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TABLE OF CONTENTS

CHAPTERIPARAGRAPH PAGE
pre
Table of Contents.. ............................................................................................................................................... 1
List of Illustrations ............................................................................................................................................... 6
10
so
List of Tables .....................................................................................................................................................

1 SAFETY PRECAUTIONS
Safety Precautions ............................................................................................................................................. l-l
po
Safety Summary ............................................................................................................................................... 1-2
Safety Check .................................................................................................................................................... l-3
Safety Warnings ............................................................................................................................................... 1-4
rG

m 2 GENERAL INFORMATION
Introduction ....................................................................................................................................................... 2- 1
AL

Safety Precautions ............................................................................................................................................ 2-l

Equipment Description .................................................................................................................................... .2- 1
Design Technical Information .................................................................................................................. .2- 1
ICI

Design Criteria ........................................................................................................................................... 2-2 .

Stern Ramp / Door.. .................................................................................................................................... 2-4
Side Ramp / Door and Side Shell Doors ................................................................................................... .2-7
A.

Side Ramp / Door ................................................................................................................................. 2-7

Side Shell Doors ................................................................................................................................. 2- 10
List of Equipment Supplied ............................................................................................................................ 2-12
CO

Special Tools and Test Equipment ................................................................................................................ .2-l 7

Safety Functions, and Equipment .................................................................................................................. .2-l 7
Regular Care and Control (Maintenance) ............................................................................................... .2-17
Safety Functions and Equipment ............................................................................................................ .2-17
MA

3 OPERATING INSTRUCTIONS
Introduction -- Operating Instructions ............................................................................................................. .3- 1
Safety Precautions for Operation ................................................................................................................ .3-2
ND

Pre-Star-t Checks.. ......................................................................................................................................... 3-3

Self-Locking Cylinders ..................................................................................................................................... 3-4
e

Section A Stern Ramp / Door

AN

Introduction -- Operating Instructions .......................................................................................................... .3A-1

Equipment Specific Warning Statements and Notes.. .............................................................................. .3A-1
Stern Ramp Operating Instructions (General Description). ...................................................................... .3A-3
TE

Description of Operating Panels .............................................................................................................. .3A-5

Mimic Panel.. ....................................................................................................................................... 3A-5
Motor Starter.. ...................................................................................................................................... 3A-6
Stern Ramp Operating Instructions .............................................................................................................. 3A- 13
08

Before Operation.. .................................................................................................................................. .3A- 14

Lowering Stern Ramp to the Quay.. ....................................................................................................... .3A-14
Raising the Stern Ramp from the Quay.. ................................................................................................. 3A-16
/10

Lowering Stern Ramp and Locking it in Horizontal or -20” Position ................................................... .3A- 17
Repositioning Stern Ramp from locked in -20” Position to Horizontal Position.. ................................. .3A-17
Raising Stern Ramp from Locked in Horizontal or -20” Position .......................................................... 3A-18
/20
11

TM-45600380
ISJUC Date: March 2WO Volume 1 TOC - 1
 TABLE OF CONTENTS
Im
CHAPTERIPARAGFUPH
pre
Section A Stern Ramp/Door (Continued)
Emergency Operation of the Stern Ramp .....................................................................................................3A-19
The Emergency Bolts (Topes) are Stuck 3A-21
.................................................................................................
so
Malfunction in the Emergency Control System,but the Pump Unit is Working.. ...................................3A-23
Emergency Operating Stern Ramp to and from the Quay .................................................................. 3A-23
Emergency Lowering 3A-24
.........................................................................................................................
p
3A-25
Stop in Intermediate Position .............................................................................................................
or
Emergency Hoisting from Quay .........................................................................................................3A-26
Operating Pressure Reducing Valves ................................................................................................. 3A-27
Emergency Hoisting from an Intermediate Position ........................................................................... 3A-28
GA

Emergency Operating with the Emergency Power Pack ......................................................................... 3A-3 1

Preparation before operating with the emergency power pack ........................................................... 3A-3 1
Emergency Lowering with the Emergency Power Pack..................................................................... 3A-32 d
Emergency Hoisting from quay with the Emergency Power Pack .................................................... .3A-34
L

Emergency Hoisting from an intermediate position with the Emergency Power Pack.......................3A-35
ICI

Section B Side Ramp / Door d

Side Ramp Operating Instructions ................................................................................................................. 3B- 1
3B-1
A.

Equipment Specific Warning Statementsand Notes .................................................................................

3B-2
General .....................................................................................................................................................
3B-3
Power Pack................................................................................................................................................
CO

Before Operation.. ................................................................................................................................

3B-3
Description of Operating Panels................................................................................................................ 3B-5
3B-5
Control Stand ......................................................................................................................................
Operating Instructions - Side Ramp / Door .............................................................................................. 3B-6
MA

Lowering Side Ramp to the Quay ....................................................................................................... 3B-6

Raising the Side Ramp.. ....................................................................................................................... 3B-7
Emergency Operation of the Side Ramp ........................................................................................................
3B-9
Emergency Operating Side ramp to and from the Quay .......................................................................... 3B-10
ND

Emergency Lowering ......................................................................................................................... 3B-10

Emergency Hoisting 3B-11
...........................................................................................................................
Diese1Powered Emergency Power Pack .................................................................................................
3B-12 J/
3B-12
Description .........................................................................................................................................
AN

3B-12
Operation ...........................................................................................................................................

Section CD - Side Shell Door

TE

Side Shell Door Operating Instructions.. ..................................................................................................... 3CD-1 j

Equipment Specific Waming Statementsand Notes .............................................................................. 3CD-1
3CD-1
Genera1...................................................................................................................................................
Power Pack.............................................................................................................................................
3CD-3
08

3CD-3
Before Operation.. .............................................................................................................................
Description of Operating Panels.. 3CD-4
...........................................................................................................
3CD-4
Operating Panel .................................................................................................................................
/1

Operating Instructions - Side Shell Door.. ............................................................................................. 3CD-5

3CD-5
Opening ............................................................................................................................................
0/2

Closing ..............................................................................................................................................
3CD-5
Emergency Operation - Side Shell Door 3CD-7
....................................................................................................
The Pump is not Running but the Control System Works .................................................................... 3CD-7
The Electric Control SystemDoes Not Work, But the Pump is Running ............................................. 3CD-7
0

3CD-7
Opening ...........................................................................................................................................
11

3CD-7
Closing .............................................................................................................................................

Thí-45600380
Volume 1 TOC - 2 Isue Date: March 2O@l
Im
TABLE OF CONTENTS

CHAPTERRARAGRAPH PAGE
pre
4 SCHEDULED MAINTENANCE
Introduction.. .....................................................................................................................................................
4- 1
so
General ......................................................................................................................................................
4-2
Assumptions ............................................................................................................................................
4-3
Measures Before Starting Service/Maintenance Work ............................................................................. .4-3
Recommended Maintenance Period ................................................................................................................ .4-4
p
Maintenance Period - Before and after a Sea Voyage ............................................................................... .4-4
or
Maintenance Period - One (1) Month ...................................................................................................... .4-5
Maintenance Period - Three (3) Months ................................................................................................... .4-6
Maintenance Period - Twelve (12) Months.. ............................................................................................. .4-6
GA

*Cr Lubrication ......................................................................................................................................................

4-9
Scheduled Maintenance -- General Hydraulic ............................................................................................... .4-23
Scheduled Maintenance -- Hydraulic Power Pack ....................................................................................... .4-24
Filters .....................................................................................................................................................
4-24
L

Filter Element Replacement .................................................................................................................... .4-24

ICI

Inspection ...............................................................................................................................................
4-25
Routine Service .................................................................................................................................
4-25
Three Month Schedule ..................................................................................................................... .4-25
A.

Six Month Schedule .......................................................................................................................... 4-25

Twelve Month Schedule .................................................................................................................. .4-26
Oil Change ...............................................................................................................................................
4-26
CO

Scheduled Maintenance -- Hydraulic Flexible Hoses..................................................................................... .4-27

Visual Inspection -- Conditions for Replacement of a Hose ................................................................... .4-27
Visual Inspection --Items which require tightening, repair, or replacement as required ..........................4-27
Scheduled Maintenance -- Hydraulic Cylinders ............................................................................................ .4-28
MA

Bearings ...................................................................................................................................................
4-28
Care of Piston Rod ...................................................................................................................................
4-28
Storing of Cylinders .................................................................................................................................
4-28
Scheduled Maintenance -- Electrical System ................................................................................................ .4-29
ND

General .....................................................................................................................................................
4-29
- Scheduled Maintenance -- Electrical Motors ................................................................................................. 4-3 1
Scheduled Maintenance -- Wire Ropes ........................................................................................................ 4-32
AN

General ...................................................................................................................................................
4-32
Examinations of Wire Rope ..................................................................................................................... 4-32
Daily Observations ............................................................................................................................ 4-32
Periodic Examination ....................................................................................................................... .4-32
TE

Interna1 Examination of Wire Rope .................................................................................................. .4-33

Points to be covered by examination ................................................................................................. 4-33
Discard Wire Ropes ................................................................................................................................. 4-33
Externa1 and Interna1 Corrosion ............................................................................................................... 4-34
08

Externa1 Corrosion ............................................................................................................................ 4-34

Interna1 Corrosion .............................................................................................................................4-34
Recommended Lubricants ...................................................................................................................... .4-35
/1

Condition of Equipment, Related to the Rope ........................................................................................ .4-35

Recommended Maintenance Requirements for Storage (Long/Short Term) ................................................. .4-36
0/2

Storage Requirements ...............................................................................................................................4-36

Hydraulic Equipment Long Term Storage Procedure ............................................................................... 4-40
Preparation for Long Term Storage................................................................................................... .4-40
0

Long Term Storage Procedures ......................................................................................................... .4-4 1

Removal from Long Term Storage Procedures .................................................................................. 4-41
11

Volume 1 TOC - 3
 MacGREGOR
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TABLE OF CONTENTS

CHAPTEFUPARAGRAPH PAGE
pre
5 TROUBLESHOOTING
5-I
Introduction .......................................................................................................................................................
Tools and Test Equipment Required ................................................................................................................ 5-2
s
Hydraulic SystemsTroubleshooting ................................................................................................................. 5-3
op
Hydraulic SystemsTroubleshooting .......................................................................................................... 5-3
Hydraulic Pumps and Motors ................................................................................................................... .5-6
Hydraulic Power Pack Troubleshooting ........................................................................................................... 5-9
or
5-9
General .....................................................................................................................................................
Hydraulic / Electrical “Problem” ............................................................................................................
.5-10
Oil 5-l 1
.....................................................................................................................................................
GA

Electrical SystemTroubleshooting ................................................................................................................ .5-16

5-16
General .....................................................................................................................................................
5-18
Switch Functions .....................................................................................................................................
Electric Motors Troubleshooting ..................................................................................................................... 5-20
L

5-22
PLC Troubleshooting .....................................................................................................................................
ICI

Externa1Failures 5-22
.......................................................................................................................................
Interna1Failures ........................................................................................................................................
5-22
A.

6 CORRECTIVE MAINTENANCE
Introduction .......................................................................................................................................................
6-1
Adjustments .....................................................................................................................................................
6-2
CO

6-2
Alignments .......................................................................................................................................................
Alignment of Electric Motor.. ..................................................................................................................... 6-2
Removal and Replacement ............................................................................................................................... 6-2
Control Stands and Cabinets ..................................................................................................................... 6-5
MA

Removal and Replacement Procedures for the PLC Unit ..................................................................... 6-5
Cylinder (RemovaVReplacement) Assembly Leve1 .................................................................................. 6-6
Removal of the Hydraulic Cylinder .................................................................................................... .6-6
Replacement of the Hydraulic Cylinder .............................................................................................. 6-6
ND

Electric Motor .............................................................................................................................................

6-7
Removal of the Motor from Service ..................................................................................................... 6-7
Replacement of the Motor to Service .................................................................................................. 6-7 d
Filters, Pressure .........................................................................................................................................
6-8
AN

6-8
Filters (Typical) .........................................................................................................................................
Filter, Retum Oil.. .......................................................................................................................................
6-9
Pipe Cleaning (General) 6-10
.......................................................................................................................... ..
TE

Pump, Variable Displacement ................................................................................................................. 6-11 4

Changing of the Pump ....................................................................................................................... 6-11
Rubber Packing (General) ....................................................................................................................... 6-12
Sheave House Assembly ......................................................................................................................... 6-13
08

6-13
Valve, Check ...........................................................................................................................................
Valve, Counterbalance ..............................................................................................................................
6-14
Valve, Directional (Typical) .................................................................................................................... 6-14
/10

Removal/Replacement of the Directional Valve from Service 6-14

..........................................................
RemovaVReplacement of the Directional Valve (Typical) ................................................................. 6-15
6-15
Valve, Flow Control ................................................................................................................................
/20

Valve, Pressure Reduced ......................................................................................................................... 6-16

11

Volume 1TOC - 4
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LIST OF ILLUSTRATIONS

CHAPTERB’ARAGRAPH PAGE
pre
Figures for Chapter 2
Figure 2- 1 2-3
Key Equipment Arrangement ......................._.__._.___..._.___________.______________..........................
so
Figures for Chapter 3
Figure 3-l 3-1
Location of Equipment ...........................................................................................................
Figure 3-2 Symbols used for operating panel components ..................................................................... .3-2
po
Figure 3-3 Diesel Powered Emergency Power Pack ............................................................................... .3-4
Figure 3-4 3-5
Self-Locking Cylinder ............................................................................................................
rG

Figure 3A-1 3A-1

Location of Stern Ramp .........................................................................................................
Figure 3A-2 ...3A- 2
Stern Ramp .........................................................................................................................
Figure 3A-3 Stem Ramp, cleating and locking cylinders ........................................................................... 3A-4 .
AL

Figure 3A-4 Stem Ramp, Mimic Panel ...................................................................................................... 3A-5

Figure 3A-5 Motor Starter for Hydraulic Power Pack for Stem Ramp 3A-6
......................................................
Figure 3A-6 Motor Starter for Stem Ramp, General section .................................................................. ...3A- 6
ICI

Figure 3A-7- Motor Starter for Stem Ramp, Motor control section motor 1 - 4, one per motor.. ...............3A-7
Figure 3A-8 Motor Starter for Stem Ramp, Motor control section motor 5............................................... 3A-7 2
Figure 3A-9 Power Pack for Stem Ramp ................................................................................................... 3A-8
3A-9
A.

Figure 3A-10 Stem ramp, Main Control Stand ............................................................................................

Figure 3A-11 Stem ramp, Repeater Control Stand ................................................................................... .3A-ll
Figure 3A-12 Stem Ramp, Location of emergency operation switch S21 inside control cabinet ..............3A-2 1
Figure 3A-13 Emergency Power Pack for Stem Ramp .............................................................................. 3A-3 1
CO

Figure 3B-1 3B-1

Location of Side Ramp ..........................................................................................................
Figure 3B-2 3B-2
Side Ramp, overview .............................................................................................................
MA

Figure 3B-3 3B-3

Side Ramp, Power Pack.........................................................................................................
Figure 3B-4 3B-5
Side Ramp, Control Stand .....................................................................................................

Figure 3CD-1
3CD-I Location of Side Shell Doors ..............................................................................................
ND

Figure 3CD-2
3CD-2 Side Shell Door, inside view ..............................................................................................
Figure 3CD-2
3CD-3 Side Shell Door, top view ...................................................................................................
Figure 3CD-3
3CD-4 Side Shell Door, Power Pack.............................................................................................. >
Figure 3CD-4
3CD-5 Side Shell Door, Operating Panel .......................................................................................
AN

Figures for Chapter 4

Figure 4- 1 Lubrication Diagram for Stem Ramp / Door (2 Sheets) ....................................................... 4-13
TE

Figure 4-2 Lubrication Diagram for Side Ramp / Door (2 Sheets) ........................................................ 4-17 J
Figure 4-3 4-21
Lubrication Diagram for Side Shell Door .............................................................................
08
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TM-45600380
Volume 1 TOC - 6 Issue Date: hlrrch 2000
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 MacGREGOR
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LIST OF TABLES

CHAPTER/PARAGRAPH PAGE
pre
Tables for Chapter 2
Table 2-l General Equipment Technical Characteristics........................................................................ .2-2
so
Table 2-2 Stern Ramp / Door (Technical Characteristics). ...................................................................... 2-5
Table 2-3 Side Ramp / Door (Technical Characteristics) ....................................................................... 2-9
Table 2-4 Side Shell Doors (Technical Characteristics) ....................................................................... .2-11
Table 2-5 List of Equipment Supplied 2-12
..................................................................................................
p or
Tables for Chapter 4
Table 4- 1 Maintenance Period - Before and After a Sea Voyage .......................................................... .4-4
Table 4-2 Maintenance Period - One (1) Month .................................................................................... 4-5
GA

Table 4-3 Maintenance Period - Three (3) Months.. .............................................................................. .4-6

Table 4-4 Maintenance Period - Twelve (12) Months ............................................................................ 4-6 d
Table 4-5 Lubrication Intervals 4-10
............................................................................................................
Table 4-6 Bearing and Grease Procedure .............................................................................................4-11
L

Table 4-7 Filter Element Replacement Schedule .................................................................................. 4-24

ICI

Table 4-8 Recommended Lubricants for Wire Ropes .........................................................................

.4-35
Table 4-9 Storage Requirements - Maintenance and Preservation for Short and Long Term ..............4-3 6 -J
A.

Tables for Chapter 5

Table 5-1 Common Faults -- Hydraulic System ..................................................................................... 5-3
Table 5-2 Fault Finding Guide -- Hydraulic Pumps and Motors (Typical) ............................................. 5-6
5-11
CO

Table 5-3 Defective Operation .............................................................................................................

Table 5-4 5-13
Incorrect Flow ......................................................................................................................
Table 5-5 Excessive Heat 5-14
.....................................................................................................................
Table 5-6 5-15
Incorrect Pressure .................................................................................................................
MA

Table 5-7 General Fault Isolation Guide -- Electrical System ............................................................. .5-17
Table 5-8 Switch Functions - Stem Ramp / Door.. .............................................................................. 8 .5-l
Table 5-9 Switch Functions - Side Ramp / Door ................................................................................. 5-19
Table 5-10 Switch Functions - Side Shell Door #l - #3 ......................................................................... 5-19
ND

Table 5-11 Electric Motor Fault Finding Guide 5-21

.....................................................................................

Tables for Chapter 6

Table 6-1 Equipment Maintenance Location Index ................................................................................6-3 d
AN

Table 6-2 Equipment Maintenance Not Covered In This Manual ..........................................................6-4

TE
08
/1 0/2
0 11

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Volume 1 TOC - 10 lssuc Date Much 2000
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Im
ATTACHMENTS
pre
Attachment A MacGREGOR Service Organization
s
Attachment B Conversions Factors
op
Attachment C/D Not Used

Attachment E Lubrication Recomrnendations (for MCG Products) (MCG 10939)

or

Attachment F Wire Rope -- Guidelines for Discard of Steel Wire Rope (MCG 10929)
GA

Attachment G Packings, Attachment of Rubber Sea1 (MGR 196)

Attachment H Hydraulic Fluid Recomrnendations (For MCG Hydraulic Systems) (MCG

L

10943)
ICI

Attachment I/J Cleanliness and Pressure Testing -- Guidelines for Hydraulic Systems. (MGR
188)
A.

Attachment K BAZAN - Interface and Other Relevant Drawings

CO
MA
ND
AN
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08
/10
/20
11

TM-45600010
Irsuc Datc. March 2Mx)
Issue 1. Chmgc A
 11
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 11
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Im
ATTACHMENT K
INTERFACE AND OTHER RELEVANT DRAWINGS
pre
Drawing No. Description
s
21-12453 Stem Rarnp/Door Layout Drawing (5 Sheets)
op
21-12578 Side Rarnp Layout (3 Sheets)

21-12629 Stem Ramp / Door Interface (4 Sheets)

or

21-12670 Side Shell Door Interface (Frarne 67-70)

GA

21-12671 Side Shell Door Interface (Frarne 82-85)

21-12697 Side Ramp Interface Drawing (4 Sheets)

L

22-10711 Stem Ramp Load Test (Supported on Quay)

ICI

22-10712 Side Ramp Load Test (Supported on Quay)

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