5
on
pop, —LUEE pont
oF
HOIST DOW,
er
HOISTING CONTROL VALVE
SLAF
EVERGENCY SJOP_VALVE
SERRA by TANT
NORMALLY OPEN
we 202
LUFFING CONTROL VALVE @
Ee | __Ww pomy
Vv
SLEWING CONTROL VALVE @®
SLEW RIGHT SLEW LEFT
XV
cs]
i ra
203
HOISTING CONTROL VALVE ©
HOIST UP ; _ HOIST DOWN
er | ec
BY-PASS VALVE
limit cancel 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
It is used for up and down hook.
By-pass valve
All Linit 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.
Emergency stop valve
Crane can be stopped by closing valve and cutting hyd.oil at onergency.
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 of 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 limit switch box.
Pay. enough attention to rest winding roll of wire rope on drum.
When rope is peid out at max,confirm that more than three roll of winding are
rest on drum, At upper limit cancel for Juffing
Pay attention to work for striker
Pay attention to jib not to touch
At lower limit cancel for luffing
Jib rest should be surely done at
When jib is fallen dawn more than
of wire rope. ( more than 3 rolls
Pay attention to work for striker
205
of linit switch box.
stopper on crane body.
(At jib rest }
no load.
~5° ,pay enough attention to rest wiring roll
)
of Limit switch box,
At Limit cancel for slewing left and right.
Pay attention to the interfere with around construction at slewing. 206
2) Ton'4 pul] the load slantly.
b) Don't operate the crane over the rated road.
©) Operate the crane smoothly.
The shock ad starting and stopping shoud be avoided as
far as possible 2nd smooth operation shoud be kept.
Ss
2-3 After operation
1) Slew.the crane to the stowing position.
2)" In case. of. lowering the 5ib, the by pass leve@)is to be
operated to the position “BY-PASS” and the jib is to be
rested.
3B) Festen'tbe Jib.
© Confirm thet 21] operation handles are‘in their neuira] position.
5) Lock all of operating handles.
6) Return the valves of Ship body to the former
Position absolutely, 1-4
1)
2)
207
Safety device
Limit valve (To be referred to 2~3 adjusting the limit valve )
Ot upper limit valve for luffing ~ ~ LVLH
@aAt lower limit valve for luffing ~ LVLL
@dat upper limit valve for hoisting ~ ome LV HE
@kt lower limit valve for hoisting ~*~ some LVL
~ LVSR
@nt Limit valve for slewing right ~
@At Limit valve for slewing left wrmreememe 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 )
@) 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.
Linit valve for luffing ( To be referred to 2-3 adjusting the limit valve )
LVL ( minimum radius )
At upper limit valve for luffing
Upper Limit valve for luffing works at jib angle ab.80° and jib stop.
( Post center form hook center at 4)
LVLL ( maximum radius )
@At lower limit valve for uffing
Lower limit valve for Juffing works at jib angle ab.30.6° and jib stop.
( Post center form hook center at 19M )
1, When limit valve (LVL, LVLL) for luffing acts, luffing winch stops ond
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 lovered to the rest table by operating handle for luffing to lover
side with lever for by-pass valve of jib rest falling back werd. 4) Limit valve for hoisting ( To be referred to 2-3 adjusting the limit valve }
LVHH
@At upper Limit valve for hoisting
At upper limit valve for hoisting works at hook stop. ( abl3N9SO from deck }
@At lower Limit valve for hoisting ~~~ LVHL
At lower limit valve for hoisting works at hook stop.
‘The head height is 33M00 when wire rope .
1. When Limit valve (LVHH, LVHL} for hoisting acts,hoisting winch stons
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.
5) Limit valve for slewing acts ( LVSR ,LVSL )
Slewing right angle is IGU' ,slewing left angle is 160" ,limit valve for slewing
act and crane stops.
1. When limit valve (LVSR, LVSL) for slewing acts,slewing winch stops end
‘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.
Fal) operating handle for slewing to slewing direction.
Slewing for 360° can be done. 209
2-5 Bwergency 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,
Hanual procedure of releasing the hyd. brake $3 as follows,
1) Hoisting winch, Lutfing winch,
2) Open iyo ‘by~pass valves of counter-balance velve mounted
on hyd, motors. ,
b) Release the turnbackle for the brake little by little.
(Wecord revolutions of the turnbackle.)
c) Return the turnbackle-te former position and close ‘twp
by-pass valves mounted hyd. wotor, after Jowering the
cargo. 210
eR W ae
Te aT aT
SC OHI OY Te
HONTM ONTAANT F ONTILSTOW ell
2) Slewing devices
a) Open the by-pass valve of double counter-balance valve
mounted on slewing motor by closing the adjusting bolt.
b) Release the turnbackle for ihe brake little by little.
(Record revolutions of the turnbeckle.)
c) Return the turnbackle to former position and close the
by-pass valves mounted hyd. motor, after slewing the
crane. . ‘
nese __
SLEVING DEVISE
[Eg Pe _yganey eno vae
Lier
ao YY. COUNTER BALANCE VALVE
eg
Nae
| ADJUSTING SCREW FOR BY-PASS V. NN
jo eo L
C
| HYD. MOTOR [20]
£ Sea
‘BY-PASS V.: CLOSED
beep y yy
~
‘ I a BRAKE CYLINDER
lis I
2 2M
‘TURN BACKLE
SrYKo PhO yA RRS
. LOCK BOLT FOR TURN BACKLE 300
S3, MAINTENANCE AND INSPECTION
3-1 Hechanical and hydéraulic parts
1) Grane house and jib
2) Confire no deformation and no crack -+-+++ every 3 nonths
sets+ every 3 wonths
b) Inspect the settings bolts, -++~
If loosend, refasten then securely.
2) Wire rope
a) Inspect the strands and
prior to operation
check the diameter.
b) Inspect the fixed end of
+ prior to operation
the rope, =~
¢) Supply the wire grease, ~ ++ prior to operstion
Replacing the wire rope with new one.
Lf the-following condition is found, the wire rope is to be replaced
with new one innediately.
© The nunber of broken yarn is over 10% of yarn for one ley.
@ The rope diameter is decrezsed over 7% of the nominal size.
© The rope is Kinked. ,
© The rope is greatly deformed or corroded.
3) Sheave
2) Inspect the weer at the groove
cesisteeseseses prior te operation
of sheave. -
Wen i is worn over 20% of rope dipmcter, it is io be repleced,
b) Confirm no deforeetion and
cirseereseeeees prior to operation
no Crack, seseeeeeeeeeee
. Af any deformation or crack is found, it is to be replaced, 4) Falling block
a) Inspect the wear at hook. ++ prior to operation
b) Confirm no deformation and
no crack, prior to operation
5) Slewing reduction gear
a) Check the level of Jubrice-
+ prior to operation
i tion of}. -
Af j4s level is Jok, of) is to be supplied 111] the adequate oi]
level.
In this case, supply the sane of}, ‘
b) Exchange the lubrication oi).
Within the first year s++eseeees +++ every B months
Aiter the first year coreeseesesseseeeees every yeer
2), Confirm no abnormal noise or vibration, ~++ prior 10 operation
4) Inspect the setting bolts. - every 3 months
‘Retishtening at loosening :
every year
€) Inspect the br
Refer to 3.5 “Maintenance of brake”.
+ prior Lo operetion
8) Grease lubrication -
Refer to 3.6 “Lubricating points”.
‘B Sdewing bearing and Hoisting winch.
Supply open seer 03}.
Qui 302
9) Hydraulic oi)
a) Check the colour and transparency. ~~ every 3 months
Pick up the samples at main circuit and head tank,
and compare them with new oil which is sampled
previously.
. + In case that its colour is milk white
and transparency is bad.—— oil nixed with water
+ In case that its colour §s brown
and it has 2 stimulant smell, —— deteriorated oi]
Jo vse oj) mixed with water or deteriorated oi] is bad
for the hydraulic devices. Please exchange hydraulic
oil, After exchanging oi] it is necessary to exhavst
the air completely.
b) Check a quality of oi! by oi] maker.
~ every year
10) Of] leakage
Oi] leaks are to be mended as soon 2s they are found,
because such leakage often leads to serious consequences.
11) Limit valve
Check the limit valve
- prior to operation
at no load operation * 303
‘0. ADJUSTMENT
11) MAINTENANCE, CHECK
1. SORKING OIL AND LUBRICATING O7L
~
USE RIND MAINTENANCE = CHECK
Wear resistance hyd. 1) Check color and transparency
WORKING OTL working oil au every voyage or every thr
ISO VG 46 ee months.
equivalent | 2) To send the sample of workin
€ oi] to ojlmaker to ask the
. WORKING OL. FOR | Ref.to item ” Recommended inspection.
HWYD.REMOTE CONTR | working oil ~ tor hyd.renote
| OL DEVICE control device 3) To accept the advice of oi}
maker whether it could be
LUBRICATING OIL | JIS K 2238 gear oil for clos used continuously or nbt.
FOR CLOSED SEAR | ed gear grade 2 180 VG 180
or 320 equivalent
LUBRICANT FOR | JIS K 2220 equivalent of gea'] Lubricete every month and
OPEN GEAR | r conpound grade 1, n0.2 before or after use,
GREASE FOR JIS K 2220 equivaient of gre| Lubricate every week and
BEARING | ase for rolling bearing before or after use.
grade .no.2 | .
Discuss about decision of brand for above vorking end luricating oi] vith oil maker
and our company.
A. Gheck of orking oi] (Inspection procedure on site)
Extract oil from main circuit and drain of oil tank.end compare it with new oi)
which has been extracted and kept beforeband.
When color shows light white and milk white, and transparency is not good,
. ——~ nix water.
When color shows brown or sme) is stimulus, ——— declination of oi}
Using water mixed and ceclined oil occur bad influence to hyd. device.
Exchange to new oi].
s
B. About exchange of working 031 and lubricating oil,
a) Use fixed same brand working oil and lubricating oil.
) Clean inside the tank at exchanging.
c) Take care so 2s not to involve dust or foreign matters, and supply working
oi] through filter of more than 200 mesh.
C. Others
Working oil #i3) decline sooner with high tenperetur
ture should not be more than 65'C .
take care that oil tempera RECOMMENDED OJLS FOR HYDRAULIC SYSTEM sud
(ANTINEAR TYPE PETROLEUK FLUID) 180 YC 46
NO] KAKER GOODS NAME
1| SYOSEK] SHELL | Tellus of! 46
2| IDENITSU Dephne super hydro 46
Neo fluid 465
2] NIPPON OIL Super hyrand — 48
4 costo Coswo hydro AK 46
5 | KYOSEKI Kyoseki hydlux 46
6 | KyGNUS: Unit oi} HR — 46
7 | MITSUBISHI Dianond hydro fluid EP 46 |
8 | Esso Huto HP — 46
Uni power SQ 46
9 | MOBIL Mobil DTE 25
10 | GENERAL Geners! panol 46 RECOMMEND
305
OILS FOR HYDRAULIC SYSTEM
( ANTIVEAR TYPE PETROLEUM FLUID) ISO VG 46
NO. MAKER
T
GOODS NAME
11/| BP
Energol HLP 46
32 | CALTEX
|TEXACO
13) CASTROL
Rando 051 HD 46
Hyspin AWE 45
14| CHEVRON
Hydraulic O11 48
16/ELF
Mechanism LP 46
| Visea 45 our
RECOMMENDABLE OILS FOR LUBRICANT
CLOSED GEAR
OPEN GEAR
RUBBING POSITION
BEARING CLUTCH
SPUR GEAR|WORM GEAR
0 | VG 150 VG 320
12 | BP Energol GR-XP 150 | Energol GR~XP 320 | Energrease 0G Energrease LS 2
Energol SG 150
13 | CALTEX Meropa Lubricant Meropa Lubricant Crater 2X Maltifak EP 2
TEXACO 150 320 Waltifek 2
14 | castRoL | Cestrol Alpha SP | Castrol Alpha SP | Rustilo $53 Spheerol aP 2
150 ’ 320
15 | CHEVRON NL Gear Compound RL Gear Compound Pinion Grease 100 | Dura-Lith Grease
150 320 . EP 2
16 | GULF | EP Lubricant BD | EP Lubricant HD | Lubcote No.1 Crown Grease No.2
150 320
17 | ELF — | Epona Z 150 Cardérexa DG 1 Multiservice
Epexe 2 306
RECOMMENDABLE OILS FOR LUBRICANT
———
CLOSED GEAR OPEN GEAR| RUBBING POSITION
‘SPUR GEAR WORK | GEAR | BEARING CLUTCH
Iso VG150 VG320 |
“y| suniKou __ _ Kori 06 7
2| SHOSEK] | Ooela of! 150 Qusle oi] 320 |
| seu | C-t of) 150 SE G-€ of! 320 SE Carian compound D| Sunlight grease 2
/ . : Albani grease 2
“| TDEHITSO | Dephne super Daphne super
{ gear of! 150 seer of] 320 i
Daphne CE Daphne CE Daphne Open | daphne Coronecks
Compound ~ 1508 Conpound 320S gear oi] No2 srexse ~ 2
4 HIIPPON O11] Bonnock SP150 Bonnock SP320 Cranock Kul Linockes
#150 320" Compound ~"2 sreuse ~ 2
5/COSHO | Coswo gear SE150 | Cosmo gear SE820 | Coswo sear coupound Cosad grease dynunex
0150 40320 | Ho? Ko?
© | KYOSEK] | Kyoseki ES veer C150 Kyoseki ES sear 0920]
“ Kyoseki Reduetus Kyosekir Reductus Ryoseki gear Kyoseki Rizonicks
150 320 Compound No2 grease Ho?
7| Kycwus | Snep oi! 1060 | Snep of} 1090 sear Compound 2 | Kygous HP grease 2
8 ]KITSUBISH]| Diewond gear Diamond gear
. Juob SP150 Juob SP820
Dimond super Diuxond super Hitsubishi gear | Diamond He! Liparpe Lh
gear Juob SP250 sear lwob SP820 Coupound ~ 2 grease ~ 2
8 | ESSO Spal ten EP150 Spaltan EP320 JUS 2563 Ristan 2
Salet fluid 4k Beucon 2
10) MOBIL | Kobi] gear 629 Mobil gear 632 Hobi} Tack 99 Mobi lux 2
1] | GENERAL | Genere] gear roll | Generel gear rol] | Genera! gear General grease
150 220 Connound Hol0 wp - 2 3-2
Procedure of replacing wire rope
Hire rope is replaced in the following procedure.
- o
@
@
Put the Jib on the Sib rest.
Renove the set bolt or chain of sprocket on the end of shaft and :
re-adjust the limit switches .
Remove the end set pin of wire rope (at the. DEADEYE side).
Cut the wire rope ‘at near the DEAD ETE and connect the new wire
rope with the old one. ‘
Loose the'set bolts on drum flange and remove the end of rope.
While Winding the old wire rope at low speed of winch, pay out
it from the machine room. : .
then 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 it passes wire guard, falling block and sheave.
Fix the end of new wire rope with the set blots on drow flange.
And fix the other end with the end set pin of wire rope.
Nake sure thet 3 or nore remaining coils of wire rope (the
Fest coil) is left on the hoisting drum.
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 : ?25 x 210
tor luiting =: 20 x 130M 309
HIRE ROPE
1) Hoisting = *
«= AXF(40) Galvanized °2” lay ‘C7 srede
Hechenice) splice Zyk74
DEAD EYE
(Aluwiniue #l joy)
+ 4XF(40) Galvanized “27 dey “C7 srade
FykF4
/TEAD EYE
yb
DET:OF DEAD EYE .
Fok Free
ow FC2O JISF3403, 1977
DEAD EYE
FoR
Rtn
SPLIT PIN
ATVy bey METHOD OF FASTING WIRE ROPE
FASTING PLATE
310
OPENING
FASTING PLATE 7 “LUFFING DRUM
PDS
311
WIRE ROPE RIGGING
244%-0-7mD
JIB TOP SHEAVE
YI byTe-7
HOUSING TOP SREAVE
7
DEAD EYE
AORb
FoR
+ FALLING BLOCK
worstine sau f >, © LEAD EYE pany yysaor
BeRPA Fok rd 2-3
oie
Procedure of re-adjjusting the limit valve
After replacing the wire rope, the limit valve needs its re-adjustaent for the
sake of keeping the safety of wire and each machinery .
+ Limit switches are as follows .
At upper limit valve for luffing ewe LVLE
@At lower limit valve for luffing rrermmm LVLL
@st upper limit valve for hoisting ~~ LVHH
@dt lower Limit valve for hoisting LVHL
@t Limit valve for slewing right ~~~ LVSR 1
At limit valve for slewing left ~ LVSL
NOTE
Adust this at no load , and confirm that ship body is level state .
@At upper Limit valve for luffing ( minimum radius) -~ LVLH
a) Hoist the jib at low speed and stop it at minimum working radius. and stop
oa
‘the crane . (ab 80) (4 FROM CRANE POST CENTER)
b) Turn the screw rod@ with hand until the striker@ come into contact with
the Linit valve (LVLH) .
( Limit valve should be in the state of being push for 2 m~ 5 mm )
¢) Set the chain or pin on the sprocket .
@) Confirm that winch will stop and limit valve works at fixed position after
setting limit valve | LYLH) .
©) If it is not stopped at fixed position, to loosen set bolt (MB).and to adjust
vlever (L, H) . to move left and right . 313
@At lower limit valve for luffing (maximum radius) LVLL (4B306%
a) Lower the jib at iow speed and stop it at maxinun wrking radius.
b) Loosen set bolt (M8) and move lever (L, L) to left and right so
that Limit valve { LVLL ) works.
©) Confirm that winch will stop and limit valve works at fixed position
after setting limit valve ( LVLL ).
CoM FROM CRANE post CENTER)
LVHB
@At upper Limit for hoisting
a) Set the
speed until the distance between felling block and jib top becomes
b at maximum radius and hoist the falling block at low
a centain height. and stop the crane.
( ab. 13.95 from upper deck}
_b) Turn the screw rod) with hand until the striker come into contact
with the limit valve (LVR).
{ Limit valve should be in the state of being push for 2 am ~ 5mm).
©) Set the chain or pin on the sprocket.
4) Confire that vinch will stop ond linit valve works at fixed position
after setting limit valve ( LVHY ). . ,
e) If it is not stopped at fixed position, to loosen set bolt (M8) ,and
to adjust lever (H, H) to move left and right.
Fan, :
LVHL
@At lower limit for hoisting
To adjust lower limit for boisting after adjusting upper limit for
hoisting .
e@) Falling block should be down to the fixed place .
( The head height is 33M when wire rope remains 4 coils on drum.)
b) Loosen set bolt (8) and move lever (i, L) to left and right so
that limit valve ( LVHL ) works .
c) Confirm that winch will stop and limit valve works at fixed position
after setting limit valve ( LVIIL } 314
@Procedure of re-adjusting limit valve for slewing
| It is no necessary to adjust limit valve for slewing as it is once
adjusted.
Adjust limit valve as follows when limit switch do not work well.
Limit valve acts when pin ismpushed for 2 ~ 3 am.
NOTE) It touches to bottom for 5~ 6 mm
Pay attention not to push more then § ~ 6 mm, as it causes
the trouble.
1) When roler on lever is not at the position of striker. 1
a) Loosen set bolt @2-M12x252 and move striker back and forth.
It can be moved back and forth for about 6 um.
Fasten set bolt tightly after movement
b) Confirm that pin is pushed by lever for 2 ~ 3 am in the,state of
moving striker.
2) In case of pin for limit vaive not being pushed.
Jn case of pin for limit. valve being over pushed. ‘
@) Loosen set bolt @2-M12x302 and move fitting table for limit valve
up and down so as to pin being pushed for 2~ 3 mm.
bb) Fasten set bolt tightly after movement. 315
SECM ARAIL
TONTISTOR) WONT AO ANU
EL MBENE |
(ET) 6-5
SNTISTON WOT NEVI
\ BErYI 6st
YOU IN Wa LITT
BEER YA GE fi
1ankY 6a
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