MAINTENANCE MANUAL

RESCUE BOAT / LIFE RAFT DAVIT & WINCH

4. MAINTENANCE MANUAL

4.1 INTRODUCTION
The maintenance program has been developed by ORIENTAL in accordance to
our supplier’s own maintenance program for each component. Conforming to this
maintenance program will ensure long-time, trouble-free operation and eliminate
unexpected occurrences.

4.2 DESCRIPTION OF MAINTENANCE ACTIONS

The maintenance program entails the following actions:

- Lubrication - Inspection
- Overhaul - Replace

Lubrication : Lub.
Lubrication is identified with following:

Apply grease to grease nipples.

Apply lubricant or oil onto surfaces due to friction or corrosion.

Refill or change oil to system or component.

Inspection : Insp.
Inspection is identified with the following:

Check component for any damage.

Check for correct function of each component.

Check for any unfamiliar noise from each component.

Check for any abnormal vibration from rotating components.

Check for correct oil quantity.

Check paint condition on all components.

Check for leaks.

Check for corrosion.

Check main fall wire for wear.

Overhaul : Ovhl.
Overhaul is identified with the following :

Remove the component from the unit.

Disassemble the component and inspection each part.

Repair if necessary :
- Bearings.
- O-rings
- Hydraulic valves fittings and hoses.

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- All bolts, nuts and washers.

Clean all components before mounting assembly.

Replace or components if required, before mounting assembly.

Repair damaged painted areas.

Replace : R
Replace is identified with the following:

Remove original component and exchange with a new component

4.3 GENERAL CAUTION

(1) WINCH

Do not let moisture, oil or dust collect on the hand brake or centrifugal
brake.
Carry out the periodical inspection on each brake lining, if possible once
6 months, and replace those which are extremely worn with new ones.

In case of the hoisting operation being stopped, the one way clutch
functions automatically to prevent the boat from dropping by its own
weight.
It is necessary that this system is inspected once every ten years.

Although this winch equipped the manual safety hoisting handle during
the hoisting or lowering operation don’t fit manual handle on the driving
shaft in any case.

The engagement of gears can be detected from the noise.
Listen to the noise from the start of operation. When opening the casing
cover to change the oil and inspect the gear, remove the cover carefully
to avoid dust of foreign matter from entering.

When in good order the winch should overturn after the boat is
waterborne so as to give; If not check free running of bearings etc.

When lowering, the centrifugal brake housing will heat up owing to the
action of the governing brake.
So long as this is not accompanied by an increase in the controlled
lowering speed, this may be ignored.
During tests or drill the brake should be allowed to cool before lowering
again.

If winch cover is removed for inspection, water tightness must be
ensured on reassembly.

Ensure that the weighted ‘deadman’ brake lever always engages the
brake under its own momentum.

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(2) WIRE CLAMPER

The end of boat fall wire must be clearly fixed into wire clamper by proper torque.

[ Fig-5 ]
(3) WIRE ROPE

1) Renew the wire rope in the following cases.

When more than 10% of the strands have been cut in one twist of the
rope.

When decrease in diameter has been 7% of the nominal diameter of
more.

When the rope has kinked.

When considerable deformation or corrosion has been found on the
rope.
2) Fall shall be turned end for end at intervals of not more than 30 months
and be renewed when necessary due to deterioration of the falls or at
intervals of not more than 5 years, whichever is the earlier.
3) Wiring.
Refer to GENERAL ARRANGEMENT & REMOTE CONTROL WIRE
4) Oiling wire rope.
Oil the wire rope periodically to protect from corrosion as well as to have
better lubrication.

(4) SHEAVE

While using sheave, the groove in contact with the rope wears.
Especially if pulling obliquely, flange wears faster and is damaged.
When the groove has worn remarkably, or the flange has got out of shape or
broken, they should be substituted.

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(5) DAVIT

1) All sheaves and rollers or pivots must be thoroughly greased and must
rotate freely.
2) Boat lashing and levers should move freely in a complete circle when the
arm is in the outboard position.

(6) LUBRICATION

Rescue boat davit is mechanical devices.

Like other machines if they are to retain their efficiency they must be
regularly lubricated and inspected. All grease point on the davits and
winch, as shown on the lubrication diagram, should be lubricated by a
grease gun not less frequently than every six weeks.

Careless painting is the most frequent source of trouble with rescue
boat davits.
When painting, It is essential to ensure that no paint is applied to
lubricating points, or to bearing or any moving parts due to impede their
free movement.

1) It is desirable that bearing and wire rope are lubricated periodically, if

possible once a month.

2) Carry out the periodical inspection of oil level in winch gear case.

The oil level of winch gear case should be frequently checked. Other
points calling for special attention are mentioned later.
Suitable grades of recommended lubricants are listed at the back of this
booklet.

3) Do not use winch gear oil containing additives as extreme pressure agent.

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4.4 WINCH MAINTENANCE

(1) REFERENCE DRAWINGS

Sectional drawings for winch assembly

Brake unit arrangement with part list.

[ Fig-6 ]
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(2) BRAKE UNITS

The friction disk & lining disk is secured to the brake carrier (Part No. 511)
The lining should be inspected annually and if it has been worn down to as much
1mm or damaged, It should be replaced.
Never let the lining wear down to eliminate groove as this will cause damage to
the steel plate half of the clutch with subsequent rapid wear of the lining.

1) REPLACEMENT OF LINING DISK.

Loosen and remove the hex. bolt(M12X50L).

Disassemble brake case cover unit.

Replace the inner disk when it is worm down to eliminate groove.

Replace the friction disk when it is bended more than 2mm at the
maximum bended point.

Check the damage of pin hole and replace if it is found abnormal.

Check the bush, bearing and oil seal state and replace if it is found
abnormal.

Re-assembly to be of opposite sequence against disassembly.

To be fasten with torque the hex. bolt.

[ Fig-7 ]

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[ Fig-8 ]

2) REPLACEMENT OF GEVERNOR BRAKE LINING

Disassemble the brake lining disk same as “1) REPLACEMENT OF

LINING DISK”.

Loosen and remove the set screw at the brake out ring. ①

Disassemble Brake out ring unit.

Loosen the counter-sunk head bolt on the brake shoe. ②

Replace the brake lining when it is worm down to 5mm from bolt head.

Re-assembly to be of opposite sequence against disassembly.

[ Fig-9 ]

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(3) MANUAL HANDLE UNITS

These are screwed into either half of the motor pinion shaft (ITEM No. 205) and
hand crank shaft (ITEM No. 308) with a left or right hand thread according to the
required rotation.

(4) REPLACEMENT OF CAM CLUTCH

Cam clutch is a brake of the winch. Before the replacement, fix the
davit jib at the rest position and the wire drum is also fixed for prevent
rotating of drum by self-weight.

Cam clutch consists of inside and outside wheel mode by special
material, and cam inside wheel only rotate by rotating direction of the
motor.

1) DISASSEMBLY

Before assembly, please confirm the rotating direction of the motor

Release the hex. bolt, and pull out the 2ND bearing cover.

Pull out the cam clutch unit & housing form 2nd shaft after remove snap
ring.

Disassembly cam clutch unit from housing.

Replace with now cal clutch unit.

Carefully remove the rust or damage that occur on the 2nd shaft by
using the proper sandpaper or etc.

Re-assembly to be of opposite sequence against disassembly.

[ Fig-10 ]

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[ Fig-11 ]

※ CAUTION !

In the case that the dent exists in the shaft, renew shaft with new one.

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4.5 MAINTENANCE PROGRAM.

M=Months, Y=Year, W=Week, H=Hours
PERIODIC MAINTENANCE PROGRAM
Equipment Lub. Insp. Ovhl R. Action
General inspection for leaks in hydraulic system
Quantity of oil, to be in top of level glass
Crane functionality
General Emergency (operation) (if applicable)
1W
Inspection Accumulator oil pressure (if applicable)
Check for wire damage
Check for damage of lifting equipment (hook
etc.)
Apply grease to all grease nipples. Include wire
1M/100H
Grease sheaves, cylinders, el.Motor and docking head.
nipples 3M/ Inspect for proper function, damage, corrosion.
(General) 100H Remove excess grease.
! Replace if damaged.
Apply special grease to drive pinion and ring
Winch / slew 1M/100H
tooth.
gear drive
pinion 1Y/500H Check for wear / abnormal tooth clearance
! Replace if damaged.
3M/200H Apply grease onto wire
Inspect due to corr. & wear. Rub length
1M/200H
of wire with a cloth to detect broken strands.
Wire
Inspect wire secured to winch drum. Check
3M/100H
torque.
! Replace if damaged.
Inspect for corrosion, wear, cracks. Check
6M/200H bolts.
Wire sheaves
Inspect that wire sheave rotates freely.
! Replace if damaged.

Inspect general condition. Check nitrogen

6M/200H
pressure value according to flow diagram.
Accumulators

Overhaul or replace if unable to hold the

! !
necessary charge. Contact OPCO. After Sales
Inspect for any abnormal noise, vibration, leaks.
3M/100H
Winch / slew Inspect valves (paint, leaks, corrosion)
motor 5Y Overhaul component.
! Replace if damaged.

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PERIODIC MAINTENANCE PROGRAM

Equipment Lub. Insp. Ovhl R. Action

Inspect for any abnormal noise, vibration,

3M/100H Tighten bolts if required. Inspect general
condition (paint, leaks, corrosion)
Winch /
hoisting 3M/50H Check gear oil level
Gearbox
1Y Change oil.
5Y Overhaul component
! Replace if damaged.
Inspect for any abnormal noise, vibration,
Electric 3M/200H
corrosion, leaks.
Motor and
hydraulic 5Y Check for wear / abnormal tooth clearance
pump
! Replace if damaged.

Sliding Apply grease

surfaces 3M/200H 3M/200H Check for wear
(If mounted)
Adjust sliding pads

Hydraulic
hoses, 6M/200H Check condition of horses.
fittings,
couplings
! Replace if damaged.
Inspect for any abnormal noise or function.
Inspect condition (paint, leaks, corrosion)
Hydraulic 6M/200H
Apply grease to the valve levers (the rubber
valves cap must be removed).
! Replace if damaged.
Inspect the entire crane for structural
Mechanical 6M/200H damage.
components Check for corrosion. Inspect paint condition.
! Replace if damaged.
Hydraulic Take oil sample for analyses
1Y
system oil Change if necessary

Hydraulic oil 6M/500H Inspect filter for abnormal contamination

filter 6M/500H Replace
Bolts and Inspect all bolts and nuts on crane.
6M/500H
nuts Foundation bolts especially.
M=Months, Y=Year, W=Week, H=Hours

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4.6 TROUBLE SHOOTING METHOD

NO Trouble contents Cause Disposal

Not power on Power on

Not operate Jib slewing-out
when the manual control valve
1 Manual control To check and
or R/C line for slewing are
operated properly. valve maintenance or valve
Damaged replace

Not power on To check and

Electric Motor maintenance or motor
2 Not operate power pack damaged replace
Not supply power
Misoperate. To check and
counter balance maintenance
3 Jib swing-out speed high valve damaged Replace the counter b.
valve
Worn down the Dismantle centrifugal
brake shoe of brake and check that
centrifugal brake there is a oil on the
brake shoes.
4 Lowering speed is too fast
Clean if necessary or
renew.

Greasing is not Check free running of

enough on the sheaves and winch.
moving parts.
5 Lowering speed is too slow
Greasing on it if
necessary.

Brake system is Dismantle brake

needed is worn housing and check the
down. clutch bearing (Part
No. 404)
Brake or clutch fails to hold
6 Check the friction disk
boat
brake lining for grease
or oil (Part No. 511)

Check the were,

renew if necessary

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Check that oil in

grease point is of
correct viscosity and
level.

Check gear teeth for

brakeage and gear
case for foreign
7 Winch not free running - matter.

Check bearing for

collapse, and bearing
and shaft for rust and
corrosion

Check that clutch case

has not broken

NOTE
SOLAS chapter Ⅲ Regulation 19 Maintenance of Falls states “ Falls used in
launching shall be turned the end for end at intervals of not more than 30
months and be renewed when necessary due to deterioration of the falls or at
intervals of not more than 5 years, whichever is the earlier”

The instruction comply with SOLAS 83 Chapter Ⅲ Reg.19.

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