fese, Tes CRAPR 10T X 18M (RK) PROVISIONS GRANE INSTRUTITON BOOK FINISHED PLAN ORDER 1 TEM WICC §-0651F SECTION SHIP i MANABE ZOKL C /LTD < 337 8, TARABE , DHABAKT - SIL, BRUNE = REN, PRY TL. (0895) 41 - $217 F 799-20 . FAX (0888) 41 = 5568 1A = 179 DATE ‘CHECKED SUB lant hitCONTENTS 8 1. Specification § 2. Operation e+: 2-1 Prerparation semen 2-2 Operation 2—3 After operation 2-4 Safety device 2-5 Emergency operation § 3. Maintenance and ifspection Mechanical parts Procedure of replacing wire rope ~ 3-3. Procedure of re-adjusting the limit valve ~ 3-4 Wechanical of brake -e-e+sesesesee seen 3—5 Hydraulic oil 3—6 Lubricating points 3-7 Adjustment of hydraulic parts 84. Trouble and remedy 4- Mechanical parts~--~ $5. Description of main parts ~~ s-~ §6 Drawings . 87 Record of inspection ~~ §8 Spare part list & Tool list s+ PAGE 100 200 200 201 206 207 209 300 300 308 312 319 320 B21 322 400 400 500 600 700 800$1 1) 2) 3) 4) 5) b) 8) 9) 10) 200 Operation and caution on operation Preparation Prior to operation , the followings are io be checked . Confirm thet all operation handles are in their neutral position After confirming of pump unit on stern side. being crived , open valve at 21-8 , 22-2. ( Refer to valve drawing NO. DCB - 158-2 } Tightness of fastening bolts on the turn table bearing is to be checked and retightened if required . Proper tightening torque 125 ket-n (M 27) Tightness of fastening bolts on the middle of the jib and crane top are to be checked and excharged if required . Supply grease sufficiently to every lubricating points . To be referred to” 2—6 Lubricating points ” . Supply gear compound on the slewing gear . hoisting end luffing gear teath . Confirm that ali the valves are set in open position . serene OPEN Stop valve for main line ( Emergency) OPEN Stop valve for brake cylinder ( Hoisting , Luffing and Slewing ) ‘The oi] lever in the slewing device is to be checked . If its level is low oil is to be supplied till the adequate of] level . To be referred to” 2—5 llydraulic oil * ‘The air in the hydraulic cireuit is to be exhausted perfectly . Confirm that the wire rope on the winch drum is winding orderly .1-2 Operation 1) Operation After the previous mentioned preparation, the crane is ta be operated by refering to the ” ARRANGENENT OF CONTROL VALVE * ARRANGEMENT OF CONTROL VALVE LEVER BY-PASS VALVE “on | Na NAHE \ = SLEWING CONTROL VALVE _@ SLEW LEFT ot Rawat LUFFING CONTROL VALVE EEE BL va HOISTING CONTROL VALVE _© EWERGENCY STOP_VALVE Saar SERIA bh oy TNT NORWALLY OPEN ae Ow202 LUFFING CONTROL VALVE © LUFF UP LUFF DOWN, ce eee SLEWING CONTROL VALVE ®. SLEW RIGHT SLEW LEFT eS eee 6 Lo: SS — 3HOISTING CONTROL VALVE © ___HOIsT UP BY-PASS VALVE limit cancel HOIST DOWN204 Control valve for luffing It is used for up and down jib. Control valve for slewing It is used for slewing crane left and right. Control valve for hoisting Tt is used for up and down hook. By-pass valve ALL Limit can be released by pushing lever of by-pass valve before operator. NOTE) Jib rest (lower limit cancel for luffing } should be surely done at no load. Energency stop valve Crane can be stopped by closing valve and cutting hyd.oil at emergency. Pay enough attention to work of crane as shown next page at limit switch cancel, © At upper limit cancel for hoisting Pay attention to the interfere with the end cf jib or sheave and falling block. Pay attention to work for striker of Limit switch box. @ At lower limit cancel for hoisting Pay attention to work for striker of Jinit switch box. Pay-enough attention to rest winding roll of wire rope on drum. When rope is paid out at max,confirm that more than three rol of vinding are rest on drun.205 @ Av upper iam cance: tor suring Pay attention to work for striker of limit switch box. Pay attention to jib not to touch stopper on crane body. @ At lower limit cancel for luffing ( At jib rest ) Jib rest should be surely done at’ no load. When jib is fallen dawn wore than 8° ,pay enough attention to rest wiring roll of wire rope. ( more than 3 rolls } Pay attention to vork for striker of limit switch box. © At limit cancel for slewing left and right. Pay attention to the interfere with around construction at slewing.206 2) Remarks a) Don't pull the Joad slantly. b) Don't operate the-crane over the vated road. c) Operate the crane seoothly. The shock at starting and stopping shoud be avoided as dar as possible and smooth operation shoud be kept. AY 1 Sih i = pats V. >: DDS z5e 23 After operation 1) (Slew.the crane to the stowing position. 2)" In-cese.of. lowering the Jib, the by pass levey(@)is to be ib isto be operated 1b the position “BY-PASS” end the vested. 3B)» Fasten’ the 3ib. 1) Confirm that J] operation handles are in theirs neutral position. '3) Lock all of operating handles. 6) Return the valves of ship body to the former Postion obsolutely. _207 1-4 Safety device 1) 2) 3) Limit valve ( To be referred to 2-3 adjusting the limit valve } At upper Limit valve for luffing LVLH @it lower Limit valve for luffing LVLL @At upper Limit valve for hoisting LVHH @At Jower Linit valve for hoisting LVHL @At limit valve for slewing right LVSR @At Limit valve for slewing left were LV SL When any limit valves act under opretion the deck crane stops. All Limit can be released by pushing lever of by-pass valve before operator. Relief valve ( Set procedure to be referred to 2-7 ) a) On operation crane, the relif valve acts, in case of higher pressure than set pressure. ‘b) When relief valve acts,reduce load or confirm of set pressure of relief valve. Limit valve for luffing ( To be referred to 2-3 adjusting the limit valve ) LVLH ( minimum radius ) Dat upper limit valve for luffing Upper limit valve for luffing works at jib angle ab.79° and Jib stop. ( Post center form hook center at aM) @s lower Limit valve for luffing LVLL ( meximum radius ) Lover Limit valve for luffing works at jib angle ab. 25° and jib stop. ( Post center form hook center at 18M ) 1. When Limit valve (LVLH, LVLL) for luffing acts, luffing winch stops and brake for winch, act automatinaiiy. 2. When Limit valve acts and crane stops,reture each operating handle to stop, and turn over operating handle to rererse’ position 3. Jib can be lowered to the rest table by operating handle for luffing to lower side with lever for by-pass valve of jib rest falling back ward.208 4) Limit valve for hoisting ( To be referred to 2-3 adjusting the limit valve ) @sAt upper limit valve for hoisting ~ LVHH At upper limit valve for hoisting works at hook stop. ( ab.tM1so from deck ) @it lower limit valve for hoisting ~~ LVHL At lover Limit valve for hoisting works at hook stop. The head height is 3500 when wire rope . 1. When limit valve (LVHH, LVHL) for hoisting acts,hoisting winch stops and brake for winch, act outomatinaiiy. 2. When limit valve acts and crane stops,reture each operating handle to stop, and turn over operating handle to rererse position. 5) Limit valve for slewing acts ( LVSR ,LVSL ) Slewing right angle is 75° ,slewing left angle is 103° , limit valve for slewing act and crane stops. ~ 1. When limit valve (LVSR, LVS.) for slering acts, sleving winch stops and brake for winch,act automatinaiiy. 2, When limit valve acts and crane stops,return each operating handle to neutral position ,and turn over operating hanle to reverse position. 3. Push lever of by-pass valve before operator. Fall operating handle for slewing to sleving direction, Slewing for 360 * can be done.209 2-5 Bmergency operation In case the pipe should be damaged hydraulic deck crane is so devised as to stop their function by means of the hyd brake. Manual procedure of releasing the hyd, brake is as follows, 1) Hoisting winch, Luffing winch, 2) Open two by-pass valves of counter-balance valve mounted on hyd. motors. ‘ b) Release the turnbackle for the brake little by little. (Record revolutions of the turnbackle.) c) Return the turnbackle .to former position and close “two by-pass valves mounted hyd. motor, after Jowering the cargo,re Rae eons s-oneH Ee TET SC oH OY TR HONTM ONTAINT ¥ ONTISTONell 2) ‘Slewing devices a) Open the by-pass valve of double counter-balance valve mounted on slewing motor by closing the adjusting belt. b) Release the turnbackle for the brake little by little. (Record revolutions of the turnbackle.) <) Return the turnbackle to former position and close the by-pass valves mounted hyd. motor, after slewing the crane, EERE _ SLEWING DEVISE “es fv pag y eo nayak Seg W.COUNTER BALANCE VALYE 1 ESR secon | | ADJUSTING SCREW FOR BY-PASS ¥. Ny RE 9 \ HYD. MOTOR Le} ‘BY-PASS ¥.: CLOSED ~ i Key y ee RL bose % iid ‘BRAKE CYLINDER ¥ BEAS—y Noon TURN BACKLE Pay Ko PWOy PB Hh LOCK BOLT FOR TURN BACKLE300 . £3. HANTERANCE AND IRSPECTION Bd Mechanical and hydraulic parts D) Grane house and jib + every 3 months 2) Confirm no deformation and no crack B) Inspect the eettings bolts. - + every 3 wonths If Joosend, refesten thee securely. . 2) Hire rope 2) Inspect the strands and ‘prior to operation check the diaeeter. - b) Inspect the fixed end of srt prior to operation the rope. ~ Prior 10 op c) Supply the wire grease. s+peeeeeeresee Replacing the wire rope with new one. -1f the following condition is Sound, the wire rope is to be replaced with new one immediately. ® The number of broken yarn ip over 1DE of yarn fer one ley. © The rope diester is decreased over 7% of She 'vomina] size: @ The rope is kinked. © The rope is greatly deformed or corroded. . 3) Sheave a) Inspect the wear at the groove seretrssessssees prior to operation of sheave, s-+++ When it is worn over 20% of rope dianeter, it is to be replaced, b) ConSirm no defornation and prior to operation no crack. + Af any deformation or crack is found, it is to be replaced.4) Falling block a) Inspect the wear at hook. stress prior to operation b) Confire no deformation and no crack, prior te operation . 5) Slewing reduction gear a) Check the level of Jubrica- Prior to operation £ tion oil. + Af its level is lok, oil is to be supplied 1i]] the adequate oi] level. In this case, supply the same oi. b) Exchange the Jubrication oil. + every 6 months Within the first year s++eeseessee After the first year tevseeeeeeeeees every year ©), Confirm no abnormal noise or vibration. --- prior to operation + every 8 nonths @ Inspect the setting bolts. ‘Fetightening at loosening every yeer €) Inspect the brake. s++++esreeee Refer 10 3.5 “Maintenance of brake” . prior te operation 8) Grease Jubrication - Refer to 3.6 “Lubricating points”. T) Slowing bearing and Hoisting winch. Supply open gear oi], + prior to operation302 9) Hydraulic of] a) Check the colour and transparency. ~~ every 3 months Pick up the samples at main circuit and head tank, and compare them with new oi] which is sampled previously. + In case that its colour is milk white and transparency is bad. oil mixed with water «In case that its colour is brown and ii has a stimulant smell. ——— deteriorated oj] To use oi} mixed with water or deteriorated of is bad jor the byéravlic devices. Please exchange hydraulic oil. After exchanging oi] it is necessary to exhaust” the air conpletely. every year b) Check a quality of oil by of] maker. 10) Oj] leakage 0i] leaks are to be mended zs soon zs they are found, because such Jezkage often Jeads to serious consequences. 1)) Linit valve Check the lini valve “= prior to operation at no Jozd operation1 PE) WeETERANCE cuECE an an cTMEKT WORKING OIL AND LUBRICATING OIL 303 USE KIND MAINTENANCE = CHECK, ‘WORKING OTL Wear resistance hyd. working oil ISO VG 46 equivalent WORKING OIL. FOR HYD. REMOTE CONTR OL DEVICE control device Ref. to iten ~ Recommended working oil ~ for hyd.renote LUBRICATING OIL FOR CLOSED GEAR | ed gear grade 2 or 320 equivalent JIS K 2218 gear oil for clos 180 V6 150 1) Check color and transparency at every voyage or every thr ee months. To send the sample of workin § oil to ojlmaker to ask the | inspection 3) To accept the advice of oi] maker whether it could be used continuously or not. LUBRICANT FOR JIS K 2220 equivalent of gea Lubricate every month and OPEN GEAR | r compound grade 1, n0.2 before or after use. GREASE FOR JIS K 2220 equivalent of gre Lubricate every week and BEARING | ase for rolling bearing before or after use. grade 1,n0.2 Discuss about decision of brand for above working and luricating oi] with oil maker and our company. A. Check of orking oil (Inspection procedure on site) Extract oil from main circuit and drain of oil tank.and compare it with new oi) which has been ex When color shows When color shows Using water mixed Exchange to nex oil. ‘acted and kept beforehand. Light white and milk white, and transparency is not good, brown or sell is stimulus, and declined oil occur bad influence to hyd. device. mix water. declination of oi} 6 B. About exchange of working oil and lubricating oi. &) Use fixed same brand vorking oi] and lubricating oil. b) Clean inside the tank et exchanging. c) Teke care so as not to involve dust or foreign matters, and supply working oi] through filter of more than 200 mesh. . Others Vorking oi] will decline sooner with high tenperature, take care thet oil tempera ‘ture sould not be more than 6st.RECOMMENDED OJLS FOR HYDRAULIC SYSTEM CANTIKEAR TYPE PETROLEUK FLUID) 10 V6 46 No} MAKER GOODS MAKE 1] syoseK) suet | Tellus oi} 48 | \ 2| wexitsy Daphne super liydro 46 Neo fluid 405 3] NIPPON OL Super hiyrend — 46 4} COSKO Cosmo hydro AR 46 8 | KYOSEKI Kyoseki hydiux 46 8 | kyanus Unit of] HR — 46 7| mitsupisHi Diasond hydro fluid EP 46 8| Esso Nuto HP = 46 Uni power SQ 46 9 | MOBIL [obit OTe 25 | 10 | GENERAL | General panol 46 304RECOMMEND OTLS FOR HYDRAULIC SYS ( ANTIVEAR TYPE PETROLEUM FLUID) ISO VG 46 305 No. MAKER GOODS NAME 11] BP Energol HLP 45 ’ 12| CALTEX Rando Oi1 BD 46 TEXACO 13] CASTROL Tyspin AWE 46 14| CHEVRON Hydraulic Oil 46 15/GULF Wechanisa LP 46 16/ELF Visga 46306 RECOMMENDABLE OILS FOR LUBRICANT CLOSED GEAR OPEN GEAR| RUBBING POSITION SPUR GEAR HORH GEAR BEARING CLUTCH 180 VG1i50 VG320 1| suKixou _ Hori 6G | _ 2] SHOSEK] | Omelu oi! 150 Duel of) 320 SUELL | G-€ of) 150 SE G-C oi! 820 SE Cargiaw coupound D| Sunlight grease 2 | Albanie greese 2 . | w| IDEMITSU | Daphne super Daphne super gear oi} 150 gear oi] 320 Dephne CE "| Dapline CE Daphne Oren Daphne Coronecks Compound ~ 150S Compound 3208 weer off No2 grease ~ 2 4 WWIPPOW O11] Bonnoek SP150 | Bonnosk SP320 Crenock He | Linockes #150 320” Coupound = 1)» erease ~ 2 5 | cosKo | Cosuo gear $E150 | Cosmo gear SE320 | Cosmo gear compound Cosmo grease dynsinas #0150 #0320 | toe No2 6 | KYOSEK] | Kyoseki ES geer G150| Kyoseki ES gear 6320 i Kyoseki Reduclus | Hyoseki Reductus —_| Kyoseki gear Kyoseki Rizonicks 150 | 820 Compound No2 grease Not 7 xyowus | Snep of) 1080 {Snev oi} 2080 | sear Coupound 2 | Kygnus HP erease 2 8 WITSUBISH] Diazond sear | Dienond sear Juob SP150 Job $820 Diasond super Diawond super Nilschishi seer | Disnond Kel Linarnath gear luob SP150 gear Juob SP820 Coupound = 2 presse - 2 9] ESs0 | Spaltan EPI50 Spalten EPS20 | Jus 2563 Ristun 2 Selet fluid 4k | Bescon 2 10[ MOBIL | Kobi] wear 629 Kobil pear 682 Nobil Tack 00 Mobilbx 2 13 | GENERAL | Genera! gear roli | General geer roll | Geners! gear Genera! greese 150 320 Counound Ho) NP 2RECOMMENDABLE OILS FOR wee LUBRICANT CLOSED GEAR OPEN GEAR RUBBING POSITION BEARING CLUTCH SPUR GEAR|WORM GEAR ve] VG 150 vG 320 312 | BP Energol GR-XP 150 | Energol GR-XP 320 | Energrease 0G Energrease LS 2 Energol SG 150 13 | CALTEX | Meropa Lubricant | Meropa Lubricant | Crater 2 Waltifak EP 2 TEXACO 150 320 Waltifak 2 14 | CASTROL | Castrol Alpha SP | Castrol Alpha SP | Rustilo $53 Soheerol AP 2 150 320 15 | CHEVRON | NL Gear Compound | NL Gear Compound | Pinion Grease 100 | Dura-Lith Grease 150 320 EP? 15 [GULF | EP Lubricant HD | EP Lubricant ED | Lubeote No.1 Crown Grease No.2 150 320 17 |ELF | Epona Z 150 Cardrexa DC 1 Wultiservice Epexa 2BL Wise rope is replaced in the following procedure, ® @ @ Procedure of replacing wire rope Put the Jib on the jib rest. Remove the set bolt or chain of sprocket on the end of shaft and re-adjust the limit switches . Renove ihe end set pin of wire rope (at the, DEADEYE side). Cut the wire rope at near the DEAD EYE and connect the new wire rope with the old one. Loose the'set bolts on drum flange and remove the end of rope. Hhile jinding the old wire rope at lon speed of winch, pay out it fron the rachine room. . When the end of new wire rope cones to the point near drum flange, stop the winch. - In case of winding the wire rope, pay attention to the connected part when i passes wire guard, falling blook and sheave. Fix the end of now wire rope with the set blots on drum flange. nd {ix the other end with the end set pin of wire rope. Hake sure thet 8 or more renaining coils of wire rope (the rest coil) is left on the hoisting drun. Fix the spying pin or chain of sprocket on the end of shaft and “ re-adjust the limit switches . ( Refor to ” adjustment of Limit valve ~ } WIRE ROPE for hoisting : P20 x 1854 for luffing $18 x 11531 WIRE ROI RIGGING 24%-0-FRD J1B TOP SHEAVE VI bo FUT HOUSING TOP_SHEAVE DEAD EYE FoRTt LUFFING DRUN DED Ss + FALLING BLOCK HOISTING pRUW Leas. BE pa-vvy7ao? BEoA .312 2~—3 Procedure of re-adjjusting the limit valve After replacing the wire rope, the limit valve needs its re-adjustment for the sake of keeping the safety of wire and each machinery . + Limit svitches are as follows . Ost upper limit valve for luffing sree LVL @bht lower limit valve for luffing LVLL ht upper limit valve for hoisting LVHH @st lower linit valve for hoisting ~ LVBL @At Limit valve for slewing right LVSR @iAt limit valve for slewing left ~ LVSL NOTE ‘Adust this at no load , and confirm that ship body is level state . Qst vpper limit valve for luffing { mininun radius) - LVL H @) Hoist the jib at Jow speed and stop it at minimus working radius. and stop ‘the crane .(AB791 (44 FROM CRANE POST CENTER) b) Turn the screw rod@ with hand until the striker® cone into contact with ‘the limit valve ( LVLH) . ( Linit velve should be in the state of being push for 2 mm~ 5 mm ) c) Set the chain or pin on the sprocket . G) Confirm that winch will stop and limit valve works at fixed position after setting limit valve { LVLH) - @) If it is not stopped at Fixed position, to loosen set bolt (NB), and to adjust wlever (L. H) . to move left and right .crc unaie bar A | AFT FORE318 { Bn | came mer 7 ~ g a | :319 3-4.Maintenance of Brake The hoisting winch and latfing winch and. slewing device are fitted each with a set of brake device, lt is released by hyd. pressure and fastened by spring force. ” Check the brake device as follow ~ every 6 months 1) Confirm that the stroke gauge indicates between -H and L, 2), Adjust the stroke gauge “H” by fastening the turnbuckle if the stroke gauge is below “L". 3) In case that the stroke gauge cannot readjust,renew the brake lining. BRAKE CYLINDER ADJUSTING BOLTa. J Bu Gaaiabo A A B F 4 ; | 1 al 7 4)°@ SANDWICH PLATE. 7 st Le @ BASE FOR FLOW : CONTROL. VALVE OF HOISTING 2 LI THE CENTER LINE OF SLEWING 4 | see | CR PAY OUT L - i NILA eas SECTIONAL VIEW. 5: | | , yore ios § ) 0 PS ( | * v 8 | ee 7 xl Re tal laps says Ke wake SERRE EPS7 L J [arse] I \ J : [ q 2 Qarseeate pee . £2 THE CENTER LiNE 2 7 OF HOUSE BASE ' 3 3 | Ria r ete ns. te 4 ‘ 2 < eo f { | ch Hl | il 1D, MoT? m SLEWNG 5 5 | ‘ L 6 | a | (ee = 8 2 hadn a[a a] we fa “| #e Se S T Ce ew 20s 3 AA PIPING OF DRAIAT J Le reoT Le | : | J sste-teet r 4 | 380 | at ee i a | Le | Et JOINT | 3 ne fo fea L | jens peu 22 S07 8 fe cow Repematett REE