTHLY IF NECESSARY

DIS POSAL

1 FREE FALL DAVIT STRUCTURE

Davit arm & Slid ramp

Operation Condition ○

Damage Corrosion Deformation

○

Supply Grease ○

Guide Roller Operation Condition ○

Damage, Rotating

○

Davit Hinge pin Sheave pin Cyl. pin


Wear Corrosion

○

Supply Grease ○

Boat fall wire & Loose gears

Replacement With new one

○

At least 5 years or Change Renew 4years

Wear Corrosion ○

Supply grease ○

Traverse Wear Corrosion

○

Supply grease ○

Main locking &

Sub-lashing


Damage Corrosion ○


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NO INSPECTION PART INSPECTION ITEM

OPERATING WEEKLY MONTHLY IF NECESSARY

DISPOSAL

2 Pump unit

Hyd. Motor

Hyd pump

Cylinder


Leakage ○

Electric Motor

Operation ○

Insulation ○

System oil

Contamination ○

3 Hoisting Winch

Hoisting Winch

Operation condition

○

Noise

Oil leakage ○

Oil level ○

Oil Replacement ○

At least 1 year

Hydro-hose & fitting

Leakage ○

○

Corrosion Damage

○


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NO NSEPCTION PART INSPECTION ITEM

OPERATION TEST

WEEKLY MONTHLY IF NECESSARY

DISPOSAL

4 ELECTRIC PART

Electric Motor

Operation condition

○

Wiring Check ○

Insulation check

○

Starter Operation

Condition

○

Contract point check

○

Wiring Check ○

Control 5/w box

Operation condition

○

Cab type cable check

○

Spear parts

○


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4.8 TROUBLE SHOOTING METHOD

4.8.1 Electrical trouble.

Troubles Causes Counter measures

1) Motor fails to start. a) Wrong wiring connection.

b) Insufficient power supply voltage.

c) Damage the fuse.

d) Motor winding may be burnt out.

a) Check wiring with circuit diagram.

b) Check the power supply.

c) Check all fuses.

d) Check that motor windings are not burnt out.

2) Motor does not run up. a) OCR set incorrectly.

b) Wrong supply voltage.

a) Set the current correctly.

b) Check the supply voltage.

3) Shut down the motor. a) Too high hyd. Oil pressure on pump unit.

a) Check the hyd. Oil pressure of relief valve on pump unit.

4)Over heating a) Motor wrongly connected.

b) Operate the over load.

a) Check connections with diagram.

b) Check the set value of over current relay.

4.8.2 Mechanical troubles.


1) Mechanical noise. a) Bearing damage or worn the HYD. Cylinder..

a) Check the bearing.

2) Vibration a) Poor, unstable and uneven foundation.

a) Check the strength of foundation and reinforce the foundation.


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4.8.3 Hydrulic troubles.


1) HYD. Pump is noise. a) The suction power of the pump is poor.

- The oil level in the tank is low.

a) Supply the oil into the oil tank.

2) HYD. Pump and motor make strange sound.

a) The parts of the pump and motor are damaged or worn away.

a) Overhaul, inspect them and exchange the bad parts or new ones.

3) Hoisting power drops down. a) The adjust screw of the relief valve is loosened.

b) AIR is mixed.

c) The viscosity of the oil is too low.

a) Readjust the relief valve.

b) Vent air perfectly.

c) Worm up oil by idling the pump.

-Exchange the HYD. Oil.

4) Hunting in lowering. a) The damper of the over center valve is loosened.

a) Readjust the damper.

4. MAINTENANCE MANUAL - opcois.com FFL_66/FFD_4... · FREE FALL LIFE BOAT DAVIT & WINCH DWG NO....

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