MAINTENANCE MANUAL

RESCUE BOAT / LIFE RAFT DAVIT & WINCH

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4. MAINTENANCE MANUAL

4.1 INTRODUCTION

The maintenance program has been developed by ORIENTAL in accordance to our 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 entails the following actions: - Lubrication - Inspection - Overhaul - Replace Lubrication : Lub. Lubrication is identified with following:

� Apply grease to grease nipples. � Apply lubricant 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.

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.

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- 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 � Do not let moisture, oil or dust collect on the hand brake or centrifugal

brake. 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 operation being stopped, the one way clutch functions automatically to prevent the boat from dropping by its own weight. It is necessary that this system is inspected once every ten years.

� Although this winch equipped the manual safety hoisting handle during the hoisting or lowering operation don’t fit manual handle on the driving shaft in any case.

� The engagement of gears can be detected from the noise. Listen to the noise from the start of 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.

� When in good order the winch should overturn after the boat is waterborne so as to give; If not check free running of bearings etc.

� When lowering, the centrifugal brake housing will heat up owing to the action of the governing brake. So long as this is not accompanied by an increase in the controlled lowering speed, this may be ignored. During tests or drill the brake should be allowed to cool before lowering again.

� If winch cover is removed for inspection, water tightness must be ensured on reassembly.

� Ensure that the weighted ‘deadman’ brake lever always engages the brake under its own momentum.

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(2) WIRE CLAMPER

The end of boat fall wire must be clearly fixed into wire clamper by proper torque.

[ Fig-5 ] (3) WIRE ROPE

1) Renew the wire rope in the following cases.

���� When more than 10% of the strands have been cut in one twist of the rope.

���� When decrease in diameter has been 7% of the nominal diameter of more.

���� When the rope has kinked. ���� When considerable deformation or corrosion has been found on the

rope. 2) Fall shall be turned end for end at intervals of not more than 30 months

and be renewed when necessary due to deterioration of the falls or at intervals of not more than 5 years, whichever is the earlier.

3) Wiring. Refer to GENERAL ARRANGEMENT & REMOTE CONTROL WIRE

4) Oiling wire rope. Oil the wire rope periodically to protect from corrosion as well as to have better lubrication.

(4) SHEAVE

While using sheave, the groove in contact with the rope wears.

Especially if pulling obliquely, flange wears faster and is damaged. When the groove has worn remarkably, or the flange has got out of shape or

broken, they should be substituted.

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(5) DAVIT

1) All sheaves and rollers or pivots must be thoroughly greased and must rotate freely.

2) Boat lashing and levers should move freely in a complete circle when the arm is in the outboard position.

(6) LUBRICATION

���� Rescue boat davit is mechanical devices. Like other machines if they are to retain their efficiency they must be regularly lubricated and inspected. All grease point on the davits and winch, as shown on the lubrication diagram, should be lubricated by a grease gun not less frequently than every six weeks.

���� Careless painting is the most frequent source of trouble with rescue boat davits. When painting, It is essential to ensure that no paint is applied to lubricating points, or to bearing or any moving parts due to impede their free movement.

1) It is desirable that bearing and wire rope are lubricated periodically, if

possible once a month.

2) Carry out the periodical inspection of oil level in winch gear case.

���� The oil level of winch gear case should be frequently checked. Other points calling for special attention are mentioned later. Suitable grades of recommended lubricants are listed at the back of this booklet.

3) Do not use winch gear oil containing additives as extreme pressure agent.

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4.4 WINCH MAINTENANCE

(1) REFERENCE DRAWINGS

Sectional drawings for winch assembly Brake unit arrangement with part list.

[ Fig-6 ]

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(2) BRAKE UNITS

The friction disk & lining disk is secured to the brake carrier (Part No. 511) The lining should be inspected annually and if it has been worn down to as much

1mm or damaged, It should be replaced. Never let the lining wear down to eliminate groove as this will cause damage to

the steel plate half of the clutch with subsequent rapid wear of the lining.

1) REPLACEMENT OF LINING DISK.

���� Loosen and remove the hex. bolt(M12X50L). ���� Disassemble brake case cover unit. ���� Replace the inner disk when it is worm down to eliminate groove. ���� Replace the friction disk when it is bended more than 2mm at the

maximum bended point. ���� Check the damage of pin hole and replace if it is found abnormal. ���� Check the bush, bearing and oil seal state and replace if it is found

abnormal. ���� Re-assembly to be of opposite sequence against disassembly. ���� To be fasten with torque the hex. bolt.

[ Fig-7 ]

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2) REPLACEMENT OF GEVERNOR BRAKE LINING

���� Disassemble the brake lining disk same as “1) REPLACEMENT OF

LINING DISK”. ���� Loosen and remove the set screw at the brake out ring. ① ���� Disassemble Brake out ring unit. ���� Loosen the counter-sunk head bolt on the brake shoe. ② ���� Replace the brake lining when it is worm down to 5mm from bolt head. ���� Re-assembly to be of opposite sequence against disassembly.

[ Fig-8 ]

[ Fig-9 ]

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(3) MANUAL HANDLE UNITS

These are screwed into either half of the motor pinion shaft (ITEM No. 205) and hand crank shaft (ITEM No. 308) with a left or right hand thread according to the required rotation.

(4) REPLACEMENT OF CAM CLUTCH

���� Cam clutch is a brake of the winch. Before the replacement, fix the

davit jib at the rest position and the wire drum is also fixed for prevent rotating of drum by self-weight.

���� Cam clutch consists of inside and outside wheel mode by special material, and cam inside wheel only rotate by rotating direction of the motor.

1) DISASSEMBLY

Before assembly, please confirm the rotating direction of the motor ���� Release the hex. bolt, and pull out the 2ND bearing cover. ���� Pull out the cam clutch unit & housing form 2nd shaft after remove snap

ring. ���� Disassembly cam clutch unit from housing. ���� Replace with now cal clutch unit. ���� Carefully remove the rust or damage that occur on the 2nd shaft by

using the proper sandpaper or etc. ���� Re-assembly to be of opposite sequence against disassembly.

[ Fig-10 ]

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※ CAUTION !

In the case that the dent exists in the shaft, renew shaft with new one.

[ Fig-11 ]

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4.5 MAINTENANCE PROGRAM.

M=Months, Y=Year, W=Week, H=Hours

PERIODIC MAINTENANCE PROGRAM Equipment Lub. Insp. Ovhl R. Action

General Inspection 1W

General inspection for leaks in hydraulic system Quantity of oil, to be in top of level glass Crane functionality Emergency (operation) (if applicable) Accumulator oil pressure (if applicable) Check for wire damage Check for damage of lifting equipment (hook etc.)

Grease nipples

(General)

1M/100H Apply grease to all grease nipples. Include wire sheaves, cylinders, el.Motor and docking head.

3M/

100H

Inspect for proper function, damage, corrosion. Remove excess grease.

! Replace if damaged.

Winch / slew gear drive

pinion

1M/100H Apply special grease to drive pinion and ring tooth.

1Y/500H Check for wear / abnormal tooth clearance

! Replace if damaged.

Wire

3M/200H Apply grease onto wire

1M/200H Inspect due to corr. & wear. Rub length of wire with a cloth to detect broken strands.

3M/100H Inspect wire secured to winch drum. Check torque.

! Replace if damaged.

Wire sheaves 6M/200H

Inspect for corrosion, wear, cracks. Check bolts. Inspect that wire sheave rotates freely.

! Replace if damaged.

Accumulators

6M/200H Inspect general condition. Check nitrogen pressure value according to flow diagram.

! ! Overhaul or replace if unable to hold the necessary charge. Contact OPCO. After Sales

Winch / slew motor

3M/100H Inspect for any abnormal noise, vibration, leaks. Inspect valves (paint, leaks, corrosion)

5Y Overhaul component.

! Replace if damaged.

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M=Months, Y=Year, W=Week, H=Hours

PERIODIC MAINTENANCE PROGRAM Equipment Lub. Insp. Ovhl R. Action

Winch / hoisting Gearbox

3M/100H Inspect for any abnormal noise, vibration, Tighten bolts if required. Inspect general condition (paint, leaks, corrosion)

3M/50H Check gear oil level

1Y Change oil.

5Y Overhaul component

! Replace if damaged.

Electric Motor and hydraulic

pump

3M/200H Inspect for any abnormal noise, vibration, corrosion, leaks.

5Y Check for wear / abnormal tooth clearance

! Replace if damaged.

Sliding surfaces

(If mounted) 3M/200H 3M/200H

Apply grease

Check for wear

Adjust sliding pads

Hydraulic hoses, fittings,

couplings

6M/200H Check condition of horses.

! Replace if damaged.

Hydraulic valves

6M/200H

Inspect for any abnormal noise or function. Inspect condition (paint, leaks, corrosion) Apply grease to the valve levers (the rubber cap must be removed).

! Replace if damaged.

Mechanical components

6M/200H Inspect the entire crane for structural damage. Check for corrosion. Inspect paint condition.

! Replace if damaged.

Hydraulic system oil 1Y

Take oil sample for analyses Change if necessary

Hydraulic oil filter

6M/500H Inspect filter for abnormal contamination

6M/500H Replace

Bolts and nuts

6M/500H Inspect all bolts and nuts on crane. Foundation bolts especially.

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4.6 TROUBLE SHOOTING METHOD

NO Trouble contents Cause Disposal

1

Not operate Jib slewing-out when the manual control valve

or R/C line for slewing are operated properly.

Not power on Power on

Manual control valve Damaged

To check and maintenance or valve replace

2 Not operate power pack

Not power on Electric Motor damaged Not supply power

To check and maintenance or motor replace

3 Jib swing-out speed high

Misoperate. counter balance valve damaged

To check and maintenance Replace the counter b. valve

4 Lowering speed is too fast

Worn down the brake shoe of centrifugal brake

Dismantle centrifugal brake and check that there is a oil on the brake shoes. Clean if necessary or renew.

5 Lowering speed is too slow

Greasing is not enough on the moving parts.

Check free running of sheaves and winch. Greasing on it if necessary.

6 Brake or clutch fails to hold

boat

Brake system is needed is worn down.

Dismantle brake housing and check the clutch bearing (Part No. 404) Check the friction disk brake lining for grease or oil (Part No. 511) Check the were, renew if necessary

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7 Winch not free running -

Check that oil in grease point is of correct viscosity and level. Check gear teeth for brakeage and gear case for foreign matter. Check bearing for collapse, and bearing and shaft for rust and corrosion Check that clutch case has not broken

NOTE SOLAS chapter ⅢⅢⅢⅢ Regulation 19 Maintenance of Falls states “ Falls used in launching shall be turned the end for end at interv als of not more than 30 months and be renewed when necessary due to deterio ration of the falls or at intervals of not more than 5 years, whichever is th e earlier ” The instruction comply with SOLAS 83 Chapter ⅢⅢⅢⅢ Reg.19.Reg.19.Reg.19.Reg.19.