Operating and Maintenance Manual For Launching-And Retrieval System of Freefall Lifeboat Type: FFA

DMF-20
Operating and maintenance manual

for launching- and retrieval system
of freefall lifeboat type: FFA
(acc. to MSC.1/Circ.1206) with under oil hydraulic power pack
TS
N
EK RE
CE
TA
H
ERNST
HATECKE
Boatyard Ernst Hatecke GmbH
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
E-mail: email@Hatecke.de
www.hatecke.de Edition 09/06
Index
1 Operation Manual
1.1 Yard and yardnumber

1.2 In the interest of safety
1.3 Description of the launching-and retrieval system
1.4 Launching instruction
1.5 Freefall launching
1.6 Launching and recovery by davit (Under deck version)
1.7 Launching and recovery by davit (On deck version)
2 Maintenance Manual

2.2 Hydraulic equipment
2.3 Hydraulic oil & lub plan
2.4.1-3 Recommended oil chart
2.5.1 Weekly inspection
2.5.2 Monthly inspection
2.5.3 Annual thorough examination (acc. to MSC.1/Circ.1206)
2.5.4 5-Years overhaul & testing (acc. to MSC.1/Circ.1206)
2.5.5 Testing according to SOLAS Chapt. III, Reg.20.11.1
2.5.6 Log Scheme
2.5.7 Authorized Service Stations
Additional:
General layout
Wires / small parts
Lashing (boat)
Wiring diagram (optional)
Hydraulic plan
Documentation of winch
Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1, 21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: email@Hatecke.de, www.hatecke.de
1.1 Yard and yardnumber
The information given in this manual is based on our long experience and "know-how" in the
building of rescue boats, all kind of life boats their equipment and their launching and recovery
systems.
In case of an emergency,also in normal practise it is very important that every body knows how
to handle the boat, the launching system and it`s equipment.
All personal should study this manual at lifeboat drills, to make them selves thorougly
conversant with the system and to ensure a speedy and safe launching in an emergency.
The technical specifications are not binding and can be altered without prior notice.
In case of enquiries regarding existing boats please quote the details given below:
Type:
FFA 6,5M
Building no.: 10881
ERNST
HATECKE
Boatyard Ernst Hatecke GmbH
Am Ruthenstrom 1
21706 Drochtersen
Phone: 0049-(0)4143-9152-0
Fax: 0049-(0)4143-9152-40
E-mail: email@Hatecke.de
www.hatecke.de
WARNING
1. During operation of the davit be cautions with long links, snap hooks and counter weights.
2. DO NOT put your hands on snap hooks, long links, counter weights and falls with tension
on this parts.
3. Always keep hands and feet clear near moving and rotating mashinery.
4. Before launching close fronthatch and door.
5. Secure all items and fasten seat belts (adjust to your size).
6. Don´t wear lifejackets during freefall launching. Failure to observe this procedure may
lead to serious injury or dead!
7. Keep off in reach of propeller.
8. Before starting read engine instruction manual.
1.3 Description of the launching-and retrieval system
This launching and retrieval system is installed in the stern area of the ship to use freefall-lifeboat
as follows:
1. freefall-launch of freefall-lifeboat up to 20° list and 10° trim of the ship from certificated height.
2. controlled launch of the freefall lifeboat up to max. number of persons it is certified by means
of davit arm and winch up to 5°list and 2° trim of the ship.
3. recovery of freefall-lifeboat with crew of max. 4persons at a speed of 5m/min (winch) up to
5°list and 2° trim of the ship.
Boat wil be turned out or swing in by A-fram. Hoisting and lowering by winch with two falls each for
one hoisting sling of freefall lifeboat.
Sheaves for falls leading out of polyamide and all bolts from stainless steel.
Davit arm as well as winch are powered by hydraulic power pack.

Max. working pressure is 200 bar. Overpressure of hydraulic power pack should be adjusted to
max. 220 bar.
Boat is secured in stowage position by hooks and lashing system.
1.4 Launching instruction
Freefall
The boat runs down the launching ramp and on hitting the water submerges briefly before
emerging and moving away from the stern of the ship.
The boat will clear the vessel irrespective of weather conditions or angle of heel. Instructions for
launching procedure on the following page.
Instruction of freefall procedure look at page 5, look also at the manual of the freefall-lifeboat.
Launching by davit
In some cases (shallow water, drift-ice, drifting parts of the cargo) it is necessary to launch the
boat with max. number of persons by davit.
Instructions for launching procedure on the following pages.
Recovery by davit
Freefall-lifeboat with crew of max. 4 persons must be sailed astern under the davit.
Instructions for recovery procedure at page 6 and 7.
1.5 Free fall launching
Close all hatches and vents.

Fasten seat belts.
Close the valve screw (pos.1), operate the hydraulic

pump (pos.2). (After abt. 20 strokes the locking device
will disengage - the boat is now free.)
CAUTION:
Before replacing the boat in the launching ramp, the
hydraulic piston should brought back into its housed
position by opening the valve screw (pos.1)
MAIN RELEASE PUMP
2
1
4
EMERGENCY RELEASE PUMP
EMERGENCY RELEASE:
HYDRAULIC PISTON
Operate only when mainrelease system is damaged.
LOCKING DEVICE
Close the valve screw (pos. 3).
Operate the emergency release pump (pos. 4). (After abt. 30 strokes the locking device will
disengage - the boat is now free.)
CAUTION:
Before replacing the boat in the launching ramp, the hydraulic piston should be brought back
into its housed position by opening the valve screw (pos. 3). After replacing the boat in the
launching ramp the valve (pos. 3) should remain in the open position.
1.6 Launching and recovery by davit (Under deck version)
Abb./fig.3
II3. II5. III2. A WINDE / WINCH
III4. III5.
B DAVIT
II4. III3.
Abb./fig.1
Abb./fig.2
II
III7.
II
I Free fall launching:

Disengage the boat lashing on the platform and enter the boat - further more information for
launching inside the boat. (Look also page 1.5 of this manual.)
II Launching by davit:
The main switch on the switch board box (fig. 1 ) is switched on. Push in the green button
on the push button box (Fig. 2 ) - now the system is ready for work.
1. Disconnect the falls from the lashing eyes and hook them to the hoisting sling.
2. Disengage the boat lashing on the platform and to the keel.
3. Tighten up the boat falls by winch (lever A fig. 3).
4. Swing out the davit to it`s max. outreach (lever B fig. 3).
5. Lower the boat (lever A fig.3 ).
6. Disconnect the falls after the boat is waterborne.
III Recover of the boat (max. 4 persons on board):

The davit is max. swung out. The falls are in reach of the boat. Both lashings at the sliding
ramp are disconnected.
1. Manoeuvre the boat astern below the falls and connect them to the hoisting sling.
2. Lift on the boat (lever A fig.3) until the distance of the falls counter weights to the stoppers
is about 1 meter.
3. Swing in (lever B fig.3) the davit to it`s resting position.
4. Pull the boat with the winch (lever A fig.3) into it`s resting position.
5. Disconnect the hoisting slings from the falls, pick the falls into the lashing eyes at the
boat station and tighten up the falls by winch (lever A fig.3).
6. Attach the boat lashings.
7. Switch off the hydraulic unit - push in the red button at the push button box.
1.7 Launching and recovery by davit (On deck version)
II3. III3.
III2. III4. III5.
II
III7.
I Free fall launching:

Disengage the boat lashing on the platform and enter the boat - further more information for
launching inside the boat. (Look also page 1.5 of this manual.)
II Launching by davit:
The main switch on the switch board box is switched on (must be switched on all the time of
course the heater inside). Push in the green button on the switchboard box - now the system
is ready for work.
1. Disconnect the falls from the lashing eyes and hook them to the hoisting sling.
2. Disengage the boat lashing on the platform and to the keel.
3. Tighten up the boat falls by winch.
4. Swing out the davit to it`s max. outreach.
5. Lower the boat.
6. Disconnect the falls after the boat is waterborne.
III Recover of the boat (max. 4 persons on board):

The davit is max. swung out. The falls are in reach of the boat. Both lashings at the sliding
ramp are disconnected.
1. Manoeuvre the boat astern below the falls and connect them to the hoisting sling.
2. Lift on the boat until the distance of the falls counter weights to the stopper is about 1 meter.
3. Swing in the davit to about it`s resting position.
4. Pull the boat with the winch into it`s resting position.
5. Disconnect the hoisting slings from the falls, pick the falls into the lashing eyes at the boat
station and tighten up the falls by winch.
6. Attach the boat lashings.
7. Switch off the hydraulic unit - push in the red button on the switchboard box.
WARNING
1. During operation of the davit be cautions with long links, snap hooks and counter weights.
2. DO NOT put your hands on snap hooks, long links, counter weights and falls with tension
on this parts.
3. Always keep hands and feet clear near moving and rotating mashinery.
4. Before launching close fronthatch and door.
5. Secure all items and fasten seat belts (adjust to your size).
6. Don´t wear lifejackets during freefall launching. Failure to observe this procedure may
lead to serious injury or dead!
7. Keep off in reach of propeller.
8. Before starting read engine instruction manual.
2.2 Hydraulic equipment
UNDER-DECK POWER PACK:

Power pack with service tank capacity of 90 ltr. is equipped
with fixed mounted starter box (400V/50Hz or 440V/60Hz)
for under deck mounting. All components are mounted to
the tank. Starter box allways shall be in ON-position.
To operate power pack push greenbutton of push button
box on deck. Pressure to hydraulic cylinders and winch
will be handeled by valve station on deck. Working
pressure 200 bar, max. pressure 220 bar should be
adjusted at valve station. Tank of power pack is filled
with hydraulic oil after ventilation of cylinders, winch
motor and piping system max. oil level should controlled
monthly. The water content of the oil has to be controlled
every month by opening the drain screw before starting
operation.
ON-DECK POWER PACK:

Power pack with service tank capacity of 90 ltr. is equipped
with fixed mounted starter box (400V/50Hz or 440V/60Hz,
IP 56) for installation on free deck. Most of the components
are mounted in the tank, under oil. Starter box allways shall
be in ON-position. Hydraulic unit is protected against
overheating. Pressure to hydraulic cylinders and winch will
be handeled by valve station. Max. pressure 220 bar
should be adjusted at power pack . The tank of the power
pack is filled with hydraulic oil after ventilation of cylinders,
winch motor and piping system max. oil level should
controlled monthly. The water content of the oil has to be
controlled every month by opening the drain screw before
starting operation.
HYDRAULIC CYLINDERS:
The working pressure of the cylinders are 200 bar. They
are designed with a very high security with a test pressure
of 400 bar. The rod material is stainless steel, chromium
plated and super finished. Both cylinders are protected with
overcenter valves, which are directly installed in the
welded cylinder bottom.
HYDRAULIC WINCH-MOTOR:
The motor is also protected by an overcenter valve for
opening and closing the brake.
2.3 Hydraulic oil and lub plan
No.: Designation: Oil/grease type: Quantity(ltrs.) Service:
1 Hydraulic oil Look at next page look at Make oil control at the hydraulic power pack monthly.
page 10a, b, c Oil change after 200 - 1000 - 2000 operation hours,
but at least every 5 years.
2 Gearbox oil Look at next page look at Check outside visually to leakage before each operation.
winch manual Oil change after 200 - 1000 - 2000 operation hours, but at
least every 5 years.
3 Grease Look at next page / Grease after four weeks
4 Grease Look at next page / Grease after four weeks
Greasing of grease points and chainging of gearbox oil of winch should be carried out during docktime with basket.
3
4
A
2
FILLING AND BREATHER PLUG

OIL LEVEL PLUG QUANTITY APPROX.:PLANETARY GEAR: Q'TY SEE WINCH MANUAL
BRAKE: Q'TY SEE WINCH MANUAL
DRAIN PLUG
A: GREASE POINT: LITIUM BASED MULTI PURPOSE GREASE
A 2
1 1
2.4.1 Recommended oil chart ( winch 07.02.08, and 10.01)
RECOMMENDED OIL CHART
OIL LIST FOR FREEFALL-LIFEBOAT DAVIT SYSTEMS, TYPE FFA
Ambient teperature for -25° up to +50° deg. C

EST Q'TY UNIT; L.O/SYS. OIL: LTRS.
GREASE: KGS.
No.: APPLICATION POINT RECOMMENDATION
Q'TY/SET SET/SHIP TOTAL/SHIP
1 hydraulic system ISO VG 22 HLP 90 1 90

or VG 32 HLP
2 winch gear *) O VG 150-200 abt. 2 / 3,5 *) 1 abt. 2 / 3,5 *)
5 wire fall wire fall grease acc. 10 1 10

to lub-oil makers
standarts
6 chain grease with 2,5 1 2,5

and EP additives
falls hook NLGI - class 2
*) = depends on winch type,look at winch manual.
2.4.2 Recommended oil chart (ZOLLERN winch 4.20)

GREASE: KGS.
1 hydraulic system ISO VG 22 HLP 90 1 90

or VG 32 HLP
2 winch gear ISO VG 220 abt. 2 1 abt.2

to lub-oil makers
standarts

and EP additives
2.4.3 Recommended oil chart ( low temperature duty winch 07.02.08, and 10.01)

GREASE: KGS.
1 hydraulic system PLANTOLUB POLAR 90 1 90

POLAR 22S
(CLP E 22
to DIN 51502)
2 winch gear *) ISO VG 629 abt. 2 / 3,5 *) 1 abt. 2 / 3,5 *)

to lub-oil makers
standarts

and EP additives
*) = depends on winch type,look at winch manual.
2.5.1 Weekly inspection
Qualification level.
By supervision of a senior ships officer in accordance with the information provided by the manufacturer.
done remark
1. Visual inspection to ensure the system is ready to use.
2. Check adjusted overpressure (220 bar) of hydraulic power pack.

(Switch on power pack and hoist the davit arm against end position)
2.5.2 Monthly inspection
By supervision of a senior ships officer in accordance with the information provided by the manufacturer.
7
7
6
6
1 2 3 4 5
done remark
1. Check oil level of hydraulic power pack.
2. Make sure there is no condensed water inside the hydraulic power pack.
3. Make sure there is no water inside the electrical box of the power pack.
4. Check adjusted overpressure (220 bar) of hydraulic.
(switch on power pack and hoist the davit arm against end position)
5. Operate the winch in order to sprincler all inner parts by oil.
6. Check the Lashing aft & fore.
7. Grease wire rope falls and chain fore runner.
8. Visual inspection to ensure that the system is ready to use.
2.5.3 Annual thorough examination (acc. to MSC.1/Circ.1206)
By manufacturers representative or a person appropriately trained and certified by the manufacturer.
Look at page 1.2.7.6 Authorized service stations.
Items listed in checklists for the weekly/monthly inspections also form the first part of the
annual thorough examination, when carrying out this examination the inspection of these
items should be performed by the ship´s crew in the presence of the manufacturer´s
representative or a person appropriately trained and certified by the manufacturer for the
work to be done.
Inspection and maintenance records of inspections and routine maintenance carried out
by the ship´s crew and the applicable certificates for the launching appliances and
equipment should be available.
Davit: Examination and check for satisfactory condition and operation *
1. Davit structure, in particular with regard to corrosion, misalignments, deformations and

excessive free play.
2. Wires and sheaves, possible damages such as kinks and corrosion.
3. Lubrication of wires and moving parts.
4. Hydraulic system.
5. Hydraulic winch and winch foundation.
6. Dynamic winch brake test with empty boat.
7. Re-inspection of stressed structural parts.
* according to manufacturer´s checklist (Doc. no. 0301)
2.5.4 5-Years Overhaul & Testing (acc. to MSC.1/Circ.1206)
By manufacturers representative or a person appropriately trained and certified by the manufacturer.
Look at page 1.2.7.6 Authorized service stations.
Items listed in checklists for the weekly/monthly inspections also form the first part of the
annual through examination, when carrying out this examination the inspection of these
items should be performed by the ship´s crew in the presence of the manufacturer´s
representative or a person appropriately trained and certified by the manufacturer for the
work to be done.
Inspection and maintenance records of inspections and routine maintenance carried out
by the ship´s crew and the applicable certificates for the launching appliances and
equipment should be available.
Davit: Examination and check for satisfactory condition and operation *
1. Davit structure, in particular with regard to corrosion, misalignments, deformations and

excessive free play.
2. Wires and sheaves, possible damages such as kinks and corrosion.
3. Lubrication of wires and moving parts.
4. Hydraulic system.
5. Hydraulic winch and winch foundation.
6. Dynamic winch brake test with 1,1 times the weight of the Lifeboat and ist full
complement of persons & equipment, or equivalent load.
7. Re-inspection of stressed structural parts.
* according to manufacturer´s checklist (Doc. no. 0302)
2.5.5 Overhauling and testing acc. to SOLAS Chapt.III, Reg. 20. 11. 1
Acc. to SOLAS, Chapt.III, Reg.20.11.1 following has to carried out with the davit system:
"Operationally test under a load of 1.1 times the total mass of the life boat when loaded with its full
complement of persons and equipment whenever the davit system is overhauled. Such
overhauling and test shall be carried out at least once every 5 years"
Overhauling of system has to be carried out acc. to requirements of class or national authority.
Testing with 1.1 times x GA:

After overhauling the davit system has to be tested with 1.1 x GA.
The winch brake of the davit system shall be of sufficient strength to withstand a dynamic test with
a proof load of not less than 1.1 times the maximum working load at maximum lowering speed (5
meters/min.).
Testing has to be carried out under supervision of class or national authority.
WARNING:
During operation of davit be cautious with long links, snap hooks and counter weights.
2.5.6 Principal log scheme
No: Kind of service: Note: Date: Name:
2.5.7 Authorized service stations
Necessary larger repairs, as well as the “annual thorough

examination” and the “5-years overhaul” should be conducted by the
manufacturer´s representative or a person appropriately trained and
certified by the manufacturer.
Please contact: HATECKE SERVICE GMBH

Am Ruthenstrom 1
21706 Drochtersen / Germany
Telefon: +49 - 4143-9152-60
Telefax: +49 - 4143-9152-44
e-mail: service@hatecke.de
Internet www.hatecke.de

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DMF-20

Operating and maintenance manual

1.1 Yard and yardnumber

2.1 In the interest of safety

Building no.: 10881

4. Before launching close fronthatch and door.

7. Keep off in reach of propeller.

8. Before starting read engine instruction manual.

Davit arm as well as winch are powered by hydraulic power pack.

Boat is secured in stowage position by hooks and lashing system.

Instructions for launching procedure on the following pages.

Instructions for recovery procedure at page 6 and 7.

Close all hatches and vents.

Close the valve screw (pos.1), operate the hydraulic

MAIN RELEASE PUMP

I Free fall launching:

III Recover of the boat (max. 4 persons on board):

I Free fall launching:

III Recover of the boat (max. 4 persons on board):

4. Before launching close fronthatch and door.

7. Keep off in reach of propeller.

8. Before starting read engine instruction manual.

UNDER-DECK POWER PACK:

ON-DECK POWER PACK:

No.: Designation: Oil/grease type: Quantity(ltrs.) Service:

3 Grease Look at next page / Grease after four weeks

4 Grease Look at next page / Grease after four weeks

FILLING AND BREATHER PLUG

RECOMMENDED OIL CHART

OIL LIST FOR FREEFALL-LIFEBOAT DAVIT SYSTEMS, TYPE FFA

Ambient teperature for -25° up to +50° deg. C

1 hydraulic system ISO VG 22 HLP 90 1 90

2 winch gear *) O VG 150-200 abt. 2 / 3,5 *) 1 abt. 2 / 3,5 *)

5 wire fall wire fall grease acc. 10 1 10

6 chain grease with 2,5 1 2,5

*) = depends on winch type,look at winch manual.

RECOMMENDED OIL CHART

OIL LIST FOR FREEFALL-LIFEBOAT DAVIT SYSTEMS, TYPE FFA

Ambient teperature for -25° up to +50° deg. C

1 hydraulic system ISO VG 22 HLP 90 1 90

2 winch gear ISO VG 220 abt. 2 1 abt.2

3 wire fall wire fall grease acc. 10 1 10

4 chain grease with 2,5 1 2,5

RECOMMENDED OIL CHART

OIL LIST FOR FREEFALL-LIFEBOAT DAVIT SYSTEMS, TYPE FFA

Ambient teperature for -30° up to +50° deg. C

1 hydraulic system PLANTOLUB POLAR 90 1 90

2 winch gear *) ISO VG 629 abt. 2 / 3,5 *) 1 abt. 2 / 3,5 *)

3 wire fall wire fall grease acc. 10 1 10

4 chain grease with 2,5 1 2,5

*) = depends on winch type,look at winch manual.

1. Visual inspection to ensure the system is ready to use.

2. Check adjusted overpressure (220 bar) of hydraulic power pack.

Davit: Examination and check for satisfactory condition and operation *

1. Davit structure, in particular with regard to corrosion, misalignments, deformations and

* according to manufacturer´s checklist (Doc. no. 0301)

Davit: Examination and check for satisfactory condition and operation *

1. Davit structure, in particular with regard to corrosion, misalignments, deformations and

* according to manufacturer´s checklist (Doc. no. 0302)

Testing with 1.1 times x GA:

Testing has to be carried out under supervision of class or national authority.

Necessary larger repairs, as well as the “annual thorough

2 winch gear ) O VG 150-200 abt. 2 / 3,5 ) 1 abt. 2 / 3,5 *)

2 winch gear ) ISO VG 629 abt. 2 / 3,5 ) 1 abt. 2 / 3,5 *)