H3-HATCH COVER 舱口盖

舱口盖１／１０９
GUIDANCE MANUAL
for
Weatherdeck hatch covers
TTS
Dry Cargo Handling
18th Floor,3255 Zhou Jia Zui Road
Shanghai 200093,China
Tel: +86 21-65398257
Fax: +86 21-65397400
E-mail: engineering @ tts-huahai.com
Yard Judger shipbuilding Co.,Ltd

Hull no. ZJ82K-1001
Order No. 940
Guidance manual
Contents Page
1. Introduction & Warnings 1

1.1 Introduction 2
1.2 Safety notes 2
1.3 Copyright 3
1.4 Guarantee terms 4
2. Specification 1
2.1 Specification of the steel equipment 2
Specification of the hydraulic system and com 4
3. Manoeuvre instructionsImportant notes 1
3. Important notes 2
3.2 Opening of the holds 3
4. Troubles, Emergency Operation 1

4.1 Troubles 2
4.2 Emergency operation 2
5. Maintenance 1
5.1 Maintenance of hatch covers 2
5.2 Maintenance of hydraulics 8
6. Service & Spare parts 1

6.1 Spare parts 2
6.2 Spare parts and tools list 3
6.3 TTS Service-stations world-wide 4
7. Certificates 5
8. Drawings steel & fittings 1

8.1 List of drawings steel & fittings 2
9. Drawings Hydraulic 3
9.1 List of drawings hydraulic 4
10. Drawings Electric 5

10.1 List of drawings electric 6
11. Drawings Pneumatic 1
12. For Your Notes 1

GUIDANCE MANUAL
1. Introduction & Warnings

1.1 Introduction
This manual for TTS hatch covers contains information especially for this
equipment on technical data, installation, start-up, care and maintenance as
well as spare parts ordering.
The advanced design and the size of this plant requires experience, skill and
special attention for safe operation and careful maintenance.
Make sure the guidance manual instructions, especially the safety

instructions in this documentation are carefully observed!
∗ General notes on safety are listed in this first chapter.

∗ Special instructions are given at the beginning of the individual chapter.
∗ Safety instructions referring to actions are given before the action itself is
described.
1.2 Safety notes
The products of TTS Hua Hai have been designed and manufactured as to
reflect the actual technological state of the art. Nevertheless, it cannot be ruled
out that danger may arise to:
− life and limb,
− the product itself and the overall plant,
− other assets
In particular, dangers may occur:

− if insufficiently trained personnel manipulates the product,
− if the product is improper installed, operated and serviced,
− if the product is used for other than the intended purposes.
All persons operating the plant or product must:

− have definitely read and understood this chapter,
− know these operating instructions or at least be familiar with those parts
where the respective activity and associated dangers are described,
− be familiar with shut-down procedures, e.g. "Emergency-Off", relating to the
entire plant or to plant items important to the relevant activity,
− have adequate technical qualifications and be authorised to perform the
relevant activity,
− know their specific duties and authority.
Moreover, it is mandatory that these persons:
− refrain from doing anything that might cause bodily harm or constitute a
danger to health, the product or other assets,
− inform their superiors in charge or the operator of any modifications made to
the product,
− inform their superiors in charge or the operator of any changes detected in
the operational behaviour of the product, for example unusual running
noises.
No modifications to the product are permitted unless the prior approval of TTS
Hua Hai has been obtained.
The user shall undertake to:

− ensure that the product and its surroundings are kept clean and in good
order,
− operate the product only when in perfect condition,
− use the product exclusively for the intended purpose,
− use the product only in the framework of the technical characteristics listed
below,
− safeguard rotating parts by means of suitable protective systems,
− instruct the personnel to wear protective clothing to the extent deemed
necessary,
− distribute these operating instructions among the personnel in charge.
Using the equipment for the intended purpose as set out above also includes
observing the instructions given in this operating manual.
In addition to the procedures and instructions outlined in this operating manual
all generally applicable statutory and other accident prevention rules and
provisions must be observed.
We reserve the right to implement technical changes for product improvement

purposes.
The figures shown in this manual may slightly deviate from the actual design.
1.3 Copyright
We reserve the right of origin for this guidance manual for the design as well as
for the technical information contained therein. Passing on to third parties
and/or reproduction of this guidance manual without our specific consent is not
permitted. All our records are to be treated as strictly confidential. They remain
our property and are to be returned on demand.
1.4 Guarantee terms
Begin and period of guarantee for the delivered equipment is laid down in the
contract.
The guarantee covers functional defects which are resulting from faulty design,
materials or workmanship.
Claims of the customers out of this guarantee can only be considered, if the
defect is advised to us immediately after it occurred stating exact details of the
damage. Guarantee-services will only be rendered if it concerns a definite
guarantee-case. The customer, therefore, will enable us to inspect the damage
and establish the necessary preconditions for our staff to carry out the repair
works.
We shall supply spare parts under guarantee terms only provided that the
damaged parts are put at our disposal.
Guarantee services will be carried out without charge. Included are the working
hours for our technical staff as well as their travel and living expenses. As far as
these services will occur in China, we will decide whether the damaged part will
be repaired or will be replaced by a new one.
Guarantee-repairs which have neither been arranged for, nor have been
ordered by us or to which we did not at least agree will not be paid by us.
In case a defect can be remedied in a foreign port only with assistance from a
third party we shall reimburse expenses only up to the amountment which
would be due if the repair would be carried out in a Chinese port.
The parts for replacements will be sent at costs and risk of the customer. Same
applies for the defective parts sent back to us.
We do not guarantee for :
− Damage which is caused by excessive stress, improper use, careless and

faulty maintenance, normal deterioration as well as neglect of the operation
instructions.
− Loss of profit
− All kinds of indirect damages (consequential damages)
− Damages which have been occurred by and with materials supplied from the
purchaser.
Manipulations in our installations undertaken by firms or persons being not

authorized by us will forfeit any guarantee claim.
GUIDANCE MANUAL
2. Specification
2.1 Specification of the steel equipment
2.1.1 Weatherdeck
2.1.1.1 Rules and regulations: DNV +CSR

The International Load Line Convention
1966 With all amendments
SOLAS 1974 With amendments
ICS 4th
2.1.1.2 Type of covers: TTS side-rolling AutoRoll system hatch

covers
2.1.1.3 Actuation: Handling: hydraulically

Cleating: Mechanical Automatically
2.1.1.4 Arrangement of covers: Hold no.1-7: two side-rolling panels,

(see also dwg. no. 940-1111; opening directions one panel portside and
1211; 1411): one panel starboard
2.1.1.5 Hold dimensions: Hold no. 1: 14705mm x 12800 mm

Hold no. 2/3/5-7: 17300mm x 15000 mm
Hold no. 4: 15570mm x 15000 mm
2.1.1.6 Structure design: Open girder construction, sloping top plate
2.1.1.7 Material: Steel plates of mild and high tensile steel

AH36 in ships quality
Axles and bolts of type stainless steel and
engineering steel. Bronze bushings with
greasing through readily accessible grease
nipples to be arranged where necessary.
Pipes in TTS equipment is of normal steel,
quality DIN 2391, if not otherwise specified.
Couplings of ERMETO type or similar.
2.1.1.8 Welding: Welding is continuously and according to

Classification Society
2.1.1.9 Wave loads: Vertical wave loads :

66 kN / m² for No.1 H.C.
40 kN / m² for No.2 H.C;
34.3 kN / m² for No.3-7 H.C
Horizontal sea load: 175 kN / m²
2.1.1.10 Uniformly distributed load: Water ballast load: 0~65.0 kN / m² (From

side skirt of one side to another side)
2.1.1.11 Helicopter Load: Winch only

2.1.1.12 Restrictions: proper function is guaranteed up to a max.
trim of ± 2,0° and max. ship's heel of ±3°.
Temperature range from -20°C to + 45°C.
2.1.1.13 Coaming deflexion: max. ± 15 mm
2.1.1.14 Weathertightness: Achieved by TTS SQUARE rubber

arranged in the split joints and on the
underside of the hatch covers against the
coaming and the adjacent panels coaming
profile. Drainage ball valves for the
coaming is arranged at the corners of the
hold and each of the drive recesses.
2.1.1.15 Cleats: The hatch covers are secured to the

coaming by cleats that automatically
engage / disengage through the operation
of the AutoRoll system. The ballast water
hatch covers will be secured with Anti-
lifting cleats by manually operated.
2.1.1.16 Wheels: With rolling bearings and nipples for

lubrication.
2.1.1.17 Anticorrosion preservation: Blasted SA 2 ½ and with approx. 25 μm

shopprimer.
2.1.1.18 Operation of covers: The hatch covers are left from the cleats
and moreover raised to the rolling position
in one operation through the action of
forward and aft wheel AutoRoll systems
driven in with two hydraulic cylinders at
each end. From this position the panels will
be driven into stowage by a rack and a
pinion driven system. This will consists of a
hydraulic motor driven pinion mounted at
the end side of the coaming. The pinion will
engage with a rack arm welded to the
underside of the panel. The hydraulic
operation system to be capable of
operating the two panels simultaneously.
2.1.1.19 Auxiliary operation In case of failure of one pump or electric

motor the remaining pump is sufficient to
proceed operating the covers.
For emergency operation, one portable
electric pump by to be used.
2.1.1.20 Single weight of covers: see drawing no. 940-1111 & 1211 & 1411
2.1.1.21 Shipping weight: abt. 447 t
Specification of the hydraulic system and com
2.1.2 Components
power unit
Power consumption : 2 x 25.6 kW

Power supply : 440 V/60 Hz, 3 phases
Rated current : 2 x 43.1 A
Insulation : class F IP 54
Pump capacity : 2 x 47 l/min
Nominal working pressure : 250 bar
Testing pressure : 375 bar
Classification : DNV Register
hydraulic cylinder
The hydraulic cylinders are made for use on board of seagoing vessels and are
approved by the classification society.
Hydraulic cylinders are according to TTS standard.
control
All control valves are manually operated and made for use on board of seagoing
vessels.
One(1) control valve stand shall be arranged for each hatch at after of hatch
coaming 。
All name plate should be in English/Chinese.
High pressure hoses

The high pressure hoses are to fulfil the class rule and are fitted with couplings
suitable for the pipes.
Hydraulic oil
Oil recommended by TTS will be used(mineral oil)
2.1.3 Opening/closing time
(Theoretically data without time for cleating/locking)
Time calculated for opening one adjacent panels of each hold is approximately
2 minutes.
Time calculated for closing one adjacent panels of each hold is approximately
2 minutes.
GUIDANCE MANUAL
3. Manoeuvre instructions
Important notes
IT IS STRICTLY FORBIDDEN TO BE IN THE HOLD DURING HATCH COVER
OPERATIONS ! (DANGER BY OBJECTS FALLING DOWN !)
IT IS STRICTLY FORBIDDEN TO ENTER ONTO THE HOLD COAMING OR

THE STORAGE SPACE AS LONG AS THE COVERS ARE NOT FULLY
OPENED AND SECURED OR IN FULLY CLOSED POSITION !
OPERATING OF HATCH COVERS BY CREW MEMBERS ONLY !

OPERATORS MUST BE INSTRUCTED, WELL TRAINED AND FAMILIAR
WITH THIS GUIDANCE MANUAL !
General hints
All control desks for operating the hatch covers are arranged on
weatherdeck.
The hatch covers are operated from the control desks arranged on AFT. end.
Attention:
When the covers are lowered and secured to the coaming check following
points:
− when loaded, the covers shall rest on all supports uniformly

− all wheels must turn free, even with load on the covers!
− When No.4 hold is full charged of ballast water, the anti-lifting device must be
locked on the end of hatch covers.
− Before No.4 hold ballasting / de-ballasting must open all ventilator covers for
air free purpose.
3.1.1 Limitation of operation
The hatch covers are designed for operation under conditions up to
max. Trim of ± 2,0° and max. Ship’s heel of ± 3,0°.

Temperature range from –20°C to + 45°C.
3.1.2 Preparations before opening the holds

− Remove deck load from the hatch covers.
− Make sure that there is no cargo or other obstructions in the path and the
stowing space of the hatch covers.
− Check cleanliness of coaming top before operating the covers.

− On weatherdeck, disengage “anti-lifting” pins of No.4 hatch cover of water
ballast hold.
3.2 Opening of the holds
At the control desks: Check all by-pass to be closed. (See drawing no.
940-9000.)
3.2.1 Start both pumps at both power units.

− Power unit no. 1,2 feeds oil for all hatches.
3.2.2 Opening the weatherdeck holds

Start the pump.
Release the locking pin of auto-roll assembly. Furthermore, release the

locking pin of anti-lifting device for water ballast hatch cover.
Open the ball valves in the control valve unit.
Push the lever for cylinders to “CLOSE” seconds, and to "OPEN" and remain in
this position. Until the cog segment touch the stopper of auto-roll assembly.
Push the control valve lever for the motor which is to be operated to "OPEN"
and hold it there until the cover has been opened.
Reduce cover speed before striking stopper by gently returning control lever to
neutral position.
Lock the panel with the pin of the end stopper for open position.
The opposite panel can now be closed or operated to outer position and locked.
After opening operation, push the lever for cylinders to "CLOSE" and remain in
this position. Until the double link touch the stopper of auto-roll assembly. And
lock the locking pin of auto-roll assembly.
Closing the ball valves.
Stop the pump unit.

3.2.3 Closing of the weatherdeck holds
Start the pump.
Release the locking pin of auto-roll assembly.
Open the ball valves in the control valve unit.
Push the lever for cylinders to “CLOSE” seconds, and to "OPEN" and remain in
this position. Until the cog segment touch the stopper of auto-roll assembly.
Release the locking pin of end stopper for open position.
Push the control valve lever for motor, which will be operated to "CLOSE" and
hold it there until the cover is stopped gently against the cog segment .
Reduce cover speed by inching control of valve lever before coming into contact
with cog segment .
Push the lever for cylinders to "CLOSE" to roll down the cover. Until the cover
has been closed completely.
After closing operation, lock the locking pin of auto-roll assembly.
Closing the ball valves.
Stop the pump unit.

GUIDANCE MANUAL
4. Troubles, Emergency Operation

4.1 Troubles
Reaching an oil temperature of 60°C the thermostat will switch off the
concerned power unit. Re-start after the oil has cooled down.
If the oil temperature is below 5°C the thermostat will switch off.
A level switch switches off the concerned power unit when the oil level is too
low.
An adjustable timer will switch off the concerned power unit after 30 running
minutes.
A pressure switch will be alarmed if the return line filter is contaminated.
4.2 Emergency operation
During operating, the covers will stop immediately in each position when putting
the hand lever of the related control valve back into neutral position.
By pushing an “Emergency off” push button(mounted in the pump room), the E-

motors of the related power unit will be switched off and all motion of the hatch
covers of the related hydraulic circuit will stop immediately.
If a pipe line between a control desk and a power unit should burst or if a power
unit should fail, all motion of the concerned hatch covers will be stopped
immediately.
If a pipe line between a control desk and cylinders should burst, the unsecured,
concerned folding pair will run downwards. However, speed is limited by flow
control valves incorporated into the cylinders and is about 1,3 of the normal
speed.
GUIDANCE MANUAL
5. Maintenance
5.1 Maintenance of hatch covers
5.1.1 Lubrication
Maintenance of the equipment is foremost systematic lubrication of the movable

parts for keeping them easygoing and to prevent corrosion. Lubrication shall be
done after every use, but latest after every two months and after heavy weather.
5.1.1.1 Lubrication of grease nipples applied with grease gun

WEATHERDECK
Part name Quant. Location
Bearing 70 AutoRoll system assembly
Wheel 56 Hold 1~7
Grease nipple 112 Oil motor bed
The pin of stowage stopper 28 Stowage stopper
Cylinder rod side 14 Link of AutoRoll system
Cylinder seat 14 The pin of seat
5.1.1.2 Lubrication with open gear grease applied with swap

Part name Quant. Location
Touch block 28 Weatherdeck covers/coaming
Guide block 28 Weatherdeck covers/coaming
Locking pin of AutoRoll system 14 AutoRoll Mechanism
Pin for eyeplate of AutoRoll 28 Eyeplate of AutoRoll
Cog wheel 42 Oil motor bed
Oil nylon touch plate 14 Oil motor bed
…all movable parts
5.1.1.3 Lubricant – alternatives: please see next page
5.1.1.4 Maintenance of the sealing
The rubber sealing must be greased with silicon grease. This will essentially
lengthen its lifetime.
Lubricants – Alternatives
Maker Gear Oil Open Gear Grease for Lubricant Grease for
Swab Nipples
Antar (Aral) Epona Z 150 Engrenage 1401 Multiservice
BP Energol GR-XP 150 Energol GR 3000-2 Energrease LS 3
Castrol Alpha SP 150 Grippa 60 S Spheerol LMM *
Rustilo 553 Spheerol AP 3
Chevron NL Gear Compound 150 Pinion Grease MS Polyurea EP Grease
(Pinion Grease 250 TCB) (Dura-Lith Grease 2)
Dow Corning Molykote 165 X * Molykote Longteam2*
Exxon (Esso) Spartan EP 150 ENL 55 * Beacon 3
Beacon EP 2
Fina Giran 150 Cabline Fluid 2750 Marson EPL 2
Gulf EP Lubricant HD 150 Spray Lubcote No. 1 Gulfcrown EP Gr. 2
Mobil Oil Mobilgear 629 Mobiltac 81 Mobilflex 47
Mobilgear 630 Mobilux EP 2
John W. Miller Black-Moly * Black-Moly *
& Son Ltd. Millergrease D-580-LC Millergrease D-180
Norus Sales Norus Plasticoat DC Black
Company
Shell Omala Oil 150 Cardium Compound D Alvania R3
Cardium Fluid F Alvania EP 2
Slip Products Molyslip MPG * Molyslip MPG *
Co. Ltd. Molyslip OGL *
Sunoco Sunep 1050
Sunep 1090
Texaco Merapa 150 Crater 1 X Multifax EP 2
Multigear Lub EP 90 Crater 2 X Fluid
Texclad 2
Valvoline Dipper Stick Lube Wheel Bearing Grease
EP 2
*) contains Molybdenum disulphide
Special grease for equipment and accessories arranged in reefer holds and when
temperatures below 0°C Celsius are to be expected: Zerolene DLF
Special silicon grease for rubber packings: Silicon paste P
…
5.1.2 Auto cleats
Check periodically that all hooks are firmly engaged on the weatherdeck hatch
covers.
If the clearance (0-3 mm is permissible) between hook and wedge on coaming

is too much, adjust it by the hexagon nut.
The elastic washer must be replaced when the rubber has lost its elasticity.
Replacing is recommended every second year.
5.1.3 External Painting
The hatch covers should be preserved according to the ship’s painting

specification.
Do not paint rubber seals, piston rods of hydraulic cylinders and flexible hoses.
5.1.4 Welding and flame cutting
− Do not damage rubber seals by heating. Dismount them when nearby areas
are being repaired.
− When large-scale repairs of the equipment are undertaken, call for a TTS
expert in order to avoid deformations and twisting by wrong welding
sequences which could avoid water-tightness.
5.1.5 Replacing damaged rubber seals
− Perform gluing as described in the enclosed instructions (see page 5.5 ff.)
− When replacing the complete rubber sealing, the corner pieces must be
glued first, then the straight line rubber strips –with an over-length of
abt. 2-3 mm per meter- have to be installed.
− For connection of moulded pieces and/or straight strips the ends have to be
cut accurately and in right or 45° angle.
5.1.6 Mounting instructions for TTS seals
5.1.6.1 The TTS SQUARE seal shall be glued in between the seal retainers
(L100x63x8).
Adhesive to be used: HAWE “Super S” or an equivalent glue approved by TTS.
Follow manufacturer’s instruction for use of the adhesive (JY-2).
5.1.6.2 Before installation of the seal strips make sure that:
a) they have been unrolled as a straight line and have

rested in this condition at least for 24 hours,
b) the seal dimensions have been checked carefully,

especially the height of the seal profile.
If the stated deviations exceed the allowable tolerances,

TTS must be informed immediately.
5.1.6.3 Cut the rubber profile accurately and in correct right angle in order to fit each
other. Prepare the straight strips by cutting with overlength (max. 2-3 mm per
meter) so that they will be slightly compressed longitudinally when inserted.
The rubber seal shall not be stretched during the installation.
5.1.6.4 The rubber seal has to be dry and free of dirt and grease. It is recommended to
roughen the contact surfaces and wipe them with thinner shortly before gluing.
Use therefore clean cotton waste only.
5.1.6.5 Mix the glue thoroughly and apply it without thinner.
5.1.6.6 First of all insert the corner pieces (use screw clamps, if necessary). Spread
rear of the rubber corners with glue by using a paintbrush. The glue is ready for
application when the surface still feels sticky but shows no threads by touching
with a finger. Fit the corner pieces into the retainers and hit them with a rubber
hammer.
Notice: It is advisable to make a test before beginning to work as the drying of glue
depends on the ambient temperature and weather conditions.
5.1.6.7 For gluing rubber to rubber (end pieces, corners and hoses) use the special
glue LOCTITE 495. Pay attention to the working instructions of the
manufacturer of the glue.
5.1.6.8 The three surfaces of the retainer channel for the straight rubber seal
(“L100x63x8”) must be painted with glue quite thickly by using a paintbrush.
5.1.6.9 Immediately after this, and before the glue has become dry, the contact
surfaces of the straight seal strips must also be painted with glue. Then press
the rubber seal into the angle bar-100x63x8. During the inserting the wet glue
shall fulfil the function as some kind of lubricant and it will act as sealing
material between steel and rubber.
5.1.6.10 Connect both profile ends (corner and straight line) with elastic rubber cement
(Loctite 495), press them together and make sure that the joint surfaces have
correct contact. If necessary, bend inwards the seal bars by hammering.
5.1.6.11 After finished installation all joining edges and gluing seams must be sealed
with elastic rubber cement (Loctite 495). Unevennesses have to be smoothed
and planned.
Caution:
The adhesive is highly inflammable!
All necessary precautions must be taken!

5.1.7 Description of the adhesive “JY-2”
The “JY-2” is a one-component high-performance adhesive. An excellent

attribute is gluing together rubber to rubber, rubber to metal, wood or plastics.
The adhesive is resistant against water and high temperatures, flexible and
qualified for high mechanical stress.
5.1.7.1 Directions for use
Before using, stir up well. The surfaces have to be ABSolutely clean and dry.
For better adhesive power, smooth surfaces shall be roughed and the work
should be done at room temperature.
Both surfaces are to coat with a thin film of the “JY-2” glue. After about 8-20
minutes, as a normal time for ventilation, press together both parts.
Thickness of coating, time for ventilation, a second coating perhaps or one-time
wet-gluing depends on materials, expected mechanical stress and other
influences of the environment, for example temperature, dampness, working
rate and others.
5.1.7.2 After use
Remarks: Storage time at room temperature 10°C-35°C is about 12 months. Colour:

yellow.
Though the quality of our “JY-2” adhesive is always constant, it is indispensable

to make tests of gluing before use in order to test the environment conditions
and the mode of working procedure.
We will not be liable for damages caused by disregarding of our directions for
use.
Safety advises
Adhesive inflammable ! Keep box well closed!
Storage must be ventilated ! Avoid flames and sparks!
Cut off electrical devices ! Don’t let reach into
Smoking prohibited ! sewerage!
Take care of good ventilation of the room during and after working !
Take steps to avoid electrostatic charges !
5.2 Maintenance of hydraulics
As pumps are working in hydraulic fluid, maintenance is limited to keep the
hydraulic fluid perfectly clean. Cleanliness is achieved by the return line filter
which requires a systematic maintenance. After repairs of pipe lines, especially
during the first operation hours, keep an eye on the filter unit, because small
particles may flow in the circuit. Therefore, clean the filter at the beginning
several times.
5.2.1 Warnings
REPAIRS ON THE HYDRAULIC SYSTEM WITH CLOSED HATCH COVERS ONLY!

OTHERWISE THE COVERS COULD MOVE UNINTENTIONAL.
BEFORE DETACHING ANY CONNECTION MAKE SURE THAT THE HYDRAULIC

SYSTEM IS PRESSURELESS. THIS HAS TO BE DONE BY SWITCHING OFF THE
PUMP UNIT AND MOVING THE CONTROL LEVERS FROM THE “OPEN” TO THE
“CLOSE” POSITION SEVERAL TIMES. OTHERWISE PRESSURISED OIL COULD
HURT PEOPLE AND CAUSE SERIOUS INFECTIONS!
PAY ATTENTION TO THAT IT IS IMPOSSIBLE FOR UNAUTHORISED PEOPLE TO

START THE PUMP UNIT AS LONG AS WORKS WILL BE DONE AT THE SYSTEM.
USE ORIGINAL HYDRAULIC HOSES ONLY! PAY ATTENTION TO PROPER

DIMENSIONS OF HYDRAULIC HOSES!
5.2.2 Regularly
Before starting the power unit, check the oil level in the tank. Refill if necessary,
but only with closed holds.
Check the condition of the return line filter.
Check the function of the “Emergency stop” switches.
5.2.3 Every six month
Check pipe-lines, flexible hoses and units for corrosion, wear, leaks etc.
5.2.4 Every year
Consult your oil company’s representative and arrange for a check on the
condition of the oil. If necessary, change the oil of the system. Take care of the
regular removal of the wear up oil.
5.2.5 Hydraulic fluid specification
Hydraulic fluid requires a certain consistence of oil. To comply with this the
hydraulic system has been filled with a sufficient oil type. When refilling, use the
same oil or an approved equivalent (see “Characteristics for hydraulic oil” page
below)
Characteristics for hydraulic oil
viscosity index (V. I.)
pour point °C
flash point °C
viscosity cSt at ...°C
relative density at °C
Remarks:
146- Viscosity index is a measure of the relative

change in viscosity for a given change in
emperature.
A high V. I. Oil (abt. 180) shows less change
in viscosity for a given change in tempera-
ture than a low V. I. Oil (abt. 100). The
greater the temperature range, the higher
V. I. Is required.
146- Requirement concerning the flash point:

American Bureau of Shipping: 157°
Det Norske Veritas: 150°
U.S. Coast Guard: 157°
146- The viscosity in cSt at 40°C is always in

accordance with the related ISO-viscosity ISO
group. For instance, the viscosity of
32 cSt at 40°C is equivalent to (ISO) VG 32.
146- For oil changing prefer the „first filling“ oil

quality. If not possible pay attention to the
miscibility of the old and the new oil filling.
Hydraulic oils for drive machinery of

cargo access equipment
.... for defined weather conditions
Hydromotorantrieb Zylinderantrieb erforderliche ISO-Viskosit’sgruppe
Hydraulic motor Hydraulic cylinder required ISO-viscosity group
A – (ISO) VG 15
W – (ISO) VG 15
W&S A (ISO) VG 22
T W&S (ISO) VG 32
– W&S (ISO) VG 32-46
– S&T (ISO) VG 46
A = artic conditions
W = winter conditions in Central Europe
S = summer conditions in Central Europe
T = tropical conditions
Note:
Oils(ISO)VG15shouldonlybeusedduring
extremlycoldconditions.Flashpointinthisgroup
isverylow,therefore,theClassificationSociety
should be consulted in any case.
Necessary ISO-Viscosity group according to page „Characteristics for hydraulic oil“
Pour Flash ISO-Viscosity group Relative

Designation V.I. point point Viscosity cSt at Density
°C °C 0°C 20°C 40°C at 15°C
ARAL Visga 15 150 -45 190 15 0,860
ARAL Visga 22 160 -42 170 23 0,865
ARAL Visga 32 180 -42 190 32 0,870
ARAL Visga 46 180 -42 200 46 0,875
BP Bartran HV 15 148 -45 160 75 28 15 0,874

(BP Bartran HV 22) 152 -39 178 135 48 22
BP Bartran HV 32 152 -33 210 240 75 32 0,870
BP Bartran HV 46 153 -36 210 400 46 0,877
CASTROL Hyspin AWH 15 150 -51 162 75 15 0,869

CASTROL Hyspin AWV 32 355 -53 111 30 0,876
CHEVRON Mechanism LPS 15 153 -51 160 15 0,860

DEA Astron Z HLP 15 150 -39 150 15 0,879

DEA Astron HLP 22 100 -30 196 22 0,873
DEA Astron Z HLP 32 160 -33 182 32 0,873
DEA Astron Z HLP 46 158 -39 175 46 0,879
ESSO Nuto H 15 100 -33 186 100 33 14 0,850

ESSO Nuto H 32 100 -30 210 340 82 30 0,872
ESSO Univis N 15 151 -45 189 77 30 14 0,862
ESSO Univis N 32 151 -42 212 250 75 30 0,870
ESSO Univis N 46 152 -39 221 420 118 44 0,873
MOBIL DTE 11 M 158 -42 168 85 16 0,871

MOBIL DTE 13 M 153 -45 195 251 33 0,874
MOBIL DTE 15 M 153 -43 200 404 47 0,877
MOBIL SHC 524 141 -60 230 30 0,851
Shell Tellus Oil T 15 150 -60 150 100 15 0,885

5.2.6 Oil exchange and pump bleeding
IMPORTANT NOTES:
OIL EXCHANGE WITH CLOSED HATCH COVERS ONLY !
ENSURE THAT THE WEARED UP OIL WILL BE REMOVED ACCORDING

TO THE RULES OF POLLUTION CONTROL !
5.2.6.1 Preparation
− Control quantity and type of the new oil (see chapter 1).
− Keep ready a new filter insert and a new copper sealing ring for the drain
plug.
− Keep ready a sufficient number of containers suitable for taking up the

weared up oil.
− To ABSorb oil running over keep ready suitable means such as sawdust or
granules.
5.2.6.2 Draining the worn up oil
− Close the ball cock in the P-line and detach the pressure hose. Insert the
pressure hose into a suitable container and switch on pump no. 1 or 2 to
suck off the worn up oil until the level switch will stop the pump.
− Screw out the drain plug at the bottom of the hydraulic power station to
remove the remaining oil.
− Renew the filter insert of the feed back strainer.
− Attach the new copper sealing ring to the drain plug and screw it into the
tank. Attach the pressure hose, too.
Note: When exchanging by reason of worn up oil the remaining small quantity of oil in
the system (cylinders and pipes) shall not be removed. To bleed the whole
system thereafter could take a long time caused by remaining air in small holes
inside the cylinders and control desks.
5.2.6.3 Bleeding of the hydraulic pump
At first initial operation, and after every oil exchange, the pumps should be bled
in order to avoid suction problems or the penetration of air into the consuming
elements. Act as follows:
− Before filling the tank with hydraulic oil unscrew the vent screw of the pump
completely.
− Fill up the tank to the upper mark with new hydraulic oil. It may be efficient to
wait a few minutes until the oil has displaced the air inside the pump.
− Screw in and tighten the vent screw and switch on and off the pump for
several times.
− Allow the pump to run in an unpressurized cycle for a short period of time
(3-5 minutes) by acting as follows:
∗ Open the by-pass valve (if existent)
∗ Reset the pressure relief valve at the power unit to a pressure value of
zero by screwing it left.
∗ Close the ball cock in the pressure line P
− Start the pump. The pressure gauge shall show no pressure. Close slowly
the by-pass valve (if existent).
− Set the system pressure slowly up to 350 bar by screwing the pressure relief
valve right. In case the pressure gauge will show no pressure, open the by-
pass valve slowly, reset the relief valve to zero, stop the pump and bleed it
again by unscrewing the vent screw.
− Bleed pump no. 2 the same way as described above.
5.2.6.4 Adjusting the rated value
− Open the by-pass valve (if existent)
− Start both pumps.
− Slowly close the by-pass valve (if existent).
− Set the system pressure slowly up to the nominal value by screwing the
pressure relief valve right.
− Secure/lock the relief valve and check pressure value again!
− Open the ball cock in the pressure line P. Keep covers closed and check oil
level again. Refill if necessary. Now, the power station is ready for use again.
5.2.6.5 Exchanging the oil by reason of emulsification (water in the system)
In this case the whole oil has to be exchanged. Empty the tank as described at
paragraph 5.2.6.2, open the tank by dismounting the cover plate and clean the
empty tank with a no-fluffing cleaning-rag. Thereafter act as described at
paragraph 5.2.6.3 and 5.2.6.4.
The remaining oil in the system (cylinders and pipes) should be removed by
scavenge with new oil as follows:
− Detach return line R and insert it into a suitable barrel
− Switch on one pump. The contaminated oil will be pushed through the pipes
into the barrel.
− Operating the hand levers situated at the control desks (opening and closing
of all hatch covers) the contaminated oil resting in the cylinders and their
pipes/hoses will be removed.
− During scavenging, refill the tank continuously with new oil.

GUIDANCE MANUAL
6. Service & Spare parts

6.1 Spare parts
6.1.1 Spare part list
The equipment has been completed with a number of spare parts according to
the recommendations of the classification society. These parts must be
available on board at every time (see the following pages “Spare Part List”).
Additionally, we recommend to establish a stock of other types of spare parts
available on board, which is a must if you wish to keep your ship in a proper
service condition and to be prepared against hazards.
6.1.2 Supply of spare parts
All important components of the equipment are shown on a respective

assembly drawing (see chapter 5). Each drawing has a drawing number (in the
below right hand corner) and the parts are marked with item numbers.
WHEN ORDERING SPARE PLEASE STATE:

1. Ship’s name, Yard, Hull No.
2. Title of assembly drawing.
3. Drawing no. of assembly drawing.
4. Item number of detail part.
5. Title of detail part.
6. Dwg.No. or DIN no. of detail part, if any.
7. Quantity required.
8. Delivery terms and forwarding address.
9. Customer and acceptor of the bill.
Attention:
− Note eventual right or left hand shape of the components.

− Don’t use part’s name only. This might cause errors or
delayed delivery.
− Clearly indicate complete description of the part as well as drawing no. and
item no.
− Use original spare parts only !
− Otherwise risk of malfunction, damages and hurts !
6.2 Spare parts and tools list
Mechanical Spare parts: See drawing no. 940-1005

Hydraulic & Electrical Spare parts: See drawing no. 940-9940
6.3 TTS Service-stations world-wide
Please turn over to find our small booklet

"Global Ship Service World Directory"
which lists world-wide addresses and the corresponding service
capabilities.
Should it be missing or outdated, please use the FAX form sheet

below for receiving a new one in return.
Make sure you receive immediate updates of your World Directory by

filling out this form and faxing it to us at TTS HuaHai Ships Equipment.
Please print your information with block capitals.
To: (Fax) ++86 021 65397400
From:
Name and Title
Company
Address
City
Country Postal Code
You will now receive your World Directory whether or not you choose to
provide us with the following additional information, which would be of help in
the updating of our database.
Which of the following areas is of interest to your company? (Check all
relevant areas)
Pumps
Cargo Access
Gas Equipment
Diesel Parts
Integrated Bridge Systems
Equipment Service Agreement with operational cost guarantee
GUIDANCE MANUAL
7. Certificates
GUIDANCE MANUAL
8. Drawings steel & fittings

8.1 List of drawings steel & fittings
8.1.1 Weatherdeck
940-1105 Spare parts list for Mechanical fitting
940-1111 Fitting installation of No.1 H.C.
940-1112 Fitting assembly of No.1 H.C.
940-1211 Fitting installation of No.2&3&5~7 H.C.
940-1212 Fitting assembly of No.2&3&5~7 H.C.
940-1411 Fitting installation of No.4 H.C
940-1412 Fitting assembly of No.4 H.C.
8.1.2 Fittings weatherdeck

940-1050 Sealing Plan Of Hatch Cover
940-1061 Wheel (Plain)
940-1062 Wheel (Flange)
940-1063 Auto-Roll System Assembly
940-1064 Touch Guide
940-1065 Stowage Stopper Assembly
940-1066 Grain Loading Scuttle Assembly
940-1067 Air Ventilation Assembly
940-1068 Installation Bolt Assembly
940-1069 Name Plate and Number Arrangement
940-1070 Gas Sampling Assembly
940-1073 Oil Motor Bed Installation
940-1074 End Stopper Assembly
940-1075 Drain Valve
940-1076 Sounding Cap
940-1079 Touch block
940-1081 Auto Cleat Side (M42)
940-1082 Auto Cleat End (M42)
940-1083 Auto Cleat Side (M56)
940-1084 Auto Cleat End (M56)
940-1085 Antilifting Device Of No.4 H.C
940-1161 Rack And Driving Arm Of No.1 H.C.
940-1261 Rack And Driving Arm Of No.2-7 H.C.
940-1451 Marking of helicopter
GUIDANCE MANUAL
9. Drawings Hydraulic
9.1 List of drawings hydraulic
9.1.1 Weatherdeck
940-9000 Hydraulic diagram for hatch cover

940-9100 Geometrical Diagram For Pump Station
940-9110 Geometrical Diagram of Transportable Pump Unit
940-9200 Control Valve Block
940-9210 Divide Valve block
940-9270 Ball valve
940-9300 Hydraulic cylinder Ø140/90-550
940-9350 Hydraulic motor
940-9400 Hydraulic hose for hy-cylinder
940-9401 High pressure hose for hy-motor
940-9402 Hose for hy-motor drain line
940-9940 Spare parts list for HY. & El.
GUIDANCE MANUAL
10. Drawings Electric

10.1 List of drawings electric
940-9005 Electric Arrangement For Hatch Cover

940-9800 Circuit diagram for starter
940-9801 Connection Diagram For Starter
940-9810 Layout for Starter
940-9820 Circuit Diagram and Layout Diagram for Starter of
Transportable Pump Unit
940-9830 Emergency button
940-9840 Socket for transportable pump unit
940-9850 Alarm bell
GUIDANCE MANUAL
11. Drawings Pneumatic
........no pneumatic drawings

GUIDANCE MANUAL
12. For Your Notes

舱口盖零部件备件清单(船东)
TTS Hua Hai SPARE PARTS LIST FOR OWNER
940-1005
序号名称规格与图号简图单位数量单重(kg) 总重发往单位

NO. DENOMINATION DRAWING NO. SKETCH UNIT QTY EACH TOTAL TO
直条橡皮
1 HRC.60.0000 m 10 5.2 52 Y
SQUARE SEAL STRAIGHT
直条橡皮
2 HRC.50.0000 m 10 4.9 49 Y
SQUARE SEAL STRAIGHT
水平转角橡皮(94x55 左式)
3 HRC.51.0101 个 1 1.8 1.8 Y
FLAT CORNER (94x55 LEFT)
水平转角橡皮(94x55 右式)
4 HRC.51.0201 个 1 1.8 1.8 Y
FLAT CORNER (94x55 RIGHT)
直角端头橡皮 (94x55)
5 HRC.52.1021 个 1 2.3 2.3 Y
VERTICAL END PIECE (94x55)
端头橡皮 (94x55)
6 HRC.53.2001 个 1 2 2 Y
END PIECE (94x55)
水平转角橡皮 (左式)
7 HRC.69.0101 个 1 2 2 Y
FLAT CORNER SEAL( LEFT )
水平转角橡皮 (右式)
8 HRC.69.0201 个 1 2 2 Y
FLAT CORNER SEAL( RIGHT )
侧部自动压紧楔 M56
9 940-1083 套 1 32.4 32.4 Y
AUTO-CLEAT-SIDE M56
端部自动压紧楔 M56
10 940-1084 套 1 32.7 32.7 Y
AUTO-CLEAT-END M56
侧部自动压紧楔 M42
11 C201-M42-40 套 1 18.1 18.1 Y
AUTO-CLEAT-SIDE M42
粘结剂
12 tin 2 3 6 Y
GLUE JY-2
速干胶
13 pcs 1 Y
GLUE LOCTITE 495
油杯
14 JIS B 1575 R 1/8 pcs 20 Y
GREASE NIPPLE
油枪
15 pcs 2 Y
GREASE GUN
自动压紧楔的螺母扳手 M42
16 pcs 1 Y
WRENCH FOR AUTO-CLEAT NUT
自动压紧楔的螺母扳手 M56
17 pcs 1 Y
WRENCH FOR AUTO-CLEAT NUT
备品箱
18 pcs 1 Y
SPARE BOX
注：
1、备品放入备品箱
"Y"=Yard "M"= Manufacture Page 2 of 2

液压&电气系统备件清单
TTS Hua Hai HY. & EL. SYSTEM SPARE PART LIST
940-9940
序号名称规格型号数量备注
NO. DENOMINATION TYPE QTY REMARKS
1.0 Seal kit A52102 1 Set for piston pump
密封件 A54101 2 Set
A54102 2 Set
A54201 2 Set
A54104 2 Set
2.0 Hose A56401 1 Set Hose For Cooler

软管 A56502 1 Set Hose for outlet pressure
A56602 1 Set Hose for outlet return line
A56301 1 Set Hose1 For Pump Pressure
A56302 1 Set Hose2 For Pump Pressure
A56102 1 Set Hose For Pump Suction
A56202 1 Set pump drain
3.0 Hose for cylinder A56701 2 Set

油缸软管
4.0 Hose for Motor A56701 2 Set Motor Pressure

马达软管 A56702 1 Set Motor Drain
Pressure Gauge A55101 1 Set

With Hose
5.0 Filter element A53101 2 Set
滤芯 A53103 2 Set
6.0 Bearing for motor A51102 1 Set D-End

电动机轴承 A51102 1 Set N-End
7.0 Starter
电控箱
Motor Circuit Breaker A81207 1 Set
Control relay A82101 1 Set
继电器
Lense A84312 2 Set
Lense A84311 2 Set
Lense A84313 2 Set
Push Button A84101 1 Set
Push Button A84102 1 Set
Fuse A89201 5 Set
Illuminated Push A84201 1 Set
B tt Page2 of 3
液压&电气系统备件清单
TTS Hua Hai HY. & EL. SYSTEM SPARE PART LIST
940-9940
序号名称规格型号数量备注
NO. DENOMINATION TYPE QTY REMARKS
Switch A84103 1 Set
Block A84111 1 Set
Block A84112 1 Set
Contactor A81101 1 Set
Contactor A81104 1 Set
LED A84501 2 Set
LED A84503 2 Set
Bulb Of Lamp A84301 2 Set
Bulb Of Lamp A84302 2 Set
MCB A83101 1 Set
MCB A83102 1 Set
8.0 Spare Parts Box 1 Set
备件箱
9.0 Filter element A53101 1 Set For Yard
滤芯 A53103 1 Set For Yard
Page2 of 3
TTS HuaHai
TTS HuaHai
1 1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2
TTS HuaHai
TTS Hua Hai Ships Equipment Co.,Ltd
Flow: l/min
Pressure: Bar
Power: Kw
Source: 3x Volt Hz
Fluid: ISO VG
Serial No.:
Add: 18th floor, 3255 Zhou Jia Zui Road Shanghai 200093, China,
Tel: +86 21 65398257 Fax: +86 21 65397400
CAUTION
1. Before starting, fill pump case with system fluid through uppermost drain port. Pump
case must be kept full at all times to provide internal lubrication. When first starting,
it may be necessary to bleed air from pump outlet line priming and reduce noise.
After starting pump intermittently when the air remains in outlet line, bleed by
loosening at outlet connection.
2. Ball valve at suction inlet must be kept open when stating pump, otherwise oil pump
will be damaged.
3. Hydraulic Fluid: ISO VG 32 and viscosity index of over 95 is recommended.
4. Cleanliness of hydraulic fluid must reach NAS 9 when hydraulic system running.
5. Recommended running fluid temperature: +5°C to +65°C, max. fluid temperature
+70°C.
6. Clean inside of tank at least once a year.
7. Replace contaminated fluid immediately, otherwise it will cause trouble.
TTS Hua Hai Ships Equipment Co.,Ltd
Flow: l/min
Pressure: Bar
Power: Kw
Source: 3x Volt Hz
Fluid: ISO VG
Serial No.:
Add: 18th floor, 3255 Zhou Jia Zui Road Shanghai 200093, China,
Tel: +86 21 65398257 Fax: +86 21 65397400
INSTRUCTION PLATE
FOR TRANSPORTABLE PUMP UNIT
1. MOVE TRANSPORTABLE PUMP UNIT CLOSED TO CONTROL VALVE BLOCK,

CONNECTED ELECTRIC PLUG TO SOCKET.
2. CONNECT BOTH HOSES TO CONTROL VALVE BLOCK.
3. CLOSE BALL VALVE UNDER CONTROL VALVE BLOCK.
4. START PUMP AND CLOSE BALL VALVE ON TRANSPORTABLE PUMP UNIT,
YOU CAN SEE THE PRESSURE TO BE ABOUT 250 BAR.
5. OPERATION LEVER OF DIRECTIONAL VALVE AS NORMAL CONDITION.
6. AFTER FINISH OPERATION, OPEN BALL VALVE ON TRANSPORTABLE PUMP
UNIT, STOP PUMP, DISASSEMBLE HOSE AND CABLE.
± 10
TTS HuaHai
TTS HuaHai
TTS HuaHai
TTS Hua Hai Ships Equipment Co Ltd
*
* *
*
* 电缆船厂提供。
TTS HuaHai
* *
*
* 电缆船厂提供。 TTS HuaHai
TTS HuaHai
TTS HuaHai

H3-HATCH COVER 舱口盖

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H3-HATCH COVER 舱口盖

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舱口盖１／１０９

Yard Judger shipbuilding Co.,Ltd

Weatherdeck hatch covers

1. Introduction & Warnings 1

3. Manoeuvre instructionsImportant notes 1

4. Troubles, Emergency Operation 1

6. Service & Spare parts 1

8. Drawings steel & fittings 1

10. Drawings Electric 5

11. Drawings Pneumatic 1

12. For Your Notes 1

Weatherdeck hatch covers

1. Introduction & Warnings

Make sure the guidance manual instructions, especially the safety

∗ General notes on safety are listed in this first chapter.

1.2 Safety notes

In particular, dangers may occur:

All persons operating the plant or product must:

The user shall undertake to:

We reserve the right to implement technical changes for product improvement

We do not guarantee for :

− Damage which is caused by excessive stress, improper use, careless and

Manipulations in our installations undertaken by firms or persons being not

Weatherdeck hatch covers

2.1.1.1 Rules and regulations: DNV +CSR

2.1.1.2 Type of covers: TTS side-rolling AutoRoll system hatch

2.1.1.3 Actuation: Handling: hydraulically

2.1.1.4 Arrangement of covers: Hold no.1-7: two side-rolling panels,

2.1.1.5 Hold dimensions: Hold no. 1: 14705mm x 12800 mm

2.1.1.6 Structure design: Open girder construction, sloping top plate

2.1.1.7 Material: Steel plates of mild and high tensile steel

2.1.1.8 Welding: Welding is continuously and according to

2.1.1.9 Wave loads: Vertical wave loads :

2.1.1.10 Uniformly distributed load: Water ballast load: 0~65.0 kN / m² (From

2.1.1.11 Helicopter Load: Winch only

2.1.1.13 Coaming deflexion: max. ± 15 mm

2.1.1.14 Weathertightness: Achieved by TTS SQUARE rubber

2.1.1.15 Cleats: The hatch covers are secured to the

2.1.1.16 Wheels: With rolling bearings and nipples for

2.1.1.17 Anticorrosion preservation: Blasted SA 2 ½ and with approx. 25 μm

2.1.1.19 Auxiliary operation In case of failure of one pump or electric

Power consumption : 2 x 25.6 kW

High pressure hoses

Weatherdeck hatch covers

IT IS STRICTLY FORBIDDEN TO ENTER ONTO THE HOLD COAMING OR

OPERATING OF HATCH COVERS BY CREW MEMBERS ONLY !

− when loaded, the covers shall rest on all supports uniformly

3.1.1 Limitation of operation

The hatch covers are designed for operation under conditions up to

max. Trim of ± 2,0° and max. Ship’s heel of ± 3,0°.

3.1.2 Preparations before opening the holds

− Check cleanliness of coaming top before operating the covers.

3.2 Opening of the holds

3.2.1 Start both pumps at both power units.

3.2.2 Opening the weatherdeck holds

Release the locking pin of auto-roll assembly. Furthermore, release the

Open the ball valves in the control valve unit.

Closing the ball valves.

Stop the pump unit.

Start the pump.

Release the locking pin of auto-roll assembly.

Open the ball valves in the control valve unit.

Release the locking pin of end stopper for open position.

After closing operation, lock the locking pin of auto-roll assembly.