OPERATION/MAINTENANCE MANUAL

REFERENCE NO. CM-P4766-69-SJTP-ISSUE- A

Cargotec CHS Asia Pacific Pte Ltd

Offshore Load Handling Mailing and Site Address: 48 Tuas Road Singapore 638500 Tel +65 6861 3922 Fax +65 6862 4334 www.cargotec.com
Domicile Singapore Co. Reg. No. 199404157W GST No. M2-0125279-2 Registered Address No. 15 Tukang Innovation Drive Singapore 618299

Cargotec Reference No.

P4766-69

Subject

Operational Manual of Deck Machinery 1. 2. 3. Cargotec Hydraulic Shark Jaw Cargotec Hydraulic Towing Pin 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 Support and Ordering of Spare Parts, please contact our Customer Service Department and provide us with Cargotec Reference Number and Equipment Serial Number. Customer Service Department: Cargotec CHS Asia Pacific Pte Ltd No. 48 Tuas Road Singapore 638500 Tel No : (65) 6868-85-62 Fax No : (65) 6862-24-52 E-mail : custsvs@plimsollcorp.com

For more information, please contact:Head Office:Cargotec CHS Asia Pacific Pte Ltd No. 48 Tuas Road Singapore 638500 Tel No : (65) 6861-39-22 (10 Lines) Fax No. : (65) 6862-43-34 E-mail : corporate@plimsollcorp.com Sales Department:Cargotec CHS Asia Pacific Pte Ltd No. 48 Tuas Road Singapore 638500 Tel No : (65) 6868-85-33 Fax No : (65) 6862-43-34 E-mail : sales.mfg@plimsollcorp.com

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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: 1.1 1.2 CARGOTEC HYDRAULIC SHARK JAW & TOW PIN PACKAGE .................................. - 5 -

QUANTITY AND DESCRIPTION ......................................................................................................... - 5 EXCLUSIONS......................................................................................................................................... - 5 -

CHAPTER 2: CARGOTEC SHARK JAW-TOW PIN ................................................................................... - 6 2.1 TECHNICAL DESCRIPTION ................................................................................................................ - 6 2.1.1 General Data .....................................................................................................................................- 8 2.2 OPERATION INSTRUCTION ............................................................................................................... - 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 REFERENCE DRAWINGS ................................................................................................................. - 11 CHAPTER 3: CONTROL FUNCTIONS ...................................................................................................... - 17 3.1 3.2 REMOTE CONTROL PANEL ..................................................................................................................... - 17 PENDANT CONTROLLER ......................................................................................................................... - 20 ELECTRO-HYDRAULIC POWER PACK AND HYDRAULIC ........................................ - 21 -

CHAPTER 4:

SYSTEM ........................................................................................................................................................ - 21 4.1 GENERAL DESCRIPTION ................................................................................................................. - 21 4.2 DATA OF POWER PACK ................................................................................................................... - 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 HYDRAULIC REFERENCE DRAWINGS ......................................................................................... - 24 4.4 ELECTRICAL REFERENCE DRAWINGS........................................................................................ - 27 CHAPTER 5: SPARES LIST ....................................................................................................................... - 40 4.5 4.6 HYDRAULIC COMPONENTS (SJTA)........................................................................................................ - 40 MECHANICAL COMPONENTS (SJTA) ..................................................................................................... - 42 MAINTENANCE / TROUBLESHOOTING .............................................................. - 43 -

CHAPTER 6:

5.1 MAINTENANCE OF HYDRAULIC & ELECTRIC SYSTEM ............................................................ - 43 5.1.1 General Instruction .........................................................................................................................- 43 5.1.2 Routine Maintenance .....................................................................................................................- 44 5.1.3 Periodic Maintenance .....................................................................................................................- 45 5.2 MAINTENANCE OF EQUIPMENT (SHARK JAW & TOWING PIN) ............................................. - 45 5.3 TROUBLESHOOTING ........................................................................................................................ - 46 5.3.1 General Instruction .........................................................................................................................- 46 5.3.2 Trouble Shoot & Remedy ................................................................................................................- 46 5.4 SERVICING OF SHARK JAWS ......................................................................................................... - 48 5.5 JAW CYLINDER REMOVAL PROCEDURE .................................................................................... - 50 5.6 WIRE LIFTER ASSEMBLY REMOVAL PROCEDURE................................................................... - 50 5.7 GEAR OIL SELECTION ...................................................................................................................... - 52 -

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CHAPTER 1:

CARGOTEC HYDRAULIC SHARK JAW & TOW PIN PACKAGE

1.1 QUANTITY AND DESCRIPTION

Quantity (1) each Description Shark Jaw Assembly. Internal hydraulic hoses and fittings are included. One set of Jaw plates is included. Dual Towing Pin Assembly. Internal hydraulic hoses and fittings are included. Hydraulic Power Unit (HPU) Control Pendant for local operation. Motor Starter in IP-54 enclosure Drop-In control panel with Programmable Logic Controller.

(1) each

(1) each (1) each (1) each (1) each

1.2 EXCLUSIONS
1. 2. On-board installation and hook-up. Interconnecting electrical wiring and hydraulic piping between the Shark Jaws, HPU and controls panels. Supply of hydraulic oil, lubricating grease, hydraulic piping, fittings and hoses. Flushing of hydraulic system.

3. 4.

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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 anchor handling operations. The unit is comprised of two opposing jaws and a wire lifter pin situated in a common frame, which is welded into the deck of the vessel. The Shark Jaws are designed to hold chain or wire with line tensions of the safe working load. The jaws plates are designed for use with a specific range 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 bottom plates are furnished with extra length and width weld bevels to facilitate an easier installation. The design and supply of supporting and / or reinforcement structures are the responsibility of others. The two jaws and wire lifter pin are independently raised and lowered by marine grade hydraulic cylinders having chrome plated stainless steel rods. The jaws are raised using the rod side of the cylinder and lowered using the blind end of cylinder. This arrangement provides a more efficient use of hydraulic pressure working against the maximum amount of surface area in the cylinder during Quick Release. The jaws are fitted with stainless steel proximity sensors to verify that the jaws are fully raised and ready to accept the loaded chain. When the jaws are raised they are locked into place by the over center linkage, keeping the cylinders away from the load path. To provide added security when holding the chain or wire, there are check valves in the hydraulic system to maintain hydraulic pressure on the cylinders. The chain or wire under tension can be released with the Quick Release system. The Quick Release incorporates the use of a hydraulic accumulator in the hydraulic system. When the Quick Release buttons are pressed, the Towing pins, wire lifter and both jaws are lowered in 5-8 seconds. The Quick Release system may be used up to the rated load. In the event of AC power loss (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 mounted below deck consisting of reservoir, pump and a motor (IP-54 rating), enclosed motor starter, solenoid valves, filters, accumulators, oil level gauge and low oil level sensor mounted below deck. The HPU is also designed to operate the Plimsoll Smith Berger Towing Pins. The Shark Jaws are remotely controlled from a drop-in control panel located in the wheelhouse. An additional control pendant is supplied for local operation. The operating system features a Programmable Logic Controller (PLC).

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The Towing Pins are designed to restrain the side to side movement of chain or wire prior to and while they are captured by the Plimsoll Smith Berger Shark Jaws during anchor handling operations. The unit is comprised of two retractable Tow Pins mounted in a common frame. The Towing Pins are designed to withstand line tensions of the rated SWL with 30 degrees of wrap, at 75% height of the two pin. The Two Towing Pins are fitted with Rollers and grease lubricated bronze bearing. They are independently raised and lowered by marine grade hydraulic cylinders having chrome plated stainless steel rods. The pins are remotely controlled by the Shark Jaw and Tow Pin Remote control Panel and HPU. For Local operation, the Tow Pin can be operated through the integrated Hydraulic Shark Jaw and Tow Pin Pendant Controller.

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2.1.1

General Data

Model No.

MG-STA-250-S 250 Tonne 38 mm to 114 mm 32 mm to 120mm Remote Control Panel Pendant Control

Safe Working Load : Chain Size Wire Size Control : : : :

For other Jaw Plate size (not supplied), please refer to Table A (Checked box indicates Jaw Plate supplied). Please contact our After Sale Department for additional Jaw Plate.

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2.2 OPERATION INSTRUCTION

2.2.1 At Power Pack hydraulic oil Reservoir Level Gauge Upper and lower isolating plungers Oil in Glass tube to be at least at Level

[Press] [Observe] 2.2.2

At Power Pack Starter Panel [ON] [OFF] [OFF] [ON]

POWER ON INDICATOR LIGHT (white light) MOTOR RUN INDICATOR LIGHT (Green light) MOTOR TRIP INDICATOR LIGHT (Yellow light) MOTOR SPACE HEATOR ON INDICATOR LIGHT (Blue light) 2.2.3 At Remote Control Panel in Wheelhouse DIMMER until Red illumination light is visible HPU POWER ON (White light) START (Green light) STOP (Red light) 24V DC to 24V DC ON (white light) STATION to

[Rotate] [Observe] [Observe] [Observe] [Switch] [Observe] [Switch]

[ON] [OFF] [OFF] [ON] [ON] [WH]

To run HPU

At HPU section [Press] [Observe] [Observe] [Observe] HPU to START (Green light) STOP (Red light) ACCUMULATOR CHARGED (Green light) [START] [ON] [OFF] [ON]

To Raise Tow Pins PORT PIN STDB PIN to to [UP] [UP]

[Switch] [Switch]

To Retract Tow Pins PORT PIN STDB PIN to to [DOWN] [DOWN]

[Switch] [Switch]

To Raise Shark Jaws PORT JAW to PORT JAW LOCKED (Green light) STDB JAW to STBD JAW LOCKED (Green light) [UP] [ON] [UP] [ON]

[Switch] [Ensure] [Switch] [Ensure]

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To Retract Shark Jaws PORT JAW to PORT JAW LOCKED (Green light) STDB JAW to STBD JAW LOCKED (Green light) [DOWN] [OFF] [DOWN] [OFF]

[Switch] [Ensure] [Switch] [Ensure]

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 LIFTER to [UP]

[Switch]

To Retract Wire Lifter LIFTER to [DOWN]

[Switch]

To Quick Release PRESS BOTH BUTTONS TO OPEN JAWS R (Red light) R (Red light) [ON] [ON]

[Press] [Observe] [Observe]

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] [Observe] [Observe] [Observe] HPU to STOP (Red light) START (Green light) POWER ON (White light) [STOP] [ON] [OFF] [ON]

Carry out visual inspection of the equipment and secure any loose components. Check Oil Reservoir level for any loss of oil during operation. Any leakage in the hydraulic system is to be rectified before topping up. Carry out thorough cleaning and preservation routine on all areas. POWER SUPPLY TO POWER PACK STARTER PANEL TO REMAIN ON FOR MOTOR SPACE HEATER.

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2.3 REFERENCE DRAWINGS

Item 1.

Title 250T Hydraulic Shark Jaw & Tow Pin General Arrangement

Drawing No. STA-250-S-0

Page 1 Of 1

Revision C

2.

250T Hydraulic Shark Jaw & Tow Pin Assembly

D60000-PM

1 Of 2 2 Of 2

C C

3.

250 MT Shark Jaws Assembly, Jaw

B59775-P

1 Of 1

4.

250 MT Shark Jaws Assembly, Linkage

B57412-P

1 Of 1

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CHAPTER 3: CONTROL FUNCTIONS

The following control functions are provided for Shark Jaw & Towing Pin unit at the following location.

3.1 Remote Control Panel

Item 1. Features Functions

Power Supply ON / OFF Turn this selector to switch ON or OFF selector with indication light the power supply. Power supply is provided for the control system. LOW LOW OIL LEVEL indication light It indicates that the oil level has reached the critical low oil level. Immediate action has to be taken. Refill the oil before any operation. It indicates the main hydraulic system pressure in bar.

2.

3.

Main Pressure display

4.

Motor Start / Stop push Push these buttons to switch on or off the hydraulic pump stations on the power pack. button with indicating light. HPU Power On indicating It indicates the system power supply available at starter panel. light LOW OIL LEVEL indication It indicates that the oil level in the power pack is below its first critical level. light The hydraulic power unit is also equip with LOW LOW OIL LEVEL switches, which will be activated once the oil level reaches the second critical level after the first low oil level warning is ignored. Upon activation of this switch, LOW OIL LEVEL indicator light and alarm will be ON again, at the same time electric motors will be shut down to protect the hydraulic pumps. Accumulator Charged indicating light Station WH selector LOCAL It indicates the accumulator is sufficiently charged to allow quick release function. / To allow control from either the remote control in the wheel house or local control near the shark jaw/tow pins. For adjusting the intensity of the indicating light

5.

6.

7.

8.

9.

Dimmer

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Item 10.

Features Motor-E Stop push button

Functions Push the button to stop the hydraulic pump station in the HPU. The button must be reset once it is activated, otherwise, the pump station would not start.

11.

buttons must be pushed Quick Release /Press both Two buttons to open jaw push simultaneously to release load quickly. The wire lifter is lowered first followed by the tow button pins then the jaws. STBD Jaw Up/Down selector Port Jaw Up/Down selector

12.

Turn the selector to raise or lower the STBD jaw Turn the selector to raise or lower the Port jaw

13.

14.

Port Jaw Locked indicating It indicates the Port jaw is fully raised. light STBD Jaw Locked indicating It indicates the STBD jaw is fully raised. light STBD Pin Up/Down selector

15.

16.

Turn the selector to raise or lower the STBD tow pin.

17.

Port Pin Up/Down selector

Turn the selector to raise or lower the Port tow pin.

18.

Lifter Up/Down selector

Turn the selector to raise or lower the wire lifter.

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Figure 1: Remote Control Panel

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3.2 Pendant Controller

Item

Features Motor Stop push button

Functions Push this button to stop the hydraulic pump of the power pack.

1.

2.

Quick Release push buttons

The wire lifter is lowered first followed by the tow pins then the jaws.

3.

Port Tow Pin Up / Down push buttons STBD Tow Pin Up / Down push buttons Port Shark Jaw Up / Down push buttons STBD Shark Jaw Up / Down push buttons Wire Lifter Up / Down push buttons Power On indicator light

Turn the selector to raise or lower the Port tow pin.

4.

Turn the selector to raise or lower the STBD tow pin.

5.

Turn the selector to raise or lower the Port jaw.

6.

Turn the selector to raise or lower the STBD jaw.

7.

Turn the selector to raise or lower the STBD tow pin.

8.

It indicates the system power is available at Pendant Controller.

Figure 2: Pendant Controller

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CHAPTER 4:

ELECTRO-HYDRAULIC POWER PACK AND HYDRAULIC SYSTEM

4.1 GENERAL DESCRIPTION

The Hydraulic Power unit is designed to provide power to operate the hydraulic shark jaw and tow pin. The HPU comprising a hydraulic oil tank, an electric motor flexibly coupled to hydraulic pump and mounted on a fabricated skid type base plate suitable for below deck 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 designed to be running only when a jaw or pin is being raised or lowered. The pump continues to run for 5 minutes after the pump would automatic shutdown by the PLC control. HPU provides for automatic charging of the accumulator every time it is started. After fully charged-up, a damping valve will be activated by a pressure switch sensing the fully charged pressure, the signal also activated the accumulator fully charged indicate the remote 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 Supply 4.2.3 Hydraulic Pump Flow Rate Maximum Pressure 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 interlink cables. : : 100 LPM 210 Bar : : 1 x 22 kW 480V, 3 Phase, 60Hz

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4.2.6

Hydraulic Oil Selection Recommended hydraulic oil would be ISO VG 68 with minimum viscosity index of 90. The respective ISO grade of oil can be obtained from the maker list as shown below.
RECOMMENDED HYDRAULIC OILS

BRAND BP OIL GULF SHELL CHEVRON TEXACO TOTAL FINA MOBIL

TRADEMARKS Energol HLP, Energol SHF Harmony Tellus Gear Compounds EP Rando HD, Rando HDZ Azolla, Equivis Hydran, Hydran HVI Mobil DTE

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4.3 HYDRAULIC REFERENCE DRAWINGS

Item 1.

Title 250T Hydraulic Shark Jaw & Tow Pin Hydraulic Schematic / Piping Layout

Drawing No. AH-HSJ250-H

Page 1 Of 1

Revision C1

2.

250T Hydraulic Shark Jaw & Tow Pin 1 x 22 kW Electro-Hydraulic Power Pack General Arrangement

P1x22-SJ-001

1 Of 1

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4.4 ELECTRICAL REFERENCE DRAWINGS

Item 1.

Title Hydraulic Shark Jaw & Tow Pin Electrical General Cable Layout

Drawing No. MG-SJTP003-A1

Page 1 Of 1

Revision C

2.

Hydraulic Shark Jaw & Tow Pin Starter Panel Layout

MG-SJTP003-B1

1 Of 1

3.

Hydraulic Shark Jaw & Tow Pin Pendant Junction Box Layout

MG-SJTP003-B2

1 Of 1

4.

Hydraulic Shark Jaw & Tow Pin Starter Control Schematic

MG-SJTP003-C1

1 Of 1

5.

Hydraulic Shark Jaw & Tow Pin Remote Control Panel Layout

MG-SJTP003-D1

1 Of 1

6.

Hydraulic Shark Jaw & Tow Pin Pendant Controller

MG-SJTP003-D2

1 Of 1

7.

Hydraulic Shark Jaw & Tow Pin PLC IN/OUT Schematics

MG-SJTP003-E1

1 Of 3 2 Of 3 3 Of 3

C C C

8.

Hydraulic Shark Jaw & Tow Pin Electrical Control Schematics

MG-SJTP003-E2

1 Of 2 2 Of 2

C C

9.

Hydraulic Shark Jaw & Tow Pin Electrical Connection Schematics

MG-SJTP003-F1

1 Of 1

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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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Level Gauge Filler Breather Return Filter Element Rotex Coupling spider - HVC Seal Kit for Hydraulic Pump - SJTA Relief Valve - HVC Pressure Gauge (0-350bar)(Stem) Seal kit for Manual DCV - SJTA Cross over relief valve Seal Kit for Hydraulic cylinder - Lock Jaw Seal Kit for Hydraulic cylinder - Wire Lift Seal Kit for Hydraulic cylinder - Towing Pin Level switch Pressure Transducer (0-250 Bars) Pressure Switch Solenoid DCV Solenoid DCV Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Position No. 2 3 4 6 8 10 12 15 17 18 18a 18b 20c 20a 20b 21 21a

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The following items are recommended standard spare for each equipment for two years.

Electrical Components (SJTA)

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Description Analog Pres. meter 72 x 72mm , 250 bar Aux. Contactor Contactor 20A - 24VDC Contactor 25A - 220VAC Contactor 18a - 220VAC Dimmer c/w control card Fuse Holder Fuse Holder Fuse, 10A Fuse, 16A Fuse, 2A Fuse, 4A Illuminate Push button (Green) 24VDC Illuminate Push button (Red) 24VDC Illuminate Selector Switch 2 way Mushroom Head Button c/w cover On Delay Timer Pendant Control Station Pilot Light (White) 24VDC Pilot Light (Green) 24VDC Pilot Light (Red) 24 VDC Pilot light (Yellow) 24VDC Pilot Light (White) - 240VAC Pilot Light (Green) - 240VAC Pilot Light (Yellow) - 240VAC Pilot Light (Blue) - 240VAC PLC Relay 24VDC c/w Led Power supply 50A -RCP Proximity Switch c/w Connector Push button (Green) Push Button (Red) Push button (Red) Relay 2P 24VDC c/w base Relay 2P 220VAC c/w Base Rectifier 600VAC Selector Switch 2 Way (1 NO + 1 NC) Selector Switch 3 Way (2 NO) Thermal Overload Relay Transformer 300VA Qty 1 1 1 1 1 1 2 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 2 1 1 2 1 1 CARGOTEC No. S 120663 S 121553 S 120803 S 122534 S 122535 S121349 + S120674 S120383 S120384 S 120391 S 120394 S 120386 S 120388 S 120685 S 120687 S 120692 S 120460 + S 120461 S 120723 S 121164 S 120677 S 120678 S 120679 S 120680 S 122533 S 122532 S 122530 S 122531 S 120595 S 122632 S120621 + S 120623 S 120869 S 120870 S 120838 S 120448 S 120446 S 121033 S 120690 S 121351 S 120818 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 1 2 3 4 5 6 7 8 Description Bushing (Wire lift - SJ) Bushing (Wire lift - SJ) Bushing (SJ) Bushing (TP) Bushing (TP) Bushing (TP) Lube Fitting (Grease nipple) Hydraulic hose 3000PSI c/w fittings Qty 1 4 1 4 1 1 16 2 Position No. 3 4 56 88 89 90 78 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: Jesslyn.huah@cargotec.com 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 of equipment. The work should be executed by appropriate qualified personnel with sufficient knowledge about dangers connected to the work to be carried out. Preventive maintenance is more profitable in the long run than using the equipment until it is ruined. Therefore, it is of great importance that all operators know how the equipment should 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 the manufacturer to obtain advice on the servicing or replacement of suspect worn parts.

(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 for different conditions and environment. In rough climates the frequency may be increased and in mild climates it may be decreased.

(ii)

Safety During Maintenance Work

Make sure that any hazardous area around the equipment is free from personnel during maintenance, as well as during operation. The work to be executed by appropriate qualified personnel with sufficient knowledge to hazards connected to the work. Ensure that all electrical supply is securely disconnected to prevent personnel injuries.

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5.1.2

Routine Maintenance The practice of planned maintenance at fixed intervals using a logbook is strongly recommended. The following list suggests some of the items, which should be checked regularly.

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 further investigation regarding their cause and the service necessary to correct them. Clean the exterior of all equipment to check for leakages. Tighten joints where necessary and replace any fittings and associates pipes, which leak persistently. Sample the hydraulic fluid and check for chemical condition and level of contamination. The first oil change should take place 50 - 100 hours after commissioning. Subsequent oil changes will last in many cases for 3,000 to 5,000 working hours or longer, particularly when regular maintenance of the oil is being carried out. To keep a running check on the condition of the oil, take a sample of the oil 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 the equipment performance is not quite up to the specified standard, a thorough overhaul of the equipment may prove economically desirable. This is a good opportunity for thorough clean up of all equipment, especially the inside of the tank. The use of a soft plastic scraper is recommended for cleaning flat surfaces, as cloth can leave particles, which will clog up strainers and generally cause trouble when the system is filled. Before undertaking a major overhaul, it may be prudent to contact the manufacturer to obtain advice on the servicing or replacement of suspect equipment. When reassembling the equipment make sure to follow the service instructions and 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 accumulation inside 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 during anchor 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 the function of the system and its components. It is therefore important to study drawing and instructions before and during troubleshooting. For troubleshooting of electric motors, hydraulic pumps and motors from other suppliers we refer to the component bulletin in the instruction manual. All tests and repairs should be carried out by appropriate qualified personnel and it is particularly important that the utmost cleanliness is observed when dismantling and assembling hydraulic/electric components. 5.3.2 Trouble Shoot & Remedy FAULT 1. CAUSE a) On it REMEDY

System Does Not Start a) MCCB is at OFF position b) Starter Isolator at OFF position c) No incoming supply

b) On it

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 Temperature

f) Ensure Cooling pump is switched on & sufficient flow to cooler.

2.

Jaws, Wire Lifter and Tow Pins cant be raised or lowered

a) Mechanical blockage

a)

Ensure there is no obstruction to the jaws, linkage and hydraulic cylinder that may have entangled.

b) Faulty hydraulic cylinder

b) If leaking and or changed, servicing or replacement is required.

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FAULT 3. Tow Pins jammed

CAUSE a) Tow pin tubes are contaminated with foreign debris

REMEDY a) Spray plenty of water on and between the tubes and tow pins 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 in good working condition.

b) Hydraulic accumulator not working due to the following possibilities: - due to loss of pressure

- Check if the accumulator charged indicator light is on. Check hydraulic pressure reading on gauge at hydraulic accumulator is it at 210 bar (default) - Accumulator could be faulty and need to be service and or replace - Leak in the hydraulic pipes, need to be serviced. Servicing and / or replacement is required

indicator light is off and no pressure reading

- Faulty pressure switch / or faulty electric-motor pump -

5.

Quick release is slow

a) Mechanical resistance to the shark jaws, wire lifter and / or tow 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 is capable 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 at Section 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 Linkage Assembly. The use of a portable A-frame with chain hoisting etc may be required as an aid to the servicing. SAFETY PROCEDURE: WARNING! BEFORE SERVICING ANY INTERIOR HOSES, LINKS, SENSORS OR ANY OTHER COMPONENTS INSIDE THE SHARK JAWS THE FOLLOWING SAFETY PROCEDURES 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. 2. Follow steps (1) to (8) from Bushing Replacement Procedure With the aid of lifting strap, wrap securely around the hydraulic cylinder as shown in Fig 3 3. 4. Remove upper cylinder pin The hydraulic cylinder may now be hoisted up.

Assembly is the reverse of removal.

5.6 WIRE LIFTER ASSEMBLY REMOVAL PROCEDURE

1. 2. 3. 4. 5. Carry out safety procedure Remove the hydraulic lines from the wire lift cylinder. Replace one off socked hydraulic Bolt (See Fig. 3a) Remove cotter pins and Pin #1 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 Lubricant ISO 3448 ARAL BP CASTROL CHEVRON MOBIL SHELL TOTAL

-20oC / +5oC VI 95 MIN

+5oC / +40oC +30oC / +55oC +40oC / +65oC -30oC / +65oC VI 95 MIN VI 95 MIN VI 95 MIN VI 140 MIN

VG 100

VG 150

VG 220

VG 320

VG 150 ~ 220

Degol BG 100 Degol BG 150 Degol BG 220 Degol BG 320 Degol GS 220 Enersyn HTX 220

GR XP 100

GR XP 150

GR HP220

GR XP 320

Alpha SP 100 Alpha SP 150 Alpha SP 220 Alpha SP 320 Alphasyn 150 Gear Compounds 100 Gear Compounds 150 Gear Compounds 220 Gear Compounds 320

N/A

Mobil Gear 627 Mobil Gear 629 Mobil Gear 630 Mobil Gear 632

N/A

Omala Oil 100 Omala Oil 150 Omala EP 220 Omala EP 320

Tivela Oil S

Carter EP 100 Carter EP 150 Carter EP 220 Carter EP 320

N/A

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