LIFEBOAT MANUAL.pdf

William Mills (Marine) Ltd

"TITAN" ON-LOAD QUICK RELEASE SUSPENSION GEAR FITTED WITH HYDROSTATIC INTERLOCK AND HOOK SAFETY INDICATOR'S

OPERATION MANUAL

mills MARINE

OPERATION MANUAL

"TITAN" ON-LOAD QUICK RELEASE SUSPENSION GEAR FITTED WITH WITH HYDROSTAT HYDROSTATIC IC INTERLOCK INTERLOCK AND AND HOOK SAFETY INDICAT INDICATORS ORS

WILLIAM MILLS (MARINE) (MARINE) LTD Manor Road Levenshulme MANCHESTER 3EJ England Telephone: elephone: 0161 224 6224 Telefax:

e:mail [email protected] [email protected]

THIS MANUAL MAY MAY NOT BE COPIED COPIED IN WHOLE OR PART WITHOUT WITHOUT THE WRITT WRITTEN EN PERMISSION OF WILLIAM MILLS (MARINE) LTD

ISSUE CONTROL details of change issue level first issu issue e , sept 1997 1

1 "TITAN" OPERAT OPERATION ION MANUAL (WITH (WITH INDICATORS) INDICATORS)

issue 1 - SEPTEMBER 1997

mills MARINE

CONTENTS SECTION

1

INTRODUCTION

2

OPERATIN OPE RATING G INSTRUCTION INSTRUCTIONS S 2.1

Important Notice

2.2

Normal Release Procedure Procedure

2.3

Emergency Release Procedure Craft is Waterborne but hydrostatic release unit has malfunctioned. 2.3.b 2.3.b

3.0

Craft is not waterborne but stuck stuck at a heigh heightt during during launch launching. ing.

2.4

Hook Resetting Procedure Procedure

2.5

Attachment Attachment of the Davit Falls

Illustrations Typical Arrangemen Arrangementt of of Titan Titan Release Gear

3.2

Instruction Instruction Poster

3.3

Correct Location Location of Cam Release Pin and Hook

3.4

Cam Release Pin Position Indicators Indicators Hook Position Indicators Indicators

The information information and statements herein herein are believe believed d to be be reliable, but are not to be construed as a warranty or or representation representation for which we assume assume legal responsibility. responsibility. Users should should undertake sufficient sufficient verification verification and testing to determin determine e the suitability fo forr their own particula particularr purpose purpose of any information referred to herein. NO WARRANT WARRANTY Y OF FITN FITNESS FOR A PART PARTICULAR ICULAR PURPOSE PURPOSE IS MADE. MADE.

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"TITAN" OPERATION MANUAL (WITH INDICATORS)

issue 1 - SEPTEMBER SEPTEMBER 1997

mills MARINE

1.

INTRODUCTION

The Mills TITAN quick release suspension gear is a release mechanism for davit-launched survival craft complying with the requirements of the amendments to chapter iii of SOLAS 1974. The on-load release capability of the equipment enables the bow and stern suspension hook assemblies to be opened simultaneously* even with the craft being towed by the parent vessel or drifting due to wind or tide whilst still attached to the davit falls. The hook assemblies are opened by cables activated by a release handle unit which is sited at the position for one person operation. Accidental release is prevented by the inclusion of three safety devices namely safety pin, locking handle and a hydrostatic interlock device which ensures that the equipment cannot normally be operated until the the craft is in the water. In the unlikely event of a malfunction of this interlock, or if the craft is not waterborne** due to some malfunction of the launching device, as the ultimate last chance of escape, the interlock may be over-ridden for emergency launch of the craft by breaking the cover glass and using the safety pin to manually lift the hydrostatic locking lever. The gear has been fitted with readily visible indicators showing the positive condition of the Cam Release Pin, so as to improve the ease of inspecting the gear to ascertain the gears safety condition. Note: Should any of the indicators be found to be in the red/unsafe zone the craft must be taken out of service immediately and the matter corrected by adopting the prescribed procedures laid down in this manual. * This means both hooks opening by one full operational movement of the release handle. It does not imply absolute absolute synchronisation of the opening instant of each hook, as exact synchronisation is not required to effect a safe launch if the gear is set-up and operated in accordance with this manual. ** Survival craft in which the twin fall Titan Release Gear are fitted are not designed to free fall into the water, w ater, therefore this thi s facility must be considered as the ultimate last chance of escape, where it is impossible to lower the craft normally to the water and in the full knowledge that serious damage to the craft and injuries to the personnel may be sustained due to this action.

The basic 1.1

the equipment is shown in Figure

CAUTION

Before this equipment is operated, this manual should be read and understood by all persons involved. This manual should then remain accessible at all times for future reference. If there is any doubt concerning the correct functioning of the equipment when the scope of this manual has been then William Mills (Marine) Ltd must be contacted to remove any doubt before the equipment is put into service. William Mills (Marine) Ltd. accept no responsibility if the scope of this manual is extended by any installer, operator or service agent.

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mills MARINE

2.0

OPERATING INSTRUCTIONS

2.1

Important Notice

The Mills TITAN quick release suspension gear, as the name implies, is designed to operate whilst there is load on the davit falls. This situation commonly occurs during the launching sequence due to wave action, tide and possible towing forces. Although a hydrostatic interlock device is fitted to prevent accidental release before the craft is waterborne, a manual override facility is provided for use in emergencies. It is possible, therefore, to release the craft from the falls from any height during its descent to the water. Survival craft in which the twin fall Titan Release Gear are fitted are not designed to free fall into the water, therefore this facility must only be considered as the ultimate last chance of escape, where it is impossible to lower the craft normally to the water and in the full knowledge that serious damage to the craft and possible fatal injuries to the personnel may be sustained due to this action. Extreme caution should be exercised if the gear is to be operated when the boat is not waterborne. This should be considered only as an extreme last resort of escape, if the lowering operation has been unable to make the craft waterborne. Careful consideration of the dangers and benefits must be made by the persons in charge of the craft prior to release, together with clear warnings being given to the occupants to check their belts and brace themselves against shock landing and possible break up of the craft. For survey and test purposes of on-load release equipment it is recommended to test the equipment off-load or lightly loaded, as this is a more onerous requirement. The craft should be positioned no higher than keel just above waterline. Frequent on-load operation also causes wear and tear to the hook tail and the cam face, so on-load operation should routinely be carried out as sparingly as possible. Routine on-load testing is not only unnecessary, but detrimental to the condition of the gear and craft. 2.2

Normal Release Procedure

i)

When the craft is look through the glass access panel in the hydrostatic lever cover and check that the hydrostatic interlock device has functioned correctly, ie. that the hydrostatic locking lever has moved to the free position clear of the operating quadrant.

ii)

Remove the Button Headed Safety Pin from the Release Handle unit by holding the button in and withdrawing the pin from the sideplates.

iii)

Lift the release handle against the spring until the locating bars are clear of the side plate slots, and depending upon the orientation of the release handle unit, pull or push the handle to its fullest extent in one firm movement to release both hooks simultaneously*. Note that the instruction label near the handle states whether the handle should be pulled or pushed for release.

iv)

Both hooks will be free to open and the craft may be driven away immediately.

* See foot note in the introduction for definition of simultaneous opening.

4 "TITAN" OPERATION MANUAL (WITH INDICATORS)


mills 2.3

Emergency Release Procedure

Situation A Craft is Waterborne but hydrostatic release unit has malfunctioned.

Take the following actions:i)

Confirm the craft is waterborne. (The helmsman to make a visual check, but if this is not the motion of the craft will change considerably when waterborne).

ii)

Remove the Button Headed Safety Pin.

iii)

Use the Button Headed Safety Pin to break the glass access panel in the hydrostatic locking lever cover.

iv)

Use the Button Headed Safety Pin to lift the hydrostatic locking lever (yellow lever) and hold it in the raised position against the spring.

v)

Operate the release handle in one firm movement, with the other

vi)

Release hydrostatic locking lever.

Situation B EXTREME CASE

Craft is not waterborne but stuck at a height during launching. Extreme caution should be taken prior to this action being undertaken and it should be considered as the ultimate last chance of escape where it is impossible to lower the craft normally to the water. THE FOLLOWING ACTION MUST ONLY BE TAKEN WITH THE FULL KNOWLEDGE THAT SERIOUS DAMAGE TO THE CRAFT AND POSSIBLE FATAL INJURIES TO PERSONNEL MAY BE SUSTAINED.

A launch may be effected, If after considering the above and in the full knowledge of the possible consequences by taking the following action:taking the decision to emergency launch, shout warning to the occupants to brace themselves. Then follow through the same actions as for "Situation A". The circumstances under which an emergency situation may arise is completely outside William Mills control or influence and William Mills disclaims any liability which may arise due to carrying out the above actions.



mills 2.4

Hook Resetting Procedure

This procedure should be followed as soon as practically possible after the craft has taken place in anticipatory preparation of hoisting, with due consideration to sea conditions. The procedure should not be delayed to coincide with actual hoisting. i)

Return the release handle to the locking position above the locking slots. Note that the locating bars will not drop into the slots in the sideplates at this stage due to the position of the operating quadrants.

ii)

At each hook assembly, by hand swing the hook bill to the closed position and the hook tail as far as it will go and lift the cocking lever upwards to its maximum extent in order to return the cam release to its position. Place by hand the hook bill in the position it would take under the falls pull and look between the hook sideplates to confirm by sight that the hook tail is behind the cam release pin and that the cam release pin is in flat to flat contact with the tail of the hook_and that the indicators are registering the locked position and not in the red zone Fig 3.4 Check that the cocking lever has dropped back towards the deck. Confirm that the hook is closed and locked by pulling the hook hard upwards twice, if the hook rotates open, then repeat the reset procedure ensuring that the tail of the hook is behind the cam release pin.

iii)

When both hook assemblies have been reset in this way, check that the locating bars on the release handle have dropped fully into the slots sideplates of the release handle and are located behind the operating quadrants.

iv)

Replace the Button-Headed Safety Pin.

2.5

Attachment of the Davit Falls

i)

Attach each davit fall by slipping its ring or link onto the hook pass the hinged guard plate.

ii)

Check that the guard plate has dropped back into the closed position, as this ensures that the link cannot drop out prior to hoisting.

iii)

Take the weight of the craft on the falls without hoisting it clear of the water, check both hook tails are on the correct side of the release cam pin and that the indicators are registering the locked position and not in the red zone. If not take the weight off the falls and reset the hooks correctly.

iv)

When the craft has been hoisted just clear of the water, Stop visually ensure that :-

then

a)

Hydrostatic interlock has returned to its locked position.

b)

Guard plates have both dropped back into the closed position.

c)

Both hooks have the tail of the hook on the correct side of the cam release pin and the indicators are registering the locked position and not in the red zone.

d)

Release Handle locating bars are located in the slots and the Button Headed Safety Pin is in place.

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"TITAN" OPERATION MANUAL

INDICATORS)

j 1


I

mills MARINE

v)

If all checks are satisfactory hoist the craft back to the embarkation or stowed position,

Important Notes If all or any one check is unsatisfactory it is unsafe to hoist the craft any further. The craft must be lowered back into the water and the gear made free for investigation and correction of the problem. If necessary expert advice should be sought. No adjustment or modification is to be made which is outside the Maintenance Manual. 2)

Once hoisting has commenced falls tension should be maintained on the hooks in all positions of the craft (ie bowsed, triced, stowed on chocks or griped etc.). Otherwise the flat to flat contact between the hook tail and the cam will be lost and shipboard vibration will cause undue wear in this area. This vibration may in extreme circumstances hammer the cam towards the open position, taking up any cable slack, causing a dangerous situation during boat lowering in that an inadvertent hook release potentially may take place.

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3.0

Illustrations

Typical Arrangement of Titan Release Gear 3.2

Instruction Poster

3.3

Correct Location of Cam Release Pin and Hook

3.4

Cam Release Pin Position Indicators Hook Position Indicators

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3. ILLUSTRATIONS

Typical Arrangement of Titan Release Gear

1 2 3 4 5 6

Hook Assembly Release Handle Unit Hydrostatic Unit Aft Operating Cable Forward Operating Cable Hydrostatic Operating Cable


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1997

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3.2

Instruction Poster


1

1997

mills MARINE

3.3

Correct Location of Cam Release Pin and Hook

Load on Hook

of Hook

When There

Load on Hook.

C o c k e d a nd C o r r e c t C a m P o s i t i o n Lever Operation

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1997

mills MARINE

3.4

Cam Release Pin Position Indicators Hook Position Indicators

PDSITIDN

SAFE. ZDNE

REFERENCE RING

INDICATOR

SAFE ZDNE

REFERENCE

RING

12


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1997

m il ls MARINE

3.2

Instruction Poster


1

1997

William Mills (Marine) Ltd

"TITAN" ON-LOAD QUICK RELEASE SUSPENSION GEAR FITTED WITH HYDROSTATIC INTERLOCK AND HOOK SAFETY INDICATOR'S

MAINTENANCE MANUAL

mills MARINE

MAINTENANCE MANUAL

ON-LOAD QUICK RELEASE SUSPENSION GEAR FITTED WITH HYDROSTATIC INTERLOCK AND HOOK SAFETY INDICATORS

WILLIAM MILLS (MARINE) LTD Manor Road Levenshulme MANCHESTER M19 3EJ England Telephone: 0161 Telefax: 2098 e:mail [email protected]

THIS MANUAL MAY NOT BE COPIED IN WHOLE OR PART WITHOUT THE WRITTEN PERMISSION OF WILLIAM MILLS (MARINE) LTD

ISSUE CONTROL details of change issue 1 sept 1997 first issue

-1(WITH INDICATORS) MAINTENANCE MANUAL

issue 1 - SEPTEMBER

mills MARINE

CONTENTS

SECTION

1

INTRODUCTION

2

CAUTION

3

EQUIPMENT SCHEDULE

4

DRAWINGS

5

MAINTENANCE General Weekly Maintenance & Inspections Monthly Maintenance & Inspections Annual Maintenance Maintenance Check List

6

OPERATIONAL TEST

7

HOOK TOLERANCES

8

HOOK PIN WEAR VERIFICATION Template for recording Hook Pin Wear

9

HYDROSTATIC UNIT Hydrostatic Unit Cable Attachment and Adjustment. Procedure for Resetting Hydrostatic Unit.

10

OPERATING CABLES Operating Cable Specifications Operating Cable Adjustment Operating Cable Replacement, Attachment and Setting

11 12

LUBRICATION PROCEDURES SPARE PARTS

The information and statements herein are to be reliable, but are not to be construed as a warranty or representation for which we assume legal responsibility. Users should undertake sufficient verification and testing to determine the suitability for their own particular purpose of any information referred to herein. NO WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS MADE.

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(WITH INDICATORS) MAINTENANCE MANUAL


MARINE

1.

INTRODUCTION

The Mills TITAN quick release suspension gear is a release mechanism for davit-launched survival craft complying with the requirements of the 1998 amendments to chapter of SOLAS 1974. The on-load release of the equipment enables the bow and stern suspension hook assemblies to be opened simultaneously* even with the craft being towed by the parent vessel or drifting due to wind or tide whilst still attached to the davit fails. The hook assemblies are opened by cables activated by a release handle unit which is sited at the helmsman's position for one man operation. Accidental release is prevented by the inclusion of a hydrostatic interlock device which ensures that the equipment cannot normally be operated until the craft is in the water. In the unlikely event of a malfunction of this interlock, or if the craft is not due to some malfunction of the launching device, as the ultimate last chance of escape, the interlock may be over-ridden for emergency launch of the craft by manually lifting the hydrostatic locking This lever is enclosed behind which has to be broken to gain access The gear has been fitted with readily visible indicators showing the positive condition of the Cam Release Pin, so as to improve the ease of inspecting the gear to ascertain the gears safety condition. Note: Should any of the indicators be found to be in the red/unsafe zone the craft must be taken out of service immediately and the matter corrected by adopting the prescribed procedures laid down in this manual. * This means both hooks opening by one full operational movement of the release handle. It does not imply absolute synchronisation of the opening instant of each hook, as exact synchronisation is not required to effect a safe launch if the gear is set-up and operated in accordance w ith this manual. Survival craft in which the twin fall Titan Release Gear are fitted are not designed to free fall into the w ater, therefore this facility must be considered as the ultimate last chance of escape, where it is impossible to lower the craft normally to the water and in the full knowledge that serious damage to the craft and possible fatal injuries to the personnel may be sustained due to this action.

The basic configuration of the equipment is shown in Figure 2.

CAUTION

Before this equipment is installed or operated, or before any maintenance is attempted, this manual should be read and understood by all persons This manual should then remain accessible at all times for future reference. If there is any doubt concerning the correct functioning of the equipment when the scope of this manual has been covered, then William Mills (Marine) Ltd must be contacted to remove any doubt before the equipment is put into service. William Mills (Marine) Ltd. accept no responsibility if the scope of this manual is extended by any installer, operator or service agent.



mills 3.

SCHEDULE

Each survival craft set of TITAN release gear comprises the following:2 off Hook assemblies. 1 off Release handle unit. 1 off Hydrostatic unit and Cable. 2 off Protective covers complete with 2 off Set of protective cover screws and washers. 2 off Keel pin spacers. 1 off Forward operating cable. 1 off Aft operating cable. 1 off Set of instruction labels. 1 off Set of instruction posters 1 off Set of manuals 4.

DRAWINGS

Reference should be made to the following drawings when using this Figure

Typical Arrangement of Titan Release Gear.

Figure 2.

General Arrangement of Hook Assembly.

Figure 3.

Details of Cam Release Pin Position

Figure 4

Cam Pin Positional Indicators

Figure 5

General Arrangement of Release Handle Unit

Figure 6

Details of Hydrostatic Lock Engagement

Figure 7

Arrangement of Hydrostatic Unit.

Figure 8

Recommended Label Fixing Positions.

Figure 9

Cam Pin Wear Indicator Reference Markings

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mills MARINE

Figure

Typical Arrangement of Titan Release Gear.

1 2 3 4 5 6

Hook Assembly Release Handle Unit Hydrostatic Unit Aft Operating Cable Forward Operating Cable Hydrostatic Operating Cable


1

1997

mills Figure 2.

Arrangement of Hook Assembly.

Lever

Ca m Plate

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INDICATORS) MAINTENANCE MANUAL

issue 1

1997

mills MARINE

Fig 3 Details of Initial Cam Release Pin and Hook Relative Setting

Load on Hook Position of Hook

When There

Load on

no Load on the Hook a Gap or Angle May Develop Between Faces. However

o f N o C o n s e q u e n c e D u ri ng S e t t i n g .

Tension Must be

When Boat

Stowed to Prevent Gap Developing Flat ro Flat C o nta ct o f

Faces

Fully Cocked and Correct Cam Position

Release

Cable Disconnected. Release Cable Adjusted For Slightly Cocking Lever

Longer Length (by 1 or 2 mm) A ft e r Alignm ent of

Operation

Holes and Then

a Residual

Force

On the Cable ( and Never Tension )

Figure 3(b). Operational Setting Check

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MARINE

Fig 4 Cam Pin Positional Indicators Details of Initial Cam Release Pin and Hook Relative Setting showing indicator set up. In order to permit the checking of the safe, face to face contact between the tail of the hook and the cam pin, indicators, which are positively fixed in register with the cam pin face have been fitted to the hook units, to provide an easy reference with regard to the interface condition. If the indicators are found to be at any time, in the red/unsafe zone thus the "wrong" condition as shown in Fig 3 , the equipment must be taken out of service. Provision must be made to safely take the load off of the hooks before the fault is investigated and corrected.

SAFE ZDNE

RING

SAFE ZDNE

REFERENCE RING

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"TITAN" (WITH INDICATORS) MAINTENANCE MANUAL


mills Figure 5.

General Arrangement of

Handle Unit.

Button Headed Safety Operating Handle

Detent

on Opera ting Handler

Operating Quadrants Operating Cable Lever Cover Hydrostatic Locking Lever Clevis Fitting Clevis

Hydrostatic

Cable

Spring

Glass Ac ces s

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"TITAN" (WITH INDICATORS) MAINTENANCE MANUAL


Fig 6

Details of Hyd rostatic Lock Engagem ent Positions

Operating

Hydrostatic

Quadrant

Locking

Lever

LOCKED POSITION

RELATIVE POSITIONS - BOAT OUT OF WATER

FREE POSITION

8 mm

Maximum

Clearance

RE LA TIVE POSITIONS - BOA T IN WA TE R

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mills Figure 7.

General Arrangement of Hydrostatic Unit.

Vent Diaphragm

Diaphragm Piston Top Fixing Nut

Washers

Fixing Nur Top Plate Piston Vent


Adaptor Connector

issue 1 - SEPTEMBER

MARINE

Fig 8. Recom men ded Label Fixing Positions.

2 X LB

VISA BLE TO PERS ON RESE TTING THE HOOKS

1 X LB 17

IN W A Y O F H E L M S M A N

1 X LB 25 / 25A

IN W A Y O F TH E R E L E A S E H A N D L E US E A P P R O P R I A T E L A B E L

1 X LB 95

R E L E A S E H A N D L E UN IT - A D J A C E N T T O T H E B U T T O N H E A D E D PIN

1 X LB 135

RELEASE HANDLE UNIT - TOP OF GLASS ACCESS PANEL

1 X LB 13 6

R E L E A S E H A N D L E U NIT - B O T T O M O F G L A S S A C C E S S PA N E L

1 X LB 97

L A B E L - A D J A C E N T T O G L A S S A C C E S S PA N E L



mills MARINE

Fig 9 Cam Pin Wear Indicator Reference Marks Hook Position Indicators

REF

3 Tonne TITAN

3

CENTRE PUNCH

REF DIMENSION

5 Tonne TITAN



mills MARINE

5.0

MAINTENANCE

IMPORTANT NOTICE Regular maintenance in accordance with William that performance and safety are not impaired.

instructions must be carried out to ensure

IT IS STRONGLY RECOMMENDED THAT ANY MAINTENANCE WORK IS CARRIED OUT BY TRAINED SAFETY OFFICERS HAVING AN ADEQUATE MECHANICAL ENGINEERING BACKGROUND TO UNDERSTAND THE OPERATIONAL AND MAINTENANCE REQUIREMENTS OF THE EQUIPMENT, AND TO CARRY THE CONCOMITANT RESPONSIBILITY OF PROFESSIONAL WORKMANSHIP ON WHICH THE SAFETY OF LIVES DEPEND. IF THE CRAFT IS TO BE RETAINED IN THE DAVIT WHILST WORK IS CARRIED THE LOAD MUST BE TRANSFERRED FROM THE FALLS AND THE MAIN HOOKS TO THE AUXILIARY SUSPENSION POINTS AND SUITABLE HANGING OFF PENDANTS AND LUGS ON THE DAVIT. (SEE DAVIT MANUAL FOR CORRECT APPLICATION) FAILURE TO HEED THIS WARNING COULD PROVE FATALLY DANGEROUS. William Mills operate Comprehensive Training Courses to certify personnel as competent in the Operation and Maintenance of their Equipment. Note the transfer of load from the davit falls to the auxiliary suspension points must be carried out with the minimum of shock loading. 5.1

General

The Mills Titan On-Load Release Mechanism is designed to have minimum maintenance requirements. All main Pivot Pins are manufactured in Stainless Steel and run in self lubricating bushes, any components not in Stainless Steel are supplied in hot dipped Galvanised Mild Steel. The operating Cables supplied by William Mills are manufactured from corrosion-resistant materials, and are sealed for life, requiring no periodic lubrication apart from the cable end rods and swivels as defined in Section Note

Operating cables cannot effectively be repaired. Faulty cables (seized or kinked) render the craft unsafe to use and must be replaced immediately if the craft is to remain in service. Under no circumstances should any part of the equipment including cables, cable swivel joints or ridged extensions be painted or coated with any other substance than the lubricant indicated in section 11.

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5.2

Weekly Maintenance & Inspections

Make a CLOSE VISUAL INSPECTION with special attention being paid to the following. i)

At the hook assemblies:Check that the fall rings or links are kept under tension by the winch through the falls, and are fully engaged in the throat of the hook with the guard plates closed correctly. Check that the hooks are fully closed, indicator arrows aligned, and that the cam pin indicators are registering the locked position and not in the red zone See Fig 3 & fig 4 Check that the cocking levers are in the lower position Check that the protective covers are in place and protecting the operating cables from mechanical damage. Check for any damage, corrosion, excessive salt deposits of foreign bodies likely to impair the operation of the equipment and correct as necessary. Check for damage and or corrosion to the operating

ii)

At the Release Handle unit:-

Check that the release handle is in the fully locked position with the locating bars fully down in the side plate slots and behind the operating quadrants. Check that the Button-Headed Safety Pin is in place. Check that the hydrostatic locking lever is in the locked position See Fig6 iii)

Check the security of all cable

iv)

Check all operating cables for damage.

v)

Check that all instruction labels are in place.

vi)

Check that the equipment is adequately lubricated, and rectify as necessary (See Section

vii)

Record Weekly Check and any action taken in Ships Maintenance Log. A template for these inspection records is shown in 5.5



mills MARINE

5.3

Monthly Maintenance & Inspections

Comply with the weekly maintenance schedule described previously and carry out the following additional work. If the craft is to be retained in the davit carrying out monthly maintenance and inspection procedures hang the craft on the auxiliary suspension points and pendants. The transfer of load from the main falls to the auxiliary suspension points must be conducted with NO PERSONS IN THE CRAFT and in a way as to ensure that the auxiliary suspension points and pendants are not shock loaded. when the main fall wires are visibly slack should persons board the craft. Following load transfer, the main fall rings are to be removed from the hook by lifting the mousing (guard) plate and the ring free. Only then test the operation of the Test.

equipment as detailed in section 7 Operational

This monthly maintenance schedule tests all parts of the equipment except for the diaphragm in the hydrostatic unit. Without dismantling the hydrostatic unit, which is an annual maintenance requirement, the only way to check the operation of the diaphragm is to make the craft waterborne and observe the hydrostatic locking lever through the glass access panel. For this reason it is recommended that the craft be launched as part of the monthly maintenance check whenever possible. This recommended launching offers the ideal circumstances for hook pin wear to be monitored by a measurement between the wear indicator reference points being taken as the craft is recovered and suspended just above the water for final checks prior to lifting to the section Record Monthly Check and any action taken in Ships Maintenance Log. Following the completion of the maintenance schedule the craft should be returned to the main

falls.



mills MARINE

5.4 Annual Maintenance Comply with the monthly maintenance schedule described above and carry out the following additional work. i)

Inspect the hydrostatic unit diaphragm as follows. See Fig 7 Disconnect the operating cable at the release handle unit and the vent pipe at the hydrostatic unit. Remove the diaphragm clamping bolts, separate the upper housing from the lower housing, and remove the diaphragm. Replace diaphragm with a new one. Clean the lower housing and drainpipe of all dirt and salt deposits. Ensure that the mating surface in way of the bolting pattern is clean, and wipe it over with a thin film of grease. Dismantle the upper housing, and clean and inspect all the component parts. Reassemble in reverse order, ensuring that all fastenings are secure, and that no sharp edges are left on the heads of the screws in the piston plate that are in contact with the diaphragm. Locate the diaphragm on the lower housing and refit the upper housing. Ensure that the projecting location lugs on the upper and lower housing are in line with each other, and replace the clamping bolts. Hand tighten any four bolts that are diametrically opposite each other, and then tighten the same four bolts in the same sequence with a torque wrench set at 34 Nm (25 Repeat this operation on all the nuts and bolts the circumference of the housing. Reconnect the vent pipe.

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mills MARINE

5.5

Maintenance Check List

RELEASE HANDLE

Visual on

WEEKLY

MONTHLY

YEARLY

devices & hook indicators

Check for free play Setting for lever lock

General Condition HOOKS Check covers / Indicators Strip & Clean all parts Check Bushes

Check gap Check hook tail condition Check cam /

pin

clevises General condition Check Hook Pin Wear Indicators HYDROSTATIC UNIT Strip & Clean

Replace diaphragm Check adaptor / piston Check top gasket Check breather pipe General condition CABLES

Visual seals Check clevises / locknuts Check for free movement Check for corrosion General condition GENERAL SETTINGS Check flat to flat contact reference hook indicators, Set Cables Check opening


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mills MARINE

6

OPERATIONAL TEST

IF THE CRAFT IS TO BE RETAINED IN THE DAVIT WHILST WORK IS CARRIED OUT, THE LOAD MUST BE TRANSFERRED FROM THE FALLS AND THE MAIN HOOKS TO THE AUXILIARY POINTS AND SUITABLE HANGING OFF PENDANTS AND LUGS ON THE DAVIT. (SEE DAVIT MANUAL FOR CORRECT APPLICATION) FAILURE TO HEED THIS WARNING COULD PROVE FATALLY DANGEROUS. i)

ii)

Remove the pair of bolts in the hydrostatic cover, slacken the lower rotate the cover downwards to expose the hydrostatic locking lever.

and

Remove the Button-Headed Safety Pin.

CONFIRM CRAFT IS SUSPENDED BY THE AUXILIARY SUSPENSION POINTS AND PENDANTS NOT THE MAIN FALLS, AND THAT THE FALL RINGS HAVE BEEN REMOVED FROM THE HOOKS. iii)

Lift and release and hydrostatic locking lever several times to check its freedom of operation, and then hold it in the raised position.

iv)

Operate the Release Handle and let go of the Hydrostatic locking lever.

v)

At each hook assembly, check that the hook can be swung clear of the cam release pin without binding at the pivot and that clearance as shown in section 7 is correct. If not check again that the quadrants in the release handle unit are up against the stop pin, and if so, make small adjustments to the clevis fitting at the hook end of the operating cable until the clearance is correct.

vi)

Remove the protective covers and check the condition of the clevis fittings, the clevis split pins and the tightness of the clevis locking nuts and cable fixing clamps.

vii)

Check the operating cable end seals and ensure that the cable rod ends and swivels are adequately lubricated. Paying particular attention to the condition of the swivel joint between the cable end and the cable rod, also the cable fixing clamps.

viii)

Reset the hooks and whilst doing so check that the operation of the cocking levers does not require the use of more than normal hand force. Excessive operating force normally is indicative of cable problems.

ix)

If the operation of a cocking lever is unsatisfactory, disconnect the operating cable at each end and test it for freedom of movement. If it is binding, check for cable rod or end seal damage, excessively tights cable bends, or accidental cable damage. If the problem is found not to be with the cable, check the cam release pin, the operating lever and the operating quadrants, together with their respective bushes, and rectify as necessary. Operating cannot effectively be repaired. Faulty cables (seized or kinked) render the craft unsafe to use and must be replaced immediately if the craft is to remain in service.

See section 10 for Cable replacement / Resetting Instructions x)

the protective covers and indicators on the hook assemblies.

xi)

Refit the hydrostatic lever cover on the release handle unit.

xii)

Attach the davit falls.



mills 7

HOOK TOLERANCES

These are the only checks required to confirm the working tolerances of the Hooks.

a.

Check the tail of the hook and the face of the cam release pin for signs of wear and damage. If wear of the hook tail is in excess of that shown in Sketch 1 the hook should be replaced. If present this wear will normally appear in the form of a rounding of the hook tail and an indented line across the cam release pin. This condition generally having been caused

i)

The hooks having been unloaded from the falls when the craft is stowed. This has allowed vibration to chatter the hook and cam face together causing the indentation and rounding.

ii) Frequent on load test releases.

b.

EXCESSIVE WEAR IS A RADIUS GREATER THAN 1 MM Sketch 1

Check the gap formed between the tail of the hook and the flat of the release pin by using feelers as shown in sketch 2, lifting the hook as this is done will take account of any wear in the bush or pin . If the gap is in excess of that allowed, the gear must be withdrawn form service and the hookreplaced. Changes in this gap can only be due to wear and should be progressive rather than sudden. MAXIMUM ALLOWED GAP 0.070 INCHES 1.8 Sketch 2



mills MARINE

8

HOOK

WEAR VERIFICATION

To allow a simple check to be made of wear in the hook pin, hook pin bushes and sidepiate, reference marks have been stamped on both the hook and the sidepiate, fig 9. 8.1

Calibration of Wear Mark Indicators.

When the craft is first into service the under load dimension between the two reference marks, on both fore and aft hooks, should be accurately established and separately entered in there respective columns of a record table a template for which is shown below at 8.3 Determine and record the limit of wear allowance for each hook by adding 0.80 mm to the calibration reference dimension. This figure which, if the ongoing measured reference dimension requires that the craft be removed from service and the causes investigated. 8.2

Ongoing measurement to check for

With the hook under load, ie. The craft is suspended just above the water after an operational launch test. The craft is suspended from the falls with the maintenance pendants attached just prior to making the transfer from main falls to maintenance pendants. Measure between the two points, with dividers or vernier and record the dimension. Compare the dimension obtained with that noted as the maximum allowed wear figure for the gear in question on the record chart. It must not be greater than this figure. If a reading greater than this is obtained then the boat must be removed from service, the hook / hook pin assembly disassembled, checked and the worn items replaced. Following disassembly and or part replacement a new reference dimension and maximum allowed wear figure must be established and recorded to allow the process of wear checking to continue. 8.3

Template of Record for recording Hook Pin Wear

LIFEBOAT No.

AFT HOOK

FOREWARD HOOK

DATE

CALIBRATION DIMENSION (CD) MAXIMUM ALLOWED WEAR (CD + 0.80 MM)


issue 1 - SEPTEMBER

MARINE

9

HYDROSTATIC UNIT

9.1

Hydrostatic Unit Cable Attachment and Adjustment.

(These adjustments cannot be carried out with the craft in the so to ensure hang the craft on the auxiliary suspension points and pendants, or transport the craft to hard standing. i)

Ensure that the relative positions of the hydrostatic locking lever and the operating quadrants are correct for the "locked" "out of position of the release handle unit. This requirement is illustrated in Fig 6

ii)

Adjust the position of the clevis fitting on the cable the pin can just be inserted through it and the hole in the hydrostatic locking lever.

iii)

Ensure that the hydrostatic locking lever will lift against the spring to the "free" the position and return to the locked position when released. This will indicate correct free functioning of the hydrostatic unit. If necessary, adjust the position of the clevis fitting on the cable until this requirement is met, then tighten the locking nut and secure the pin with the clip provided.

9.2

Procedure for Resetting Hydrostatic Unit.

i)

Undo and remove the four fixing bolts from top plate.

ii)

Lift cable and top plate clear of top housing thus exposing bottom cable fixing nut.

iii)

Undo top and bottom cable fixing nuts nuts to their full extent.

iv)

Place the top plate assembly back in its original position and replace two top plate bolts.

v)

By holding the end of the inner and outer cable is the opposite end to that which passes into the Hydrostatic unit ) establish free movement of the inner cable be before next step.

vi)

Press by hand the inner cable until resistance is obvious. This means that the piston plate is resting on the diaphragm, hold this position and proceed to hand tighten top cable fixing nut.

and proceed to unscrew both

Remove the two top plate bolts and lift assembly to full extent, hand tighten bottom cable fixing nut, then proceed to spanner tighten top and bottom cable fixing nuts simultaneously thus locking top plate position.



mills MARINE

10.

OPERATING CABLES

The Mills Titan On Load Release Mechanism depends upon the operating cables for its safe operation. Their ability to transfer compressive load to the release handle unit, without or premature failure is an integral part of the design of the equipment. Hence it is of paramount importance that only the quality and type of cable as specified by William Mills be fitted to the equipment. Equally important is that they should be correctly fitted, protected from mechanical damage by the equipment covers and continue to be maintained in such a way as to ensure their continued by the prevention of corrosion. Points to check

i)

Corrosion on the extended ridged rod between the swivel and the clevis.

ii)

Corrosion of the swivel joint, this may need the displacement of the rubber seal to detect.

iii)

Correct fitting, and continued tightness of the cable clamps.

iv)

Kinks or sharp bends in the cable run within the

v)

Damage to the outer cable within the craft.

Under no circumstances should any part of the operating cable, swivel joint or ridged extension be painted or coated with any other substance than the lubricant indicated in section 11. OPERATING CABLES CANNOT EFFECTIVELY BE REPAIRED, FAULTY CABLES OR KINKED) RENDER THE CRAFT UNSAFE TO USE AND MUST BE REPLACED IMMEDIATELY IF THE CRAFT IS TO REMAIN IN SERVICE.

10.1

Operating Cable Specifications

All operating cables if not supplied by William Mills Marine Ltd, must be approved by William Mills Marine Ltd and their specification should be submitted and approval in writing obtained, prior to their use. Without this approval the company cannot be responsible for the system or the certification supplied.

Stainless steel support tubes, end rods Plastic lined metal conduit, polished steel inner armoured sliding inner. Operating temperature range -65 F to + 230 F Application

Hydrostatic

3 tonne

5 tonne

12 tonne

Travel

2

3

4

6

Min Load

150

210

170 Ib comp

300 Ib comp

End Rod



mills MARINE

10.2

Operating Cable Adjustment

ON NO ACCOUNT MUST ANY ADJUSTMENTS BE PERFORMED WITH THE CRAFT SUSPENDED BY THE hang the craft on the auxiliary suspension points and or transport the craft to hard standing. Only then carry out cable adjustment as follows:i)

Apply a MINIMAL load to the hooks, by hand, in order to produce a contact between the hook tail and the cam pin as shown in Section 7

to flat

Disconnect each clevis fitting from its respective cam operating lever. iii)

Ensure the

of the hook is flat against the cam of the release pin.

PUSH through any slack in the release cable. v)

Adjust the clevis fitting to line up with its respective cam operating lever hole while maintaining a slight force on each cable not tension).

vi)

Put clevis pins in place to reconnect cables to cam operating levers, ensuring that all clevis locking nuts are tight and split pins have been replaced. Replace all protective covers and indicators .

The adjustments above can be carried out at any time as required, however it is particularly recommended that they be carried out after any load or overload tests to take account of any cable stretch that may have occurred due to the tests. 10.3

Operating Cable Replacement, Attachment and Setting

ON NO ACCOUNT MUST THESE PROCEDURES BE PERFORMED WITH THE CRAFT SUSPENDED BY THE hang the craft on the auxiliary suspension points and pendants, or transport the craft to hard standing. Only then carry out cable replacement as

Install the fore and aft operating cables, making sure the correct lengths for the craft are used. The lifeboat manufacturer should be contacted with regards to the correct length of the cable and the correct routing in the boat, prior to removal or installation of a replacement. Take care to run the cables with the absolute minimum number of bends and when bends are necessary ensure that they have the largest possible bend radius. For efficient operation the total amount of bend in any cable should not exceed degrees and should be in excess of 205 mm (8 in) radius. ii)

It is recommended that all cables that have bends in their run, be restrained by clips at a minimum spacing of one clip per meter of cable run with additional clips at the start and finish of any bend.

iii)

Remove the protective covers and the forward hand aft hook assemblies and ensure that the hooks are in the closed position, i.e. with the cam release pin (item 3, Figure 2 ) in flat contact with the tail of the hook. This requirement is shown in Fig 3. Temporarily clamp the operating levers of each hook ensuring that the hooks and release pins are set in accordance with Fig 3a -24(WITH INDICATORS) MAINTENANCE MANUAL


mills MARINE

iv)

Remove the protective cover from the handle unit. Remove Handle stop pin (item 12, Figure 5 ). Lift hydrostatic Locking lever. Lift operating handle against spring until locating bars are clear of side plate slots. Pull or push operating handle until access to quadrant clevis forks is obvious. Remove clevis forks and fit them to threaded cable ends, above the locking nuts.

v)

When fitting clevis forks to the cables, screw on for approximately mm of the threaded length. Refit clevis forks to quadrants and proceed to return the release handle unit to its closed or locked position, see Figure 5. Secure operating cables to the release unit sideplate with the cable clamps provided, ensuring that the groove in the cable fitting is aligned with the ridge in the clamp before tightening. A pattern of six holes are provided in the release unit sideplates for the attachment of the cable clamps. From the top these determine the correct outer cable fixing for 3 tonne, 5 tonne gears. Replace the Handle stop pin (Item 12, Fig 5) in the correct location for the size of gear being operated. Hole nearest the handle for 3 tonne, hole farthest from the handle for others. Check that the required length of cable travel, 3 inch on 3 tonne, 4 inch on others is available, by moving the quadrants by means of the operating handle. Ensure that the clevis split pins are replaced and the under

vi)

are tightened.

Proceed to hook assemblies. Secure operating cables with cable blocks provided. (Item 4, Figure 5) ensuring that the groove in the cable fitting is aligned with the ridge in the cable block before tightening. Remove clevis forks from the operating levers, (Items 5 & 6, Figure the threaded end of the cable above the locking nut.

and fit clevis fork to

PUSH the inner cables in to the outers to remove any end movement and backlash in the system.

Offer up the clevis fork to the operating lever and align the holes by rotating ftie clevis fork up or down ftie cable end until the pin can be inserted with a small compressive push of the cable. Note residual tension in the cable should not be permitted as it may turn the cam towards its opening position. Ensure that the clevis split pins are fitted and the clevis locking nuts tightened. vii)

When the is satisfied that the settings are correct, Check that all cable clamps and clevis locking nuts have been tightened, clevis split pins fitted and secured. Replace Button Headed Safety Pin in release handle unit, remove any temporary clamps and refit all covers. Ensure that the covers at the hooks fully protect the operating cables to the point of entry into the deck of the craft.



mills MARINE

11

LUBRICATION PROCEDURES

Item

Cleaning

Lubrication

General steelwork ie. Pendants lugs, guard side plates, etc

Dependent upon condition the use of wire brush or emery cloth, wiped clean with non-fluffy oil soaked cloth. ANY PAINT IS TO BE REMOVED

Re-assemble with thin film of clean grease.

Stainless Steel pivot / cam pins in bushes

Use turpentine or paraffin based product to clean off. Use a light emery cloth on pins. Wipe clean with non-fluffy oil soaked cloth. ANY PAINT IS TO BE REMOVED


Cable clevis end / pins

Use turpentine or paraffin based product to clean off. Use a light emery cloth on pins. Wipe clean with non-fluffy oil soaked cloth. ANY PAINT IS TO BE REMOVED


Cable end Rods

Use turpentine or paraffin based product to clean off. Wipe clean with non-fluffy oil soaked ANY PAINT IS TO BE REMOVED

Coat sparingly with a thin film of clean grease

Control Cables

Cables supplied by William Mills are Factory Sealed for life and require no lubrication. ANY PAINT IS TO BE REMOVED.

Non Required. STIFF OR SEIZED CABLES MUST BE REPLACED IMMEDIATELY IF THE CRAFT IS TO REMAIN IN SERVICE.

Lubricants suitable


Shell Grease R2 or G3 B.P. Grease Mobilux EP2


LIFEBOAT MANUAL.pdf

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