OPERATION AND MAINTENAN CE

MANUAL

MASTEK HEAVY INDUSTRIES CO., LTD.

SHIPYARD COCHIN SHIPYARD LTD.

SHIP No. CSL016

CRANE TYPE HDSS3026

~
TSUJI HEAVY INDUSTRIES Co., LTD .
[1] Consideration about the Instruction Manual

1. Before using the deck crane be sure to read and understand the contents of
this Instruction Manual well.

2. This Instruction Manual is edited for the superintendents of the vessel (on which
the crane is to be mounted).
We would like to ask them to educate the operators crane enough and provoke
their attention to safety precautions.

3. From section to section, this Instruction Manual describes the specifications,

operation, maintenance, etc.
Please keep this manual safe so that you can refer to it .anytime.

4. If you have any question, please contact the offices below:

Tsuji Marine Services, Main office:

17?-2 Hikari-machi, Sasebo-city, Nagasaki-pref. 858-8501 , Japan
Tel. : +81-(0)956-47-3119
Fax. : +81-(0)956-48-5443

Tsuji Marine Services, Tokyo Branch Office:

Nihonbashi Saruya Bldg,, 16-10 Nihonbashi-Koamicho, Chuo-ku,
Tokyo, 103-0016,Japan
Tel. : +81-3-3639-5721
Fax. : +81-3-3639-5737

Tsuji Marine Services, Osaka Branch Office:

Osaka-ekimae Dai-ni Bldg., 1-2-2 Umeda, Kita-ku,Osaka,530-0001,Japan
Tel. : +81-6-6344-6501
Fax. : +81-6-6344-6503

~
Tsuji Marine Services, Hiroshima Branch Office:
Onomichi Water-front Bldg., 9-1 Higashii Gosho-machi, Onomichi,
Hiroshima, 722-0031,Japan
Tel. : +81-848-22-3652
Fax. : +81-848-22-6952

1
[2] Precautions on safety

1. To use the deck crane for a longer time, pay enough attention to safety.
To keep "Safety first" in mind, be sure to observe the following precautions on
safety.
2. According to the degree of danger, the precautions in this Instruction Manual are
classified into three levels as follows :

Highly dangerous:
wrong operation might cause death or serious
:;1\DAN GER injury

There is possibility of death or serious injury

caused by wrong operation
.Lt.WAR NING
Wrong operation may cause injury and/or
property damages
.Lt.CAU TION

Of the three above, we have made "Danger" and "Warning" plates and put them
up inside the operator's cab. so that they are visible to the operator.
General precautions and those specific to this crane are listed as below:

2
 ~DANGER

Instruction Manual is well

1. Starts operating the crane only after the
understood.
sed.
Otherwise a serious accident may be cau
n area before operation.
2. Confirm safety within the crane operatio
approach the rotating and moving
3. Do not allow any part of human bod y to
sections during operation.
ng operation.
4. Keep out of the area of slewing post duri
king at a high place.
5. Maintenance operation may require wor
ys wear a lifeline.
In this case, pay special attention and alwa

- --

3
 ~W ARN ING

1. Be sure not to position yourself under any hoisted load or the jib during
operation.

2. Confirm that the safety device is under operation and that the safety cover is
correctly installed before operating the crane.

3. If abnormal noise or motion is found during operation, stop the machine

immediately and repair the malfunctioning section(s) .before restarting.

4. Never open the door of the control panel during operation. Under the control ·
panel, a high voltage is running, which is very dangerous.

5. The hydraulic devices on the crane use high fluid pressures. If inspecting
and/or adjusting them, pay enough attention to prevention of spouting of high
pressure fluid, winch is dangerous to human bodies.

6. Fully wipe up the grease and hydraulic fluid having dropped on the floor, etc.
Otherwise they may cause the workers to slip and fall.

7. Before inspection and maintenance, be sure to switch the power off, prepare
a plate showing "Never switch the power on" , and put it up in front of the
control panel.

r · 8. Do not start the motor during inspection/maintenance.

I

4
 LhcA UTIO N

1. Periodically inspect the following devices/instruments:

1) Mechanical and structural sections :

(1) Deformation and crack on the slewing post, slewing base plate, jib,
hook, bearing and drum.
(2) Abrasion on the gear, sheave, wire ropes and brake lining.
(3) Abnormity of any brake device.
( (4) Loose mounting bolts.

2) Electrical section:
(1) Dust and moisture at the control panel and slip ring.
(2) Loose terminals

3) Hydraulic section:
(1) Fluid. leakage from the hydraulic devices and piping.

2. The manufacturer shall not be liable for any modification on the deck crane
with~ut permission from the manufacturer and the Classification Association and
any malfunction and/or accident resulting from that modification.

3. To repair and replace any major component/part, you must obtain permission
from the manufacturer.
(
4. Always keep clean the plates indicating "Warning", "Caution", "Operation", etc.
when· they are unreadable, replace them with new ones.

5. The Instruction Manual may not deal with all the safety requirements concretely
and systematically. Be sure to give safety the highest priority when handling and
operating the crane.

5
6. Precautions on the inspection records.
To use the deck crane for a longer time, strictly observe the criteria for
inspection and maintenance described in Chapter 5.

1) Be sure to execute inspection before and after operation and record the
results on the inspection journal.

2) When executing periodical inspection, check all the inspection items and
keep the records.
If you find any defect, re-adjust or replace that part.

3) If any trouble occurs on the crane restore it according to the troubleshooting.

Record the state where the trouble occurs, the conditi.on, and the measures
taken and keep that record .

4) In addition, prepare and keep the results of the tests conducted under the
periodical classification inspection of the vessel.

'

6
[3] Rang .e of Warranty and Exclusion

1. Range of warranty

ths after delivery at the vessel.

1) The period of warranty shall be twelve(12) mon
nt that goes defective or
The manufacturer will replace any part/compone
the defect or damage to
damaged within the warranty period, provided that
manufacturer's designing or
that part/component is caused by any defect in
manufacturing, or the used materials.
e of warranty any defect or
However, the manufacturer excludes from the rang
consumables as wire rope,
damage caused by user's mishandling and such
lubricant, contactor, brake lining and fuse.

repairing works according to

2) The crane(s) and electrical power required for
this warranty are to be provided by the customer.

of such indirect costs as

3) The manufacturer shall not be liable for any
rgone by the vessel.
loading/unloading losses and the time loss unde

2. Changing the application

the original design specification
1) If using the crane for applications other than
ling, offshore load ing/
(for example, load ing/ unloading of nickel hand
hatch cover handling)
unloading, tandem use with another crane and
it may be damaged seriously.
any damage to the
Note that the manufacturer is not responsible for
ed by application
crane, vessel, load and other facilities if it is caus
changes.
application.
2) Contact the manufacturer before changing the

7
3. Changing the specifications
applied/
1) For the specifications/items of the deck crane and the
related laws and regulations, refer to Chapter 1.
us damage to the
2) Changing these specifications/items may.cause a serio
crane .
d by changes
The manufacturer shall not be liable for any damage cause
facturer
of the specifications/items without permission from the manu
and the Classification Association.
regulations,
3) To change the specifications/items and applied laws and
contact the manufacturer.

4. Resale
the original
1) The product warranty of this deck crane is valid only for
user.
this
2) If you resale the deck crane in the future, be sure to attach
Instruction Manual.
ificat ions/ items
3) Chapter 1 of the Instruction Manual describes the spec
and the appli_ed/related laws and regulations.
dures of
After resale, too, observe the specifications and the proce
ce can be
inspection / maintenance so that the deck crane performan
maintained .
d by modification
4) The manufacturer shall not be liable for any dama ge cause
on to such
of deck crane and / or any damage took place with relati
d out
modification of the deck crane if the modification is carrie
and the Class ificati on Society.
without permission of the manufacturer
of and maintenance
5) After resale of deck crane, when repair to, replacement
the manufacturer's
of component of the deck crane is required, please obtain
consent prior to work commencement in advance.

8
 MAIN TENA NCE AND
INSP ECTIO N DIGE ST

manual, but here

Details in mainte nance and inspec tion are accord ance to the instruc tion
especia lly
are the minimum items require d. Please do mainte nance and inspec tion
on the driving parts and wire ropes and also on the hanging unit.

based on your
1. Interva ls are roughly mentio ned, and they may be change d in each case,
experie nce.

operati on
2. In case the crane is out of operati on for a long time, please try to make
withou t load once each month for an approp riate length of hours.

-
 a recom menda tion
DECK CRAN E MAINTENANCE & INSPECTION UST NOTE : The following items of maintenance & inspection are
of the manuf acture r based on the finished drawings, etc.
MACHINERY PARTS
.. Remarks
Check Method/Caution Stand ard Value Check Interval
Equipment Check Points
Visual check. Every after voyage
Jib · No crack is observed.
Visual check. Every after voyage.
&jib top · No damage cause d bending & any damage.
Visual check. Every after voyage.
· No abnormal at welding part.
Visual check & loosen bolts. Every after 3 voyage.
· No abnormal at jib bearings.
Visual check. Every before loading.
· Enough oiling at jib bearings. Bette r to make groove model.
Visual check . 15~20 % ofrop e dia. Every before loading.
· No abrasion of sheav e grooves.
Visual check & sheav es no shift. Every after loading.
· No abnormal at sheav e bearings.
Visual check. Every before loading.
· Enough oiling on sheav e bearings. Bette r to make groove model.
Visual check. 15~20 % ofrop e dia. Every before loading.
Post top · No abrasion at sheav e grooves.
Visual check & sheav e no shift. Every after loading.
sheav e · No abnormal on sheav e bearings.
Visual check. Every before loading.
· Enough oiling on sheav e bearings.
Hitting by hammer. Every 3 voyages.
Slewing · No loosen bolts at inner/ outer ring.
Visual check . 50H Every before loading
ring · Enough oiling at ball or roller.
Visual check . Every after loading.
· No scoring pitch on internal gear & pinion.
Visual check. 100H Every 3 voyages.
· Enough oiling at gear face.
Visual check. & no 'metal powder Every before loading.
· No abrasion on gear face.
in grease.
Visual check. Every 3 voyages.
Reduction · Enough oiling oil quantity.
Confirm it. Oil replacement.
gear of · Check for oil type & model.
Confirm it. 1000 ~ 1500H Replace every 6
Hoisting · Check timing of oil replac ement.
months.
Visual check. Every after loading.
· No oil leakage.
Visual check. Every after loading.
· No aged lubricant oil & dirt.
Visual check & confirm it on Every after loading.
· No abnormal noise & heatin g on bearing.
operation.
•' Every after loading.
· No pitching & scoring on each gear faces. Visual check .
Hitting by hammer. Every after loading.
· No loosen bolts.
- 1-
 Check Points Check Method/Caution Standard Value Check Interval Remarks
Equipment
Reduction · Enough oiling oil"quantity. Visual check. Every 3 voyages.
gear of · Check for oil type & model. Confirm it. Oil replacemen t.
luffing · Check timing of oil replacemen t. Confirm it. 1000 - 1500H Replacemen t every
6 months.
· No oil leakage. Visual check. Every after loading.
· No aged lubricant oil & dirt. Visual check. Every after loading.

· No abnormal noise & heating on bearings. Visual check & confirm on Every after loading.
operation.
· No pitching & scoring on each gear face. Visual check. Every 3 voyages.
· No loosen bolts. Hitting by hammer. Every after loading.

Reduction · No crack on gear box. Visual check. Every 6 voyages.

gear of · Enough oil quantity. Visual check Every 3 voyages.
slewing · Check for oil type & model. Confirm it. at oil replacemen t.
· Check timing of oil replacemen t. Confirm it. 1000 - 1500H Replacemen t every
6 months.
· No oil leakage. Visual check. ~
Every after loading.
· No aged lubricant & dirt. Visual check. Every after loading.
· No abnormal noise & heating on casing. Visual check & confirm on Every after loading.
operation.
· No loosen bolts. Hitting by hammer. Every after loading.

-2-
Equipment Check Points Check Method/Caution Standard Value Check Interval Remarks
Slackover · No abrasion on rollers. Visual check. Every 3 voyages.
device · Rollers are rotating. Visual check & confirm operation. Every during loading.
· Proper spring forces. Visual check & confirm operation. Every during loading.
· Bearing conditions. Visual check & confirm operation. Every during loading.
(abnormal noise & heating)
· Actuation of limit switch. Visual check & confirm operation. Every during loading.
· Proper adjustment is done. Visual check & confirm operation. Every during loading.
· Enough oiling to bearings. Visual check. Every before loading.
Hoisting · No abrasion on rollers. Visual check. Every 3 voyages.
drum · Push rollers are rotating. Visual check & confirm operation. Every during loading.
· Proper spring forces. Visual check & confirm operation. Every during loading.
· Bearing conditions. Visual check & confirm operation. Every during loading.
(abnormal noise & heating)
· Actuation of limit switch. Visual check & confirm operation. Every during loading.
· Enough oiling to bearings. Visual check. Every before loading.
Luffing · No abrasion on rollers. Visual chec_l<. Every 3 voyages.
drum · Rollers are rotating. Visual check & confirm operation. Every during loading.
· Proper spring forces. Visual check & confirm operation. Every during loading.
· Bearing conditions. Visual check & confirm operation. Every during loading.
(abnormal noise & heating)
· Actuation of limit switch. Visual check & confirm operation. Every during loading.
· Enough oiling to bearings. Visual check. Every before loading.
Operation · No water entering from maintenance Visual check. Every during loading.
cab. door.
· No abnormal on the window. Visual check. Every during loading.
(Oil leakage, dirt or cracks)
· No abnormal on fan, heater or wiper. Visual check. Every during loading.
· No damage on every control equipment. Visual check. Every during loading.
· All lights are illuminated. Visual check & confirm operation. Every during loading.

-3-
Equipment Check Points Check Method/Caution Standard Value Check Interval Remarks
Machine · No water entering from entrance door. Visual check. Every during loading.
room · No damage on c·ontrol panel door. Visual check. Every during loading.
· Cleaning of floor. Visual check. Every during loading.
· Control panel door is closed tightly. Visual check. - Every during loading.
· Room light is illuminated. Visual check & ~onfirm operation. Every during loading.
Wire rope · Rope oil is applied. Visual check. 150 ~ 200H Every before voyage.
· No core wire breakage. Visual check. 10% break in 1 lay. Every after loading.
· Proper rope is used. Visual check. 5% break in 1 strand. Every before loading.
7% abrasion of rope Every 700~ 1000 hours in
· Replacement period is not over. Inspection Every before loading.
dia, deformation. crane operate. (for reference)
· No deformation of strand or kinking. Visual check. Every after loading.
· Confirm S or Z strand. Visual check. Wire rope replacement.
· No abnormal at wire end treatment. Visual check. Every 3 voyages.
· No abnormal at wire connecting socket. Visual check. Every 3 voyages.
Limit · Proper setting. Visual check & confirm operation. Every before loading.
switch · No loosen on roller chain. Visual check. Every before loading.
· Enough oiling. Visual check. Every before loading.
· No abnormal on bolts. · Visual check. Every before loading.
· No abnormal on sprocket. Visual check. Every before loading.
· Proper setting of microswitch & roller. Visual check. Every before loading.
Air duct · Confirmation of oil cooler fan rotating. Visual check. Every before loading.
· Not forget dumper closing. Visual check. Every during voyage.
· Not forget dumper opening. Visual check. Every loading.(every day)
· Water tightness of packing. Visual check. Every during voyage.
· Oiling at hinge part. Visual check. Every during voyage.
· Cleaning of filter. Visual check. Every loading(every day)
Slewing · No crack on welded part. Visual check. Every loading(every day)
post · No backing is occured. Yrsual check. Every 3 voyages.
..
· No crack on platform handrail, etc. Visual check. Every 3 voyages.
· Water tightness of door. Visual check. Every loading(every day)

-4-
Equipment Check Points Check Method/Caution Standard Value Check Interval Remarks
Cargo · No abrasion of s'heave groove. Visual check. 15-20 %of rope dia. Every 3 voyages. Better to make groove model.
block · No abnormal on sheave bearing. Visual check & sheave no shift. Every after loading.
· Enough oiling for swivel sheaves beari ng. Visual check. Every before loading.
· No crack on welded part. Visual check. Every loading(every day)
· No crack on hook & shackles. Visual check. Every loading(every day)

,,

-5-
 ELECTRIC EQUIPMENT :

Equipment Cht!ck Points Check Method/Caution Standard Value Check Interval Remarks
Slip ring · No abrasion on carbon brushed. Visual check. Every 3 voyages.
· Contact condition of ring and carbon brush. Visual check. 80% of touch face Every 3 voyages.
· No color change of ring. Visual check. Every 3 voyages.
· Carbon powder is clean off. Visual check. Every 3 voyages.
· No spring come out. Visual check. Every 3 voyages.
· Good insulation resistance of power It checks in insulation resistance Every 3 voyages.
source. tester.
· No terminal bolts loosen. Retighen them. Every 3 voyages.
· Fixing method of lower part of box. Visual check. Every 3 voyages.
· Oiling to bushes. Visual check. Every 3 voyages.

Control · No abrasion on contactors of main control. Visual check. Every 3 voyages.

panel · Setting of every time relays. Visual check & see setting value Every 3 voyages.
on instruction manual.
· No dust in control panel. Visual check. Every 3 voyages.
· Retighten of terminal screws in panel. Retighten. Every 3 voyages.
· No auxiliary relays came off. Visual check. Every 3 voyages.
· No abnormal noise during operation. Confirm. -
· No abnormal heating. Confirm. Every before loading.
· Confirm thermal relay setting. Confirm & check on circuit. Every before loading.
· No lamps broken. Confirm. Every before loading
· Main source voltage, AC440V. Confirm by measuring. Every 3 voyages.

Electric · No abnormal noise. Confirm. Every before loading.

motor · No abnormal heating. Confirm Every before loading
· Nor terminal bolts loosen. Retighten. Every before loading
· Enough oiling to every bearing. ..
Visual check & oiling 2 year. Every 6 voyages .

-6-
Equipment Check Points Check Method/Caution Standard Value Check Interval Remarks
Hoisting · No damage on rubber cover. Visual check & during loading. Every after loading.
controller · Auto-retu rn of lever. Confirm by operation. Every after loading.
· No loosen set screw of terminal. Retighten. Every after loading.
· No abnormal movement at every part. Confirm by operation. Every after loading.

Luffing · No damage on rubber cover. Visual check & during loading: Every after loading.
& · Auto-retu rn of lever. Confirm by operation. Every after loading.
slewing · No abnormal movement at every part. Confirm by operation. Every after loading.
controller
 MAINTE NANCE AND INSPEC TION STANDA RD

Maintenance Name of check

systems Check items Check methods Maintenance Repair (replace )
Compen ents Period Remarks
Standard s Standard s
1. motor insulation measure at 500V one more than 1OM Q
condition· insulation resistan ce year between grounds
tester
2. control circuit insulation measure at 250V
Related one more than 1OM Q
to condition insulation resistan ce year between grounds
Electricity tester
3. electric wire insulation measure at 500V one more than 1OM Q An electric wire is
condition insulation resistan ce year between grounds removed and
tester measure d from
electric apparatu s.
1. hydraulic oil quantity of oil measure by level one quantity of oil change the oil in
gauge month should be within the tank every 1000
regulated range hours
purity of oil ask the sample ask oil-maker for
oil maker replacem ent
2. hydraulic pump chain coupling disassembly and one existenc e of when heavily worn if heavily worn
check year abnormal sounds replace with a new in a short period
wear of chain one recheck the centerin g
abnormal sound check by listening four usually 97-103 dirtiness of hydraulic
Hydraulic measure by decibel months decibels oil, loading of filter,
System meter valve chatterin g
thermom eter fit thermom eter to one maximum 85° C when tempera ture
the pump main body year rises rapidly, check
by joint the pump and other
related compon ents
pressure measure by pressure two maintain the
,
gauge months regulated pressure
..
without variation
oil leakage check visually and two change packing look out for aging in
by touch months pump shaft seal
-R-
Maintenance Name of check Maintenance Repair (replace)
Check items Check methods Period Remarks
systems Components Standards Standards
2. hydraulic pump air suction put grease, etc. two
on intake pipe months
3. filter foreign matter take out and check one no foreign matters in case of foreign never use dirty
attachment visually, according month attached to the matter attachment, oil
to indicator surface and no change the oil
damaged spots
4. pressure pressure control check by pressure two pressure can be if the pressure replaced to pump
control valve gauge, control from months kept without change in great, and other components
maximum to minimum change and control check the inside,
pressure is possible if abnormal change
5. flow control flow control one. when operation is
valve year. defective check
inside; if abnormal,
change
Hydraulic 6. stop valve internal leak shut the valve and one according to the if there is leakage
System check outside leaks year purpose for use no change
internal leak
7. solenoid valve insulation measure at 500V one more then 1OM Q
condition mega year between grounds
voltage with voltmeter, two be in permissible when voltage change coils bum if voltage
measurement measure the months range of rated is big recheck is out of permissible
maximum voltage voltage electric equipment
during operation
operation sound check by listening one
year
wear of push rod ,check the shape two no burr on edge change the worn
and looseness of looseness of screw month~ surface. no loose- parts. loose screws
screws of terminal piece ness at any part are a cause of coil
and casing burning

-A-
Maintenance Name of check Maintenance Repair (replace)
systems Check items Check methods Period Remarks
Comp·~nents Standards Standards
7. solenoid valve operation pressure gauge, two temperature rise when operation in depending on the type,
condition coil cover part months at confirmation defective, change more than regulated
temperature coil part under parts; or depending flow makes operation
switching condition on the content defective
is less than 85° C change the whole
8. check valve internal leak increase pressure according to the in case of leakage,
. outside, remove, purpose for use no change depending on
and check leak internal leak the content
9. pressure insulation measure at 500V one more than 1OM Q
switch condition mega year between ground
operation measure by pressure two confirm operation
condition gauge months within setting
pressure range
10.piping vibration visual check two pipe shouldn't
Hydraulic-
System months vibrate greatly
during switching
pipe support visual check six no looseness and tighten up
fittings months nothing missing
11 . hydraulic spline of apply "MOLY-COAT- approx. apply "NEW GREASE" after removal of
brake brake hub GREASE" to the every "OLD GREASE'.' as the "MOLY-COAT-
(For hoisting, teeth of the spline 500-800 GREASE" has tendency being stiffen
luffing, slewing) provided inside of hours year by year
the hub of brake period
drain pot Residual oil should Prior to If there is oil remained in the drain pot,
not remained in the operation untighten the drain pot and then discharge
drain pot the remaining oil. When the oil will become
I
full of drain pot in a short time (for about
..
5 to 10 hours), O-ring of hydraulic brake
is necess-ary to be replaced.
- 10 -