4. MAINTENANCE MANUAL

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Dominic Gilbert
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1 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. DWG. NO.RD / 14

2 - 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. DWG. NO.RD / 14

3 (2) WIRE CLAMPER The end of boat fall wire must be clearly fixed into wire clamper by proper torque. (3) WIRE ROPE [ Fig-5 ] 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. DWG. NO.RD / 14

4 (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. DWG. NO.RD / 14

5 4.4 WINCH MAINTENANCE (1) REFERENCE DRAWINGS Sectional drawings for winch assembly Brake unit arrangement with part list. [ Fig-6 ] DWG. NO.RD / 14

6 DWG. NO.RD / 14

7 (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 ] DWG. NO.RD / 14

8 [ Fig-8 ] 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-9 ] DWG. NO.RD / 14

9 (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 2 ND bearing cover. Pull out the cam clutch unit & housing form 2 nd 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 2 nd shaft by using the proper sandpaper or etc. Re-assembly to be of opposite sequence against disassembly. [ Fig-10 ] DWG. NO.RD / 14

10 [ Fig-11 ] CAUTION! In the case that the dent exists in the shaft, renew shaft with new one. DWG. NO.RD / 14

11 4.5 MAINTENANCE PROGRAM. M=Months, Y=Year, W=Week, H=Hours PERIODIC MAINTENANCE PROGRAM Equipment Lub. Insp. Ovhl R. Action General Inspection Grease nipples (General) Winch / slew gear drive pinion Wire Wire sheaves 1M/100H 1M/100H 3M/200H 1W 3M/ 100H 1Y/500H 1M/200H 3M/100H 6M/200H 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.) Apply grease to all grease nipples. Include wire sheaves, cylinders, el.motor and docking head. Inspect for proper function, damage, corrosion. Remove excess grease. Apply special grease to drive pinion and ring tooth. Check for wear / abnormal tooth clearance Apply grease onto wire Inspect due to corr. & wear. Rub length of wire with a cloth to detect broken strands. Inspect wire secured to winch drum. Check torque. Inspect for corrosion, wear, cracks. Check bolts. Inspect that wire sheave rotates freely. 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 5Y Inspect for any abnormal noise, vibration, leaks. Inspect valves (paint, leaks, corrosion) Overhaul component. DWG. NO.RD / 14

12 PERIODIC MAINTENANCE PROGRAM Equipment Lub. Insp. Ovhl R. Action Winch / hoisting Gearbox 1Y 3M/100H 3M/50H 5Y Inspect for any abnormal noise, vibration, Tighten bolts if required. Inspect general condition (paint, leaks, corrosion) Check gear oil level Change oil. Overhaul component Electric Motor and hydraulic pump 3M/200H 5Y Inspect for any abnormal noise, vibration, corrosion, leaks. Check for wear / abnormal tooth clearance 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. 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). Mechanical components Hydraulic system oil Hydraulic oil filter Bolts and nuts 1Y 6M/200H 6M/500H 6M/500H M=Months, Y=Year, W=Week, H=Hours Inspect the entire crane for structural damage. Check for corrosion. Inspect paint condition. 6M/500H Take oil sample for analyses Change if necessary Inspect filter for abnormal contamination Replace Inspect all bolts and nuts on crane. Foundation bolts especially. DWG. NO.RD / 14

13 4.6 TROUBLE SHOOTING METHOD NO Trouble contents Cause Disposal Not power on Power on 1 Not operate Jib slewing-out when the manual control valve or R/C line for slewing are operated properly. Manual control valve Damaged To check and maintenance or valve replace 2 Not operate power pack 3 Jib swing-out speed high 4 Lowering speed is too fast 5 Lowering speed is too slow Not power on Electric Motor damaged Not supply power Misoperate. counter balance valve damaged Worn down the brake shoe of centrifugal brake Greasing is not enough on the moving parts. To check and maintenance or motor replace To check and maintenance Replace the counter b. valve Dismantle centrifugal brake and check that there is a oil on the brake shoes. Clean if necessary or renew. Check free running of sheaves and winch. Greasing on it if necessary. Brake system is needed is worn down. Dismantle brake housing and check the clutch bearing (Part No. 404) 6 Brake or clutch fails to hold boat Check the friction disk brake lining for grease or oil (Part No. 511) Check the were, renew if necessary DWG. NO.RD / 14

14 Check that oil in grease point is of correct viscosity and level. 7 Winch not free running - 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 Ⅲ Regulation 19 Maintenance of Falls states Falls used in launching shall be turned the 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 The instruction comply with SOLAS 83 Chapter Ⅲ Reg.19. DWG. NO.RD / 14

WARNING. Electric Recovery Winch. General Safety Precautions

WARNING. Electric Recovery Winch. General Safety Precautions 1 Electric Recovery Winch Thanks for purchasing a WINCH. This manual covers operation and maintenance of the winch. All information in this publication is based on the latest production information available