MAINTENANCE MANUAL

FREE FALL LIFE BOAT DAVIT & WINCH

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.
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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.

1 minute value by 1000 V megger at 40 degree rated

High voltage
voltage[kV] + 1[MQ]

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

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

Space heater
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

N INSEPCTION PART INSEPCTION OPERATION WEEKLY MONTHLY IF DIS
O PART NECESSARY POSAL

1 FREE Davit arm Operation

FALL
DAVIT
&
Slid ramp
Condition ○
Damage
STRUCTURE
Corrosion
Deformation
○
Supply
Grease ○
Guide Roller Operation
Condition ○
Damage,
Rotating ○
Davit Hinge Operation
pin
Sheave pin
Condition ○
Cyl. pin Wear
Corrosion ○
Supply
Grease ○
Boat Replacement At least
fall wire With 5 years or
& new one Change
Loose gears
○ Renew
4years
Wear
Corrosion ○
Supply
grease ○
Traverse Wear
Corrosion ○
Supply
grease ○
Main locking Operation
&
Sub-lashing
Condition ○
Damage
Corrosion ○

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INSPECTION CHECK LIST OF FREE FALL DAVIT

NO INSPECTION PART INSPECTION OPERATING WEEKLY MONTHLY IF DISPOSAL

ITEM NECESSARY

2 Pump Hyd. Operation

unit Motor Condition ○
Hyd
Leakage
pump
Cylinder
○
Electric Operation
Motor ○
Insulation
○
System Contamination
oil ○
3 Hoisting Hoisting Operation
Winch Winch condition ○

Noise

Oil leakage
○
Oil level
○
Oil Replacement At least 1
○ year

Hydro- Leakage
hose & ○ ○
fitting

Corrosion
Damage ○

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INSPECTION CHECK LIST OF FREE FALL DAVIT

NO NSEPCTION PART INSPECTION OPERATION WEEKLY MONTHLY IF DISPOSAL
ITEM TEST NECESSARY

4 ELECTRIC Electric Operation ○

PART Motor condition

Wiring Check ○

Insulation ○
check

Starter Operation ○
Condition

Contract ○
point check

Wiring Check ○

Control Operation ○
5/w box 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. a) Check wiring with circuit
diagram.
b) Insufficient power supply
voltage. b) Check the power supply.

c) Damage the fuse. c) Check all fuses.

d) Motor winding may be burnt out. d) Check that motor windings are
not burnt out.

2) Motor does not run up. a) OCR set incorrectly. a) Set the current correctly.

b) Wrong supply voltage. b) Check the supply voltage.

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

4)Over heating a) Motor wrongly connected. a) Check connections with

diagram.
b) Operate the over load.
b) Check the set value of over
current relay.

4.8.2 Mechanical troubles.

Troubles Causes Counter measures

1) Mechanical noise. a) Bearing damage or worn the a) Check the bearing.

HYD. Cylinder..

2) Vibration a) Poor, unstable and uneven a) Check the strength of

foundation. foundation and reinforce the
foundation.

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4.8.3 Hydrulic troubles.

Troubles Causes Counter measures

1) HYD. Pump is noise. a) The suction power of the pump a) Supply the oil into the oil tank.
is poor.

- The oil level in the tank is low.

2) HYD. Pump and motor a) The parts of the pump and motor a) Overhaul, inspect them and
make strange sound. are damaged or worn away. exchange the bad parts or new
ones.

3) Hoisting power drops down. a) The adjust screw of the relief a) Readjust the relief valve.
valve is loosened.
b) Vent air perfectly.
b) AIR is mixed.
c) Worm up oil by idling the pump.
c) The viscosity of the oil is too low.
-Exchange the HYD. Oil.

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

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