cm p4766 69 sjtp issue a
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Cargotec CHS Asia Pacific Pte LtdOffshore Load HandlingMailing and Site Address:48 Tuas RoadSingapore 638500Tel +65 6861 3922Fax +65 6862 4334www.cargotec.com
Domicile
Singapore
Co. Reg. No. 199404157W
GST No.M2-0125279-2
Registered Address
No. 15 Tukang Innovation Drive
Singapore 618299
OPERATION/MAINTENANCE MANUALREFERENCE NO. CM-P4766-69-SJTP-ISSUE- A
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Cargotec Reference No. : P4766-69
Subject : Operational Manual of Deck Machinery
1. CargotecHydraulic Shark Jaw
2. Cargotec Hydraulic Towing Pin
3. Electro-Hydraulic Power Pack
Hull No. : ZJB10-ZJ3001
Project Name : SPA80 AHTS
Buyer : Zhejiang Shipbuilding Co., Ltd
Owner : Surf (Offshore Division of Group Bourbon)
Designed & Built By : Cargotec CHS Asia Pacific Pte Ltd
Equipment Serial No. : Cargotec Hydraulic Shark Jaw - Tow Pin
P4766-69-MG-STA-250-S
Electro-Hydraulic Power Pack
P4766-69- P1x22-SJ-001
Year Built : 2011
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INTRODUCTION
The Operation Manual consists of Cargotec unit components, system, operating instruction,maintenance, troubleshooting and recommended spare parts.
For Customer Supportand Ordering of Spare Parts, please contact our Customer ServiceDepartment and provide us with Cargotec Reference Number and Equipment Serial
Number.
Customer Service Department: -
Cargotec CHS Asia Pacific Pte LtdNo. 48 Tuas RoadSingapore 638500Tel No : (65) 6868-85-62Fax No : (65) 6862-24-52
E-mail : [email protected]
For more information, please contact:-
Head Office:-
Cargotec CHS Asia Pacific Pte LtdNo. 48 Tuas RoadSingapore 638500Tel No : (65) 6861-39-22 (10 Lines)Fax No. : (65) 6862-43-34
E-mail : [email protected]
Sales Department:-
Cargotec CHS Asia Pacific Pte LtdNo. 48 Tuas RoadSingapore 638500Tel No : (65) 6868-85-33Fax No : (65) 6862-43-34E-mail : [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected] -
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SAFETY PRECAUTIONS
WARNING!!
CARELESS OPERATION CAN RESULT IN SERIOUS INJURY OR DAMAGE.
READ AND UNDERSTAND ALL SAFETY AND OPERATING INSTRUCTIONS
BEFORE INSTALLING AND OPERATING THE PLIMSOLL DECK MACHINERY.
CAUTION!
DO NOT EXCEED THE LINE PULL RATING SHOWN ON THE IDENTIFICATION
LABEL.
DO NOT EXCEED THE MAXIMUM RATING OF THE WIRE ROPE BEING USED.
THE EQUIPMENTS DESCRIBED HEREIN ARE NEITHER DESIGNED NOR
INTENDED FOR LIFTING NOR MOVING PEOPLE.
INCOMING INSPECTION!
ON THE ARRIVAL OF THE EQUIPMENTS AND PACKAGING, THERE SHOULD
BE A VISUAL INSPECTION WITH REFERENCE TO THE PACKING LIST, FOR
ANY DAMAGES INCURRED DURING TRANSPORTATION.
ALL DAMAGE REPORTS SHOULD BE SUBMITTED TO THE MANUFACTURER
WITHIN 7 DAYS FROM THE ARRIVAL OF THE EQUIPMENTS AND
PACKAGING.
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CONTENTS
INTRODUCTION............................................................................................................................................ - 2 -
SAFETY PRECAUTIONS.............................................................................................................................. - 3 -
CHAPTER 1: CARGOTEC HYDRAULIC SHARK JAW & TOW PIN PACKAGE.................................. - 5 -
1.1 QUANTITYANDDESCRIPTION......................................................................................................... -5-
1.2 EXCLUSIONS................................................................ ................................................................. ........ -5-
CHAPTER 2: CARGOTEC SHARK JAW-TOW PIN................................................................................... - 6 -
2.1 TECHNICALDESCRIPTION............................................................ .................................................... -6-
2.1.1 General Data ................................................................................. .................................................... - 8 -
2.2 OPERATIONINSTRUCTION........................................................... .................................................... -9-
2.2.1 At Power Pack hydraulic oil Reservoir Level Gauge .......................................................................... - 9 -
2.2.2 At Power Pack Starter Panel ............................................................................................ ................. - 9 -
2.2.3 At Remote Control Panel in Wheelhouse ..................................... .................................................... - 9 -
2.3 REFERENCEDRAWINGS................................................................................................................. -11-CHAPTER 3: CONTROL FUNCTIONS...................................................................................................... - 17 -
3.1 REMOTE CONTROL PANEL............................................................................................................... ...... -17-
3.2 PENDANT CONTROLLER......................................................................................................................... -20-
CHAPTER 4: ELECTRO-HYDRAULIC POWER PACK AND HYDRAULIC........................................ - 21 -
SYSTEM........................................................................................................................................................ - 21 -
4.1 GENERALDESCRIPTION................................................................................................................. -21-
4.2 DATAOFPOWERPACK................................................................................................................... -22-
4.2.1 Rating ........................................................... .................................................................... ............... - 22 -
4.2.2 Electric Motor .............................................. ................................................................. .................. - 22 -
4.2.3 Hydraulic Pump .................................................................. ............................................................. - 22 -
4.2.4 Oil Reservoir ............................................................. ................................................................ ....... - 22 -
4.2.5 Motor Starter ............................................................................................ ...................................... - 22 -
4.2.6 Hydraulic Oil Selection .................................................................. .................................................. - 23 -
4.3 HYDRAULICREFERENCEDRAWINGS....................................................................... .................. -24-
4.4 ELECTRICALREFERENCEDRAWINGS............................................................. ........................... -27-
CHAPTER 5: SPARES LIST....................................................................................................................... - 40 -
4.5 HYDRAULIC COMPONENTS (SJTA).................................................................. ...................................... -40-
4.6 MECHANICAL COMPONENTS (SJTA)..................................................................................................... -42-
CHAPTER 6: MAINTENANCE / TROUBLESHOOTING.............................................................. - 43 -
5.1 MAINTENANCEOFHYDRAULIC&ELECTRICSYSTEM............................................................ -43-5.1.1 General Instruction ....................................................................... .................................................. - 43 -
5.1.2 Routine Maintenance ................................. .................................................................. .................. - 44 -
5.1.3 Periodic Maintenance ................................................................................................... .................. - 45 -
5.2 MAINTENANCEOFEQUIPMENT(SHARKJAW&TOWINGPIN)....................................... ...... -45-
5.3 TROUBLESHOOTING............................................................................................. ........................... -46-
5.3.1 General Instruction ....................................................................... .................................................. - 46 -
5.3.2 Trouble Shoot & Remedy .............................................................. .................................................. - 46 -
5.4 SERVICINGOFSHARKJAWS......................................................................................................... -48-
5.5 JAWCYLINDERREMOVALPROCEDURE.................................................................................... -50-
5.6 WIRELIFTERASSEMBLYREMOVALPROCEDURE............................................................. ...... -50-
5.7 GEAROILSELECTION...................................................................................................................... -52-
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CHAPTER 1: CARGOTEC HYDRAULIC SHARK JAW & TOW PIN
PACKAGE
1.1 QUANTITY AND DESCRIPTION
Quantity Description
(1) each Shark Jaw Assembly. Internal hydraulic hoses and fittings are included.One set of Jaw plates is included.
(1) each Dual Towing Pin Assembly. Internal hydraulic hoses and fittings areincluded.
(1) each Hydraulic Power Unit (HPU)
(1) each Control Pendant for local operation.
(1) each Motor Starter in IP-54 enclosure
(1) each Drop-In control panel with Programmable Logic Controller.
1.2 EXCLUSIONS
1. On-board installation and hook-up.
2. Interconnecting electrical wiring and hydraulic piping between the Shark Jaws,HPU and controls panels.
3. Supply of hydraulic oil, lubricating grease, hydraulic piping, fittings and hoses.
4. Flushing of hydraulic system.
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CHAPTER 2: CARGOTEC SHARK JAW-TOW PIN
2.1 TECHNICAL DESCRIPTION
The Shark Jaws are designed to secure chain or wire during anchorhandling operations. The unit is comprised of two opposing jaws and a wirelifter pin situated in a common frame, which is welded into the deck of thevessel.
The Shark Jaws are designed to hold chain or wire with line tensions of thesafe working load. The jaws plates are designed for use with a specificrange of Chain and Wire size.
The Shark Jaws mounting frame is watertight and has three drain fittings for
connection by the installing shipyard. The mounting frame top and bottomplates are furnished with extra length and width weld bevels to facilitate aneasier installation. The design and supply of supporting and / orreinforcement structures are the responsibility of others.
The two jaws and wire lifter pin are independently raised and lowered bymarine grade hydraulic cylinders having chrome plated stainless steel rods.The jaws are raised using the rod side of the cylinder and lowered usingthe blind end of cylinder. This arrangement provides a more efficient use ofhydraulic pressure working against the maximum amount of surface area inthe cylinder during Quick Release.
The jaws are fitted with stainless steel proximity sensors to verify that thejaws are fully raised and ready to accept the loaded chain. When the jawsare raised they are locked into place by the over center linkage, keeping thecylinders away from the load path. To provide added security when holdingthe chain or wire, there are check valves in the hydraulic system to maintainhydraulic pressure on the cylinders.
The chain or wire under tension can be released with the Quick Releasesystem. The Quick Release incorporates the use of a hydraulic accumulatorin the hydraulic system. When the Quick Release buttons are pressed, theTowing pins, wire lifter and both jaws are lowered in 5-8 seconds. The QuickRelease system may be used up to the rated load. In the event of AC powerloss (dead ship) the quick release system operates on back-up 220VAC /24VDC control power from the vessel.
The Shark Jaws operates from a dedicated Hydraulic Power Unit mountedbelow deck consisting of reservoir, pump and a motor (IP-54 rating),enclosed motor starter, solenoid valves, filters, accumulators, oil level gaugeand low oil level sensor mounted below deck. The HPU is also designed tooperate the Plimsoll Smith Berger Towing Pins.
The Shark Jaws are remotely controlled from a drop-in control panel locatedin the wheelhouse. An additional control pendant is supplied for local
operation. The operating system features a Programmable Logic Controller(PLC).
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2.1.1 General Data
Model No. : MG-STA-250-S
Safe Working Load : 250 Tonne
Chain Size : 38 mm to 114 mm
Wire Size : 32 mm to 120mm
Control : Remote Control Panel
: Pendant Control
For other Jaw Plate size (not supplied), please refer to Table A (Checked boxindicates Jaw Plate supplied).
Please contact our After Sale Departmentfor additional Jaw Plate.
*
*
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2.2 OPERATION INSTRUCTION
2.2.1 At Power Pack hydraulic oil Reservoir Level Gauge
[Press] Upper and lower isolating plungers[Observe] Oil in Glass tube to be at least at Level
2.2.2 At Power Pack Starter Panel
POWER ON INDICATOR LIGHT (white light) [ON]
MOTOR RUN INDICATOR LIGHT (Green light) [OFF]
MOTOR TRIP INDICATOR LIGHT (Yellow light) [OFF]
MOTOR SPACE HEATOR ON INDICATOR LIGHT (Blue light) [ON]
2.2.3 At Remote Control Panel in Wheelhouse
[Rotate]
DIMMER until Red illumination light is visible[Observe] HPU POWER ON (White light) [ON]
[Observe] START (Green light) [OFF]
[Observe] STOP (Red light) [OFF]
[Switch] 24V DC to [ON]
[Observe] 24V DC ON (white light) [ON]
[Switch] STATION to [WH]
To run HPU
At HPU section
[Press] HPU to [START][Observe] START (Green light) [ON]
[Observe] STOP (Red light) [OFF]
[Observe] ACCUMULATOR CHARGED (Green light) [ON]
To Raise Tow Pins
[Switch] PORT PIN to [UP][Switch] STDB PIN to [UP]
To Retract Tow Pins
[Switch] PORT PIN to [DOWN]
[Switch] STDB PIN to [DOWN]
To Raise Shark Jaws
[Switch] PORT JAW to [UP]
[Ensure] PORT JAW LOCKED (Green light) [ON]
[Switch] STDB JAW to [UP]
[Ensure] STBD JAW LOCKED (Green light) [ON]
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To Retract Shark Jaws
[Switch] PORT JAW to [DOWN]
[Ensure] PORT JAW LOCKED (Green light) [OFF]
[Switch] STDB JAW to [DOWN]
[Ensure] STBD JAW LOCKED (Green light) [OFF]
WARNING!
ONLY RAISE WIRE-LIFTER WHEN SHARK JAWS ARE FULLY RAISED
SHARKJAWS TO BE RETRACTED ONLY WHEN WIRE LIFTER IS FULLY
RETRACTED. OTHERWISE, DAMAGE TO WIRE LIFTER MAY OCCUR
DO NOT USE WIRE LIFTER TO HANDLE CHAIN
To Raise Wire Lifter
[Switch] LIFTER to [UP]
To Retract Wire Lifter
[Switch] LIFTER to [DOWN]
To Quick Release
[Press] PRESS BOTH BUTTONS TO OPEN JAWS[Observe] R (Red light) [ON]
[Observe] R (Red light) [ON]
NOTE!
The QUICK RELEASE is a facility to release a load quickly by first retracting the wire
lifter and immediately followed by both shark jaws. The QUICK RELEASE is powered by
high pressure oil from the accumulator.
Shut down Operation
At HPU section
[Press] HPU to [STOP][Observe] STOP (Red light) [ON][Observe] START (Green light) [OFF]
[Observe] POWER ON (White light) [ON]
Carry out visual inspection of the equipment and secure any loose components. Check OilReservoir level for any loss of oil during operation. Any leakage in the hydraulic system is to berectified before topping up. Carry out thorough cleaning and preservation routine on all areas.
POWER SUPPLY TO POWER PACK STARTER PANEL TO REMAIN ON FOR MOTORSPACE HEATER.
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2.3 REFERENCE DRAWINGS
Item Title Drawing No. Page Revision
1. 250T Hydraulic Shark Jaw & Tow PinGeneral Arrangement
STA-250-S-0 1 Of 1 C
2. 250T Hydraulic Shark Jaw & Tow PinAssembly
D60000-PM 1 Of 22 Of 2
CC
3. 250 MT Shark Jaws Assembly, Jaw B59775-P 1 Of 1 C
4. 250 MT Shark Jaws Assembly,Linkage
B57412-P 1 Of 1 C
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CHAPTER 3: CONTROL FUNCTIONS
The following control functions are provided for Shark Jaw & Towing Pin unit at the followinglocation.
3.1 Remote Control Panel
Item Features Functions
1. Power Supply ON / OFFselectorwith indication light
Turn this selector to switch ON or OFFthe power supply. Power supply is providedfor the control system.
2. LOW LOW OIL LEVELindication light
It indicates that the oil level has reached the
critical low oil level. Immediate action hasto be taken. Refill the oil before any
operation.
3. Main Pressure display It indicates the main hydraulic systempressure in bar.
4. Motor Start / Stop pushbutton with indicating light.
Push these buttons to switch on or off thehydraulic pump stations on the power pack.
5. HPU Power On indicatinglight
It indicates the system power supplyavailable at starter panel.
6. LOW OIL LEVEL indicationlight
It indicates that the oil level in the powerpack is below its first critical level.The hydraulic power unit is also equip withLOW LOW OIL LEVEL switches, which willbe activated once the oil level reaches thesecond critical level after the first low oillevel warning is ignored. Upon activation ofthis switch, LOW OIL LEVEL indicator lightand alarm will be ON again, at the sametime electric motors will be shut down to
protect the hydraulic pumps.
7.Accumulator Chargedindicating light
It indicates the accumulator is sufficientlycharged to allow quick release function.
8. Station selector LOCAL /
WH
To allow control from either the remotecontrol in the wheel house or local controlnear the shark jaw/tow pins.
9. Dimmer For adjusting the intensity of the indicating
light
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Item Features Functions
10. Motor-E Stoppush button Push the button to stop the hydraulic pumpstation in the HPU. The button must bereset once it is activated, otherwise, thepump station would not start.
11. Quick Release /Press both
buttons to open jaw pushbutton
Two buttons must be pushedsimultaneously to release load quickly. Thewire lifter is lowered first followed by the towpins then the jaws.
12. STBD Jaw Up/Downselector Turn the selector to raise or lower the STBD
jaw
13. Port Jaw Up/Downselector Turn the selector to raise or lower the Portjaw
14. Port Jaw Locked indicatinglight
It indicates the Port jaw is fully raised.
15. STBD Jaw Lockedindicatinglight
It indicates the STBD jaw is fully raised.
16. STBD Pin Up/Downselector Turn the selector to raise or lower the STBDtow pin.
17. Port Pin Up/Downselector Turn the selector to raise or lower the Porttow pin.
18. Lifter Up/Downselector Turn the selector to raise or lower the wirelifter.
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Figure 1: Remote Control Panel
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3.2 Pendant Controller
Item Features Functions
1.Motor Stoppush button Push this button to stop the hydraulic
pump of the power pack.
2.Quick Releasepush buttons The wire lifter is lowered first followed by
the tow pins then the jaws.
3.Port Tow Pin Up / Downpush buttons
Turn the selector to raise or lower the Porttow pin.
4.STBD Tow Pin Up / Downpush buttons
Turn the selector to raise or lower theSTBD tow pin.
5.Port Shark Jaw Up / Downpush buttons
Turn the selector to raise or lower the Portjaw.
6. STBD Shark Jaw Up /
Down push buttons
Turn the selector to raise or lower theSTBD jaw.
7. Wire Lifter Up / Downpush buttons
Turn the selector to raise or lower theSTBD tow pin.
8. Power On indicator light It indicates the system power is availableat Pendant Controller.
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CHAPTER 4: ELECTRO-HYDRAULIC POWER PACK AND HYDRAULICSYSTEM
4.1 GENERAL DESCRIPTION
The Hydraulic Power unit is designed to provide power to operate the hydraulic shark jawand tow pin. The HPU comprising a hydraulic oil tank, an electric motor flexibly coupledto hydraulic pump and mounted on a fabricated skid type base plate suitable for belowdeck mounting.
Within the power pack; mounted are all necessary components including solenoid valves,filters, accumulators, oil level gauge and low oil level sensor. The HPU pump is designedto be running only when a jaw or pin is being raised or lowered. The pump continues torun for 5 minutes after the pump would automatic shutdown by the PLC control. HPUprovides for automatic charging of the accumulator every time it is started. After fullycharged-up, a damping valve will be activated by a pressure switch sensing the fullycharged pressure, the signal also activated the accumulator fully charged indicate theremote panel.
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4.2 DATA OF POWER PACK
4.2.1 Rating
1 x 22 kW (140LPM x 210Bar)
4.2.2 Electric Motor
Output : 1 x 22 kW
Supply : 480V, 3 Phase, 60Hz
4.2.3 Hydraulic Pump
Flow Rate : 100 LPM
Maximum Pressure : 210 Bar
4.2.4 Oil Reservoir
Steel fabricated oil reservoir with an oil capacity of 475 litres.
4.2.5 Motor Starter
Star/Delta Starter to suit 22 kW motor, IP55 enclosure containing all main circuit
control breakers, relays, contractors, transformer, fuses, terminals and interlinkcables.
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4.3 HYDRAULIC REFERENCE DRAWINGS
Item Title Drawing No. Page Revision
1. 250T Hydraulic Shark Jaw & Tow PinHydraulic Schematic / Piping Layout AH-HSJ250-H 1 Of 1 C1
2. 250T Hydraulic Shark Jaw & Tow Pin1 x 22 kW Electro-Hydraulic PowerPack General Arrangement
P1x22-SJ-001 1 Of 1 C
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4.4 ELECTRICAL REFERENCE DRAWINGS
Item Title Drawing No. Page Revision
1. Hydraulic Shark Jaw & Tow PinElectrical General Cable Layout
MG-SJTP003-A1 1 Of 1 C
2. Hydraulic Shark Jaw & Tow PinStarter Panel Layout
MG-SJTP003-B1 1 Of 1 C
3. Hydraulic Shark Jaw & Tow PinPendant Junction Box Layout
MG-SJTP003-B2 1 Of 1 C
4. Hydraulic Shark Jaw & Tow PinStarter Control Schematic
MG-SJTP003-C1 1 Of 1 C
5. Hydraulic Shark Jaw & Tow PinRemote Control Panel Layout
MG-SJTP003-D1 1 Of 1 C
6. Hydraulic Shark Jaw & Tow PinPendant Controller
MG-SJTP003-D2 1 Of 1 C
7. Hydraulic Shark Jaw & Tow PinPLC IN/OUT Schematics
MG-SJTP003-E1 1 Of 32 Of 33 Of 3
CCC
8. Hydraulic Shark Jaw & Tow PinElectrical Control Schematics
MG-SJTP003-E2 1 Of 22 Of 2
CC
9. Hydraulic Shark Jaw & Tow Pin
Electrical Connection Schematics
MG-SJTP003-F1 1 Of 1 C
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CHAPTER 5: SPARES LIST
The following items are recommended standard spare for each equipment for two years.
4.5 Hydraulic Components (SJTA)
Item Description Qty Position No.
1 Level Gauge 1 2
2 Filler Breather 1 3
3 Return Filter Element 1 4
4 Rotex Coupling spider - HVC 1 6
5 Seal Kit for Hydraulic Pump - SJTA 1 8
6 Relief Valve - HVC 1 10
7 Pressure Gauge (0-350bar)(Stem) 1 12
8 Seal kit for Manual DCV - SJTA 1 15
9 Cross over relief valve 1 17
10 Seal Kit for Hydraulic cylinder - Lock Jaw 1 18
11 Seal Kit for Hydraulic cylinder - Wire Lift 1 18a
12 Seal Kit for Hydraulic cylinder - Towing Pin 1 18b
13 Level switch 1 20c
14 Pressure Transducer (0-250 Bars) 1 20a
15 Pressure Switch 1 20b
16 Solenoid DCV 1 21
17 Solenoid DCV 1 21a
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The following items are recommended standard spare for each equipment for two years.
Electrical Components (SJTA)
Item Description Qty CARGOTEC No.
1 Analog Pres. meter 72 x 72mm , 250 bar 1 S 120663
2 Aux. Contactor 1 S 121553
3 Contactor 20A - 24VDC 1 S 120803
4 Contactor 25A - 220VAC 1 S 122534
5 Contactor 18a - 220VAC 1 S 122535
6 Dimmer c/w control card 1 S121349 + S120674
7 Fuse Holder 2 S120383
8 Fuse Holder 1 S120384
9 Fuse, 10A 1 S 120391
10 Fuse, 16A 1 S 120394
11 Fuse, 2A 6 S 12038612 Fuse, 4A 1 S 120388
13 Illuminate Push button (Green) 24VDC 1 S 120685
14 Illuminate Push button (Red) 24VDC 1 S 120687
15 Illuminate Selector Switch 2 way 1 S 120692
16 Mushroom Head Button c/w cover 1 S 120460 + S 120461
17 On Delay Timer 1 S 120723
18 Pendant Control Station 1 S 121164
19 Pilot Light (White) 24VDC 1 S 120677
20 Pilot Light (Green) 24VDC 1 S 120678
21 Pilot Light (Red) 24 VDC 1 S 120679
22 Pilot light (Yellow) 24VDC 1 S 120680
23 Pilot Light (White) - 240VAC 1 S 122533
24 Pilot Light (Green) - 240VAC 1 S 122532
25 Pilot Light (Yellow) - 240VAC 1 S 122530
26 Pilot Light (Blue) - 240VAC 1 S 122531
27 PLC Relay 24VDC c/w Led 4 S 120595
28 Power supply 50A -RCP 1 S 122632
29 Proximity Switch c/w Connector 1 S120621 + S 120623
30 Push button (Green) 1 S 12086931 Push Button (Red) 1 S 120870
32 Push button (Red) 1 S 120838
33 Relay 2P 24VDC c/w base 1 S 120448
34 Relay 2P 220VAC c/w Base 2 S 120446
35 Rectifier 600VAC 1 S 121033
36 Selector Switch 2 Way (1 NO + 1 NC) 1 S 120690
37 Selector Switch 3 Way (2 NO) 2 S 121351
38 Thermal Overload Relay 1 S 120818
39 Transformer 300VA 1 S 122770
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The following items are recommended standard spare for each equipment for two years.
4.6 Mechanical Components (SJTA)
Item Description Qty Position No.
1 Bushing (Wire lift - SJ) 1 3
2 Bushing (Wire lift - SJ) 4 4
3 Bushing (SJ) 1 56
4 Bushing (TP) 4 88
5 Bushing (TP) 1 89
6 Bushing (TP) 1 90
7 Lube Fitting (Grease nipple) 16 78
8 Hydraulic hose 3000PSI c/w fittings 2 85
NOTE!
PLEASE CONTACT OUR AFTER SALES FOR ORIGINAL SPARES QUOTATION AND DELIVERY
ADVICE.
Tel: (65) 68613922 (Ext 303)
Fax: (65) 6558 7751
E-mail: [email protected]
Attn: Jesslyn Huah
Date : 24/05/11-rev
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CHAPTER 6: MAINTENANCE / TROUBLESHOOTING
5.1 MAINTENANCE OF HYDRAULIC & ELECTRIC SYSTEM
5.1.1 General Instruction
This must always apply both for maintenance as well as for normal operation ofequipment. The work should be executed by appropriate qualified personnelwith sufficient knowledge about dangers connected to the work to be carried out.
Preventive maintenance is more profitable in the long run than using theequipment until it is ruined.
Therefore, it is of great importance that all operators know how the equipmentshould work, so that he will be able to know if something is wrong.
Read and study all drawings and instructions prior to any maintenance.
Before undertaking any major overhaul. It is recommended to contact themanufacturer to obtain advice on the servicing or replacement of suspect wornparts.
(i) Inspections
In this instructions manual we have stated recommended guidelines for
maintenance and inspection of the equipment.
These instructions are guidelines only; the frequency has to be adapted fordifferent conditions and environment. In rough climates the frequency may beincreased and in mild climates it may be decreased.
(ii) Safety During Maintenance Work
Make sure that any hazardous area around the equipment is free frompersonnel during maintenance, as well as during operation.
The work to be executed by appropriate qualified personnel with sufficientknowledge to hazards connected to the work.
Ensure that all electrical supply is securely disconnected to prevent personnelinjuries.
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5.1.2 Routine Maintenance
The practice of planned maintenance at fixed intervals using a logbook isstrongly recommended.
The following list suggests some of the items, which should be checkedregularly.
HYDRAULIC SYSTEM
Check and record the following:-
The running temperature of the fluid.
The readings of the various pressure gauges.
Unusual noise.
Significant changes in any of the above five items may require furtherinvestigation regarding their cause and the service necessary to correctthem.
Clean the exterior of all equipment to check for leakages. Tighten jointswhere necessary and replace any fittings and associates pipes, whichleak persistently.
Sample the hydraulic fluid and check for chemical condition and level ofcontamination.
The first oil change should take place 50 - 100 hours aftercommissioning. Subsequent oil changes will last in many cases for3,000 to 5,000 working hours or longer, particularly when regularmaintenance of the oil is being carried out.
To keep a running check on the condition of the oil, take a sample of theoil and pass it through a filter paper or clean cloth once a week.
Clean or replace filters as necessary.
Check all high pressure hoses for abrasions and leaks.
ELECTRIC CONTROL SYSTEM
Check that all control functions are operational
Check for moisture and damage.
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5.1.3 Periodic Maintenance
If after several years of use, routine service inspection shows, that theequipment performance is not quite up to the specified standard, a thoroughoverhaul of the equipment may prove economically desirable.
This is a good opportunity for thorough clean up of all equipment, especiallythe inside of the tank. The use of a soft plastic scraper is recommended forcleaning flat surfaces, as cloth can leave particles, which will clog upstrainers and generally cause trouble when the system is filled.
Before undertaking a major overhaul, it may be prudent to contact themanufacturer to obtain advice on the servicing or replacement of suspectequipment.
When reassembling the equipment make sure to follow the service instructionsand take every possible precaution to keep the inside of your hydraulic
equipment spotlessly clean.
5.2 MAINTENANCE OF EQUIPMENT (SHARK JAW & TOWING PIN)
We recommend below maintenance of equipment to be carried out once every week.
Raise up both jaws and check whether there is any sea water accumulationinside the housing frame due to block of drain pipe. If there is, drain away.
Remove inspection covers at side of housing, clean and remove the sand,
mud or any foreign particles that may have been inside housing frame duringanchor handling operation.
Check for excessive wear and damage on joints and linkage.
Check all joints, pins and shafts are receiving proper lubrication.
Check all bolts and nuts are properly tighten.
Check hydraulic cylinders, hoses and piping for leakage and abrasion.Tighten fittings where necessary.
Flush base of housing and check blockage of drain system.
Check lock plates at pins are in position.
Check for cracks along welding joints.
Lubricate shark jaw at grease point. (See fig 1a & 1b)
Wire bush any areas where corrosion occur and touch-up with paint.
Install inspection covers c/w silicone sealant / gasket upon completion of
maintenance.
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5.3 TROUBLESHOOTING
5.3.1 General Instruction
To be able to execute effective troubleshooting, it is important to understand thefunction of the system and its components. It is therefore important to studydrawing and instructions before and during troubleshooting.
For troubleshooting of electric motors, hydraulic pumps and motors from othersuppliers we refer to the component bulletin in the instruction manual.
All tests and repairs should be carried out by appropriate qualified personnel andit is particularly important that the utmost cleanliness is observed whendismantling and assembling hydraulic/electric components.
5.3.2 Trouble Shoot & Remedy
FAULT CAUSE REMEDY
1. System Does Not Start a) MCCB is at OFF position a) On it
b) Starter Isolator at OFFposition
b) On it
c) No incoming supply c) Check in coming supply
d) Starter fuses blown d) Replace with new fuse
e) Oil level low e) Fill up to the required level
f) High Temperaturef) Ensure Cooling pump is
switched on & sufficient flow to
cooler.
2. Jaws, Wire Lifter andTow Pins cant beraised or lowered
a) Mechanical blockage a) Ensure there is noobstruction to the jaws,linkage and hydraulic cylinderthat may have entangled.
b) Faulty hydraulic cylinder b) If leaking and or changed,servicing or replacement is
required.
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FAULT CAUSE REMEDY
3. Tow Pins jammed a) Tow pin tubes arecontaminated with foreign debris
a) Spray plenty of water on andbetween the tubes and towpins to wash down foreign
debris.b) Wire brush any stubborn debris
stacked on the tow pins
4. Cant Quick Release a) Faulty control a) Ensure all electrical ports,switches and wiring are ingood working condition.
b) Hydraulic accumulator notworking due to the following
possibilities:- due to loss of pressure
- indicator light is off and nopressure reading
- Faulty pressure switch /or faulty electric-motor pump
- Check if the accumulatorcharged indicator light is on.Check hydraulic pressurereading on gauge athydraulic accumulator is it at210 bar (default)
- Accumulator could be faultyand need to be service and orreplace
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Leak in the hydraulic pipes,need to be serviced.
- Servicing and / orreplacement is required
5. Quick release is slow a) Mechanical resistance to theshark jaws, wire lifter and / ortow pins
a) See 2a, 2b, 3d and 4b
CAUTIONS!
DO TAKE NOTE THAT QUICK RELEASE FUNCTION CAN ONLY BE USED ONCE
AND NOT REPEATITIVE IN EVERY OPERATION. IT TAKES TIME TO RE-CHARGE.
THE PLC IS PROGRAMMED TO ACTIVATE THE ELECTRIC MOTOR-PUMP TO
CHARGE THE ACCUMULATOR WHEN THERE MINIMUM SET PRESSURE IS
REACHED.
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5.4 SERVICING OF SHARK JAWS
Servicing or parts replacement of Shark Jaws is required if the following occurs;
1. Jaw plates are worn out
- It is recommended to replace with a new set of Jaw plates to ensure that it iscapable to hold/clamp the specific wire or chain in use / intended for.
2. Any of Jaw assembly and or linkage assembly becomes loose due to worn bushings
- Replace the worn bushings with new ones(See drawing assembly Jaw B59766-P and Assembly Linkage B59804-P atSection 2.3)
3. If leaks are found on the cylinder rod of the Jaws and Wire Lifter hydraulic cylinder.
NOTES:
Refer to Bushing Replacement Procedure to replace worn bushings in the Jaw and LinkageAssembly.The use of a portable A-frame with chain hoisting etc may be required as an aid to theservicing.
SAFETY PROCEDURE:
WARNING! BEFORE SERVICING ANY INTERIOR HOSES, LINKS, SENSORS OR ANYOTHER COMPONENTS INSIDE THE SHARK JAWS THE FOLLOWING SAFETYPROCEDURES MUST BE FOLLOWED.
1. The hydraulic pump electric power MUST be locked out.
2. The accumulator high pressure oil MUST be drained to tank by slowly opening ball
value (Item 1, DWG AH-HSJ200-H Section 4.3). The pressure gauge will read zero
pressure when the accumulator is drained.
3. The control power MUST be disconnected.
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5.5 JAW CYLINDER REMOVAL PROCEDURE
1. Follow steps (1) to (8) from Bushing Replacement Procedure
2. With the aid of lifting strap, wrap securely around the hydraulic cylinder as shown
in Fig 3
3. Remove upper cylinder pin
4. The hydraulic cylinder may now be hoisted up.
Assembly is the reverse of removal.
5.6 WIRE LIFTER ASSEMBLY REMOVAL PROCEDURE
1. Carry out safety procedure
2. Remove the hydraulic lines from the wire lift cylinder.
3. Replace one off socked hydraulic Bolt (See Fig. 3a)
4. Remove cotter pins and Pin #1
5. Wire lifter and hydraulic cylinder can now be hoisted-up/removed for servicing.
Assembly is the reverse of removal.
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5.7 GEAR OIL SELECTION
Ambient
Temperature-20
oC / +5
oC +5
oC / +40
oC +30
oC / +55
oC +40
oC / +65
oC -30
oC / +65
oC
Lubricant VI 95 MIN VI 95 MIN VI 95 MIN VI 95 MIN VI 140 MIN
ISO 3448 VG 100 VG 150 VG 220 VG 320 VG 150 ~ 220
ARAL Degol BG 100 Degol BG 150 Degol BG 220 Degol BG 320 Degol GS 220
BP GR XP 100 GR XP 150 GR HP220 GR XP 320Enersyn HTX
220
CASTROL Alpha SP 100 Alpha SP 150 Alpha SP 220 Alpha SP 320 Alphasyn 150
CHEVRONGear
Compounds100
GearCompounds
150
GearCompounds
220
GearCompounds
320N/A
MOBIL Mobil Gear 627 Mobil Gear 629 Mobil Gear 630 Mobil Gear 632 N/A
SHELL Omala Oil 100 Omala Oil 150 Omala EP 220 Omala EP 320 Tivela Oil S
TOTAL Carter EP 100 Carter EP 150 Carter EP 220 Carter EP 320 N/A