O-01 Deck Crane - Voc Daisy

M/V "VOC DAISY"
PANAMA
22 JUNE 2012
AT SEA
TO: J.P. SAMARTZIS MARITIME ENTERP. Co. S.A.

TECHNICAL MANAGER
FR: CH. ENGINEER
SUBJECT: DECK CRANE PUMPS/ MOTORS PARTICULARS
MAIN ELECTRIC MOTOR

3 PHASE INDUCTION MOTOR (FROM NAME PLATES)
ENERGY POWER SERIES
K.W-12 / RATING-40% ED/ SERIAL N0.70251177
H.P.150/ AMBIENT TEMP. 45°C/THERMOSTAT-140°C
POLE-4 / F.L.EFF. 92-5 % /SPACE HEATER 110 V AC
RPM-1,165 /MIN / F. L/INPUT-121K.W
VOLTS-440VAC / INS. F / AMPERES-184 Hz-60
FRAME- 250S BRNG. DE.6313 /NO. 0.0.E.- 6313
MAKER -TATUNG CO.
MADE IN TAIWAN R.O.C
AUX. ELECTRIC MOTOR (FROM NAME PLATE) AUX. HYDAULIC PUMP (FROM NAME PLATE)
3 PHASE INDUCTION MOTOR MAKER - UCHIDA HYDRAULICS
MODEL NO. FBFC - HD IP44 MODEL NO. GSP2 - AOS12AR
H.P -50 IAMB. TEMP. 40°C N0.30881-79
K.W. 3.7 I FL .EFF. 84,5% I LS. 62306ZZ
POLE -4 /FL. INPUT. 4.4 KW /OS. 6206ZZ
Hz- 60 / INS.F/ RATING -CONT.
VOLTS - 440 / FRAME - 112 N
RPM -1700/MIN /SERIAL N0.70210978
MAKER -TATUNG CO.
MADE IN TAIWAN R.0.C
HOISTING PUMP (NAME PLATE ) LUFFING & SLEWING PUMP( NAME PLATE)
MAKER - UCHIDA - REXROTH MAKER - UCHIDA - REXROTH
MODEL NO. A2F107RIP3 - U MODEL NO. A2F17.2L6.2P3-999- P
SERIAL NO. -051635-79 SERIAL NO. 061736 79
MADE IN JAPAN
HOISTING HYO.MOTOR LUFFING HYO.MOTOR SLEWING MOTOR

MAKER - UCHIDA - REX ROTH MAKER - UCHIDA - REXROTH MAKER - UCHIDA - REXROTH
MODEL NO. A6V500H06.2F2 MODE.L NO-A2FM180/6.1W MODEL -A2FM180/6.IW
23320 - 946-0 5808-975-0 SB08-974-0
N0.058526 7X N0.061721 7X NO. 061717X
MADE IN JAPAN MADE IN JAPAN MADE IN JAPAN
FROM NAME PLATE FROM NAME PALTE FROM NAME PALTE
CHIEF ~ENZUEIA
PREPARED BY:
OSHIMA SHIPBUILDING Co. , LTD.
H. No. 10222
FINISHED PLAN
30//25 TON X 22/23. 5 M/R
ELECTRIC- HYDRAULIC
DECK CRANE
'
'', '' :
TSU.II I !FAVY li'.JDUSTRIES CO., LTD.

M/V voe ROSL
PANAMA
06JULY 2007
AT SEA
TO: J.P. SAMARTZIS MARJTIME ENT ERP.

TECHNICAL DEPARTMENT
FR: MASTER I CH. ENGINEER
RE: DECK CRANES MOTOR SPEC!f
DECK CRNE No. 1

HOIS11NG MDTOR ~(!;ft~\-91 l:UFFiNiJ MOTOR (UCHIDA -R..EXROT.H)
MODEL A6V500HD6.2 FZ MODEL A'2fM180/6.l W
23320-946-0 SB08-975...0
No 058638 7Z 062284 7X
MADE IN JAPAN - 110150358 MADE iN JAPAN -- H003l4433
SLEWING
MODEL
No 062266 7X
MADE !N JAPAN 1100314437
DECK CRN'f. No.2

HOISTING MOTOR. {t1,JN]'OA LUFF ING MOTOR {Ul."IDDA -REXR.OTHJ
MODEL 1\10DEL A2FMl&0/6.J W
23320-946-0 ~975
No 00058137 73 No 06:2285 7X
MADE IN fviA.Dl::, ll'l ,tAPAN I :00314,·UJ
SL.EWING MOTOR -REXROTHi

MODEL A2FM 18016. l W
-SB08-97 4-0
No 062267 7X
MADE lN JAPAN -- l 100314413
DECK Cll,,}.,JE No.3 ..

HOISTING MOTOR ~HIDA LUFFING MO fOR tt1mrti~~··~·•JiiE:md:tfl
MODEL A6V500HD6.2 FZ MODEL !A 2FM ! 80
23320946-0
No 058640 7l 062..?.36 rx
iviADE IN JAPAN - l l00J50359 .M./\DFJNJAPAN iJ003144J3
SLEWING MOTOR iv~_,niufi --.,_,...,_,,._, .."',

MODEL A2FM1
-SB089744
No 062268 7X
M..ADE fN JAPAN - 1100314433
//wvvvv.gfi corn
OPERATION AND MAINTENANCE
MANUAL
SHIP YARD OSHIMA SHIPBUILDING Co. , LTD
HULL NAME 10222
CRANE TYPE Nl-CHRS 3022 (2523. 5)
TSUJI
~
I IEJ\ VY INDUSTRIES CO. , LTD.
DECK CRNE No.4
HOISTING MOTOR (UCIDDA - n ...,.,., ..,..,, I.l. 'FFING MOTOR (UCHIDA - REXROTHf
MODEL A6V500HD6.2 FZ MODEL A2FM180/6.1 W
23320-946-0 SB08-975-0
No 058637 7Z Nu 062287 7X
l\1ADE IN JAPAN - 1100150359 MADE iN JAPAN - l 100314433
SLEWING MOTOR (UCHIDA ·-fi.J:o.l'\..I'\.~.J

MODEL A2FMI80/6.l W
-SB08-974-0
No 0622697X
fl.1ADE IN JAPAN l
RESPEC ffULLY YOURS,

C 0 N T E N T S
1. INSTRUCTION MANUAL
a.MACHINERY PARTS
b. HYDRAULIC PARTS
c. ELECTRIC PARTS
, \
~,
2. SPARE PARTS & TOOLS LIST
a.MACHINERY PARTS
b. HYDRAULIC PARTS
c. ELECTRIC PARTS
3. TEST RESULT
[1] Consideration about the Instruction Manual
1. Before using the deck crane be sure to read and understand the contents
of this Instruction Manual well.
2. This Instruction Manual is edited for the superintendents of the vessel (on which
the crane is to be mounted ) .
We would like to ask them to educate the operators crane enough and provoke
their attention to safety precautions.
3. From section to section, this Instruction Manual describes the specifications,

opera hon, main tenance,etc.
Please keep this manual safe so that you can refer to it anytime.
4. If you have any question, please contact the offices below:
Tsuji Marine Services, Main office:
177-2 Hikari-machi , Sasebo-city , Nagasaki-pref. 858 , Japan

Tel. : 0956-47-3119
Fax. : 0956-48-5443
Tsuji Marine Services, Tokyo Branch Office:
Nihonbashi Saruya Bldg,, 16-1 O Nihonbashi-Koamicho, Chuo-ku,

Tokyo, 103,Japan
Tel. : 03-3639-5721
Fax. : 03-3639-5737
Tsuji Marine Services, Osaka Branch Office:
Osaka-ekimae Dai-ni Bldg., 1-2-2 Umeda, Kita-ku,Osaka,530,Japan

Tel. : 06-344-6501
Fax. : 06-344-6503
[2] Precautions on safety
2-1) To use the deck crane for a longer time, pay enough attention to safety.
To keep "Safety first" in mind.be sure to observe the following
precautions on safety.
2-2) According to the degree of danger.the precautions in this Instruction
Manual are classified into three levels as follows :
Highly dangerous:
wrong operaion might cause death or serious
---DANGER injury
There is possibility of death or serious injury

caused by wrong operation
Wrong operation may cause injury and/or

property damages
Of the three above, we have made "Danger" and "Warning" plates and put
them up inside the operator's cab. so that they are visible to the operator.
Gen~ral precantions and those specific to this crane are listed as below:
11\oANGER
1. Starts operating the crane only after the Instruction Manual is well
understood.
Otherwise a serious accident may be caused.
2. Confirm safety within the crane operation area before operation.
3. Do not allow any part of human body to approach the rotating and
moving sections during operation.
4. Keep out of the area of slewing post during operation.
5. Maintenance operation may require working at a high place.

In this case, pay special attention and always wear a lifeline.
/!\WARNING
1. Be sure not to position yourself under any hoisted load or the jib during
operation.
2. Confirm that the safety device is under operation and that the safety
cover is correctly installed before operating the crane.
3. If abnormal noise or motion is found during operation, stop the machine

immediately and repair the malfunctioning section(s) before restarting.
4. Never open the door of the control panel during operation. Under the
control panel, a high voltage is running, which is very dangerous.
5. The hydraulic devices on the crane use high fluid pressures. If

inspecting and/or adjusting them, pay enough attention to prevention of
spouting of high pressure fluid, winch is dangerous to human bodies.
6. Fully wipe up the grease and hydraulic fluid having dropped on the
foor,etc. Otherwise they may cause the workers to slip and fall.
7. Before inspection and maintemance, be sure to switch the power off,

prepare a plate showing "Never switch the power on" , and put it up in
front of the control panel.
8. Do not start the motor during inspection/maintenance.

~
!l\cAUTION
1. Periodically inspect the following devices/instruments:
1) Mechanical and structural sections :

(1) Deformation and crack on the slewing post, slewing base plate,
jib, hook, bearing, and drum.
(2) Abrasion on the gear, sheave, wire ropes, and brake lining.
(3) Abnormity of any brake device.
(4) Loose mounting bolts.
2) Electrical section:
(1) Oust and moisture at the control panel and slip ring.
(2) Loose terminals
3) Hydraulic section:
(1) Fluid leakage from the hydraulic devices and piping.
2. The manufacturer shall not be liable for any modification on the deck crane
without permission from the manufacturer and the Classification Association
and any malfunction and/or accident resulting from that modification.
3. To repair and replace any major component/part, you must obtain

permission from the manufacturer.
4. Always keep clean the plates indicating "Warning", "Caution", "Operation",

etc. when they are unreadable, replace them with new ones.
5. The Instruction Manual may not deal with all the safety requirements
concretely and systematically. Be sure to give safety the highest priority
when handling and operating the crane.
2-3) Precautions on the inspection records.
To use the deck crane for a longer time, strictly observe the criteria for
inspection and maintenance described under item 1 in Section 4.
1) Be sure to execute inspection before and after operation and record

the results on the inspection journal.
2) When executing periodical inspection, check all the inspection items
and keep the records.
If you find any defect, re-adjust or replace that part.
3) If any trouble occurs on the crane restore it according to the
troubleshooting.
Record the state where the trouble occurs, the condition, and the
measures taken and keep that record.
4) In addition, prepare and keep the results of the tests conducted under
the periodical classification inspection of the vessel.
G
[3] Range of Warranty and Exclusion
3-1) Range of warranty
1) The period of warranty shall be twelve(12) months after delivery at the

vessel.
The manufacturer will replace any part/component that goes defective
or damaged within the warranty period, provided that the defect or
damage to that part/component is caused by any defect in
manufacturer's designing or manufacturing, or the used materials.
However, the manufacturer excludes from the range of warranty any
defect or damage caused by user's mishandling and such consumables
as wire rope, lubricant, contactor, brake lining, and fuse.
2) The crane(s) and electrical power required to repairng works according
to this warranty are offered by the manufacturer at its exepense.
3) The manufacturer shall not be liable for any of such indirect costs as
loading/unloading and the time loss undergone by the vessel.
3-2) Changing the application
1) If using the crane for other applications (for example,

loading/unloading of wooden materials, loading/unloading using a
grab, tendem use with another crane, and hatch cover handling)
then it may damaged seriously.
Note that the manufacturer is not responsible for any damage to the
crane, vessel, load, and other facilities if it is caused by application
changes.
2) Contact the manufacturer before changing the application.
I
3-3) Changing the specifications
1) For the specifications/items of the deck crane and the applied/

related laws and regulations, refer to Section 2.
2) Changing these specifications/items may cause a serious damage to the

crane.
The manufacturer shall not be liable for any damage caused by changes
of the specifications/items without permission from the manufacturer
and the Classification Association.
3) To change the specifications/items and applied laws and regulations,

contact the manufacturer.
4) Resale
(1) The product warranty of this deck crane is valid only for the original
user.
(2) If you resale the deck crane in the future, be sure to attach this
Instruction Manual
(3) Section 2 of the Instruction Manual describes the specifications/iems

and the applied/related laws and regulations. After resale, too, observe
the specifications and the procedures of inspection/maintenaces so that
the deck crane performance can be maintained.
8
MAINTENANCE AND
INSPECTION DIGEST
Details in maintenance and inspection are according to the instruction manual, but here
are the minimum items required. Please do maintenance and inspection especially on the
driving parts and wire ropes and also on the hanging unit.
1. Intervals are roughly mentioned, and they may be changed in each case, based on your
experience.
2. In case the crane is out of operation for a long time, please try to make operation
without load once each month for an appropriate length of hours.
DECK CRANE MAINTENANCE & INSPECTION LIST NOTE: The following items of maintenance & inspection are a recommendation
of the manufacturer based on the finished drawings, etc.
Equipment Check Points Check Method/Caution Standard Value Check Interval Remarks
Jib No crack is observed. Visual check. Every after voyage
No damage caused bending & any damage. Visual check. .
Every after voyage.
No abnormal at welding part. Visual check. Every after voyage.
No abnom1al at jib bearings. Visual check & loosen bolts. Every after 3 voyage.
--·
Enough oiling at jib bearings. Visual check. Every before loading
No abrasion of sheave grooves. Visual check. 15 ...... 20% of rope dia. Before loading.
No abnormal at sheave bearings. Visual check & sheaves no shift. Every after loading. Better to make groove model.
Post top No abrasion at sheave grooves. Visual check. 15-20% of rope dia. Every 3 voyage.
sheave No abnormal on sheave bearings. Visual check & sheave no shift. Every after loading
Enough oiling on sheave bearings. Visual check. Every after loading Better to make groove model.
-~----
Slewing No loosen bolts at innerI outer ring. Hitting by hammer. Every 3 voyages.
ring Enough oiling Visual check. Every before loading.
No scoring pitch on internal gear & pinion. Visual check. Every after loading.
Enough oiling at gear face. Visual check. Every 3 voyages.
No abrasion on gear face. Visual chec. & no metal powder Every before loading.
in grease.
--·---·-----
Heduction Enough oiling oil quantity. Visual check. Every 3 voyages.
gear of Check type & model of oil. Confirm it. Every 6 voyages.
Hoisting Check timing of oil replacement. Confirm it. Replace every 6 Every 3 voyages.
months.
--
No oil leakage. Visual check. Every after loading. ..
No aged lubricant oil & dirt. Visual check. Every after loading.
---
No abnormal noise & heating on bearing. Visual check. Confirm it on Every after loading.
operation.
-------·
· No pitching & scoring on each gear faces. Visual check. Every after loading.
· No loosen bolts. Hitting by hammer. Every after loading.
~-
----·-·------ ~--
f~eduction Enough oil quantity ditto Every 3 voyages.
gear of Check oil type & model. Confirm it. Every 6 voyages.
luffing Check timing of oil replacement. ditto Every 3 voyages
No oil leakage. Visual check. Replacement every Every after loading.
6 months.
No aged lubricant & dirt. ditto ditto
No abnormal noise & heating on bearings. Visual check & confirm on ditto
operation.
No pitching & scoring on each gear face. Visual check. Every 3 voyages.
No loosen bolts. ditto ditto
Reduction No crack on gear box. Visual check. Every 6 voyages.

gear of Enough oil quantity. ditto Every 3 voyages.
slewing Cheack oil type model. Confirm it. Every after loading.
Check timing of oil replacement. ditto Every 3 voyages.
No oil leakage. Visual check. Replacement every ditto
6 months.
No aged lubricant & dirt. ditto ditto
No abnormal noise & heating on casing. Visual check & confirm on ditto
operation.
No loosen bolts. Visual check. Every 3 voyages.
Slackover No abrasion on rollers. Visual check. ditto

device Rollers are rotating Visual check & confirm operation. Every during loading.
Proper spring farces. ditto ditto ..
Bearing conditions. ditto ditto

(abnormal noise & heating)
Catuation of limit switch. ditto ditto
Proper adjustment is done. ditto ditto
Enough oiling to bearings. Visual check. Every before loading.
-·
Hoisting & No abrasion on rollers. Visual check. Every 3 voyages
Luffing Rollers are rotating. Visual check & confirm operation. Every during loading
drum Proper spring forces. ditto ditto
Bearing conditions. ditto ditto
(abnormal noise & heating)
--
Actuation of limit switch. ditto ditto
Enough oiling to bearings. Visual check. Every before loading.
Operation No water entering from entrance door. Visual check. Every during loading.
-·--
cab. No abnormal on the window. Visual check. ditto
(Oil ge, dirt or cracks)
No abnormal on fan, heater or 1pe Visual check. ditto
·-
No damage on every control equipment. Visual check. ditto
All lights are lit. Visual check & confirm operation. ditto
~-
Machinery No water entering from entrance door. Visual check. ditto

& No damage on control panel door. Visual check. ditto
\:~:~,'.'
Cleaning of floor. Visual check. ditto
icol Control panel door is closed tightly. Visual check. ditto
Room light is lit. Visual check & confirm operation. ditto
--
~·
Wire rope f~ope oil is applied. Visual check. Every before voyage.
No core wire breakage. Visual check. 10% break in 1 lay. Every after loading.
Proper rope is used. Visual check. 5% abrasion of rope Every 6 voyages.
Replacement period is not over. Inspection dia, deformation. H.G--every 5-6 voyages. Every 6 months.
No deformation of strand or kinking. Visual check. Every after loading.
--
Confirm S or Z strand. Visual check. Wire rope replacement.
No abnormal at wire end treatment. Visual check. Every 3 voyages.
Each limit Proper setting. Visual check & confirm operation. Every before loading.
switch No loosen on roller chain. Visual check. ditto
Enought oiling Visual check. ditto
No abnormal on bolts & taper pins. Visual check. ditto
Clutching condition of vebel gear. Visual check. ditto
·----
No abnormal on sprocket. Visual check. ditto
·-
~oper setting of microswitch & roller. Visual check. ditto
Exhaust Confirmation of rotating direction. Visual check. ditto

device No loosen door closing. Visual check & during sea going Every 6 months.
Door is keeping closed. Visual check & during loading. Every during voyage.
Water tightness of packing. Visual check. Every loading(every day)
·-
Oiling at hinge part(cover) Visual check. Every during voyage.
---·-
Slewing No crack on welded part. Visual check. Every loading(every day) Cleaning by air.
post No backing is occured. Visual check. Every 3 voyages.
No crack on platform handrail, etc. Visual check. ditto
Cargo No abrasion of sheaves. Visual check. ditto

block Enough oiling for swivel sheaves. Visual check. ditto
·--··-----
Lifting No abrasion on sheave bearing(bush). Visual check & check grease. Every 3 voyages.
be arn Enough oiling for swivel sheaves. Visual check. ditto
-
-~--~---- ·----- ----
ELECTRIC EQUIPMENT :
>--·-
Electric No abrasion on carbon brushed. Visual check. Every 3 voyages.
collecting Contact condition of ring and carbon brush. ditto 80% of touch face ditto
device No color change of ring. ditto ditto
(slipring) Carbon powder is clean off. ditto ditto
No spring come out. ditto ditto
Good insulation resistance of power Check by megohmmeter. ditto
source.
No terminal bolts loosen. Retighen them. ditto
Fixing method of lower part of box. Visual check. ditto
Oiling to bushes. ditto ditto
Source No abrasion on contactors of main control. ditto ditto

control Setting of every time relays. Visual check & see setting value ditto
panel on instruction manual.
· No dust in control panel. Visual check. ditto
· Retighten of terminal screws in panel. Retighten. ditto
No plug-in relays came off. Visual check. ditto
No abnormal noise during operation. Confirm. -
-·
No abnormal heating. Confirm. Every before loading.
Confirm thermal relay setting. Confirm & check on circuit. Every before loading.
No lamps broken. Confirm. ditto
Correct voltage, AC440V. Confirm by measuring. Every 3 voyages.
Electric No abnormal noise. Confirm. Every before loading.

motor No abnormal heating. ditto ditto
MAINTENANCE AND INSPECTION ST AND ARD
Maintenance Name of check Maintenance Repair (replace)

Check items Check methods Period Remarks
systems Components Standards Standards
1. motor insulation measure at 500V one more than 1OM Q
condition mega year between grounds
2. control circuit do do one more than 1OM Q
year between grounds
Related
3. electric wire do do one more than 1OM Q
to
cord year between grounds
Electricity
4. electric wire do do one
pipe year
piping condition check the piping one no looseness at tighten up
in general year screw joints
1. hydraulic oil quantity of oil measure by level one quantity of oil change the oil in
gauge month should be within the tank every 1000
regulated range hours
purity of oil ask the sample ask oil-maker for
,_. oil maker replacement
chain coupling disassembly and one existence of when heavily worn if heavily worn
check year abnormal sounds replace with a new in a short period
wear of chain one recheck the centerin
2. hydraulic pump abnormal sound check by listening four usually 97-103 dirtiness of hydraulic
Hydraulic measure by decibel months decibels oil, loading of filter,
System meter valve chattering
thermometer fit thermometer to two maximum 85° c when temperature
the pump main body months rises rapidly, check
by joint the pump and other
pressure measure by pressure two maintain the related components
gauge months regulated pressure
oil leakage check visually and two without variation change packing look out for aging in
by touch months pump shaft seal
air suction put grease, etc. two
on intake pipe months
3. filter foreign matter take out and check no foreign matters in case of foreign never use dirty
attachment visually, according attached to the matter attachment, oil
to indicator surface and no change the oil
(yellow) damaged plots
4. pressure pressure control check by pressure two pressure can be if the pressure replaced to pump
control valve gauge, control from months kept without change in great, and other components
maximum to minimum change and control check the inside,
pressure is possible if abnormal change
5. flow control flow control one when operation is
valve year defective check
inside; if abnormal,
change
6. stop valve internal leak shut the valve and one according to the if there is leakage
check outside leaks year purpose for use no change
internal leak
Hydraulic 7. solenoid valve insulation measure at 500V one more then 1OM Q
System condition mega year between grounds
voltage with ampere meter, two be in permeable when voltage change coils burn if voltage
measurement measure the months range of rated is big recheck is out of permeable
maximum voltage voltage electric equipment
during operation
operation sound check by listening one
year
wear of bush rod check the shape two no burr on edge change the worn
and looseness of looseness of screw months surface. no loose- parts. loose screws
screws of terminal piece ness at any part are a cause of coil
and casing burning
operation pressure gauge, two temperature rise when operation in depending on the type,
condition coil cover part months at confirmation defective, change more than regulated
temperature coil part under parts; or depending flow makes operation
switching condition on the content defective
is less than 85° c change the whole
8. check valve internal leak increase pressure according to the in case of leakage, never use dirty
outside, remove, purpose for use no change depending on
and check leak internal leak the content
9. pressure insulation measure at 500V one more than 1OM Q
switch condition mega year between ground
10. pressure insulation measure by pressure two confirm operation
switch condition gauge months within setting
pressure range
11. hydraulic operation check for smooth two in case of operation related to pump,
cylinder condition operation months defect inside valve, etc.
oil leakage check visually and two no external leakage change packing
(external) by touch months
12. oil leakage one
year
oil leakage two
Hydraulic months
System 13.piping vibration same as above two pipe shouldn't
months vibrate greatly
during switching
pipe support same as above SIX no looseness and tighten up
fittings months nothing missing
14. hydraulic spline of apply "MOL Y-COAT- approx. apply "NEW GREASE" after removal of
brake brake hub GREASE" to the every "OLD GREASE" at the "MOL Y-COAT-
teech of the spline 500-800 GREASE" has tendency being stiffen
provided inside of hours year by year
the hub of brake period
H. No. 10222
INSTRUCTION MANUAL
(MACHINERY PARTS)
30/25 TON X 22/23. 5 M/R
ELECTRIC- HYDRAULIC
DECK CRANE
TSUJI IIEJ\VY INDUSTRIES CO., LTD.

CONTENTS
CHAPTER. 1. OUT LINE OF DECK CRANE ---------------------------- A- 1----- 3)
CHAPTER. 2. MECHANISM----------------------------------------- B - 1-----14)
CHAPTER. 3. OPERATION ----- - --------------------------- c - ( 1----- 7)
CHAPTER. 4. ADJUSTMENT ---------------------------------------- D- ( 1-----18)
CHAPTER. 5. MAINTENANCE --------------------------------------- E- ( 1-----26)
CHAPTER. 6. DRAWINGS
A - 1
CHAPTER 1 OUT LINE OF DECK CRANE
1-1. Deck Crane
It's the machine that is equipped on the ship deck to handle the cargo.
The deck crane consists of the slewing post (housing), operation room and the jib as
structual parts, fitted with each winch for hoisting, luffing and slewing functions.
The deck crane is installed on the fixed post prepared on the ship hull by intervention
of slewing ring.
This slewing ring is internally geared to engage with the final pinion of slewing gear.
Thus the crane as a whole is effectuated for rotation (slewing).
Hoisting, luffing winches and slewing gear are driven by electric hydraulic system.
All the operations are made at the operator's cab, and the crane is also equipped with
various safety device.
Power Supply to Deck Crane

The deck crane receives the electric power from the ship generator by the slip ring fitted
lower part the slewing post (located inside of the fixed post),as shown on Fig. 1.
The main power is supplied during the crane in operation, but the power to space heater
is always supplied.
Fi . l
SHIP'S
GENERATOR DECK CRANE
····································~~
SLIPIRitl(;
LIMIT CONTROL
SW. BOX PANEL
MAIN
· E.MOTOR
A-2
1-2. Prescribed Condition for Use
Please use the crane under the following conditions.
Ship heel 5Q or less

Load swing 2Q or less
Use in excess of the above conditions, brings damage and trouble in crane, so please
observe the above prescribed conditions. (Refer to Fig. 2)
FIG. 2
,L\ - 3
Particulars
30/25TON x 22/23.5 M/R ELECT.-HYD.CRANE

MODEL
TYPE : N 1-CHRS3022 (2523.5)
Hoisting load (ton) 30 / 18 / 6 25 / 18 / 6
Hoisting speed (m/min) 11 / 17 / 44 11 / 17 / 44
Lowering speed (m/min) 40 40
Luffing time (sec) abt. 4 7 (22M/R - 4.5M/R)
Slewing speed (rpm) ave. 0.7
Working radius ( m) 22 - 4.5 23.5 - 4.5
Slewing angle (deg) 360° free
Distance to hoist ( m) 35 m at min. radius
Rule and regulation DNV witness. AWWF
Ship·s heel & trim Heel 5°, Trim 2°

Design condition
Ambient temp. -15° c- +40° c
Strength & Safety factor NK base
Power source AC 440V, 60Hz. 3 ¢
Electric motor AC 112 kw. ED 40% 1 set
Electric collection Slip ring

Note;
Available cargo handling combination.
Full load at heel 5° ,Trim 2° --- Three motion possible.
Certificate : Maker certificate
· Loose gear certificate : PAKISTAN. INDIA. CANADA. AUSTRALIA
8 -1
CHAPTER 2 MECHANISM
General (Refer to Fig. 3)
The deck crane is structured by the slewing post, and the jib, and it LS also fitted
with each winch to operate the following three functional movements.
Hoisting movement of load

up and down.
Luffing movement of load
far and near.
Slewing ------ movement of load
right and left.
FIG. 3
1. Slewing post
2. Jib
3. Operators cab.
i
4. Machine Room
5. Apparatus Room
6. Hoisting Device
7. Luffing Device
8. Slewing Device
9. Pwnp unit
10. Rope slackover prevention
device
11. Push roller device
12. Rope end stopper
13. Stage and Ladder
14. Oil tank
15. Electric equipment
16. Hydraulic equipment 8
17. Others
i ·1 !
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8 - 2
2-1. Slewing post

The slewing post is of welded steel plates, in the from of housing.
All the machinery is enclosed in this housing. The post is made in three comportments,
upper operator's cab. apparatus room and the lower machine room.
Sheave unit are fitted on the post top, and the slewing ring are equipped on the rear
surface of the bottom base plate.
2-2. Jib (Refer to Fig. 4)

The jib is of welded steel plates in the box shape. The jib consists of the sheave unit
at the top, the main body and the bearing at its root. It is also fitted with angle
indicator of standard model by which it is possible to confirm the working range permitted
(luffing angle).
(Fig. 4)
2-3. Operator's Cab.

(Refer to Fig. 5)
The operator's cab. is equipped with the Fi

following articles.
1. Controller for hoisting set

2. Controller for luffing &slewing set
3. Operator's chair set
4. Room heater, lkw set
5. Fan 1 set
6. Window-panes 6 sets 4 'i
7. Wiper(manual) 1 set ·.. __j
8. Shade set
9. Room light, 60w set ' 1
10. Ash tray set
11. Fire extinguisher set
12. Control panel set
6-3
Please use room heater, fan, wiper, and room light, as the case may be.
All the electrical equipment's inside the room are of drip-proof type, so please be
careful not to let them get subject to the direct raining, etc.
2-4. Machine room (Refer to Fig. 7)

The machine room is located at the lower part of slewing post.
The room accommodates each device for slewing movement, hoisting movement, luffing
movement, hydraulic blocks and room light of 20w fluorescent lights.
There is also the slackover prevention device, push roller device, limit switch device
and large maintenance door on the rear wall.
The base plate of the room is equipped with two drain pipes.
On the under surface of the base plate, there is the ladder and turn table and the
slip ring set under the turn table.
The bearing at the root of the jib are supported by the shafts fixed on both sides of this
base plate.
Fig. 7
L I Ml T S !Y_l__T_C_tl.___6_Q_ X_
J_l 8____ 8 E !<R.Li'Ji!: J ! B
E-4
2-5. Apparatus room

The apparatus room is equipped with the following articles.
1. Oi 1 tank 7. Valve unit

2. Room light
20w fluorescent 1ight
3. Hydraulic blocks
4. Axial-flow fan
r-
0. Oil cooler
6. Pump unit
2-6. Hoisting device

The hoisting device consists of the hydraulic motors, reduction gear, disc brake
and the grooved drum to wind up the hoisting rope.
It is also fitted with the "push roller·· to avoid the irregular winding rope,
and the "rope slack over prevention device~ to stop the motor by detection of rope slack.
The device control is made by the pump control type of excellent characteristic.
The reduction gears are enclosed by the oil tight cylindrical casing.
The gears are of the multiple planetary gears since the greater reduction ratio
is required.
All the gears are elaborately machined and finished to secure the lower noised,
excellent working efficiency and engaging conditions.
The bearings are all of ball or roller types, which work in higher efficiency and easier
maintenance.
The drum is grooved to accommodate the rope in one layer to serve for longer durability of
rope and prevention from irregular winding.
The disc brake is fitted for the hoisting motor.
6 -5
2-7. Luffing device

The luffing device is the same
structure with hoisting device.
The controls on this device is
of valve control system.
The reduction gears are enclosed
in the oil tight casing. This casing
also incorporates those gears for
hoisting purpose, the lower part
is for hoisting gears and the upper
part for luffing gears.
Gears, bearings and the drum are
designed and manufactured in the
same manners as those for hoisting
device.
2-8. Slewing device

(Refer to Fig. 8)
The slewing device consists of the hydraulic motor, reduction gears, disc brake,
and the pinion which engages wi the internal gear of the slewing ring.
Controls of the slewing device are of valve control system.
The reduction gears are enclosed by the oil tight cylindrical casing.
The gears are of the multiple planetary gear since the greater reduction ratio is required.
All the gears are elaborately machined and finished to secure the lower noised, excellent
working efficiency and engaging conditions.
The bearing are all of ball or roller types, which work in higher efficiency and easier
maintenance. The disc brake is fitted for the slewing motor.
B - 6
2-9. S1i p ring uni t

(Refer to Fig. 9) Fig. 9
The slip ring unit to serve as
the collector of electric power
is supported by the lower part
of slewing table and fixed post.
The power is supplied from the
ship generator through the cable,
passing through this unit, up
to the crane panel.
The slip ring unit consists
of rotating ring (slip ring),
fixed brushes and the casing
of steel plates in box shape.
Mechanism is that slip ring
flange is fixed by bolts of
base plate for slewing post,
and inside slip ring is turned.
2-10. slack over ion devise

This is the device to stop the hoisting motor automatically by detected slack
in hoisting rope so that the trouble by rope slack is prevented in advance.
In case it is necessary simply to pay out the rope such as in rope replacement
work, operate switching "ON .. the by-pass switch on the control panel.
2-11. Push roller device

This is the device to push the rope always with the constant tension so that
the hoisting rope and luffing rope are regularly wound on the drum grooves if the rope
may be a little slack, and this is equipped on the slewing table in such a manner
to have the rope between the device and the drum.
B -7
Fig. lL!
2-12. Hanging unit

(Refer to Fig. 10)
The hanging unit
consists of falling
block, swivel, shackle
and hook.
The falling block is respectively
marked with the permissible
load to apply(S.W.L)
1. FALLING BLOCK
2. SWIVEL
3. SHACKLE
4. HOOK
2-13. Stage and Ladder

The stage is paid consideration to facilitate the wire rope replacement work maintenance
of painting on the slewing post and passage to each part of the crane.
When the work at a higher position is required, please use the equipment's for
safety working.
2-14. Oil cooler

The oil cooler intends to suppress the temperature rising by hydraulic pump hydraulic motor,
valve, piping resistance, and etc., for avoid any adverse influences by heat to the
machinery.
The electric axial-flow fan for oil cooler set in apparatus room.
c -8
2-15. Electric equipment

This crane is fitted with various electric equipment·s of each purpose of good reliability.
Electric motor (For driving hydraulic pump)

Control panel
Illumination lamp
Ventilation fan
Fan
Heater
Limit switch, etc.
The explanation is herein made mainly on the electric motor, control panel, and
illumination lamps.
1) Electric motor (for driving hydraulic pump)

The motor is fitted with the shaft to both sides main pump for hoisting is coupled
on one end, and pump for luffing, slewing connected by coupling on the other end to drive
each hydraulic pump.
8-9
2-1) Control panel
01 02 ~QQ
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19
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11 BB
20 21
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12
1. "SOURCE" lamp
The lamp illuminated by switching on "MAIN SWITCH".
2. "SPACE HEATER" lamp
4. "OIL LOW LEVEL" lamp

When oil level fall less determined level in oil tank, and
the lamp to be illuminated.
5. "OIL HIGH TEMP" lamp

When the oil temperature in the tank gets in excess of
85° C, and the lamp to be illuminated.
stop.
B -10
6. "LIMITING" lamp
The lamp illuminated by 1imi ting. ¥!JJa.en aux. motor
7. "ROPE SLACK" lamp

The lamp to be illuminated by slack over of hoisting wire rope.
~<l~i1l}~i~lrBut hoisting operation is possible.
When over load and the to be illuminated. B•";'~fitit

But hoisting operation is possible.
9. "CABIN LIGHT" switch
The switch is used for switch on and off the cabin light.
10. "BYPASS" switch
The key type switch is used for "BYPASS". (For JIB REST)
Combine use of slack over limit switch.
11. "WARNING HORN" button switch
12. "BUZZER"
13. "MAIN MOTOR START & RUNNING" switch and lamp
The switch is used for switch on main motor and lamp
to be illuminated.
14. "AUX.MOTOR RUNNING" lamp
The lamp to ill nated by running on aux. motor
when limiting, the lamp to be illuminated off, then aux.
motor running again to be run by control lever at
neutral position.
15. "OIL COOLER RUNNING" lamp
The lamp to be illuminated by running on motor for oil cooler.
16. "MAIN MOTOR STOP" switch
The switch used is used for switch off the main motor at normal stop.
17. "HO I ST ING UPPER L!MIT'' 1amp
When hoisting upper limit, and the lamp to be illuminated.
18. "LUFFING LOWER LIMIT" lamp
When hoisting lower limit, and the lamp to be illuminated.
19. "JIB RADIUS 22M/30TON - 23.5M/25TON" switch
The key type switch is used for setting of maximum working radius depended on
the hoisting load by changed over switch.
20. "ROOM HEATER'' switch
The switch is used for switch on and off the room heater.
21. "FLOOD LIGHT" switch
The switch is used for switch on and off the flood light.
~ - 11~
- !
3) Illumination lamps
The following lamps for illumination are equipped inside and outside the crane slewing
post.
For outer illumination ;

400w MERCURY flood lights
over the operator's cab ------------ 2
For inner illumination

60w pendant light
in operator's cab ------------------
20w fluorescent light
in apparatus room -----------------
20w fluorescent light
in machine room -------------------
There is also a receptacle prepared in the machine room, so please utilize for the work
lamp, etc.
E - ·2
2-16. Hydraulic equipments

The hydraulic apparatus suit for various purposes and have set is factory
results are used on the crane.
Pump unit
Hydraulic pump
Valve unit
Hydraulic motor
Others
1) Pump unit
The pump unit is horizontal set, fitted with the luffing and slewing pump on gear side,
the electric motor on the middle part, and hoisting pump on the front side.
Each is connected by couplings.
2) Hydraulic Pump
The pump unit consists of the hydraulic pump, so refer to "The instruction manual for
hydraulic equipment's".
3) Valve unit
The valve unit is compactly as a whole, and each hydraulic component is arranged
so that maintenance and inspection are easily made.
Please refer to "The finished hydraulic drawing" as for the arranged hydraulic components,
and "The instruction manual for hydraulic equipment's" as for the maintenance and
inspection.
4) Hydraulic motor
(Hoisting & luffing winch motor)
The motors in use are hereby
listed. One motor is used Table 2
for hoisting purpose;
one motor for luffing purpose. Hydraulic I
All motors are compactly motor for A6V 500 x 1 set
manufactured plunge motors, hoisting
mounted by bolts on the Hydraulic
reduction gear. motor for A2FM180 x 1 set
Please refer to "The instruction luffing
manual for hydraulic equipment's".
1. -
'
...,
.....
5) Hydraulic motor
(Slewing gear motor)
This is the compactly manufactured
plunger motor, mounted by bolts Table 3
on the cylindrical reduction
gears. Hydraulic
Please refer to "The instruction motor for A2FM180 x 1 set
manual for slewing hydraulic slewing
motor ...
6) Controllers
Controllers are set at the operation room. There are the level type controller
for hoisting and lowering on the right side, seeing from the operator,
and the universal lever type controller for luffing and slewing on the left side.
Controllers are drip-proof, and also "Interlocked with 0-notch", where it is
impossible to resume starting if not putting the lever at the neutral position.
2-18. Safety devices
1) The deck crane is equipped as normal with the following safety devices for
the safe and positive operation.
In hoisting,
Upper limit Interlocked with the upper limit in luffing-up.
Lower limit Drum end.
Rope slackover
Operation lever "O" notch interlock;

Main motor can not start unless handle is positioned
at neutral position.
In luffing,
Upper 1imit Minimum radius
Lower limit Maximum radius possible to BY-PASS till lowest limit.
Lowest 1imi t Drum end
Operation lever "O" notch interlock:

Main motor can not start unless handle is positioned
at neutral position.
In slewing 360° free
Emergency stop Stop in all operations.
Remarks
*In case cargo hook is lifted upto the position where hoist moving upper limit being
actuated, the crane jib can not by lowered.
Lift down the cargo hook first, and then lower the crane jib.
*When each limit switch actuate, motion shall stop.
At this time, controller shall be turned to neutral position, then operate the crane.
2) Brake unit (hoisting, luffing, and slewing)

The braking device is fitted between the reduction gear and hydraulic motor.
The braking is effectuated by hydraulic disc brake with the handle being in the neutral
position. And the braking is released by hydraulic control with handling of control
lever.
(' - 1
'J '
CHAPTER 3 OPERATION
General
In operating the deck crane, please never fail to do the required works of the following
three steps;
(1) Works for preparation prior to operation.
(2) Regular operation for the cargo handling work.
(3) Works after the regular operation.
Negligence or omission from the aboves may bring troubles and it will be unprofitable
after all.
"Haste makes waste."
Cautions in operation
Keep in mind "the safe operation" and "the smooth operation ... It's especially important
to operation the crane with safety. The slewable machine such as deck crane can not
escape from the load swing. The load swings much more in rough operation, which may
develop to a serious accident of hitting with or dropping the load. It's also very
important to operate smoothly.
It means to make the slower start and stop operation to reduce shock. It brings less
load swing and easier operation. It also reduces the operator·s fatigue, and increases
the working efficiency. Furthermore, the crane will be more durable.
1. Workings for preparation

Prior to operation
Please do the following works for preparation prior to the regular operation.
1. Lubrication to each point

Please refer to 193930
2. Maintenance and inspection Prior to operation

Please refer to P.E-1
3. Unlash the jib

2-1 Operation of each crane
Please operate each crane in the following order.
1. Confirm that each control lever is at its neutral position.

2. Confirm that the oil level of the tank at the apparatus room is up to the regular
position by the oil level gauge.
3. Should be open the oil cooler flap and ventilator.
4. Confirm that thermostat of main motor is off.
5. Switch on MCB in the switch board of ship.
6. Push the button-switch "START" of the control panel rn operators cab.
7. Should be changed setting of maximum working radius depended on the hoisting load
by changed over switch on control panel in operator·s cab.
8. Wait a few minutes after starting main motor.
9. Should be operated luffing up over 25° for jib angle from jib rest.
*Controllers operation of attention

Controllers are drip-proof, and also "Interlocked with 0-notch", where it is
impossible to resume starting if not putting the lever at the neutral position.
(There is an electrical interlocking device where operation cannot be resumed
if levers are at ir positions.)
Also the limit switch to detect full handle shift is set up to the hoisting controller,
so that it is impossible to hoist at high speed unless the handle is taken fully even
with non-loading.
Stepless speed control is possible according to the operating angle of control lever.
* Caution
Don·t change over radius change switch key until taking the cargo off after hoisting
up the cargo.
C-3
2-2. Hoisting I lowering operation

Hoisting I lowering operation is made by the hoisting controller prepared to the right side
of operator.
When the lever is release from the hand, it automatically return to the neutral position
(spring return mechanism) and the crane movement stops.
Please refer to Fig. 12 for the operating method.
Also hoisting and lowering speeds can be changed by changing angle of the handle lever.
Fig_ 12
dom Lowering
up 8 Hoisting
Left < > Right

Slewing
Chair
C-4
* Remakes
1. Operating lever shall be operated softly not but rapidly.
2. In case of lowering, please make sure that speed should be slow and stopped before
touching the ground (deck).
3. When each limit switch actuate, aux. motor shall stop. At this time, controller shall
be turned to neutral position, and aux. motor shall be re-driven then operate the crane.
4. When starting to hoist, take half handle for hoisting at first. after sling wires
are strained, take full handle for hoisting.
HALF HANDLE OPERATION FULL HANDLE OPERATION

ill
I
I t x I
SLW_G WIRE ,A /\
LOAD t \ I \
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FIG. 2
5. In case of full handle being taken from start (Fig. 1), hoisting may be imperative
after sling wires are strained.
In this case, return handle to neutral and take handle again.
6. Do not pull the load slanting.
HOISTING & LUFFING SLEWING
I
I
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\
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W%jl Ja ~
\
x 0 x x 0 x
C-5
2-3. Luffing operation

Luffing operation is made by the luffing controller prepared to the left side of operator.
This controller for luffing purpose is commonly used for slewing purpose at the same time.
(Simultaneous operation of slewing and luffing to be operated by one universal lever.)
In case cargo hook is lifted up to the position where upper limit being actuated,
the crane jib can not be lowered.
Lift down the cargo hook first, and then lower the crane jib.
* Remarks
1. When each limit switch actuate, aux. motor shall stop. At this time, controller shall
be turned to neutral position, and aux. motor shall be re-driven then operate the crane.
2. During cargo handling, special attention shall be paid to actuation of luffing lower
limit particularly on around max. radius.
3. When slewing operation is carried out at around max. radius, jib shall be luffed up
a little, then carry out slewing operation.
(This is to prevent luffing lower limit from acting)
2-4. Slewing operation

Slewing operation is made by the slewing controller which 1s common to the luffing
controller.
Please refer to Fig. 13 for the operating method.
* Cautions
1. Don't move the operation lever abruptly, but slowly.
2. In case of lowering operation, please be sure to slow down the speed before the load 1s
not aground, and then make a stop.
3. Please operate crane taking care that cable reel and jib nose do not
interfere each other in slewing operation when jib is stowed or released.
2-5. Simultaneous(or combined) operation

Each operation for hoisting, luffing and slewing is naturally available individually,
but at the same time operations may be available simultaneously, depending on the
working condition.
Combination examples;
A) Hoisting (or lowering) and slewing
B) Hoisting (or lowering) and luffing
C) Luffing and slewing
D) Hoisting, luffing and slewing-(At the same time three operations may be available,
depend on load and heel condition)
2-5. Emergency stop
In case it is necessary to stop the cargo handling work in as emergency while in
operation, push the mash room red button for "EMERGENCY STOP" on the wal 1 in operator·s
cab. so that all the crane motions stop.
When resuming the operation, return each control lever for hoisting and luffing &slewing
to "O" position once. Should be reset MCB (return "OFF" position), and switch "ON"
position
and then push the button-switch "START" on control panel so that the operation can be
started again.
Normal operation emergency stop reset start
2-6.Safety devices
The deck cranes are equipped with various safety devices every where to keep the safe
operation, so please utilize them in the right manner.
Their arrangement and functions are explained at Chapter 2. As for the devices which can be
bypassed, please make operation very carefully.
(It is required that the key for bypassing the safety device is kept in custody of the
engineer of the officer of the ship who is appointed to be responsible to do so.)
c- 7
3. Works after regular operation

When the cargo handling work is finished and the crane is stowed, please make
the following works.
3-1. Stowing work

1. Turn "BY-PASS .. switch provided on the control panel by "BY-PASS .. key.
* Now, the jib can be lowered to its rest.
2. Operate the crane for slewing and luffing movements so as to get the position right
over the jib rest.
3. After getting the position over the jib rest, make the luffing operation to keep
the luffing wire rope somewhat "strained ...
* If being to loosened, the rope may get out sheave grooves.
4. Make lowering operation till the hook comes aground.
5. Lash the hook with the eye plate on the deck.
6. After lashing the hook, operate for hoisting movement, to keep the hoisting rope
somewhat "strained".
* rt·s because of the same reason as mentioned in 3.
7. Should be closed oil cooler flap and ventilator.
(CAUTION)
"DECK CRANE BYPASS" key should not be used at normal cargo handling.
Operation on machines
1. Push "STOP" button on the control panel.
2. Switch "OFF" the "MCB .. in the control panel.
3. Switch "OFF .. the "LIGHTING" on the control panel.

CHAPTER 4 ADJUSTMENT
4-1. Limit switches system

All limit switches for hoisting-up, hoisting-down, and luffing are arranged in this
system.
The switch box is fitted at side of drum bearing of front side in machine room, and are
connected via drum shaft, chain sprocket.
The hoisting and the luffing are interlocked each other.
As to each selling figure, please refer to the list of limit switches setting figures.
Fig.14
LIHIT SWITCH
BOX \ CHA TN
SPROCKET
TENS! ONER
(1) Luffing upper limit

Please put off free system at the end of luffing drum shaft and luff-up to minimum radius,
then turn luffing limit shaft with hand so as to have striker.
Striker at luffing upper limit switch and make striking sound, then set free system at
that point.
Please set at the full end of shaft thread.
If too much allowance, is taken, the stroke for hoisting lower limit may by short.
(2) Luffing lower limit

Please set luffing lower limit switch after setting jib at maximum working radius.
0-2
(3) Luffing lowest limit

This is the lowest limit of jib, and it is set so as to leave 2.5-3 winding of wire rope
on luffing drum.
Please be careful to leave above wire on drum. other wise serious accident such as
jumping out of wire rope may occure.
(4) Hoisting upper limit (fixed)
The hoisting upper limit switch is fixed on switch box, and is not interlocked with
luffing limit switch.
Please adjust by setting jib at minimum working radius at the lifting height mentioned
in limit switch setting figure list.
(5) Hoisting upper limit (moving)
The hoisting upper limit switch is set on striker, and switch itself can not be adjusted.
This limit switch is interlocked with luffing limit switch so that jib top sheave and
hanging unit may not each other by excessive hoisting-up no matter where
jib is positioned.
Please adjust it after setting jib at maximum working radius, putting off free system
of hoisting up chain sprocket, by setting clearance between sheave by hook at set figure,
then turing hoisting up limit shaft with hands, and confirming that upper limit strikes
at striker(for luffing) and makes a striking sound.
Please set free system at that position.
In case the upper limit in hoisting is being actuated, the jib doesn't get lowered,
so please lower the hook.
(6) Hoisting down lower limit
This is the lower limit position of lifting height, and is set to leave 2.5-3 winding
of wire rope on hoisting drum.
However. in general. there is some allowance in lifting height, and the hadling becomes
easy because wire trouble. etc. is prevented if the hanging unit is lowered onto ship's
bottom and the lower limit is set in this case please do not reduce the wire rope winding
on drum.
Note) The above is the explanation of adjusting of interlock limit switches.

Make is sure to confirm that limit switches will actuate or not at on load
condition after adjustment.
C:-3
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No. NAME POSITION MARK

CJ) LUFF[ NG UPPER 4 M 5 00 LSU
@ LUFFlNG LOW'ER<22M/R) 2 2 M 000 LSD!
® LUFF! NG DRUM END - 5 0 LSE
·- \II Iii ·ii
@ HO!ST!NG UPPER t 6 M 816 LSH J l B

® HO!ST!NG L 0 W' E R 3 5 M 000 LSL MESSRS
MANAGER S.NO.
@ LUFFING LOW'ER<23.5M/R) 2 3M 500 LSD2
(j) MLSH _,_K"--'-'A_,W'.:_:_;Ac....:S"-'-A"-'K,_,__,[_----i PRO J Ec T
1-c_H_IE_F_--+l_,_N'---!-. NM1 E ORDER NO.
HOIST!NG MOVE UPPER 4000-4800
SUB CH I EF K . Mu R A H A R A
IN CHARGE K . T suJ [ SCALE PROJECTION
l / 3
IF . N ! s H [ LIMIT SWITCH TH r RD ANGLE
1
DRAWN
DATE
ADJU'3T ! NG METHOD
9 9 6 5 AUG.2!.1997
D.NO.
TSUJI HEAVY I NDUSTR I E:S CO .. LTD. 197670
l97670A /.J.. '"':<, ( l I I )
J-4
4-2. lacement of wire
1. Particulars and dimension of wire rope

Prior to start of the replacement work, please confirm that the new wire rope is
the same to the existing rope in kind and dimensions.
2. How to remove the old rope

Make the work on the fo 11 OW ing sequence.
(1) Place the jib on its rest.
( 2) Both in hoisting and luffing put out bolt of free system of each limit shaft end.
In this case, it is advisable to make marking on each position of micro switch in
the interlocking limit switches, at it makes it easier to do adjustment after the
replacement work.
(3) Revolve both hoisting and luffing drums till no dead winding of rope remains.
Please work after switching bypass switch "on·, other wise the slack-over prevention
device works.
(4) Remove the fitting which is fixing the wire rope end. (FIG.16)
(5) Connect by knitting the leading rope (about i;610mm) with the existing rope, and
thus the old rope can be removed. But please be careful not to let this knit
part come struck at the guard.
Remarks ;
Confirm that the openable window of operation room is being closed, because the window
glass may by broken, hit by the wire rope at the time of replacement work.
Fig. 16 SECT A
'
l-~~--1
3. How to fit the new rope
(1) When the old rope is removed and the leading rope only is passed, set the eye
spliced end of the new wire rope to the fixing point first, and knit and connect
the leading rope to the opposite end of the new rope. (FIG.17)
(2) Operate the hoisting and luffing winches and wind up the leading ropes till the jointed
part between the leading rope and the new rope comes just before the drum.(FIG. 18)
(3) Fix the end of the new wire rope at that position, using the chain block, and disconnect
the leading rope with the new rope, and reverse the winch and remove the leading rope.
(4) After removing the leading rope, set the new rope to the drum.
(5) When winding up the wire rope for the first time, please make it at slower speed,
helping the rope to be wound right along the grooves. When the rope is replaced,
please be sure to de operation with less than half the rated load to give practice to
the rope.
Thus, the rope is expected to be effectively durable and longer in service. Then, make
adjustment for interlocking limit switches (refer to page D-1), and confirm that each
device can be actuated alright in the right and regular manner.
FIG.17 FIG.18
NEW ROPE
LEAD ING ROPE
DRUH
I
0-6
I IHJ STORY CF D. f DA7E I R.EW,RKS I ITC:~A l DR. IJ I .- I '<
~
'
I
I 3
I'·'.
DAIT
I I I i
I I I I I ! - I
7-SHEAVE I i I
~--- I I I I I I •
!
LENGTH
' - -·~~~~~~~~~~~~-7"1-
_I
ROPE END STOPPER ~I ;;< [

-s \
(LUFFING) "r------.l
.~+--
___:==---=----_-_-=-.....:.../~_:::::::-
__::::::::-=::.-_-==-=----~~""""='= -
ffiTHIMBLE
/I I
\LOCK SHEATHED END\
A TYPE
HOISTING WIRE ROPE

DI A x LENGTH FORMAT I ON LAY KI ND BREAKING THIMBLE
(mm) (m) STRENGTH (TON)
+~. 5 NON ROTATING ORDIN.AR.Y 4 MORE THAN

A-36
¢ 3 4 x 2 2 9. 0 GALV · CZ LAY) S T RA. N D 8 l. 7
6-SHEAVE
¢710
ROPE END STOPPER
(HOISTING)
LUFFING WIRE ROPE
DIA x LENGTH FORMATION LAY KIND BRE.AK I NG THIMBLE
(mm) (m) STRENGTH (TON)
I
IWR.C+O. 5
6 tv!ORE THAN
CARGO BLOCK i 6xF i (29)
0
¢3QX182. 5 CLASS A
OHDINP,RY
CZ LA'·') STRAND 58. 4
A-32
*~
GALV.
Total 1790.4 kg
ss~,oo I 1 I
I I
oi 4 I TH I MB LE I A-32 I I 1. 2 11
I
GALV. I I
I
0 3 I THIMBLE A-36 I ss.;oo i f I I' 1. 611 I GALV. I I

IWRC 6xF i (29) I ...
'
0 2 I wI RE ROPE ¢3QX1 ~?. 5 +g. SM i I 722. 7 ii GALV. I I I
NON ROTATING I -- I
0 I 1 I wI RE ROPE ¢ ".3L!.x229. 0 +~.SM I I 1 I 1064. 911 I GALV. I I
MEMBER
I
M~-E-1::i: !i
R. i,L
pi= q
ONE' I
WEiGi-11
TO-
TAL
I;>.
1;i,;;
3 REM.ARKS
I """'Wl I'"·;ii I '"JH"''1'-:
~;' ::!?:.
I - e= n- t;t t* j;i
;IE'
?t!vd I I SC:T
I II FtEMARKS
I
I
;\
MESSi'l.S S.NO.
MANAGER.
LUFFING DRUM CRDEi'l. NC.
SCALE I PROJECT[ON
,,__,, I THIR.D ANGLE
DAE
\HOISTING DRUM
DEC- 5. 1996
TSUJI HEAVY INDUSTRIES CO.,LTD. ').;~O. 193929 D

7C21 l 3 0 4 6 5
A3 I c1/1)
C-7
HOW TO INSTALL HOIST ROPE
1. Procedure of installation
(1) Reel should be on to a stand to be rolled smoothly.(agreeable to set in the diagonal

back of the operation room.)
Rope should be unwind from the bottom of the reel. Which has a braking unit to avoid
excessive unwinding.
Fig. A
DRUH
0 WIRE ROPE
REEL m I
BRAKE
(2) HOIST ROPE should be connected with a pilot rope(natural or synthetic fiber rope)
by a shackle.
The length of pilot rope is desirable to be almost same as the HOIST ROPE.
The purpose of using fiber rope is to avoid dislocation of HOIST ROPE.
In case of using on old wire rope for a pilot, it is necessary to lay at least
about 3 feet fiber rope between them.
s s s s s s s s s ~~
'> >. >,
r
\
~
\
\
\
1101sr ROPE Lackie \ Pi Io t rope (fihcr roneJ
(3) The pilot rope should winded carefully with constant speed and tension.
A rotatible guide should be laid where it is necessary to change the direction
of pulling line.
Fig. C
gu id c DU 11 ey
\~<
I
I
I
I
I rii lot rooe
I
'~
C-9
(4) When winding HOIST ROPE onto another drum or reel, make certain that it bends
in the same direction Rereel from the top of one reel to the top of another,
or vice versa.
Following the same procedure when winding on to machine drums.
x wrong Fig. D
0 right
nEEL
(5) It is necessary to lay falling block well apart from top sheave, and see that
HOIST ROPE dose not touch the ground.
Fig. E
too sheave ra l I i ng b I oc k
I I
(6) It is also necessary to see that there is no scrubbing in the rope line.
(7) When winding HOIST ROPE onto a machine drum, proper braking tension and careful
arrangement on grooves most be applied to maintain tight winding on to drum.
Fig. F
back tens ion
(8) When leading the rope end to the bracket, it is required to see that there does not
f- occur unjust twist on bend in the rope.
For the successfal leading, the joint of pilot rope to HOIST-ROPE should be properly
located.
Fig. G
pi lot rope
bracket
D - 11
(9) Immediately after initial installation lift the hook to the highest position
and test run the rope several times with light loads.
Carefully observe rope and hook behavior as new hoist rope often needs adjustment
immediately after initial test run.
It twisting angle ( ) is below 20° , adjustment is not necessary. On that occasion
test running with ordinary loads is to be followed.
Fig. H
cl.. (twisting angle) ~±20·
(10) Also in test running with ordinary loads, observe rope and hook behavior.
At this time especially when lifting loads from the ground, it is necessary
to lift most slowly.
Fig. I
1 v
:;iost slowly
/!!///I /l//1/I I/ /Iii/,//
c - 12
(11) If rope hook tends to untwist the rope lay, lower the hook adjust rope end
untwisting slightly in accordance with "THE PROCEDURE OF ADJUSTMENT OF HOIST ROPE"
If you adsob [ +] twisting, lower the hook adjust rope end [ +] twisting stightly.
HOW TO ADJUST HOIST ROPE
HOIST ROPE is one of non-rotating ropes and is constructed by 4 strands, and has
much better non-rotating properios compared with other ropes.
For the sake of making full use of its real abillity, following procedure us recommended.
(1) Immediately after initial installation lift the cargo block to the highest position
and carry out the test run server times with light load.
(2) After test run, carefully observe the behavior of cargo block.
1) If the inclination angle of cargo block at the tank top in the hold is with
in the standard as shown in Fig. 1 adjustment is not necessary.
2) Unfortunately, if the inclination angle is without the standard, following adjustment

is necessary.
(3) Adjustment should be does as follows:

/This shown Z-lay. If the wire rope is S-lay,
turn to reverse direction. ( ) shows S-lay.
1) If the inclination angle of cargo block is less than ±0° , lower the cargo block
and twist rope end of winch side in the direction of clockwise (in the direction of
loosening of rope lay seen from rope end. (counter - clockwise)
2) If the inclination angle is more than +20° , twist rope end in the direction of
counter-clockwise(in the direction of tightening of rope lay.)
(clockwise)
-14
g,
~
r I j
+10° ±10°
st<rndard
crcine body
di re ct ion
crane body
direction
Standard for inclination angle of cargo block viewing from the too sheave.
usually, cargo block tends to incline toward-direction, rope end has to twist
clockwise, most of the time.
(counter-clockwise)
For reference, number of twisting is shown in the Table I.
(4) After twisting rope end, test run with light load is to be carried out and observe
the inclination of cargo block, and following confirmation is to be done.
1) If the inclination angle of cargo block within standard, adjustment is finished.
2) If the inclination angle is without standard, the adjustment is to be repeated in

accordance with item(3), and the confirmation is to be done as the method
described in this item.
Ta b 1 e I . Number 0 f t w s t n g ( f o r reference)
Inclination angle ,..._,_ 3 0 - 3 0° ,..._, - 4 5° -4 ~
;:)
0
--...,
of cargo block
Number of twisting 4 --...,
6 6 ""'"" 9 9 --...,
1 2
THE PROCEDURE OF ADJUSTWENT OF HOIST ROPE
When the hoist rope tangled, adjustment should be done according to the following
procedure.
(1) Set to the jib angle to minimum radius.
(2) Fall the hook down to the bottom of hold or on the wharf.
(3) Release the 1 imi t switch.
(4) Reeving the rope from the winch drum.
(5) Fig. K - a
Grip the rope by chain and chain block, and anchor it at any position above winch drum.
(6) Remove the clamps for the rope from the flange of winch drum.
(7) Take the rope end off from the winch drum.
(8) Bring out the rope end near to the hand rail by the chain block.
(9) Fig. K - b
Connect the rope end becket to the swivel fixed to the hand rail. If rope end has no
becket, insert the rope end to the cable sock.
(10) Release the chain block.
(11) Bind the chain to the rope.
(12) Fig. L
Install a log or a pipe to the binding chain and twist it in accordance with the
adjustment manual (see "How to adjust unirope")
(13) Fig. L
Bind the chain to the rope near the hook.
(14) Perform the same adjustment as described in (12)
(15) Shake the near the hook and drum so as to equalize the 3djusted twist.
D -16
(16) Grip the rope by chain block, and anchor it at any position above drum.
(17) Remove the rope end and fixed it to the winch drum by clamps.
(18) Arrange the limit switch and remove the chain and chain block described in (16).
(19) Wind the rope to the winch drum and carry out test run in the maximum list by five
minutes.
G)
~~
_c_h_·~_;n_b_l_o_c_k_/•• 1
/ I
VIEW
Fig. L
\r11re roo~
o- 17
Ovoir Load Test Outline fer crane regular inspection
H 0 I ST I i~ G
JJ I<. 0 C E D U l<. E 0 f 0 V E E L OA 0 T E ST
(l) Pressure adjustin1: of hoist pump relief valve CGG-1)

After marking, Turn the adjusting screw to the clockwise abt. 90 °
a
(2) Set the inclined ani!le of l11>ist motor to max.
Qt§connect the electric conicctor of solenoid valve
I' I' 0 ,.; ~t~ • for incl ina ti on.
C:l) f'riicecJure of overload buzzc;ir cultini;.
Disconnect the quick te-st hnsc connector o[ pressure swilcll
-- Q])CONTROLL(;~
• f'S2~ for over l or.id.
(4) Kake slow speed operation under overload test.

Take the lever of controller to half notch.
(;j) After the over I oad te-s t is linished.

make the ubove item (1) - Cl) to ordinary condition.
(a) Re-set the relief valve Pressure.
., I
0 l
I
(b) Connect the electric conngctor of solenoid valve.
(c) Connect the quick test hose connector of pressure switch
I I
I I ( NOTE )
I I
I I The udjustinr. pressure of pressure switch is not necessary
under overload test.
~ ~~! 11.o!il 0 This is to indi<;.ate adjust111ent outline for over load te:;t.please use
w L~!Jfl .o l. -:-:_i w IZO crnne in normal condition nfte-r completion of over land test.
!'lease be r~minded that ve ore not responsible- for the accidents occure<l
fro111 normal operation in ove-r load test condition.
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(:" - 1
CHAPTER 5 MAINTENANCE
The greatest factor to influence the crane durability is how the

crane is maintained. We would like you to put the crane in service with no troubles,
and for this purpose, the maintenance service we would like you to de is hereby expained.
1. Daily maintenance and inspection.

2. Periodical maintenance and inspection.
3. Maintenance and inspection at the time of docking.
4. Lubrication
1. Daily maintenance and inspection

Explanation is made, subdividing the daily maintenance as follows;
1-1. Prior to operation

1-2. During operation
1-3. After operation
1-1. Daily maintenance and inspection prior to operation

Safety device
Brake
Wire rope
Control lever
Axial flow fan
Rubber hose
Hydraulic components
Qi 1 tank
E -2
1). Safety device

Please confirm that various safety device are positively actuated as intended,
prior to operation. Make the operation in slow speed with no load, and confirm that
each limit switch is actuated at the regulated point.
If it doesn't get normally actuated, please check the following points;
(1) Due to mechanical trouble?
* Sprocket works even if any set bolt missing?
(2) Due to electrical trouble?

*Micro switch in the limit switch box normal?
Check it by manually actuating the micro switch lever during operation.
* Cables well connected?
* Set bolt for micro switch not loosened?
Please lubricate to sprocket chain prior and after operation.
2). Brake
Each winch motor for hoisting, luffing and slewing in fitted with the disc brake at
the outer circumference.
Please be sure to check that the brake is normally working.
3). Wire rope

In this device, the wire rope is most frequently required to be replaced. Accordingly,
it is thought that you have very much interest in this respect.
Also, if accident caused by cutting occur, it brings very serious accident. So, greater
attention is required to handle the wire rope.
(refer to page D-6 as for the reeving, kinds and length.)
Wire rope for hoisting and luffing is subject to the regulations on limits in service,
by various safety regulations.
Please replace the rope with the new one at an appropriate time, especially paying
attentions to, the following four points for maintenance and inspection.
E -3
(1) Element wires

Please replace the wire rope in case more than 10% wires for one strand of rope are
being cut.
Number of strand
Hoisting rope 39/1 strand x 4
Luffing rope 22/ 1 strand x 6
(2) Rope diameter

Please replace the wire rope in case the rope diameter is reduced by 7% the original.
(3) Deformed shape

The wire rope is subject to the deformed shape such as untwisted strand, kinked condition.
Especially if kinked, the strength of the rope gets half the original, and it is
dangerous. Please replace the rope, judging from the deformed condition.
(4) Fixed end

Please check the fixed end of the rope on the drum, and the metal fittings.
It is effective to apply the rope oil on the rope as one of the means to prolong
durability of the rope.
recommend the black oil(or composition oil) of asphaltic character, excellent rn
adhesion, pressure resistance, weatherproofness, anti-corrosion, generally as
the rope oi 1.
INSPECTION METHOD OF CRANE WIRE ROPE
The life of wire ropes defers by the characteristics crane and its operating conditions.
But, in any cases, it is very important for a safety operation to inspect wire rope
correctly, replace it at proper times, keep the periodic maintenance and operate the crane
properly.
1. Wire rope before setting and equipment ;

(1) Wire rope to be replaced shall be prepared the same one which is specified on the
crane specification as its type, grade and stranding derection. If the difference
type and grade of rope from the specification is used, please use it after throughly
conforming as well as examining its specific difference between them.
(2) Prior to replacement of the wire rope, the rope pass route such as crane drum and
sheave groove shall be checked fully its appearances and movement without any abnormal
conditions to be found.
(3) If an abnormal condition is found on sheaves or drum, it shall be replaced or repaired

quickly and then set the wire rope. Or if unexpectable damage on the equipment is
found, the reason of damage caused shall be rectified.
2. Setting wire rope and problem initial operation

(1) When the rope wound on reel or in coil is paied out, special care on the wire rope
being strained shall be contributed. If the strain is added on the wire rope, it
makes a kink, being or deformation by irregular pitch on the wire rope.
(2) Special attention shall be paid for the wire rope not to touch with other equipment
at the time of setting wire rope.
(3) There shall be no align matter on the surface of wire rope such as sand or iron powder
at the time of setting wire rope.
The adhering of align matter on the wire rope shall make not only the life shorten
but also the damage on sheaves and drum accelerated.
(4) After setting wire rope, the crane shall be operated for trial running under 10 to 20%
of rated load a few hours.
If there is a small bend or impact on the wire rope depending on the particular crane
charatericity, it shall be further important to operate for trial running.
(5) At initial stage of wire rope replaced there are some deformations or swell on the
wire rope causing by lack of proper setting wire rope. Therefor, it shall not careless
for observing and inspecting wire rope for a few days after replacement of wire rope,
by the reason of too short period of running which can be considered not to be happen
anything on them.
3. Maintenance of wire rope being used :
The maintenance of wire rope shall be carried out in accordance with the crane type,
purpose of use, environment at use, type of wire rope, etc. The life of wire rope may
depend on how perfect maintenance being paid. The wire rope passing through sheaves and
having bend on it shall be cleaned and painted with grease.
4. Inspection :
All wire ropes are obliged to check its deformation or any damage every day or before its
operation by the law. Especially its contacting part with drum or sheaves and with the
other equipment shall be checked carefully.
(1) Place of inspection

Although entire length of wire rope shall be inspected. key point of inspection are
shown below :
a. The part of wire rope ends.
b. The passing portions on drum and sheaves under loading condition.
c. In case repeated operations under the same condition, at the point after the
load leaves the ground or at the point of stop operation, the contacting point of
wire rope with drum and sheaves.
d. The contacting part of equalizer sheave.
e. The contacting part of overload protecting and overwinding device.
f. The possible part to receive damage by contacting wire rope with other equipment
(Ship's hatch corming, etc.)
g. The changing part of groove or lay on the flat drum or multi layer on the drum.
h. The part of random winding if random winding is on the drum.
i. Corrosion.
=-6
(2) Abolishment
As there is a standard to abolish the wire rope for the safety operation of the
equipment by the law, it shall be checked and replaced at the most proper period under
its usage and conditions following the points mentioned below.
a. Labor rule on safety and sanitation

The basis of abolish of the wire rope stipulated on the labor rule on safety and
sanitation, safety rule on cranes and structural rule on cranes as "The wire rope
which more than 10% core wires on the strand except filler wires is broken in one
pitch of lay."
If the core wire breakages are distributed on each strand, there in on way other
than to abolish wire rope.
But, in case of core wire breakage less than 10% the core breakage are concentre-
ted in one part of one strand, it is better to follow with the guidance shown in
Table 4 below due to the wire rope strength being lowered.
Table 4 abolishing by core wire breakage
Type of rope No. of breakage in No. of breakage

one rope lay concentrated in one
distributed strand
U4 x SeS (39) 15 8
6 x Fi (29) 13 6
b. Wire rope diameter ;

By the rule stipulated by the where the law wire rope diameter is reduced less than
7% of nominal diameter, it shall be abolished. The reduction of wire diameter
appears fast at initial stage of its service and later slow down of its progress.
The initial reduction of wire diameter is due to tightness of rope itself and the
later reduction is caused by the abrasion or aging of the core.
E-7
When wire diameter is observed and inspected, it is necessary to check and confirm
not only wire diameter but also the grade of abrasion and its condition.
For example, in case of abrasion occurred at only one side of wire rope, it may be
required to replace with new one even if wire rope diameter reduction is not
reached at 7%.
There is a rule stipulated the abolishment of wire rope (Replacement standard for
rail road wire rope. ~ine rule in U.S.A., etc.) if more than 50% of the core wire
of its most outer layer reduce its diameter less than 2/3, than the wire rope
shall be abolished. This can be use as reference.
c. Kinking ;
If there is a kinking portion on the wire rope, it shall be abolished. When the
kinking appears on the wire rope, the breakage load of wire rope drop remarkably.
If once kinking is appears it makes partial abrasion and wire breakage at this
point and causes the root of wire breakage.
The breaking strength reduction ratio by kinking is shown in Table ~.
TABLE 5. Breaking strength reduction ration

by kinking
Condition of rope Reduction ratio

Rope rectified kinking 15 - 25 %
Rope doubled kinking (adding strand) 30 - 55 %
Rope reduced kinking (releasing strand 50 - 60 %
d. Deformation ;
The wire rope having the following deformation shall be abolished.
-1. Kinked core wire, strand or rope.

-2. Relocated of center core and the other strand.
-3. Center core appeared on the top layer.
-4. Just like corkscrewed condition.
-5. More than one strand loosen and floated around.
E-8
-6. Condition shown like a case.

-7. Remarkably flat.
-8. Core wire become as shape.
-9. Core wire floating due to abrasion or rust.
-10. Irregular diameter in pitch.
-lL Folding marks.
e. Corrosion ;
If there is a rope core surface pitching by corrosion, it shall be abolished due
to its weaken strength and elasticity.
It is also necessary to check inside of the wire rope after a long period services.
f. Reduction of elasticity ;
The wire rope has an elasticity so that it can absord a reasonable impact load.
If the elasticity of wire rope reduces, the resistance against impact load becomes
low. It is a difficult to find out the reduction ratio of elasticity, but it can
be observed the combined phenomenous such as reduction of rope diameter, elongation
of wire rope lay, elongation of whole rope length, reduction of clearance between
core wires as well as strands, and appearing fine powder from grooves on strands.
g. Others damages ;
When the wire rope touches with structure, damaged sheaves I rollers are use or the
ropes are entangled, it may be harden the core wires being accelerated by friction
heat by due contacting. If heat herdening the core wires, it becomes very brittle
and easy to happen wire breakage.
The portion of socket attachment and end part of lock treatment are most fatigue
concentrated part by vibration of string as well as most difficult to find out wire
breakage, therefore, wherever the wire breakage is found, the wire rope shall be
abolished or retreated the subject part.
The part of equalizer is also difficult part to find wire breakage in spite of easy
fatigue by horizontal pulling load swing, then careful inspection is needed.
If the wire breakage is found at the part of equalizer, the wire rope shall be
replaced instantly to avoid subsequential danger.
It shall be abolished the wire rope being damaged by electrical spark other than
heat.
t:. - 9
5. Control :
(1) Oi 1 ing
The wire rope shall be applied oiling during in its services. The wire rope is also a
machine and it can be said as oil is a vitamin of the wire rope. Oiling can serve as
not only anti-corrosive effect but also reducing abrashion fatigue of wire rope and
extending its longer. It is reported experimentally that wire breakage caused by
fatigue was reduced in half. Therefore, the expenses and time needed for oiling can
economically be paid back sufficiently.
Of course, time of oil supply is totally depending upon the site conditions, but please
decide it the most proper time by customer's end basing on its oil cleanliness.
(2) Inspect ion

Whale area passing the wire rope, the rope and equipment shall be checked periodically.
Especially, the condition of sheaves, abrasion of rope stopper or rope support, wire
breakage, corrosion, deformation or other damages shall be throughly checked.
The wire rope shall be used as answering "ON" against the following questions
a. Is there an irregural winding on drum?
b. Is there lack of oil on rope?
c. Have there ever been kinked on rope?
d. Is there rope being touched at corner like stone?
e. Is there going to kink when rope is loosen?
(
f. Is there a damage at rope support?
g. Is there uncertain part at socket, clamp, fitting or splice?
h. Is there a rope guide untighten?
i. Is there too small drum or sheaves?
j. Is there a damage on sheaves or ree 1s?
k. Is there unsmooth groove of sheaves or too deep grooves against original design?
=--10
1. Is there a broken edge on sheaves or drum?
m. Is there a sheave being over run or pushing rope when stop the crane operation?
Is there a sheave not being run when the crane operates?
n. Is there a brake not being smoothly run?
o. Is there a portion of waving on the rope?
(3) Change over of rope setting and end treatment ;

After the wire rope is used a long period, the particular part of the wire rope becomes
weak due to load deviation, impact and/or vibrato. And also the contacting part with
drum or sheaves becomes eccentric abrasion or easy to damage, therefore, the rope end
shall be cut short off and the wire rope itself shall be changed over its setting
back and forward. This makes the life of wire rope longer.
4). Control lever

Please confirm that both two levers are their neutral positions.
(There is an electrical interlocking device where operation cannot be resumed if
levers are not at their neutral positions.)
5). Axial - flow fan

There is an axial-flow fan for ventilation purpose, on the side wall of the apparatus
room.
The electrical interlocking is so that axial flow fan don't get started unless the
main electric motor is started. Please check the cables for being cut at times.
6). Rubber hose

With the rubber hose being damaged, or with its metallic fittings being loosened, there
may occur a serious accident of dropping the load or of falling of the jib.
So please check it sufficiently.
E - 11
7). Hydraulic components

Please check them for any oil leakage, and check the bolts for being loosened.
Please refer to "The instruction manual for hydraulic equipments" for maintenance and
inspect ion.
8). Oil tank

The oil tank is equipped with the float switch and oil level gauge.
Please check the oil level.
1-2. Daily maintenance and inspection during operation
Visual check
Auditive check
Others
The easiest checking during operation is to see the working condition visually and to
hear the working noise auditively.
1) Visual check
See the movement of wire rope ----- Normally wound on the drum?
Sheaves are normally revolving?
No knocking in hook and jib movement?
See the limit switch device -------Sprockets are normally revolving?
2) Auditive check
· Gear engagement noise are not abnormal?(slewing ring and pinion)
· The revolving noises of hydraulic motor, electric motor and pump unit are not abnormal?
No abnormal noise on the jib bearing and sheave bearing?

If checking the above points at times daily, majority of troubles will be eradicated
in advance.
3) Others
Please check the following points well carefully as well as checking prior to operation.
*Wire rope condition
* Sheave revolution
* Jib movement
* Brake effect
* Limit switch
*Oil and grease, etc.
There is nothing better than finding trouble in its earlier stage and precautions,
to avoid any accident and trouble.
1-3. Daily maintenance and inspection after operation
Cleaning
Electric power
Operator's cab
Machine room
Apparatus room
Outside
Jib stowing
Please overhaul any slight point that was found trouble or abnormal by daily inspection
during operation in preparation to the next service.
Negl1gency may escalate the trouble or defect much more next time.
Please do the following maintenance and inspection after operation.
c
L -
. j-
1) Cleaning
Clean the operation room, apparatus room and machine room. If various things are
in disorder, safety may not be maintained. And if any foreign matter is caught by
machinery, trouble will be brought up. Also pay attention not to let any spark
of fire exist.
2) Electric power
After operation, switch off the "MAIN SWITCH" on the control panel.
3) Jib stowing
To make sure following point when jib stowing.
Is the jib set on the rest completely?
Aren·t cargo wire ropes slacken? (Too much slack facilitates the ropes jump off from
the sheave groove)
Is cargo hook lushed on eye plate on deck?
4) Operator's cab.
Please check the followings:
(1) Both two control levers are at there neutral positions?
(2) The openable window is closed, and the butterfly nuts are fully locked?
(3) The door of control panel is neatly closed by corner bolts?
5) Machine room
(1) No oil leakage from hydraulic motor, valve unit, pump unit, aux. pump casing
and rubber hose?
(2) No bolts and nuts loosened?
(3) The rear door is closed?

6) Apparatus room
(1) No oil leakage from oil tank and gauge.
(2) No bolts and nuts loosened?
7) Outside
(1) No injurious damage on the post and the jib?
(2) Grease pipings are not crushed, nor disconnected?
(3) Bolts for slewing ring are not loosened?
(4) No abnormal conditions on the slewing final pinion and internal gear surfaces?
Also they are well greased?
Check the above points, and if necessary, do greasing and bolt tightening-up.
2. Periodical maintenance and inspection

The periodical maintenance and inspection as hereby referred mean those to be done
at the particular time such as during sea navigation.
Some pointas mentioned for the daily maintenance and inspection after operation are
hereby repeated, so please refer to page E-13---15.
Details for the repeated points are omitted.
Cleaning
Illumination lamps
Oil and grease
Wire rope
Water exhaust
Hanging unit
Sheaves
Interlocking limit switch
Slewing post and jib
Slewing ring
Brakes
Others
1) Cleaning
Do cleaning in case this cannot be performed as daily maintenance and inspection
after operation.
2) Illumination lamps
Open the door for control panel equipped at the operator's cab. and check the fuses
and the cables for lighting by tester.
That way the condition for the lamp filaments can be judged. Please do this checking
when the crane is not powered.
3) Oil and grease

Please refer to "Lubricatio~· on page E-21 for details.
4) Wire rope
1) No adhesive matters injurious to the rope?
2) No abnormal condition at the fixed end (drum side, post top side), etc.?
Check the following points as well as item "Wire rope, page E-3~10'' before-mentioned.
5) Water exhaust
Two drain pipes sets at machine room.
Water that comes in and accumulated from man hole, will be exhausted by
these drain pipes.
Please check the drain pipes for not checked by dust.
6) Hanging unit
(hook, swivel, shackle)
(Refer to fig. 10)
Check these articles for a""

HJ injurious and for well greasing. Judging form the
damage condition, please replace newly.
~
t. - 15
I
7) Sheave
Sheave is subject to wearing at its groove and flange, due to constant contact to
the rope.
The wearing limits (s) is about to to 15% the rope diameter .
. In case of wearing in excess of the above, or deformed flange and damage flange.
Please replace newly.
F i g. 2 0
8) Gear
It is also important to check clutching condition of gear clutch condition of hoisting
and luffing winch should be checked with cover through observation window.
Tooth to be changed for new one if wearing thickness of tooth come to 10%""-'15% of
original dimension (Thickness of tooth in PCD is rrM/2 ----- M=Module).
Normal clutching of tooth shows mirrow face at P.C.D line.
However if pitching so on is found, to extent, please consult to maker. For change to
new one, it is preffarable able to change both pinion and gear in pair.
9) Gear oi 1
One of important thing for gear is suite and unsuite of lubrication oil.
In case viscosity of oil is low break down of tooth face.
In case viscosity of oil 1s high ---- resistance increases, and efficiency

will decrease.
As above problem may be caused, please use maker recommed oil.

- ,
t.. - 1 .
-
10) Interlocking limit switches for hoisting and luffing

Please refer to "Interlocking limit switches on page D-1 before-mentioned, as for the
check points.
11) Slewing post and jib

Please make the visual inspection on the slewing post and jib for any injurious damage
on the welded parts.
12) Slewing ring

Please check the followings
(1) No bolts loosened?
(2) Seal isn·t peeled off?
(3) Internal gear and balls are

well greased?
13) Others
Check the followings, and replace if damage or abrasion is in excess of the permissible
standard.
Rope slackover prevention device push roller device
* Brake (refer to page B-14)
*Hydraulic components (refer to instruction manual for hydraulic equipments)
3. Maintenance and inspection at the time of docking
Most of the ships are coming in dock for repair service at some constant interval
(about one year).
Explanation is hereby made for the maintenance and inspection at that docking time.
If the maintenance and inspection are both daily and periodically made-as explained
before, there will be not much points to be made in details at the time of docking,
so the main points to be done are those maintenance and inspection that couldn't be made
due to insufficient time, and those points that are expected to be done only at this
time of docking.
Oil and grease Door

Brake Hanging unit
Winch Slewing ring
Sheave Painting
Window-panes Greasing
Wiper
1) Oil and grease

Please be sure to do oil replacement and greasing on each winch.
Please refer to "Lubrication" on page E-21 as for the method.
Also make checking on grease pipings for choking, pipe bending and damage, nipple damage,
etc. and make replacement newly judging from the conditions.
2) Brake
Check the abrasion condition on Brake disc.
3) Sheave
Check sheaves at the time of wire rope replacement. Sheave where wire rope is not
running can be manually turned. If any abnormal noise or turning stop is found,
please overhaul the sheave and bearing. After replacing the part, re-assemble them,
wiping out dust, and greasing on the bearing.
4) Window-panes
There are the fixed type and openable type windows. For the fixed type window,
check the H-shaped rubber packing to hold the window-pane for any deterioration
or damage. Slight damage may be method by binding agent, but in other cases, the
H-shaped rubber packing has to be replaced. For openable window, please check
the tightening clips and hinges as well as the rubber packings. If mending is
considered impossible, please contact in advance to the maker.
5) Wiper
The front of the openable type window is equipped and blade for their condition to
let the wiper be in contact uniformly on the glass surface and let it get well actuated.
6) Door
There are two doors; greater for maintenance service rear of slewing post, and an
entrance operator's cab. and working.
These doors are of hinge type, so please check the hinge pins for being not stuck.
When being stuck, door handling gets heavy. Also check the door clips for their
functions to keep tightness. If any paint and foreign matters adheres to the packing,
tightness gets worse, so please remove them appropriately.
7) Hanging unit
The hanging unit for the single crane is of falling block.
Please check the followings;
(1) Sheave
(2) Sheave bearing
(3) Swivel for any damaged screws and abnormal condition on bearing.
(4) Hook for abnormal deformation and abnormal wearing.
8) Slewing ring
Set bolts slewing ring for both inner and outer races are tightened by the torque
wrench with the regulated torque.
Consequently they are scarcely loosened, by not absolutely fixed. So it is necessary to
check them for loosening. Easier method is to hit the bolt head by test hammer,
and loosening can be judged auditively. When loosened, please tighten-up bolt
with the regulated torque by the torque wrench as shown on the Table 5. Excessive
tightening makes the bolt to be apt to get cut.
The bolt is tightening after applied anti-rusting oil.
TABLE 5.
Ki n d Bolt size Tightening torque Material

30T x 22M/R Inner M36 x 150L x 70s P=3 225 Kg-m SCM440H, CLASS 10.9T
Outer M36 x 205L x 65s P=3 225 Kg-m SCM440H, CLASS 10.9T
Overhaul and inspection
No overhaul is needed for the slewing ring if well maintained.
In case of overhauling by inspection of classification society or spontaneously by
owner, please consult with us.
9) Painting
In case of touching on the peeled parts, or re-painting, please observe the attached
"Painting Specification...
10) Greasing
When completing all the mending work, please confirm again for greasing.
4. Lubrication
Lubrication is very important for maintenance of machine.
Appropriate lubrication protects the machine from wearing, corrosion or damage,
and prolongs durability of the machine.
1) Lubrication system for this crane

1) Grease lubrication
* Partial concentration lubrication system by grease gun.
* Directly lubrication system by grease gun.
* Manual greasing by brush, etc.
2) Lubrication points
1. Partial concentration lubrication system by grease gun.
* Winch drum bearing
* Sheave shaft (post top, jib top)
* Jib pin
* Slewing ring
2. Directly lubrication system by grease gun.
* Door
* Locking piece
* Falling block
3. Manual greasing by brush, etc.
* Internal gear of slewing ring and pinion
* Screw shaft of limit switch
* Wire rope
* Slip ring
* Coupling of pump unit
E - 21
2) Oil lubrication
(1) Lubrication system (winch casing)
Oil bath system is adopted, and lubrication is performed by splashing the oil by gears.
(2) Lubrication points

Winch (hoisting, luffing, slewing)
( 3) Inspect ion
Winch is equipped with the oil level gauge as shown on the sketch, so make inspection
by this oil level gauge.
Inspection points
Oil amount is up to the level between H and L marks? If the level is near the L-line,
/
please replenish oil up to the level in the middle of H and L marks. Be careful not to
fill oil in excess.
Oil condition is white and muddy or black? When being white and muddy, or getting black,
please replace the oil. Negligence brings damage on gears and bearing fast.
(4) Oil replacement

1. Remove the lid for oil pouring hole.
2. Replenish the oil from this oil pouring hole.
Fig. 21
(5) Oil drainage
Waste oil of hoisting luffing and slewing (Drainage method inside of slewing post)
1) Connect the hose with the drain pipe provided on the winch.
The hose and to be led at on adequate place through drain hole provided at slewing
base plate.
2) Open valve fully and make oil drainage.
3) As slewing winch has also provided the drain pipe at fixed post(ship body side)
inside, mark drainage from fixed post inside after completion of crane operation.
(6) Oil replacement sequence

1. Exhaust the oil perfectly.
2. Cleaning the casing inside fully for the remaining oil, using the light oil or
flashing o i 1.
_,---..
r 3. Dry the casing inside.
4. Fully close the drain valve.
5. Pour the new oil up to the level between H and L marks of oil level meter
or regulated quantity.
(7) Cautions
Please use the designated oil or its equivalent, as it has been selected as appropriate
for the intended place, judging from the gear kind, and v1scos1ty at the oil temperature
in operation, etc.
If using the oil other than the designated brand.
Oil of lower viscosity increases wearing of touching tooth surface.
Oil of higher viscosity brings much resistance of gears and bearings.
\ 3) Working fluid
Refer to page E-25 for the recommendable brands, but it is necessary to start operation
observing the following conditions which are required for the hydraulic equipment
generally.
1. Most appropriate oil temperature for operation is

+25° C to +60° C
When the oil temperature is lower than +20° C, please continue warming-up operation
in hoisting and luffing at a slower speed, till the oil temperature is up to +20° C.
If the atmosphere temperature -10° C to +5° C please make inching starting.
(Please refer to the instruction manual for hydraulic equipment.)

2. Interlocking with oil temperature
When the oil temperature in oil tank is more than about 85° C, the hydraulic
operation circuit is closed.
In the case, please make idling of the pump for cooling of the working fluid till
the temperature, gets about 60° C.
.Y
('
PAINTING SPECIFICATION
I
::kJ!b/10222
PR IMAR YSU RF ACE SECONDARY
ITEM PREPARATION SURFACE UNDER COATING FINISH COATING COLOR PAIHT MAKER
--
S. BLAST S.PRIMER PREPARATION PAIHT COATING PAINT COATING
JIB OUT SA2.5 ZP ST2.5 CR·R/P•HB 80 /J xl CR•F/P 40 /J x} N-9. 50036) CHUGOKU MARIHE PAIHl
IN Ji II - (V. p. I.) -
POST OUT Jl II ST2.5 CR•R/P·HB 80 /J x} CR·F/P 40 /J x}
N-9. 50036) CHUGOKU MARINE PAINT
---
(WITll WINCH) IN JI II II OL•R/P 3511. xz OL·F/P 3511. x}
N-9.5(1036) MAKER STANDARDS
OPERATOR'S CAB. OUT )) II )) EP·R/P 150 /J x} CR•F/P 40 J.l x}
N-9. 50036) CHUGOKU MARINE PA INT
IN )) )) II OL·R/P 3511. xz OL•F/P 35 t1 x}
SIDE WALL MAKER STANDARDS
2. 5G 8/3 (501)
FLOOR DECK
PAINT (GREEN)
----- ~· --·----------
llYDRAULIC PART OUT MANUFACTURE'S STANDARDS MANUFACTURE'S STANDARDS N-9. 50036) & MAKER STANDARDS
MAKER STANDARDS
-- - · -·~-·---
ELECTRIC PART OUT MANUFACTURE'S STANDARDS MANUFACTURE'S STANDARDS 7.5BG7/2(Sl4-632) MAKER STANDARDS -··-----·-
CARGO BLOCK OUT .SA2.5J=~p ST2.5 CR•R/P•HB 80 /J x} CR•F/P 140,,xJ YELLOW &BLACK CHUGOKU MARINE PAlttl
TIGER MARK - - ·------~------------
UNDER COATING FINISH COATING
ZP: ZINCRICH PRIMER CR·R/P•HB : Chlorinated rubber based CR•F/P : Rubber chloride finish paint
rust-preventive paint
(lligh build type color:grey)
EP•R/P : Epoxy antirust paint
OL·R/P : Oil antirust paint OL·F/P : Oi I finish paint
E - 25
OIL AND LUBRICATION
Oil and Lubrication

Lubrication is indispensable for maintenance of the equipment.
The following table for lubrication is made with the produces by JOMO OIL CO.,LTD.
and please select the equivalent brands in quality if choosing other maker's products.
The reguired guantit1 on the list is for one cranEt:..
0i1 Lubrication Lubrication

Kind Brand
amount interval method
Hydraulic working
HYDRUX ES32 4 50 .Q
Refer to hydraulic I
fluid instruction manual
First change time
J Winch 19 .Q abt.500-600 Hours
for hoisting REDUCTUS 7 .Q (6 months) Oil splash
for luffing 220 4 5 ,Q From second change
for slewing time abt. 1000-1500
Hours
Electric motor LIZONIX EP2 ~~equate Grease gun I
I
Internal gear GEAR
Slewing 4 kg Manually
A COMPOUND 2
bearing
Ball race B
Sheave, door hinge
grip, hunging unit, 2 - 3 times
jib~pin, drum bearing, of
slackover, prevension, LIZONIX EP2 10 Kg navigation Grease gun
push roller Manually
I
Limit switch,
chain and sprocket,
bevel gear
I
Wire rope
GEAR
COMPOUND 2
8 kg Manually
SLETING BEARING
TD GREASE NIPPLE STAND )

( IN SLEVING POST
:: - 26
TABLE OF LUBRICANTS FOR DECK CRANE We recommend the following products or those of proven equivalent
quality for use when lubricating our deck crane.
.A
~ =
- Ch1vron
Outside
@ rJ
~ <§> ~3 (j
Lubricant points
I
Temperature.
I
M@bil I
Shell
j I
from +35° c CASTROL SHELL Super DAPHNE
RANDO OIL COSMO BP BARTRAN Hydrofluid Mechanism
to -15° c HYSPIN AWH NUTO HP32 Mobil DTE 13M TELLUS OIL Hyrando Super Hydrau-
HD AZ32 HYDRO HV32 HV 32 EP 32 LPS 32
(ISO VG32) I 32 K32 wide 32 lie fluid 32 I
from +45° c CASTROL SHELL Super DAPHNE
Hydraulic fluid to -10° c HYSPIN AWH NUTO HP46 Mobil DTE1 SM TELLUS OIL
RAND OIL
Hyrando I HYDRO HV46 Super Hydrau-
BP BARTRAN I Hydrofluid Mechanism
HD C-46 HV 46 EP 46 LPS 46
(ISO VG46) 46 K46 wide 46 lie fluid 46
...\
~ SHELL
from +45° c RANDO OIL
TELLUS OIL
to -20° c HD AZ32
T32 I
WINCH
CASTROL SPARTAN Mobil gear
SHELL
Multi gear EP BONNOCK COSMO GEAR
DAPHNE
i BP Energol Super Gear Gear compound
Hoisting all section OMALA CE COMPOUND
ALPHA SP220 EP220 630 SAE 85w/90 M220 M0220 GR-XP220 Lube SP220 EP220
Luffing No.220 220S
I I CASTROL I SPARTAN I Mobil gear

SHELL
Multi gear EP I BONNO CK I COSMO GEAR DAPHNE i'
BP Energol Super Gear
I Gear compound
I
Slewing gear all section OMALA CE COMPOUND I
ALPHA SP220
I
EP220 630
No.220
SAE 85w/90 M220 M0220
220S
i
i'
GR-XP220 Lube SP220 EP220
I
Open gear !
CASTROL SHELL COSMO GEAR
Slewing pinion SURETT Mobil tac Open gear BP Energrease
RUSTILO CARDI UM Crater 2 COMPOUND
oil No.2 iI OG Open Gear
gear FLUID N-5K 375NC
553 COMPOUND D Cranoc No.2 OG Grease
all section ' Lubricant
Slewing ring !
1 compound 2 500
CASTROL SURETT Mobil tac
SHELL COSMO GEAR
Open gear
! BP Energrease 250CB
Wire rope CARDI UM Crater 2 COMPOUND

RUSTILO 553 FLUID 4K 375NC oil No.2S j OG I
COMPOUND D SPECIAL No.2
Slewing ring CASTROL SHELL BP Multipurpose Dura-Lith

LITHTAN EP2 Multi fak DAINAMAX GREASE
Other greasing all section SPHEEROL Mobilux EP2 AL VANIA EPNOC AP2 Energrease EP Grease Grease
I
points AP2 I
(BRACON) EP2
I GREASE EP2
EP2
I EP No.2 CORONEX EP2
MM-EP2 I No.2 EP2 I
NOTE : 1) For lubricant and grease quantitier and maintenance intervals, see instruction manual.
2) Open gear (Slewing pinion gear. slewing ring) wire rope Comply with special lubricating instructious issued by lubricant suppliers.
H. No. 10222
FINISHED DRAWING
(MACHINERY PARTS)
30/25 TON X 22/23. 5 M/R
ELECTRIC- HYDRAULIC
DECK CRANE
~
TSUJI HEAVY INDUSTRIES CO. , LTD.
CONTENTS
GENERAL ARRANGEMENT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19 3 9 2 8
MACHINE ROOM & OPERATOR'S CAB. ARRANGEMENT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 194 91 5
PASSAGE PLAN 193656
LUBRICATION SYSTEM ARRANGEMENT - .. · ...... · ... · .......... · · .. · · · · · · · · · · · · · · · · · · · · · 19 39 30
SLEWING POST UNIT ASSEMBLY ............................ - ......... - .. · · · · · · · · · · · · · · · · 1 9 7 8 3 1
SLEWING POST TOP UNIT ASSEMBLY 191827
ROPE END STOPPER UNIT ASSEMBLY 173992
OPERATOR'S CABIN UNIT ASSEMBLY 183370
HOISTING & LUFFING WINCH UNIT ASSEMBLY ··········································· 185240
HOISTING GEAR ASSEMBLY DRAWING · · · · · · · · · · · · · · · · · · · · · · · · · · ................ - . -· .. - . . KHA 3 1 4 G
LUFFING GEAR ASSEMBLY DRAWING ..................................................... KHA315G
HOISTING & LUFFING WINCH SPECIFICATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · - · · - - · · · · · - -- · · · LO 101 2
HOISTING & LUFFING LIMIT SWITCH UNIT ASSEMBLY -.............. - - ...... - - - .. · - - - . - 19 25 9 8
PUSH ROLLER UNIT ASSEMBLY .......................................................... 185360
SLACK OVER PREVENTION DEVICE UNIT ASSEMBLY · · · · · · · · · · · · · ·· · · · · · · · · · · · ·· ·· · · · · · 18 2 3 2 3
JIB UNIT ASSEMBLY ······························· · ·· ·· ····························· ·· ····· 18182 7
JIB TOP UNIT ASSEMBLY · · · · ... · .... · ... -...... - . - . - - .. - - - . - - . - - - . - ... - . . . . . . . . . . . . . . . . . . . 1 81 8 2 8
JIB BEARING UNIT ASSEMBLY ··········· ······ ··· ······ ··· ····· ······················ ···· 17994 7
JIB NOSE ··················································································· 197924
30T CARGO BLOCK . ................ ................ .. . . ........... .................. ...... 190400
SLEWING BEARING OUTLINE VIEW · .......... - -.... - -.... - -..... - - - - - -... - . - -... - . -... - - . 18 4 8 7 4
SLEWING GEAR OUTLINE VIEW · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19 74 7 2
SLEWING GEAR ASSEMBLY DRAWING .................................................... KHA448G
TENSION BOLT (FOR INNER) · · · · · · · · · · · · · · · - . · · - . - · ............................ - . . . . . . . . . . . 1 8 0 7 2 9
TENSION BOLT (FOR OUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 O7 2 8
FLAT WASHER ············································································· 162006

H 0 lit D l.::.L i :r-;Jr
1
~,j
1
.:::tillt:ft•:l? 1flolit <-t1Ji111t1tl
r:J: 1 N . R . 4 5 , 0
~~!~~------------.
~ '• ~
. I
A
A
/;/i
SLEll'ING POST
/; / I.
! :I HOOK MOVING CURVE
/ ,I:I I
I f'·J I ti!
:i I 0
0
0
<I"
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45 THRUST WASHER I 2 SUu lwsstt32 5 PLANETARY GEARI 3 lscMa1sHI
46 THRUST WASHER I 2 sPc: 1As 1102 6 nRUST WASHER I 6 /s?cc I
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121 ROLLER BEARJNGI 4 ISUJ IR!157D2PX1
131 SPACER(1) I 4 /5541 I
141 PLANETARY GEAR 4 jscM415HI
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21 ROLLER BEAR! NG I 1 ISUJ I230'108
22 CASI NG I 1 IFC045 I
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331 BALL BEARfNG / 2 SUJ /6014
351 or L SEAL i 1 /NBR lsB011515

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23 ROLLER BEARING 4 SUJ IR097302PX1
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29 PLUG 4 jFCMB I112
30 SOCKEi 2 IFCMB I 112
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32! BALL BE.A.RING 1 jsuJ 16232
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133 TAPi=~=n pr P• pi nr.
34 MOUNTING FLANGE 1 IS45C II
35 AIR VENT 1 5541 I 11s
) 36 STREEi ELBOW 1 FCMB I 11a
37 OIL SEAL I 1 INBR lo2002co20
38 COLLAR I1 S45C I
39 BALL BEARING I 1 SUJ lso12
40 SPACER(3) 1 SS41 I
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TABLE OF HOISTING & LUFFING WINCH SPEC.
D.No. L01012
ME SSE R S. OSHIMA SHIPBUILDING Co., LTD.
S H I P N o . 10221. 10222
C R A N E T Y P E Nl -CHRS3022
HOISTING LUFFING
REDUCTION GEAR TYPE CPHFL-150A-OS-43 CPHFL-llOA-OS-83
REDUCTION GEAR RATIO 1/42.39 . 1/81.57•
HYDRAULIC M01UR (r.p.m) UP 341/518/1351' 1537'

DOWN 1198
DRUM P.C.D (mm) 900' 800
WIRE ROPE SPEED (m/min.) UP 22.8/34. 6/90.2' 47.3.

DOWN 79.8
DRUM LOAD (kgf) 18250 . 9535
WIRE ROPE SPECIFICATION NON-ROTATING ROPE 6Fi(29)IWRC

¢34 SH GALV. ¢30 A GALV.
REDUCTION GEAR MACHINE OIL VOLUM 19 Jl. 7 Jl.
(ISO tt220) (ISO tt220)
DATE ; Aug. 26 1997
MANAGER
SUB CHIEF (< ~.d~a.._ .

IN CHARGE K ~·
DRAWN F. NISHI
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179529
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UNIT ASSEMBLY OCT. 31. 1995
1~~§~/ Nl 1143
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DRAWN Ji, Nl:)h,l,, ~?i4. SLEWING BEARING
D.N0.184874. 6
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SPECIFICATION
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DRAWN F, Nish,~ 9:14
OUTLINE VIEW D.~~.184874. 6
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TSUJI HEAVY INDUSTRIES CO., LTD. (A3) c1/1rn·
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27.0"-30.4~~t ·m
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Af R VENT/ MATERIAL ISCM440

GAUGE I
INLET SURFACE HARDNESS! Hs63"v70
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LUBRICATION METHOD OIL BATII LUBRICATION
~
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OUTLINE DI.MENSICN & WEIGhi
DIM.ENS IONS OUTLINE mm. HO. F Q. A 0 2 6
TOLERANCES JIS B-0401-1976 "f8" •."HT
CROWNING DIMENSION WEIGHT f l6 0 kg (WITIIOUT MOTOR)

PINION
I
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REMARK MANAGER
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DIMENSIONS WITH *MARK ARE 2.Smm " ,.
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IO'T IO'T~MATEH1A~ REMARKS Ior
0
NO. PARiS NAME MATER1A4 REMARKS INo.1 PARiS NAME NO. PARiS NAME REMARKS
!---'--~~~~~---'----'~~-.-~~___,
911 PIPE I 1 !STPSl ~8X292 .:'.!.61 BUSHING I 1 jFCMB 11; x1/4 1 OUTPUT SHAFT SCM440
92 CONNECTOR 2 IFCMB I KCT08-020CE 47 SOCKET I 1 FCMB 1. 2 I COLLAR I 1 S45C
931 PINION j 1 jSCM440 48 PIPE I 1 !SGP i112x125 3 0 IL SEAL I 2 INBR 1023027020
94 END PLA"iE SET l1sE~SS41 ZINC PLATED '1.9 REDUCING ELBOWf 1 IFCMB ''/?Xi/4 I
4 HEX. HEAD BOLT 12 SCMd35IM16X45 I
57 95 HEX. HEAD BOLT j 2 SCM435 M30X80 501 PIPE 1 SGP l1/4X60 5 PLAIN
{CIRCULAR BRIGHT WASHERJ 24 S'.. :i~ca-1
WASH"R I M16
9 6 NIPPLE 1 IFCMB 51 KEY (SQUARE ENO) 1 S45COil 10X8X40 6 OUTPUT COVER 1 FC0.15 I
97 UNION 1 IFCMB 52 HYDRAULIC BRAKE! 1 IHNBD405M 7 ROLLER BEAR I NG 1 jSUJ 1222408
60.1 I 53 HEX. HEAD BOLT 4 jscM435hnsxss I 8 SPACER (1) I 1 SS41 I
54 HYDRAULIC MOTOR! 1 I 9 CASING 1 FCD.15
I 1 jSK5M 140 1 0 ROLLER BEAR I NG 1 f SUJ . 230408
I 1 SK5M lso 11 SPACER (2) 1 jSS41
I 4 SCM435IM12X35 I 200
13 THRUST WASHER 2 jSPCC AS! 102
5 91 BALL BEAR I NG I1 SUJ 16208LLU 14 CARR I ER 1 jFCD.15
6OI PLUG I1 FCMB I -;i/4 1 5I pIN I 4 ISCM43Sj55x15 6
611 ELBOW I 1 IFCME hid 4 jSCMd35jM10X35
621 PIPE 1 jSGP 13/dXBO
6 3 SUN GEAR 1 SCM420Hj 181 ROLLER BEAR I NG 4 SUJ IR! 157D2PX1 I
64 THRUST WASHER ! 1 SUJ lwss1130 19 PLANETARY GEAR 4 jsCM41SHj
6 51 0 IL GAUGE I 1 I KCM-20 2 0 INTERNAL GEAR I 1 SCM435H
6 61 INTERNAL GEAR I 1 jscM43SH! 21 CARRIER l1JFC045
67 CARRIER I1 JS45C 2 2 P!N 3 jsCM43s-+j-4-3x_1_3_2_
6 8 THRUST WASH ER I 1 SUJ iwss 1116 23 3 SCM435 M10X30
6g c
ARR I ER I 1 Fc04 5 f 241 THRUST WASHER 6 jSPCC I
25jCONNECTING COVER 1 IFC045
711 SUN GEAR I 1 jSCM420HI 2 6 HEX. HEAD BOLT 22 SCM435 M24X190
721 SPRING PIN I 2 jSKSll. !16X65 2 7 ~~1kM~~H~~IGHT WASHER) 24 jS45CQTIM24
/7 31 SPR i NG pi N I 2 ISK51ii 10X63 28 ROLLER BEARiNGj 3 1SUJ R0973D2PX1
74 CONNECilNG COVER I 1 jFC045 I 29 PLANETARY GEAR 3 jscM41SH
7 51 EYE. NUT I 2 S20C ! M2d 3 OI I NiERNAL GEAR I 1 jscMoSH
76 TAP END STUD 2 SCM435IM24X200 3 1 P 1N 3 IscM4 3 sI2sx94
7 7 HEX. NUT I2 ls45COT! M2d 32 SPRING PIN 3 ISKSM 8X16
78 SPRING PIN I 2 SKSI<'. l16X100 33 HEX. HEAD BOLT j !2jSCM435 M20X140
791 SPRING PIN 2 SKSll l1ox100 34 ~~~~U~~~H~~IGHT wmERll 12jS45CQT M20
80 RETAINING ~ING 1 SK511 j 95 3 5 THRUST WASHER 6 SPCC
81 SUN GEAR 1 jsCM420H! 3 6 ROLLER SEAR I NG 3 jSUJ R06A1702PX1
821 SPRING PIN I6 jsKs11 l2ox130 37 P~ANETARY GEAR 3 isCM41SHI
83 SPRING PIN I6 SKSll ! 12X130 38 INTERNAL GEAR 1 SCM435HI
I 1 SKSI-' I 1'15 3 9 P! N I3 SUJ3 '3ox5s. 5
I 1 SCM4.!0H! 40 THRUST WASHER 3 SPCC IAS1106
0
86 PLUG J 1 FCMB li 41J ROLLER BEARINGj 3 ISUJ ~~::tmox3
871 SCREWED GLOBE VALVE! 1 jB. C i lX5kgf 42 PLANETARY GEARJ 3 SCM415H
88 PIPE J 1 SGP l1XB5 4 3J HEX. HEAD BOLT B ISCMd35j Mi 6X175
8 9 PLUG I 2 jFCM.3 ! 1/d 4 4 ADAPTOR I1 FC20 I
90 SCREWED GLOBE YALVEj 1 jB. C i 1/4X10kgf 4 51 Ai R VENT I 1 jSS41 1/4
SLEWING GEAR
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\cusTOMER! IWORK. NO. ; I1T!:M NO. I

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DATE HI STORY OF 0. RIV. DATE REMARKS ITEM OR 0 C K B
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FINISH TOLERANCE RANK-A
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D.NO.
TSUJI HEAVY INDUSTRIES CO .. LTD. 180729"6
I A A I I t , I \
DATE Ht STORY OF D. RIV. DATE REMARKS ITEM DR D C K B
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DATE HISTORY OF O. RIV. DATE REHARl<S I TEH OR I0 c K B
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TSUJ l HEAVY INDUSTRIES co. ,LTD. O~NO. l 6 2006 &

I 11 1 Fi? n nr; 11 lr11 \ 'i5"
S H I PYARD 0 S I MA ,S H I P B U I L D I N G C 0 . . L T D.
SHIP NO. 10221. 10222
~ INSTRUCTION ~ANUAL
(HYDRAULIC EQUIPMENT)
ELECTRO HYDRAULIC DECK CRANE
30/25 TON X 22/23. 5 M/R
TSUJI HEAVY INDUSTRIES CO . . LTD.

- CONTENTS -
PAGE
1.HYDRAULIC CIRCUIT --------------------~---------------------~----- A-1
OIL PRESSURE TABLE --------------------------------------------- A-2
2.CAUTION OF NORHAL RUH ---------------------~---------------------- B-1
3.EHERGENCY HANUAL OPERATION -----------7--------------------------- C-1
4. IHSTRUCTJOH HAHUAL FOR BRAKE ------~--~------7-------------------- 0-1
5.REPLACEHEHT PROCEDURE Of FILTER ELEHEHT ------------------------- E-1
6.HAHAGEHEHT.:of HYDRAULIC OPERATING FLUID -----------------7------ F~1
7.TABLE OF LUBR1£AHTS FdR DECK tRAHE ------------~---------------- G-1
8.HAMAGEHEHT FOR NORHAl RUH ----- - -- --- - ---- H-1
9.TROUBLESHOOTIHG AND HEASURE ----------~~-------------------------- 1-1
10.HAlHTEHAHCE AHO IHSPECTIOH STANDARD--------------------------~--- J-1
11.CHECK· HETHOO FOR HOSE --------------------------------------------- K-1
12.HOSE ORDER CIST --------------------------------------------------- l-1

1 2 ·3 4 5 6 A -1
DAfo I' .. i STORY OF o. R.I v. _. .... 1 i:. : ~.EMARKS l TE:~A I DR ID j c !K I3
HOISTING,--~
SLEWING
'
SOL.~ i;tL~~-------__,
~ a p,,r b LUFFING I
>.6VSOO
Wr·:-i · ·-· •oR
•PPO ·--c~----4--~----
' 0. 4
• 0. SOL.~
~a
\J7
P11Tb
,, -t~.,~ Q TYj TYi'.'£ REMARK
A -------------~~--.' l jOIL TANK 1 I 250L A
W>lfOR
I 2 I 1 CA8-50A
!OIL !NLET&AIR BREAIHER.
' 3 !LEVEL GALGE WITH !HEFM) 1 ID6xH!50
4 IFLOAT SNITCH 1 jM565
5 jeuTTERFLY VALVE I 1 lOAL-L-!OOA I
s jSALL VALVE I 1 l&OORS-1 V4
7 I TriERM)STAT 2 !1NS-TYI'.'£
,3 !LINE FILTER I 1 .FH441-24-100-P020x50
9 iC.'1€0< VALVE 1 iCA-16F-A2-30-330-942-0
\' - - - - - - - -
153:VARIA8LE
l J JFP.N COOLER I 1 IOA-2827
~3.0
iI 1 1 jro;PLJl\G 1 jKC8022
PISTON MOTOR !
1 2 !ELECTRIC MJTffi ~RINEJ 1 ~OV-60f.'Z l 12KW-4P
1 3 I PlSTCf'J PlM' 1 !A2Fl 07Rl P3-U
1 4 jPISTCf'J PlM' 1 A2Fl 72Ll l"..rU
1 5 IOEO< VALVE I 2 F}illO-PSR.-ED
1 o !ELECTRIC M)Tffi ~IN8 1 j~0-60f.'Z 3. 7KW-4P
1 7 ICOJPLI l\G I 1 KC4016
l 8 lcv.~ PlM' 1 GSP2-AOS12AR-AO
l 9 ICCUPLI l\G I 1 jKC8018
201 I -- B
2 l JM!Nl. CHECK CCOJPL I N:J1 6 100-52.000
~2 I~SSURE SWITCH 3 ITDZ-TYI'.'£
2 3 IMl>RJf-€ DIR£C. rofr. VALVE 1 CHP40F21Pl0000-952-0
2 4 IM'IRIN::
DIR£C. a:::NT. VP.LVE: 1 CHF32F20Bl0000-953-0
2 5 11.'AAIN:: DIR£C. o:::NT. VAL'/€. 1 CHP32F20EI0000-959-l
!2 6 iJOYSTiO< VALVE 1 j2R£7LOS-l3-994-2
i2 7 IJOYSTIO< VALVE I 1 i4Tl-17Zl4-l:>!V1.M
['2:3 jSO!..EM)lD OPERATED VAL'/€. 2 i 4'1.f&D-&;;:M)/P.Wl 1ONZ5L
2 9 iota< VALVE 2 jFIC-03-1. 0 Ill. 0
_J i3 0 jotCK VALVE l IF !C-03-0. 8 ¢0. 8
3 l Iota< VALVE 2 IF!C-03-Cl. 6 I .oo. 6
13 2 !BALL VALVE I 1 600RS-3/4
13 3 !BUTTERFLY VALVE I 1 I
lOAL-L-65A
57:MAN!FOLD 3LOCK 4 c
E9 TMM THC
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l......-~~----.....i.--------------.::........----------1--....._-----------
•DR •P. ?3·---~1······•
WM:: jq TYi TYPE IREMARK I

53 V.M)TOR I l I I I
53-1 VARIABLE PISTON I.OTO:: I l IA6V500HD6.2FZ23320-9-4<';-0
53-2 WJNTER BAl..AN::E VALVE I 1 RF1C32Jl081Alit-899-2 I I
53-3 MINI. CHECK (COJA...11'.G I 2 I 100-52. 000
LOOIC COVER 53-4 ISOLEN() ID OPERATED VAL:Jc.•_ _,.I__,l'-'-i4.:;WC..=6.:..J-....;6:...~--
......::._A_Wl.:..!:::..;.G;:...NZ..=.;5L=---'----'
D MI NI. CHECK CCOJPLll'.Gl 100-52.000 I ! CHRS3022 (CH RS D
54 1 .----------------.--------------,----------~
MANAGC:R MESSR.S $.NO.
54-1 PISTON MJTCR l I A2FM180/6. l W-SBOS-975--0 10221. 10222
CH:EF
52 Mo>.N L
BLOCK 2 1 54-2 l IRF1C32Jl0A1Alit-900-0 > - - - - - ' - - - - - - - - - - - l PROJECT NAM€ OP.GER NO.
52-1 SOLENOID OR':RATED VALVE 1 4W€.6D-6~AW110NZ5L 54-3 2 I100-52. 000 2ua CH!Ei'
52-2 RELIEF VALVE 1 DBl0-2-4*/100 I !.'i C~ARGE

SC~LE I PROJECTION
! Ti-' IP.!) ,.;NGLE
52-3 LINE FILTER 1 CM--04Z-2-l OU-IV 55 1 I I I 1--~~~~~~~--~--JHYDRAULIC
Di=l.AWi'.J
CIRCUIT
52-4 MIN!.CM'EO< CCOJPL!l\G 2 100-52.000 55-1 l i A2FM!80/6. JW-$008-974-0 l ;;~:i-r·
55-2 I 9 9 3 6
52-5 REOU:::ll\G VALVE 1 ZDR6DP2-3V75YM 1 IRF2825Jl08JBM/.:<-915-0
55-3 2 i l00-52. 000 I TSUJI HEAVY
') L i::;
0 - 18
-·- VAL.VE lJNIT. ~
/.:. ;1, 7' .:i. .::. .7 I·
P lJ M P U N I T
:I! / "1 .1 .:::.. ·:; I·
- 1lfo u c r 1
.• :'.'7}··-
o ti! ,qo; on
AC 110 k• 4P Etl401'\
1.urr 111c
lA~f1'2 l.I
t 1 ) ( 2 ) (3 )
HOIST PU¥P ffO 1ST ¥0TOR

;{; J: 'E- - 9
~; 1·'. CT. i\
OIL PRESSURE TABLE A-2
------------
NO. OF HYD. PRESSURE
CIRCUIT (kg/cml)
PUIP PRESS; @J 265
COUNTER BALANCE .
DOI STING VALVE ~ 2 8 0 (PC)
LOURING PRESS.
6 130
BACK UP PRESS. @ 1 1 0
PUIP PRESS.
6 25 0
UP PRESS. @ 210
LUFFING
COUNTER BALANCE
VALVE e 2 B 0 (PC)
SLEJING
SLEJING PRESS.
® 10 5
COUNTER BALANCE
VALVE ~ 115
CONTROL
AUX. PUIP PRESS.
~ . 7 0
LINE CONTROLLER
PRESS. ~ 4 5
HOISTING
SPEED CHANGE @ 165
( p s 1)
PRESSURE HOOi.
SIITCH OYER LOAD (30TON)
(PS 2)
® 2 5 0
·-
HOOI
OYER LOAD (25TON)
CP53)
®3 215
J
8 - 1
2. CAUTION OF NORMAL RUN
~-1. For usual opera~ion
To maintain for a ·1ong time stable and normal performance

of 'the crane, attened to the following matters.
1) Previous confirmation matters to ope~ation :
( l) The surface level of the:. working oil ·.that lies between
marks H and L on the. level gauge.
(2) The oil· te~peratur~ (by th~ :th~~mome~er equipped ~~th the·
f
\._j level gauge)
(3) The gate~ valve should be full open.
I For the working oil quantity I

a. It can be observed on the level gauge equipped with the
...
oil tank.
b. When th.e oii level less than the mark L, .. a· s~pplement of
oil should be done.
c. In this case the· happening of oil leaks may be supposed
therefore the oil tark, machine&, instruments, and pipings
should be checked for existence of oil leaks.
For the working oil tem;erature J
a. Read the ~il:te~perature b~fore: starting, by the thermometer

equipped with the level gauge.
b. If the oil temper~ture. ..le~s
. . t~an io"c, it 1s necessary
to care about the matter for starting in case of low
temperatures mentioned·.later.
level
ternoerature
B -2
Por the butterfly valves and ball valves opening

a. The butterfly valves and bal I valves (Ho.5.6,32,33 in the
hydraul.ic circuit drawing) should be full open.
b. D\ain st·op valve will be required to ~~ etas.ea generally,
and opened only at the drain~ge.·of .the oil.
c. Position of levers.
lever
ful I open closed ha rf open

0 x x
2-2. Matters that deman~ attention at starting

(l) lnching starting to oe done .
.
(2) No ~ load running to be done.
·(3) The airflap should be confirmed to be in opening position.
' I
'-...
For inching ·starting J
a. The inching startin~ means that the starting is done

after several repeats of ON, OFF.
b. Continuous running should not be done successuvely after
the s~arting, but should be done after several inching:
ON__..OFF- ON ~OFF--+ON Continuous
c. The rotators will be accustomed, and the hydraulic
equipment will be warmed up entirely, by the inching.
d. The trouble on hydraulic equipments will be subject to
occurring at the starting, and the care about pump
starting will be required extremely.
B -3
1-····
(a) Procedures of starting
The consequence in case of low temperatures is as stated

earlier, and the starting in this condition should be
done by the inching stating. ..
= The point of inching starting •
...: •.
·........
The· motor (inc 1 uding. the p~rnp) ·Will be ...speed· up gradually
as repeated ·starts and s~ops:
·~The· of rep~ats of· start and stop depends. on

. . .frequency
·the· a tomashere .t.emperature:
. . ).
. :. running time
\. _s_t....a_r_t_.
.. .. 1- 2 s e,,c_:..___
In the .. 'beginning, the running
stop t irne .time shouldt be ·short er;i, :'and . the
stop· . .
_ __
_..._·2-3sec
I sto~
. time
.. lengthened
. ..
following illustration.
as the
Gradu~lly, the running should

sta:rt
be lengthened. 1 and :the .stop
1- 2sec
shorten, as repeated starts·and
stop stops, and slowly increased the
2 -3sec speed up to the rating speed.
start
2 -3sec
stop
1....::..2sec
start
2 -3sec
stop
c£;2sec
3 -~sec j
(___s_...to-p-)
j l -1. Ssec
/ '
s~4
.·:
(b) Procedure of starting and warming. up in' case of low~

temperatures.
b-1) Procedure or starting
For the electro- hY<1rau11c· crane, the low temperatures
mean the atmosphere temperatures less than ten degrees
centig;rad.~,
=The condition of working oil in case of low temperatures.=
i) The viscosity of oil will be.come higher.
ii) Dete~ioration of liquidity will increase flowing
. res'ist.ance and make flo.w. difficult ...
. . ..
The. similar starting to usual starting, in case of' low
temperatures, may occur troubles as follows.
a) A~push on the starting switch will rotate the motor·
.. only a little, but it wili stop immediately.
b) .. The possibility of generating.cavitation in the
.pump will be great.
8 -5
(C) For warming up

Fo~ instsnce, if a man raises abruptly a weighty beggage,
or starts r~nning suooenlYi it may affect his health,
therefore, light exercise must be previously done as
·- the ·p.revension against it: ..... ·Similarly. also for a machine.
~he warming µp will be necessary.
Especiall~1 1 . in case of low temperatures, the warming up
.:should .. be. c:i'one< sat isf ac toriry ~·:.: :. · ·,\·;

' .... ..i...... "
,, ......
.•••.•• ' ••••
.. .
·~ The procedure and point of . warming "Up
. ....
(~o be~done· Under no~laad condition)
a) Idling iunning to be done for about ten minutes under

~be .neu~ral~condi~ion.of~every~contrbller .
···· .
.... . .
b) ~.ake· s~owly @ controller to hoisting,· and do the same
operating
. . for five to twenty seconds,
'. .
then,
. slowly change
to the con:rary operating. Do this operating three to
five times.
c) Do @ controlling by usual handle operating two or
three times.
d) Do © controller operation by the procedure and point
mentioned in above b) and·c)'items.
e) Do ® controller operation by the procedure and point
mentio~ed in above b) and c) items.·
f) Warming up should be performed by the above procedure

.·.. of a) t'o e ). for twenty to iol"ty minut'e 1. . ·
(lf will be required for the warming up to do ror a long

time in case of low temperatures.)
8-5
Ifor no-load running
a. After inching operation, do not immediately hoist a load,

anq do slowly·hoisting, lowering, raising, and laying
operations under no-load condition, as running in and
w~r-mi.n5 up.
f ......
h: Especially, in case of low temperatures, do carefully

. the no-load running or warming up . running.
*·.It is similar to the starting of a· motorcar in
.:Winter ... ·
I.For air.flap! ...

a. The air flap is the door· to do ventilation in the crane
post.
b .. Make sure complete opening and closing of the door.
c When the doo~ not opened, the air will~m~ke.ohiy
circulation
. ... in the post, and not exchanged for. external
air,
.
therefore,
. '
the ~emperatur~s in . ~h~ post a~d
. working
oil will rise and become the cause of hydraulic trouble.
2-3 Matters that demand attention during running

L,
{i) Check the temperature of the working oil.
(2) Check the run~~ng sounds.
For the temperature of working oil

. a. Check ·the temperature of the oil by the thermometer
equipped with the oil level gauge.
b. The oil temperature will t>e a 'factor that e.1:ercises
important influence to the hydraulic equipment, and in
case of a man, it will correspond to the body heat, arid
it will be undesirable for the temperature to be either
too high and too low.
c. Generally, the proper temperature of working oil will be
about forty degrees centigrade, and it will be normal
provided the oil temperature in tank less than sixty-five
degrees centigrade.
.8-7
(3) Caution for hoisting operation
d· WHEN STARTING TO HOIST, TAKE HALF HANDLE FOR HOISTING

AT FIRST. AFTER SLING WIRES ARE STRAINED, TAK~ PULL
HANDLE FOR HOISTING.
HALF HANDLE OPERATION FULL HANDLE OPERATION
i
SLING IIRE
LOAD
(FIG.-1) (FIG.-2)
b. IN CASE OF FULL HANDLE BEING TAKEN FROM START (FIG.-1),
HOISTING MAY BE IMOPERATIVE AFTER SLING WIRES ARE STRAINED.
IN THIS CASE, RETURN HANDLE TO NEUTRAL AND TAKE HANDLE AGAIN.
c-1
3. EMERGENCY MANUAL OPERATION

3-i. HOISTING DEVICE
'
In case of power failure,.and
in trouble
1) Prepare the by-pass assembly.
Fig. 1 BY-PASS ASSEMBLY
(See fig. 1.)
* Close
. . . the gauge cock .
2) Conne.c.t the. hand pu~p and hose -i!~=~~~±::£~iCiiii;;;;;;;iiiiiiiiiiiiiiiiiii\E:
assembly. ( See fig. 2 ) GAUGE COCK
3) Loo~en the caps of mini-
.. ·;· ....
check -valve. . : .. :...
. . (..·See fig. ·3.)
4) Connect the mini-check (Y with",
Fig. ~ HAND PUMP ASSEMBLY
®by by-p··~ss assembly.
( See fig. 1l )
PRESSURE GAUGE
5) Remove the hose fitting Q) ,
and.. the ..hose
. assembly for th~
hand pump. ( See fig.· 5

6) Operate the hand pump,
·the pressure gauge and observi.
the movement of the auspended
load.
Fig. 3
0
The brake is released with the
. . . COUNTER BALANCE VA
pressure gauge indication bein OP HOISTING MOTOR.
\ 17 bar. Don't give pressure
'r
to be more than 30 bar.
7) Lower the suspended load little
by little not to let it come to
stall, op~rating
the gauge cock.
tci o~en ari~·to close.
8) Finish lowering the suspendectMINI-CHECK \MINI-CHECK (?
load.
Fig. LI
, ' ...
1
c - 2
..
·~~.·
fig. 5
9) Loosen the return cock of the ~and
I
pump, and confirm that the indicator

or pressure gauge has come to iero. -----ri
(0). After confirmation disconnect 1
~~~~--11-+--+-~tr++-~-=:::;:--t--tt"'
the hand pump, and fit the hose

·fitting ·as originally fitted to
the brake port.
).0) Remove the mini-check hose, and
BRAKE PORT
screw up the caps of mini-
:· :·~heck. valves CD@ . .'. .
·. 11 )> .. ~1ake ·~ir.~brea tl'i·i'ng. ·:sat i'sr actor iry
~ When the hose fitting in the
p;.ping line is removed, .. oil ·leaks 1
and when it is ~gain fited, ~ir
is inholed. So it is necessary
to make air-breathing to the
satisfactory degree.
C-3
3•2. LUFFING DEVICE Pig. 6

Manual operat.ion for jib lowering HYD. MOTO'R
method 15 Bame as suspended load ./FOR LUF'FIN~
lowering, however conne~ted points
I
are difficult. (See fig. 6)
\/lEW. A
BY-PASS ASSEMBLY
c- 4
...
3-3. SLEWING DEVICE
Pig. 7
!OPERATION (A))
(1) Comfirm that the ship condition
is level keel.
(2) Fix the crane Jio from

its both sides by means
\
of chain blocks and wire ropes.

(See Fig. 7)
IN BLOCK(B)
*,Use the chain blocks for 5 tons.
(3) Prepare the by-pass assembly Fig. B

and hand pump assembly. MINI CHECK
VALVE
(~) ~oosen the yellow or black caps
of mini check valves of hyd.
motor for slewing.
(5) Connect the mini-check valve

by the by-pass assembly. HOSE PIT.TING
(See Fig. 9)
( 6) Remove the hose fitting ® that

is connected to brake port of slewing
winch.and connect the hose of hand pump.
(See Fig. 8)
(7) Operate the hand pump, and release

the brake.
* The brake is released with Fig. 9(\/IEW Y)

2
the pressure being 10 to 12 kg/cm ·
Don't give pressure more than
2
18 kg/cm .
I
GAUGE COCK
BY-PASS ASSEMBLY
....
c -5
(8) Open the gauge cock of by-pass assembly.

. ' . ' . . .
When slewing the ·jib to righti wind up the wire rope by chai
block (A), loosen the chain block (B).
When slewing the jib to left, wind up the wire rope by chair
block. (B), loosen the chain blo'ck ·(A).
(9) After the work is finished, loosen the·rcturn cock of the

hand pump, and confirm that the indicator .of pressure gauge
has come .to zero.
. ·, .···. . ..
Af'ter. 'conr1rmat1on",;' a16conriect the hand pump,: anc.1· fit··
the hose·fitting·as originally fitted.... to the brake port .
. ......
(10) Remove the by-pass assembly, and screw up the yellow or blac
dips of mini-check valves.
(11) Make air-breathing.
··'."
."
" "·'·
c -6
3~4. SLEWING DEVIC£

. F'ig.10
lorERATIOH (5))
(1) Comfirm that the ship condition
is level keel.
(2) Fix the crane jib from

its both sides by means
of chain blocks and wire ropes.
(See Fig. 10)
A N BLOCK(B)
* Use the chain block~ ror 5 tons.,
(3) Prepare the hand pump assembly. Fig, 1 ~

MINI CHECK
(4) Pleas~ take .off fastehing bolts LJ...
LJ...
VALVE
tot slewing hydraulic motor. 0
(Hunging on air.) (See fig.11) HYO.MOTOR
HOSE FITTING
(5) Remove the hose fitting © that

is connected to brake port of slewing
winch.and connect the hose of hand pump.
( S e e F i g'. 11 )
(6) Operate the hand pump, and release

the brake.
n The bra};e is :released with
2
the pressure being 10 to 12 kg/cm '
Don't give pressure more than
. 2
18 kg/crn
C-7
(7) When slewing the Jib to right, wind up the wire rope by chain
block (A), lossen the chain block (8).
When slewino the Jib to !eft, wind up the wire rope by chain
block (B). loosen the chain block (A}.
(8) After the work is finished, loosen the return cock of the
\ hand pump, and confirm that the ind.icator of pressure oauoe
has come to zero.
After confirmation, disconnect the the hand pump, and fit
the hose fitting as originally fitted to the brake oort.
(9) Please fit slewing hydlaul ic motor with bolt fastenino

toroue of Table 1.
(10) Hake air-breathing.
NOTE: If the OPERATION (A) is difficult,

please operate according to the operation (B).
Table 1
TYPE BOLT SIZE FASTENING TORQUE

A2F 8 0 4-Ml2 12-14.5 kg1-m
A2Fl07 4-M16 27--30.4 kot-m
A2F125 4-Ml6 27-30.4 kgf-m
A2Fl60 4-Ml6 27-30. 4 kg1-m
A 2 FM 180 4-M16 27-30. 4 kgf-•
c -8
3-5. The procedure of brake manual re~ease on solenoid ·valve

trouble.
When the brakeB 10r hoisting, and luffing equipment
do not open because of the obstacle that is break down of
coil, etc. of each solenoid .. valve to open them (N0.28-1
28-2 in the hyd:r~ulic circuit drawing), a push on the. push
button equipped with the solenoid valve will change the
spool position of the valve,.. 'then the. hydraulic pressure
will act to the brake cylinder, and open the brake.
J. . I
button
±I
There are the solenoid valves for hoisting and luffing in
the valve unit.
D-1
MODEL HNBD NEGATIVE OPERATING

HYDRAU~IC BRAKE
1NSTRUCTION MANUAL
(FOR HOISTING)
D-2
Pref ace
Model mnrn dry-type multiple · disc hydraulic brake is a
negative operating type (spring closing type) brake, it is

released when opera tine; oil is .supplied to brake cylinder. It,
does not need any ad;ustment aft:er installation. But a
periodical inspection and maintenance hav& to be continued for

keepih9 good workable C<:!".di.+:ion of th'e brake. This instruction
manual may be effective for the works.
Con.ten.ts
1 . Specification ................................................................... 0.-3
2 Construction and Operation ..................... :............... . 0-3.
o-s·
4 Installation ······································································ D-5
s Precautions during Operation .................................. O- 5
6 ..Main.tenance
·
....................~ ..................................................... D - 6
7 . Overhauling and Assembling ...................................... 0- ·5·
8 . Trouble shooting ....................... :..................................... 0- 8
/ 0-3
1 . Specification
Model HNBD SOSM-04
Drawing No. 32700777
Static Torque 370 kgtrn
Maximum Oil Pressure 250 kgf /cm 2

Released Oil Pressure 21 kgf/ cm 2
Cylinder
I .
Capacity 110 cm'
2 . Construction and Operation

This brake is composed of 20 pieces of parts as shown
in Fig.1.
The cylinder(1J is bolted· with pr~ssure pla.te(7) and
side plate ( 1 O) from two . side. Inside side plate, there are
outer discs (15} geared into a tooth-shaped spline of the
cylinder, and inner discs (14) geared into hub (1 3), and they
are alternately inserted.
On the other hand, there is a piston(4) inserted inside
of the pressure plate. When operating oil does not supply
to the cylinder, the piston receives a spring torce !rom the
coil springs{12) and presses axially the friction discs and
the brake is "o N".
This piston is sealed by o-rings (2), (5) and back-up
r inqs ( 3) , ( 6) . When opera ting oil is supplied from the oil
inlet of the cylinder, the piston is pushed back to the
pressure· plate against the coil . .spring force, so that the
pressure on the discs become zero, the outer discs and inner
11
discs will be freed,and the brake is 0 FF".
I 0-L
C\5
Fig .. 1 .co.nstruc:tion·DWG. of ·Hydr-atrlic brake·
. ~)
N 0 Parts Name N 0 ... ...Part:,s Name

'-.../ ..
." 1 · .. Cylinder 1 1 I Hexagon Socket . .Head Bolt·
•'
2 0-ring 1 2 Spring Lock Washer

.
3 Back-up Ring 1 - I
::J. Hub
4 Piston 1 4 Inner Disc
5 0-ring 1 5 Outer Disc
6 Back-up Ring 1 6 Flu.sh Screw
7 Pressure.. ?late
. 1 7 Th.rust Plate
8 Hexagon Socket 1 8 Coil Sprin~
I
Head Bolt '. 1 9 I ?lug _J
I
'
9 Spring Lock. Washer 2 0 Hexagon Socket
1 0 Side Plate Headless Set Scre\.J
..... "'
2 1 Drain Pot
- ·- - ---- -----··-~ ..... _,...__,.._ ---------
D-5
3. General Cautions at HanalinQ
(1) Handle with ca~c so OS not to maxe scratches by blows and
othe~ especially on ed9e and side sur!ace o! the pressure
plate and side plate.
(2) Keep oil inlet out o! dust or water.
(3) As this is a dry-type brake, rnaY.e sure to keep the
friction surface free from any oil or grease.
4 . Installation
(1) H~ndle with care so as not to give an unreasonable force
or a.shock and the like to the brake.
(2) Securely assemhle the huo to the shaft usinq the hexagon
socket headless· set· screw.s (1 6) and 111ake sure no end play.
·(~) Keep concent~icity of th~ .brake and the sh~ft under 0.1mm
T.I.R.
Keep perpendicula=ity of the brake and the shaft under
O.OSmm T.I.R.
(4) Be sure to tight~n the bolts for mountipg the brake with
spring lock washers.
5 . ?recautions during Op~ration
5.1 Check the following items prior to startin9 operation.

(1) C~eck:.if · the.;;e is a movement ln the a>~ial direction.
(2) Check if the oil pressure is between the specified
maximum and released oil pressure.
(3) ChecX. if the piston move smoothly when the brake is
11
o N " or '' o F F "
5.2 Test operation

(1) Check if there is any ahnormal noise o= abno=rnal
generation o:f heat au.ring -::he brake is " 0 ? F II
(2) Check and see if the.re is any cil leak.

D-6
6 H~intenance
(i ) Sin c e th i s b.:; o. r. e ~ ~ .:. u i;- y - t y pc 1 l:1 c .s u ;:.:- e. t o Ke e p the
·friction surface !ree from any oil, w~tc:= o= dust.
Cheek ~eriodiealy inside of • DRAIN ror· ,

?P~n u~ • DKhin ror· and arain OIL, 1! OIL found inside of ~DRAIN POT ·
(2) Se sure to keep the oil ?ressuxe between the.specified
~axirn~m and released oil pressu=e.
.. '• .
(3) When du.st, metallic J;>owoer rnix with the operating oil, it
m~y cause abnormal op~ration at tha piston. Be su=~ to
' .
execute supervision z.nd inspeet'ion pe.rio'dica.lly.
(4) ApJ:>lY • MOLY-COAT-GREASE • to the teeth.of the 'spline provided

. '
i~side of ~he hub of brake,
ATTENTIO:N
@Crease interval· ·
• Appj y grc:isc: ~pprox. every 500 ..... 800 hours period .
. •,', .... ... .'
. • Ji'ppl y • NU GREASE - after ruova l of " OLD. GEE.Ii SE • as the
·... " ..
:·~··l;~t·.:.··:
• ~OLY-COAT-GREASE • has t~nd~ncy beinz stiffen year by .Y~2r.
'•·" .
. .··:.
·.;:...;:~.
'
.
7 . Overhauling and Assernblin;

·Overhauling and assembling of the brake. shall be
•.
· ··· executed in accc:>~danc·e with the following order.
7.1 Dismounting and overhauling

(1) After disconn~cting the pipeline for operating oil
supply, place a blind plug in the port so that dust and
toreign matter do not enter into the port.
(21 Remove the brake trom the machine after loosening the
, .,
·. bolts.
(3} ~fter removing the brake, first, lay the pressure plate
on the lower side and start overhauling ~ork.
•.
0-7
(4) Stamp or paint a marking for assemblinq on s~itable
surfaces of the cyliride~, the side plate, and the

pressure plate and then loosen the hexa9on socket head
bolts. (14) unitormly'. Remove the side plate and then the
outer and inner discs.
(5) Loosen the hexagon socket head bolts (16) uniformly.
When th~se bolts ~c• being loo~ened, the pressure plate
will be floated up by the coil spring force ...
(6) Remove th~ pressure plate, this will enable you to remove
the .coil spr{n9s and the piston.
(7) Remove the 0-rings and the back-up rin9s from the piston
and the cylinder. Th~ abova completes the overhauling.
7.2 Assembling
After washing and che ck.ing of all parts, ass em bl e the brak,e
in the reverse order from that of overhauli~g. Be careful
about the !allowing items:
(1) Do not wash the outer discs, but.clea~.them with thinner

or the trichloroethane.
(2) Apply a little arno4nt of lithium grease to the o-rings
and the b~ck-up
.
~i~gs.
. ·,~
)
·. When placin9 the piston to the cylinder, first, care
should be taken na_t·;.·~o, damage the O-rin9s and the back-up
rings.
(4) Alternately inse.rt<the outer and inner discs into the
tooth~shaped splitie bf the cylinder.
(5) Match the tooth-shape of the hub with that of the inner
discs and insert th,e side plate. And tighten the side
plate with the hexagon socket head bolts.
----- ------------
D-8
S . Trouble shootin9'
-
PhenorHna Ca usu Countnmcasures
SlQw nltOH o! Dad operation due t0 dust Disusemble, overhaul and
the brake getting .. on .. the sliding face dean
• of the piston
Dad opt ration of solenoid Nor .. lia the solenoid
valve
" 1 VI J Ve
Drvpping ol oil pressure Raise the oil pressure t0
specified v2lue
.·.J_ T.empcrature rise DtforHtion o! 'discs shape Exchange the discs
due to generation of heat
.. Due t 0 drop of. oil pressure, Ched: oil pressure circuit
l:IU'Sing ini:ornplete relezse ind the 0 i l port of b fi! l:e
Decrease of I Bruk of c 0 l.L spr1n1;s or.. Exchan&e the c 0 i l s p.r in &s
brake "function weakening of sprlnr force

Oil I dust on friction surf ace Clean the friction
..
0 lS cs
and ma~: e sure that 0-::-inhs
. . .. a.nd .back-up ring-3 a r c -nu r-· · ·

. - ..... '"" ~
broken
Deformation 0 f discs sh a pc \Er.change the discs
Bad opc,ration due. to dust Di s a s n mb l e ,· over.heul and
.
getting on the sliding clean
face 0 f the piston

81 d opcretion of solenoid l'lor1alize the solenoid
valve Y&l-..•e .•
D-·9
MQDEL HNBD NEGATIVE OPERATING

HYDRAULIC 6RAKE
INSTRUCTION MANUAL
(POR LUFFING}
··-. ·--·· ... --·· - ·- ---·-··

······-·-·· .
·.....
D-10
Preface
Model HNBD dry-type multiple disc hydraulic brake is a
negative operating type (spring closing type) bra.ke,it is

released when operating oil is supplied to b.rako cylinder. It
does not need any adjustment after installation. But a
periodical inspection and maintenance have to be continued for
keeping good workable condition ot the brake. This instruction
manual may be effective for the works.
Con.ten.ts
1 Specification .......... ., ....................................................... D-11
2 . Construction and Operation ........................... : .......... D - 1 l
3 General Cautions at Handl.ing '.'"'.'......._. ............ ,.... ,,_,, D -13 ·

• •• •w ·• • •• ·•·•~•••· •• • • •• • '" • - • •· •·" ~ •- • - • •·•••·• •••• ·-· ••·
4 . Installation ...................................................................... 0-:-13
5 . Precautions during Operation .................................. 0-:-13
-· ~· ..... 6 . Maintenance ........................................................................ 0.-14

.7 . Overhauling and Assembling ...................................... 0- 14
8 . Trouble shooting .................................. ,........................... D - 16

D-11
1 . Specification
I '
Hodel HNBD703H-04
0 raw i n q No • 3 2 7 010 5 7_
Static Torque ! . 100 kgfm
Maximum oil Pressure 2sb'k•t/em 1 '
Released Oil Pressure 17 kgf/em 1

Cylinder Capacity 100 cm'
2 ~ Construction and Operation

r This brake is composed of 18 pieces of parts as shown in
Fig. 1 . .
The cylinder (i) is bolted with pres:sur o plate {1 0) ~nd
side plate(11) from.two side. 'Insid·e side plate, there are

outer discs ('7). 9ea.red into . a tooth-shaped spline of the
cylinder, and inner discs(B) 9eared1~nto hub(9), and they are
alternately inserted.
on the other hand, there is. a piston (4) inssrted inside
of the pressure plate. When o~erating oil does not supply to
the Cylincier I the piston recei VIS 8 SprinQ' fOrC::e fr071\ the
coil sprin9s (12) and presses a,xially the :friction discs and
the-brake is "o N".
This piston is sealed by O-rings(2), (5) and back-up
rings (3), (6). When operatinq oil. is supplied from the oil
inlet ot the cylinder, the pi$ ton ·.is pushed back to the
I~
pressure· plate a911inst the coil spring· f~rce, so that the
pres~ure on the discs
..
.becom~
'
zero, t~e
I
outer discs and inner
' I
discs will be freed, and the.brake is

I
to FF".
I
,1
D-12
~2
i• .....
:r;
~ ~
.,... ..,,
"'• .. • ..."
0
"-- " IC
s
"'
U>
N
IO
OI
N
·$
•
Fiq.1 Construction DWG. of Hydraulic brake
N 0 Parts Na.mo NO Parts Name

1' Cylinder 1 0 Pressure Plate
2 o-rinq 1 1 Side P l"ate
3 Back-up ~in9 : 1 2 1C61i.l Spring
4 Piston 1 3 Pl,uq
... Hexagon
I
5 O-rin9' 1 4 . I
Sock.et Head Bolt
I
6 Back-up Ring 1 5 Spring Lock Washer

7 Outer Disc 1 6 H'.exagon·Socket Head Bolt
'
8 Inner Disc 1 7 Spring Lock Washer
9 Hub 1 8 Hexagon Socket
Headless Set Screw
nr!li" o .. +
1 "
. -·-·-------
D- l3
3 . General Cautions at Haridling

(1) Handle with care so as not to make scratches by blows and
other especially on ed9e and sido surface of the pressure
plate and sido plate.
(2) Keep oil inlet out ot dust or w~tor.
{3) As this is a dry-type brake, make sure to ke~p the

friction surface free:from any oil or grease.
4 . Installation
{1) Handle with care so as not to give an unreasonable force
or a shock and the like to the brake.
\
(2) Sec~rely assemble the hub·to ~h~ shaft using the hexagon
socket headless set screws(18) and make sure no end play.
(3) Keep concentricity ot the brake and. the shaft under O.lmm
T.I.R.
Keep perpendicularity ot the brake and the shaft under
0 • 0 5 rnrn T • I • R.
(4) Be sure to ti9hten the bolts for mounting the brake with
spring lock washers.
5 . Precautions during Operation

5.1 Check the following items prior to.starting operation.
(1) Check if there is a movement in the axial direction.
(l) Check if the oil pressure is between the specified
(3) Check if the piston move smoothly when the brake is
.
" o N " or " O F F "
5.2 Test operation

{1) Check if there · i~ any abnormal noi.se or abnormal
generation of heat during the bral(e is " O F F "
(2) Check and see if ther~ is any oil leak.
D-14
6 Maintenance
(1) Since this brake is a dry-type, b~. su::e to keep the
f=iction surface free from any oil, water or dust.
Check periodicaly inside of • DRAIN POT" .

gpen up • DRAIN POT• and drain OIL. if OIL found inside of .·DRAIN POT •
(2) Be sure to keep tne oil ~~essure between the specified
(3) When dust, metallic powder mix with the operating oil, it
may cause abnormal o?eration at the piston. Be su=~ to
e~ecute supervision and in~~ect1on periodically.·
(4) Apply "MOLY-COAT-GREAS£. ·to the teeth.ct the.spline prov.ided

i~side of the hub of brake.
JiTTENTION
@Grease interval
• Apply grease approx.. every 500-800 · hour.s period.
·Apply • NEW GREASE " ~fter removal of OLD.GREASE • as .the
• MOLT-COAT-GREASE ~- has tend~ncy being stiffen year by year.
7 . Overhauling and Assembling

. .
·Overhauling and assembling of the brake shall be
executed in accordance wi~h the tollowing order.
7.1 Dismounting and overhauling

(1) After disconnecting the pipeline for operating oil
supply, place a blind plug in the •poet· .so that dust and
foreign matter do not enter into th~ port.
(2) Remove the brake t~qm .the: machine after loosening the
·.
, I • ~·
bolts.
(3) After removing the brake, first, l•y the pressure plate
on the lower side and start overhauling work.
0~15
'· (4) Stamp or paint a marking for asse~bling on suitable

surfaces of the cylin~sr, the side plate, and the
pressure plate and then loosen the hexaqon socket head
bolts (14) uniformly R!move the side 'plate and then the
outer and inner discs.
(5) Loosen the hexagon socket head bolts (16) uniformly.
When these bolts are being loo~ened, the pressure plate
will be floa~ed up by ~he coil s~ring force,
(6) Remove the pressure plate, this will enable you to remove
th~ ~oil springs and the piston.
(7) Remov• the 0-rings and the back-up rings from the piston
and the cylinder. The·abovo completes the overhauling.
7.2 J\ssembling
1\f ter washing and checkin9 of al~ parts,, assemble the brake ..
in the reverse order from that of.overhauling. Be careful
about the· followin9 items:.
(1) Do not wash the outer discs, .but clean them with thinner
or the trichloroethane,
J
(2) Apply a little amount of lithium grease to the 0-rings
and the'back-up rings.
(3). When placin'q the piston to the cylinder, fir~t, care
!. '.( '
sho~ld be taken not to damage the Orr~ng$ and the back-up

rings.
(4) Alternately insert· the outer and inner discs into the
tooth-shaped spline of the cyiinde~.
(5) Match the tooth-shape of the hub with that of the inner
discs and insert the side plate. And tighten the side
plate with the hexagon socket head bolts.
:
D-16
8 . Trouble shootin9
'Ph!noraena i:tiUSU Countermeasures

s 1 ow release o( Bod opH11ti9n due to du at Diuuc11bl,, OVHhnu l And
the brake getting on the sliding face clean
of the piston
Bad operation of solenoid Normalize the solenoid
valve ' valve
Dropping of oil pressure Raise the oil pressure t 0
" specified value

\
Temperature rise Def.ormetic-~ of discs sh~pe Exchange the discs

due to genHation of heat
Ou e to drop f i l pressure, Check oil pressure circuit
. 0 0
causing incompJete release and the oil port of brake

Decrease of ,B rtak of coil springs or Exchange the c 0 i 1 springs
!
brake function wukeninG" (.1 r spring force,.'
'
Oil, dust (JO f ri ct i o'n sud ace Clean the friction discs
and make sure that O-rings
.
and back-up rings are not
broken
Deformation___..,_of discs shape Exchange the d is cs
Bad operation due to dust Disassemble, overhaul and
'getting on the sliding clean
face of the piston
Dad operol ion of solenoid I Normalize 1.h e solenoid
valve valve
0-17
Procedure for Replacing

Hydraulic Brakes and 0-Rings
Applicable Types of Brakes:
HHBD 805M-04 For Hoisting

HNBD 704M and 703M For Luffing
CONTENTS
1. Disassembly Procedure
1) Preparation for Disassembly of Hydraulic Brake
2) Disassembly ,of Hydraulic Brake
2. Assembly Procedure
1) Assemhl~r;of'Hydraulic Brake
2) After Assembly of Hydraulic Brake
3. Drawings
1) Hoisting Brake Outline
2) Luffing B1·ake Outline
3) Hydraulic Circuit (Outline)
4) Layout Drawing for Hydraulic Brake
Prepared by Mechanical Design ·se'ction, Tsuji Heavy Industries Co,, Ltd.

D-18
1. Procedure for Replacing Hydraulic Brakes and 0-Rings
1-1. Disassembly Procedure
1) Preparation for Disassembly of Hydraulic Brake

(1) House the crane jib on the jib rest and Hook on the Deck .
(2) Turn off the power of the crane and close the stop valves @, @ and@under the oil
tank and@in the valve unit perfectly.
Far the. stop valves (ID, @,@and@, refer to the attached hydraulic circuit
(outline).
(3) Remove the hydraulic motor.
a) Lift the hydraulic motor with the chain block.
b) Loosen the bolt ® fo~ the hydraulic motor.
c) Remove the hydraulic motor from the hydraulic brake while the hydraulic
motor is being lifted.
In this time, do not remove the hydraulic hose for the hydraulic motor.
(4) Remove the hydraulic hose for the hydraulic brake.
(5) Lift the hydraulic brake with the chain block.
(6) Loosen the bolt for the hydraulic brake and remove the brake from the reduction
gear.
HYO. HOSE FOR

BRA
".l..
::
•; ....
-_QRUM FOR LUFF ING
- ----------·-· .·~--·
E!l_:_: .. ,
.:~!~.
..~-t
''
.HYO.MOTOR
FOR LUFFING
(WEIGHT: obt .100kg)
LUFF I NG OllAK(
HY .H SE FOR BRAKE
''
'
'
I
n
FO_R_HO_IS_TJ_NG______ -i,,11-h~._;,;r::· -·-
__D_R_UM__
.: :1:-:.........
,,;
:f
·-·
'
'
\
HYO.MOTOR FOR '' ''

~·
HOISTING 2· .. ! ·-
(WEIGHT :llbt.200kg
'iQJSTING IBU.E -..........~~~~--~~~~~~~~~~
D -19
2) Disassembly of Hydraulic Brake
(1) Keep the hub of the hydraulic brake mounted on the reduction gear.
(2) Disassemble the hydraulic brake removed in the above step 1)·(6) according to the
following procedure.
(3) Disassembly procedure for the hydraulic brake:
a) Make matchmarks on the outer surfaces of the cylinder <D, the pressure
plate (!!)and the side plate ®·
b) Loosen the bolt ® and remove the side plate ®>. the outer disks (f5) and the
inner disks. In disassembling the outer disks and inner disks, put down the
setting number on each of them.
Note: Make 1:1 matchmark on the spline teeth of each inner disk
before disassembling them.
c) After warming the head of the machine screw ®with a dryer, loosen the
machine screw {$with a screwdriver and remove the thrust plate @.
d) Loosen the bolt @and remove the pressure plate CT),
e) Remove the spring ®and the piston ®·
f) Remove the O~rings and backup rings (ID, @, @and @from the piston @
and the cylinder CD.
Make a matchmark on the outer surface.
HUB
I ~ ,.
! ~
•••
Bolt for Hydraulic Brake
•3.
0-20
1-2. Assembly Procedure
1) Assembly of Hydraulic Brake

After washing and drying fl.ll. the parts of the hydraulic brake, assemble them in th<:!
reverse orcier of the disassembly procedure for the brake. In this time, pay attention.
to the following items:
(1) Do not wash the outer disks @but wipe the particles produced by friction from
the friction surfaces of them with a clean cloth or the like.
(2) Apply a small amount of grease (Shell Aivania Grease #2 or equivalent) to the Q.
rings and backup nngs so that the 0-rings can easily be inserted into the cylinder
CD. In this time, use new 0-rings and backup rings.
(3) Be sure not to damage the 0-rings or the backup rings when installing them in the
cylinder CD and the piston ®·
(4) Wash the screw area of the piston@. the machine screw ®and the thrust plate
@well.
(5) After applying Lock Tii;ht (#601 or equivalent) to the machine screw ®l, tighten it.
(6) Set the outer disks an·ci t:hen the inner disks in the order of setting numbers put
down on them when they were disassembled.
a) Put all the inner disks in the right positions by matching the matchmarks on
tha splint. te.::tl:. d 1::·.1cin perfectly. (See the figure below.)
Match the matchmarks on the spline teeth of all the inner disks.
(7) Be sure to match the µiatchmarks on the outer surfaces of the cylinder Q), the
pressure plate ®l and the side plate ® in installation.
(8) Tighten the bolts and the machine screw in the following torque values:
Machine Screw W 0.45 · 0.68 kg' · m
Bolt® 22. 34.5 kg · m
Bolt@ 9.5 · 14.3 kg · m
. 4.
0-21
I
PAR··j S LISl-
l ::''F IND.
I
1 2 3 I, s 6 NUMBER ·NAME RED. NOTE REMARK
I I
1I I 3 2 7 0 0 B!7 0 CYLINDER 1
I i
2!
I
I
I ! oso1oola7 O-RINO 1 P175
i I iI
3! I I
I
0.5.~. 110,018? 9P.,Cl<-UP RING
'
1
SPIRAL
P175
l I l l
!
4j I i 3 2 7 0 0718 0 PISTON 1'
I
Si I 050100 95 0-RING
I 1 P210
I
:
I
- SPIRAL
51 I !
I I
os31ool9s BACK -UP RING 1 P210
l
71 l I 100 2 8 91 OUTER DIS!< 5
BiI 10067.9 INNER DISK 4
!
91 I
I 3 2 7 0 05,0 0 HUB 1
101 I 327004 99 PRESSURE PLATE 1
Ji_ i
I
l
I 3 2 6 2 3 81 SIDE PLATE 1
12!I' I
iI 0 0 0 0 0 4\5 g COIL SPLING ·15 TH22X50
I
nl I
~
! o o o o o 2lo 3
HEXAGON SOCKET
HEADLESS PLUG 1 PT 3/8
I II
l
i HEXAGON SOCKET
14! 023212 25 HEAD CAP SCREW 8 lvl12X25
I
1s! I !
l
I 0 2 7 0 12.00 SPRING WA.SHER 8 2X12S
HE:<AGON SOCKET
16! I
! I 0 2 3 2 1Bis0 HEAD CAP SCREW 6 lvl16X50
I
111 I I
!
i
029903 39 SAFETY SffiNO WASHER 6 S-16
I I CROSS-RECESSED HEAD
181 . ! ! 0 2 100 611 4 i=LUSH SCREWS . 3 lvl6 X1~
l
19! I
!
l l! 325476 THRUST PLATE 1
I
20
I
I I 024108.1 6 HEADLESS SET SCREW 2
HEXAGCX>I SOCKET
M6X16
i I
!
I
I I
21! I
I
! 0 0 0 0 0 1!0 8 DRAIN 1 AL 12315

I --·
I I
I I I ' ~ ~ :,' '' ' .
__.:· . .... ,·
~
J.J
,Y
c~o,-1l/,
<'U/HI )-,IM A
%A.<P*'
OAlf
-/>~!'- ::t
DAlW"c ) 'f.J
/
6 1· I
Cll<O Rt:V REVISION RECORD NOTE
)I, 1a.1a"c.l..i DA!E/J~c .o~'H
HISTffiY CUSTCNER
0'1114
N.Morila lJAlE Dec.Ol3'93 · ; ;
32700777 6 .
. ' ~ ' •' : I~ I \ • · ., • .
ISSUE NO P\..A.4T 1 N.AMG: DRY TYPE NEGATIVE Oil MOOEL

PRESSURE MUL Tl-DISK BRAKE HNBO 805M-04
ISSUE DATE
:J.77nn777 Ml~T.1 I
') ,' ,:. OWO NO
' A
20 @
735
6-M 16 OfPTH 30
ftOUALL Y SPACEOI
20JS9
H5H7
I
;
2-MO
MOX16
CAGOI s:oE1 IENlESS ~l S:r£ttS
VIEWA
INVOLU1E SPLINE
JICJ\ Tim OF DIN. N70 X3X22X9H
DIN 51.80
lOOTH PRU:ILE TOOTH SlH/\CE FITS
oa. NODULE 3
PRESSURE ANGLE 30 ..
JMOER !F 10011-1 22
fCH ClfCLE DIA 66
: TVIEEN AN OIA
\f OIA 5.25 SPECIFICATl()\J
\SE CIRCLE DIA 57.156 STA TIC TOOOUE 370
:ooENOJM CIRCLE DIA 101-111.·:~
kgtm 0
MAX.al PRESSUrf: 250 kgl/cm 2 I
)QENDLM CnGLE DIA.
ll:LEJ\SE OL PRESSmE 21 kgltan 2 N
llF lEO QUANTITY -0.35
CYLINDER CAPACITY 110 cm 3 I ..)
TIM OIA 69.1.l.l
D-23
PARTS LIST
I ~V!;'l NO.
1 2 3 4 5 0 NUlv18ER NAME REO. l·~OTE RE MARI<
'
1I I I 3 2 7,0 0 616 g CYLINDER 1
21 I I o.·5 o 1 o olg o 0-Rll'-JG 1 P190
! SPIRAL
3\ Il 0 5 3 100\9 0 BACK-UP Rll'-IG 1 P190
! I
4l I 3 27,00813.2 PISTOl'-J
l 1
sl I I o501ool8s 0-RING 1 P170
SPIRAL
5 I os31ooles BACK -UP RING 1 P170
7 I 100278 OUTER DISK 3
6 I 10,06 7 8. INNER DISK 2
' .
g 327008 03 HUB 1'
10 I 3 2 7 0 0,5.0 3 PRESSURE PLATE 1
11 325980 SIDE PLATE 1
12 0000.04 02 COIL SPLING · 8 TH25X70
HEXAGON SOCKET
131 000002 03 HEADLESS PLUO 1 PT 3/8
HEXAGON SOCKET
1G 0 2.3.2 0.8 25 HEAD CAP SCREW 3 M8X25
1sl 027008 00 SPRING WASHER 3 2X8S
HEXAGON SOCKET
151 0 2 3 2 16185 HEAD CAP SCREW 6 M16X85
17 ' 0270·16!00 SPRING WASHER 6 2X15S
....
18 I 0 2 4.108 1 6
HEXAGCJ-1 SOCKET
HEADLESS SET SCREW 2 M8X16
191 0 0,0 0 0 1 08 DRAll'-1 1
\
(~ } AL 12316
{__; )
..
....
I
APf'Ok"
CHKO -
r,JJJ,•MIA1J
I (/
A.-. /7 OAl_h./" b /J~
6 I .~ I
DATE
REV REVISION RECbRD NOTE
CHICO r/J( J;/, fu
1 DAlE/11, b • flt,
OWN HISTORY .. CUST().IER
0 1
N.Morila " e Dec.01'94 TSU~ HEAVY INDUSTRIES CO. L
ISSUE NO A..ANT NAME ORY TYPE NEGATIVE OL MOOEL
1 PRESSURE MUL Tl-DISK BRAKE ' ,.,.!
Hl\JBO 703M-04
ISSUE DATE DWG NO 91T.
. '
. 327 010 57.6 1I
NOTE
18
6--1> 18 THRCXJGH
<EOUALL Y SPACEOI
4-M 15 OEPTH30
IEOUALL Y SPACEOI
18J59
~
,._
?o A I
.....
-., <O
0 ,._
~-
Ol ~ N
w Cl $ $ &
06C!H7
l-EXAGa-1 SOCK£! ltAOLESS S:f ~WI
VIEW A
INVOLUTE SPLINE lANSI 892.1)

FHCH •6 /16
ffiESSURE ANGLE 30°
NUMBER OF TOOTH 13
ATCH CIRCLE DIA. 41.275 SPECIFICATION
SASE CIRCLE DIA 35.745 STATIC TffiOUE 100 kgfm
OEOOENOUM CIRCLE DIA. 45.22 MAX.OL ffiESSIJRE 250 kgf/cm2
ADDENDUM CIRCLE DIA. 3&.26 ~
1
RELEASE Cll ffi:SSURE 17 kgf/cm2
BETWEEN PIN DIA. 32.983~' CYLl'IDER CAPACITY 100 cm 3
PIN DIA 5.486 WEIGHTIAOOJTl 70 kgf
(
LAYOUT DRAWING FOR HYO BRAKE
HYO. HOSE FOR

BRAKE
@© FASTNfN €r 1DRQUE; 23.~~-ln

(MIG BoLT)
0
I
f\)
Ul
2 4 5 6
DATE ! H1 STORY CY O. I ITEM OR ID c l I':; j e
SLEWJNG HOIS7JN!.
54:FIXED
~9
PISTON MOTOR
'
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·-----------------· ....... •"fat;;:;·--··--·---------;
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57-2 !MINI. C>-ECK «:O..PUN3l 1 I 100-52. 000
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51-1
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RELIEF VAL\/£
RELIEF VAL\/£
L.OOIC ELE>E:>lr
L.OOIC COVER
Q 1Y
1
1
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TYPE
DA3i)-;H;./20()-l 7
LC32805E5o
LFA32DA1Yl'-S
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MINl,0£0< «::nPl..llG
S::V:>OID 0'£AATED V"'-llE I
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52-1 SQ..£}'()10 OPERATED VAL\/£ l -~..W:lONZSL I 54-3 MINI. 0£0< Ol.PdN:ll ? I 1oo-52. 000 sue OHEF
52-2 RELIEF VAL\/£ 1 0810-2-4•/100 I JN CHA.AO£
SCALE ?Jl~JE.CTJON
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I\)
52-3 Lit€ FILTER 1 CM-04Z-2-l0U-!V 55 F.M'.JTOF\ 1
52-4 MINl.0£0< i:O.JPL.llG 2 loo-52.000 55-1 PISTON l()TOR I 1 "3'1~-0
H9. 7. 7 OJ
52 5 A£W::(N:; VAL\/£ 1 Zllll60P2-3"V75"' ''>'>-:.e cn.NTER !W.HC!:
_,VAL\/£
. ,,..__.. 1 RFJS25J 1OE l ™"""'91 S-0 I ONO.
"" "' HYUt .... r,_., ..., 11~"1 nnn I T<::;i I I T ~J:" A VY TNrll !<:;TR 1 J:" c; l.0.. I TD. , 0 7,, ~A_ /\
E - 1
5 REPLACEMENT f ROCEDUbE Of' FILTER ELEMENT"
.5-1) Judgement for TCplacement
Line filter have the i~dicator which show the degree

of filter contaminatiori.
Th~ indi~ator moves depending on the degree of contamination.
"' Caution =
Even i f the indicator points to the yel101,• zon! as the result of
some loading of the filter element, the indicator returns to the
position. of normal condition (blue) after the operation stops .
..... .
Take care not to restarc tl1e operation without taking necessary
procedures only by reason that the detector indicates blue after
the o~rati~!'l has been .s".::u!)fi•Hi.
5-2. Exchanging way of filter element'

1) Matters that demand attention before filter element enchange.
Close the but~erf ly valves.
'
·Prepare a receptacle for receiving oil.
\.J • There is an arro1,• mark to show flowing direction of oil on
the top cover of the filte~. Put matching marks on the cover
. to set up again without fail after overhaul.
,-
, ... ·· . .:·· .... '.""'- .. _,. ___ . .. .....

f=" -2
.,
J•
5-3) Set up
·-oo in contorary sequence to overhaul, but give attention to
the following.
(1) Omission of 0-ring and packing should be absent.
(2) 0-ring and packing should not have !auits.
(3) 0-ring should not be eaten into.
( Ll) Dust should not be·' entered.
·· (5) The arrow mark·tn~t shows the flowing direction sh6uld be

:.;' •·,'··
as ever.
"" P LA N E D RAW I. N G 0 F VA L VE UN I T
..
c-
l Notice I
After exchange working finished,
• Open the butterfly valve,·
·When starting, ·vent the air certainly without

forgetting.
--- -------------------
· ..
/ .i
' ~ ..,
. ·':.'.'
":
.
' '
,; ..'.
E-3
ME-82-035
---------~----~~~~~~~~--~---------$--~----
0 P E R A T I 0 N .MA N U A L
\
u'
LINE FILTER
~
u
•,
. E-4
.. e Cnnstruction
0 Case
~ 0 ring
6) Drain Plu8
0 0 ring
@) Cover
(8 Relieving valve
.J· fl SuPPort rins
v (~xcl. FH 340- 03--FH34·>.<·-08)
@
C) o rins
CD Element
€) (D> Wesher
@
ID Hexason socket head cap .s.: rews
(f) Nome Plate
® Plus COP
DRAIN (?) Differential Pres.sure inaicatcr
E-5 ·
• Installation and Operation
l. Install the unit to insure that INLET and OUTLET are in the
correct direction and that the drain plug points

down\./ard.
2. Reserve enough space over the unit to take out the
element for serv.icin9.
3. When the pipin9 line is flashed uith the unit instal-

v led, REPLACE the element, before placinq the system
into operation.
4. Before starting operation. mike sure that there is no
leakage out of the seals.
• Maintenance and Inspection
.In such cases that th~ differential pressure reaches
2. 75 kgf/crn 2 dur.in9 operation,or the indicator rin9 (red)
of the differential pressureindicetor11oats.up1ofillthewhole of hole,

immediately stop the. unit, and disassemh1y the unit ahd
repalee the element in accordance with the procedure

descrlbed in "Replacement of Eleme~t." However, it should
be remembered that var'ious di!:ferential pressure indicators
may function in lower temperature season such winter

· hisher viscosity. In such a case, locate tree cause
E-6
whether' it is due to higher viscosity or clogged element
~!tel the unit is ~~~ 1ne~ ~ormal operation.
• Replacement of Element
l. Remove drain plug Q) and drain the oil in casing (D .

2. Unfasten he:<as:on socket head caP screw:S@ a.nd rer.1ove cover @,
and then element @ comes out ·with covE=ir ©.
.•
J. Replace paper element used with new one.
,,
E-7
I
•I
: .
!
Installation of Element
l. Check O rings for damage, defor:ma tion', expansion,
or r..ardeni'ng. • i
;'..f.i . f ee t.i ve
ae 0 ring requires replace-
...'-
ment.
2 • Place 0 ring on drain plug and install them
to casing. (D .
3. Insert element \.V to cover @ paying utmost care
so as not to damage the element. ond upon contirma-
tion of INLET and OUTLET, bolt cover @ to casing @ ..

4. HexcS01sockethecdc:apscrewsmust be evenly tiqhtened by the use
of an ~uxiliary pipe.
S. Thoroughly evacuate the air ih the line, and make

sure that there is no leakage out of the seals, before
placing the unit into operation.
6. RESET cifferentia1 pressure indicator @ after the

.(\__
element has been replaced (cleaned) .
• Operation of Accessories (Differential Pzessure Indicators)
1. The sight holes of the differential pressure indi-
cators are provided a transparent plastic cover.
,;
E-8
Special care should be exercised to avoid adherence
.
of organic solvent and scratches by tools such as a
wreneh .·
2. The indicators are factory-adj~sted: do not disas-

...... \,'
seinble them.
Blue:Normal
(" i
L
All red:Ch.ange the element
Red : Ind i cat in g
ring Blue at the upper pa~t
Red at the lower part
·-:Warning
Description ot indication
for a differential pressure indicator·
E- 9
..
I •
SERVICE INSTRUCTION
... ..
ON
G1\t1 TYPE GASKET Fil TER
'. ' .. '
.. ·
.....
... .. .
·... .
•I • • '. • ',: ...... : ' t ' o
·. ,'
..
. .
'·.·
..
·..
E~10
(1 )Con f i gu ration
This rilter consists or G)Body. ®Cover. ~Shell. @Filter Element.

~Drain Plug. ~Set Screw~. ~®A!r Vent. ®@@"O"rings. @·o·r·ing
in Filter Element, @@Sack-up rings. Q}By-pes s Valve, @Blind Plug,
@@·a-rings on Blind Plug.(ref. Figure 1)
I
It can also be .rurnished wi.th following Items optionally.

1
1 ) DI f f e r e n t I a I P r e s s u r e ind i c a t or
Visual Indicator (lJ
. tvrJe)·
) ' .
Elec~rical Switch (E type)
2) Filter Element with hign collepse pressure
(210kgf/c:;;' cotlepse pressure)
I
3) Reverse Flow Valve

\ .. . .
4) Blind Plug for Non Sy-pass type
(2)Srief Notes on the Function of the Filt·er & Accessaries

1) Filtration ..
The oil from inlet port .flows into t:-i2 filter cese. where the oil
is filtered from outside to insfce and goes to the outlet cs
shown with arrow marks in Fig. 1.
2) Sy-pass Valve
AS the filter becomes c\ogge.s with darts, the ditrerentlal
pressure across the filter increases. and tile pressur~ reaches
the terminal piessure drop, the built-in by-pass valve opens to
prevent the filter e I em en t from collapse.
The'crac!<ing pressure of the by-.pass l/alve is 3.5kgf/c:i.
3) Oifferentiel Pressure lndica tor
Differential pressure indicator strnws the contarninents loed
level of the element. Both tne.·.visuel and eie~trical indicators
are availe.bte.
i ) Vlsuel Indicator (U type)
When the differential pressure reeches to the prese~ velue
or the indicetor, red button pops up. Reset t;ie inGic~tcr
m2nu211y after renewcl bf tne filter element.
-1-
--·-·--···-· ··-·
.. .·-
. .....
E -1.1
ii) Electrical Switch (E type)

The electrical switc:i Is automatic reset type.
The electric ratings are
..
3A. 250V. AC. Resistive Load
2A, 250V, AC, lnduc tlve Loed
-. •,
4) 'filter.Element with High Collapse Pressure
The rflter element Is used in conjunction with. non by-p2ss
filter. As the structual strength of the element is very high
(210kgf/c:r'), the eteri-l~rit wfthstands the hign differenticl
pressure due to the clogging the element.
5) Reverse Flow Ve Ive.·
Thfs velv~ serves to oy-pess the reverse flow of oil.
The valve bloc:< is attached 'under the filter essembly.
c
(3) I n s p e t l on 2 n d M a in t ~ n a n c e
1) Inspection Period
It ~~Odl czily II wee~ty

I montniy
I t'lery 3 montl"IS
I tr.nuelly II
I I I I
aooy
I I I I 0
I
.I
I
.
Snell
I I
I
'
I
I
0
I
I
C;111er I
;".',•,:
i I u i
Element
I I
initially
0 I 0 I II
-o·r1n9s
I ' '!' ... 0
I 0 I I
'loc:Jlcn tor
.. , " I initially
0 I 0
I I I
Le2lc2Qe
I I d I I I
2) lnspec~ion or ~ilter· element
i) 60-350 mesh wire element
Cileck visuclly end, wash if it is soiled with contemincnts.
When the different!2! pres!!ur2 indicator tells tne element
cloggect, the element shall be washed with suitable solv;rnt.
-2-
E-12
ii) 20-3.u wire or peip,ai- element

It Is difficult to essess the conteminent toed level or tne
element or this class. Wilen the dif~2r2nti21 pr2ssur2
Indicator tells the element clogged, renew(paper element) or
.
wash with ultresonlc cleener(wire rnesn element) .
. !4)
..
(4) E x D~ c t e d s e r v i c e d u rat I o n o t 'f 11 t er p a rt s
Sarvice duration of t~e f!lt~r parts depends lergely upon the
service condition, surrounding atmosphere end maintenance.
This table shows the expected service durations or filter parts
under the normal sarvic e and enviromental co nditlon.
'i)
" Items IeApecao sar.,lce our1tlon I rtmerks
I aooy !I o ye us i
I speciel atmosphere
lnccor use with no
Sn t II
I O ye:r:s i
I ottto
Fiiter
Case
II Cover I 0 j'•UrS 1
I renew eny r1ew is alt to
I
1-~·rtno I I ooserveo
I
I
if
l
Iaack:-·.1~ rin~s 1 I c1::0
I
.
I
I
?aper etemtnt
I till tne !I em en t cto~~!d
l
i
·-
:""\.a • • •
•:''•' '""' ""........
cont&minz :ion te•1tl of oil
...
-~
~
I
Element rWire mesn element., i ·2 years
I
I·o·rtn9 in element 1..
I
1 ·2 /!US
I
I
I
r!new it !n·y :11•11
oose_:-ved
~r!
I
P1v9 10 '/et.rs
I
Ora In
"O"rln9
I
"
I
renew If any fie w Is I
l '·
'
ooservec
J
-----·--------- -- ---- ------··----------
...
.
. 1:-· ' ".
t -13
-··- ·-··-' · . . . . ; . · , -... ..:..,,_, •• _ . _ . . ...... • J •
. . . . : ~,,.. '··.···:·~~·~-·.: .. _. . ... ·.: : ·~.-,.-_· ...·~-~-..".~.-.·.'.~,.:;...:~;.~.~.~:.·.· :· .~.·-· .~.· ·· '.·...... :. ... •·:. ....... . . •. i.: ..··
:. -; ..>.. .....;;7·. ~~-::.~ . •. .... ~::: ~··.:·
•.
~ ~· ·,; ..: ': • .i•'. •• ·.:
• • 1' • -
... .. ..
(5JTroub I e· Shooting .. . .
: i'
.
Trouotc
I Poss•DI• C.>W•
I 1'emt<:y
I ,AcmV'lS
' ;.,
.. Brc.,.:lnc;i or ·.o·nni;i •,
... .......
"'
IRen•w
.1 ., . ';
...
011 1u1t.a9c from· sc•I Plnc:.-.inc;i or ·o-l"\n9 lRen~w - :I
·
C:iec 11. :.ac1r.-.i::1 nn9
&110 l'rnew If 1ny II~··
IS OOsll:l"'Yt'O
. ..... Fie"'°"
llUM'•C:•
·.
Ult matJng I i=:1aw snoulo ::!• ::>oll5neo
out or re:iiac:e ti.u1r1 ll&l"'C
~
"·
I
• •. ..., .• t
. ,.
.., . 011 •OOll•G outs•O• oal'"1:
.. .. .
: . ·.......... '\ 011 scaln· &rouno _.cal or ••-' our1nc;i
,.
sorcaes out
aslltmOly
on 1oot1co OUl"ino
assemo1y keep minimum
·I .. .
"
; )
··.;.•'·· .. ..
))
L. Nonna I trow
IF•llura or tilter mtOlum I Renew CltmC'f1C"
I
011 oacomei·
llly•IMISS l:'ypc
Fiiter tlcmcnl CJ~OtO I~. enc• .. ... ..
c:ontamlna.ceo ano oy-~ass va1ve oocns I 11cmC"'C
I
.. .. .. .
......
.';.. :;··.-:·
·~··
Wltn rwvc,,e IB'•&lee out or tllttr
rtow .... ivc •••,,,.,,t ov• to rcllut'e
I1'aOI•~.' ~. valve
I ..
..
,•
..
I <tlemc~:).
l
;:tc"'•-(::e:ar
tnclc::s t:r c:ocna te.11 soon
Filtet' eitmcnt e109oec:
I Wc~n(-irc mclln •ttmcnt)
I
•ftcr tl'I• 1ystem St.&t'U
l
\11.Jc:os•t"/ or 011 1.., :oo
hl9n cur1n9 c:o10 s tJ:r-::
I
I
He• tlrHll :nc ell
I I
.. ~
"
. ·.
)l)
-c-
. .,..· - . .
E -14
.. ...... ....
;~ ::'.:. ·" ' :, .
-·. ,.·.-·'
:
.. ,.
. . ·-
-··
::-.::•'I
.. (61
.. 1) Oisc:ssembly · ...
·...
··Remove the drain plug~ and drain
. ·. . the oil . ·.,..:..
in tne ·filter c2s2 .
- ,.
Remove the cover~ and.... pull t.he element.up. rhe element shall
.be wcshed 6r.
. .
re~e.~ed :as"me~tioned
.
ln,("3).:2)·.
.
.
~. ' ' ~
A·s ·to .th~ cleaning pr-ocedure.' ·.

. .
.i) .f?~-:--~5'? mesh wire element ....
OiP the element into the cleaning flu.id .such c:s i<:erosine ·or.'.
.ga·s:oil. :a·nci"ci'c)';;'..~~:.·=9·1ush the. 'S"urface
:snake ·erement._up of:·
;rf1ter·ar6n.g 'the p:,·~~-t,..l1~-~~=:'·a1~w t:;~'di~t~ off by .ei~:;~., ·
'u'f 20:.3µ pap~r. ~~ wi~~· ~e.~t1 ri~'t:·~~-:~·-~'.~:.:-·:::::.:~:.:··:-:.;-.: ...... ~ ..
.. .. ..... . ' ~ . . :·
. Renew(Pap.er ··element)' or
. ..
wesh( Wire mesh . element) with
......
·
.. . ...
..
·.·.; . ..: ultrasonic cleane''r.....
*. ' :. :: . ~·. .. " . .... ~-";··
-:· :.·. -··::. . · 2) A~sembly .' .. · ... ~. ·:.~·~· ·.. :,: : . ~·.;:· ·
-· ·. ).:~ .; =.::" Io-~sserriol e . the fil ter;'.~:ce~.e_r.s e
..
.:~.he_. e~o'-:.e _.sequence. Check
-o-iings and bac~<-up rings and renew if ~ny flow is observec.
·' '
.·: ....
(7}Caution ...
· 1) if .the ·.filter is installed in reverse position by mistake.
by-pass vc.fve c.nd differenticf pressure indic.::tor will not
operate and the paper fiiter medium-wUI be brol<en by the
oil flow.
2) If the re 11erse flow vc.lve is installed in reverse position. only
the re'lerse flow is directed in tne filter c:=se 2nd the p2pe:-
element'will be broken . . ·.,
I
8 y-pcss valve and di ff er en tia I pressure indicator will not

operated.
ever/ si~ aonths to =ain:ain ~er-
ioi.-:ianc.:::_ Vhcncver a bl.indl.nK o! ele2cncs occurs (snovn.by :ed on lndJ.c~tor),~c

plac.: ~he part:s_
-5-
F-·
6. MANAGEMENT Of HYD~~~~rc orERATIHO PLUlD
Among the maintena!)':i'!, and management "'orks are carried out

for obtaining efficient operation of the oil hydraulic
equipment, preventing troubles and maintaining rated
perfo!mance, those concerning hydraulic operating fluict'are
·particularly important. It is necessary to make sufficient
prearr~ngement with your hydraulic operating fluid rnanu-
....
facturer about the content of management.
Here are given ,minimum instructions concerning management
.. ::.:ah·d~::.inspe~ t' ~"o r:·:,~,eq ',; ~·~-';;,j for: ,'~ur ·oil· hY draul ic : eq u ipment,::~o.
• ~• ' ,t "r'~,; o!,' • • ::: • • , ,_ • I',• ,• ' ' • ' •
'be used'for:·1ong''time,,
I)
' .....
1) Kind,of fluid: (re~er to page G-1)
Us e add i t iv e' tu r bin e o i 1 VG 3 2 or \/ G6 8 ( I SO 3 Lt Lt 8) .
'2) Viscosity Pange:
Use the fluid in the viscosity range from 700 to
~~~~~:~:~:ge ~b;·re:s:~~o~·~s t'o th·~"<;i~id <·~~~,~,~·~ture range

o'.f ~o ·t,o so·c ~~ c~·s·~>~'f-"· ~he oi1"\ic32 and 20 to 6o·c
in case of the oil VG68. It is desirable tu obtain a
J
viscosity ternyerature chart concerning the hydraulic

operating fluid to be used from the manufacturer 0f
,...._
' '
,. the fluid.
}) Degree of contamination:
It shall be within class 10, NAS 1638.
q) Periodic inspection:
Initial stage of trial ~un --- after 500 h'ours

Normal run --- every 1,000 hours
Take about 1 litre of the working flu~d 2 sample and
~equest its inspection to the manufacturer of the
"
hydrauJ.ic operating rluid.
F -2
.. ..... .... • .. : - .....
5) Renewal:
Suitable.renewal period is usually l,ooo hours
although it depends upon the results of inspection.
In general,· total quantity of hydraulic operating
fluiQ shall .be replaced, removing the olQ fluid as
much as possi~le. First renewal is 500 hours. '•
"
I
6) Everyday check points:

..
*Discolo.ra';;;.;::. ····"The ~iscoloring results from
.... : .. ~ ... " . .. .. :. . . . :
"
f '
.. .
'
.'. .'. : .
. i.ntrus ... on ... of .:va tcr 1.:or::air :·ort:progr ess "of:
• ~I : t, ••• '
.
' 'o • • t o ' f o •'
:de t'e r:: i

.......... o:·. ~:f... ion' ....
..
.)
'.) *Smell --- Pteuliar smell.is generated after oil
stain and progress· of deteri9ra~ion;.
'f~~str~s~on·6r:rore~gn matter~-- Deterioration

••• t • ' ••
: some~i~i.e.s. proceeds as a result of intrusion

' ..
of .foreign matter.
·.,.: ..
*Rem9va1 .. o'.i\,"~ter :---·Remove water form drain
.;,port:·:."inra .1(n.ie'i:;j,ortion' of. oil r'eservoir one e
. ...,.t t •• ' • ••
pe;r- month. . .....

' I , ' ' • , ~ ' • '
'· ;. ' ' ., ( '.
:.tf •';
F 3
..
7)AIR-BREA'l'HI~C
(1) HYDRAULIC PARTS

According to the fo~lowing illustrations, connect the
accessory ·mini. cht;;..~~ hose· to . the mini, . check· coupling
.('"'.i~h. ~<Y:ell,ow ·a; 1blac}\ ... c~p)··~·e.qu'i1{ped'\dth: ..the····rea.pective.
hydr.au11·d"P~·rts ..:(~~~.· Pi.g. 2) ·"· ... · . .. . . ...:·
(2).The air-breath~ng plug set to the flange ·Of upper oil cooler
Loosen that's plug 1 make air-breathing. (See Fig. 1.)
(Also, another air.venting.plug exists on the cooler body.)
'::'·j>
REATH NG PLUG
(STOP VALVE)
. {.
1. , .. , OIL COOLER
r
. A_I_R_V_E_NT_l_N_a_r_L_u_o__,,/ ' '
F -4
(3) Make inchihg to~ pump under no load at

any times, an~ leav~ this condition at
15 20 minutes. t the air-breathing in
ry
oil of oil ta~k ~ake 15--20.minutes.)

CJ[) Make .. air-~reathing of item 3 again,
after finished.item~.
(5) Do operation ~f item ~ and item·3; at,
five times over
·.*T.he. ai:r:-brea thj ng '. i& · ycry inpor tan t
in"
.. hydraulic
. ... . . . · By ·air-nr.eathin'g'.,
uni'.t, . . ... '
" '•
i.t is. possible avoid ~he roost. o'r

troubl'e .. when oi~: replaccm.ent. and
oil chatgin~, ~l~ase make air~ breathing.
'
mini. check hose for accessory pressure gauge unit
l I • : '
pressure gauge unit.

' .. \. •. ·.
·.mini. che.ck hose

1 .
F'ig .. 2
the air
h \I n 'I" '.'.:! 1 1 1 -i I' n :l T' t C

F-5
GUIDELINE FOR REPLACEMENT' OF HYDRAULIC FLUID
1. PREFACE:
1) In order to use hydraulic fluid properly, it is essential to keep control of hydraulic fluid and it
is necessary to check hydraulic fluid periodically.
2) Inspection data of hydraulic fluid must be retained In the records. Then, you can see the
deterioration level of hydraulic fluid by comparing with previous data and can 'judge when
you have to replace it.
3) Interval of replacement of hydraulic fluid:
(1) Initial replacement: about 500 - 600Hrs.

(2) From second replacement: about 1,000 - 1,500Hrs.
(Please refer to Instruction Manual for details.)
Notes: Initial replacement after about 500 - 600Hrs. is required in order to prevent that
contamination of hydraulic fluid shall be increased by initial wear-down and running-in
of hydraulic equipment and consequently mal-function and drop of lifetime of hydraulic
equipment shall be caused at early stage.
2. Guideline for replacement of hydraulic fluid
1) Contamination of hydraulic fluid
( 1) Control standard: . . NAS 1Oclass ( ~~ ~ )

(In case of mili pore filter value, less than 5mg/1.00ml)
(2) Limit of use: · NAS 11 class ( ~ tl4ht dlJ-4.d )

(In case of NAS 12 class, hydraulic fluid should be replaced promptly.)
(In case of mili pore filter, less than 10mg/100ml)
(In case mili pore filter value is over 15mg/1 OOmL, hydraulic fluid should be
replaced promptly.)
2) Water contained In hydraulic fluid (Wt%)
(1) Control standard: less than 0.1 %

(Z) Limit of use: less than 0.2%
(In case of over 0.5% or emulsification, hydraulic fluid should be replaced promptly.)
3) Viscosity regulation
( 1) Control standard: below ± 10%

(2) Limit of use: below + 10- 15%
(In case of more than; iSo/o 1 hydraulic fluid should be replaced promptly.)
F -6
4) Total Acid Number (mgKOH/g)
As to Total Acid Number, it is difficult for us to advise you of the figure for guide line since
the value varies according to oil maker and its brands.
(Therefore, please send the sample of hydraulic fluid to oil maker for analysis.)
(For reference)
RELATION OF TOTAL ACID NUMBER AND TIME OF USE
Total Acid Number
-itiitialvaiue.(New-C:iif ···--···············--······· : Upper Limit

~ : Value
'
''
Towerfimit. . . v-a-1u-e-=---·--·-···-------------·-·-------·-------~
~Limit of Use
!
Time of Use
F- ~
OIL REPLACEMENT METHOD

...
1. OIL FAN .
1) Prepare the 2oot drua on .deck house top or on upper deck.
2) Connect the hose to the stop.valve under oil tank.
OIL INLE.T 3) Lead the hose to 200• drum.
~~D
4) Open the stop_v~lve.
ll tElEl GAUGE. 5) Close the stop valve after finished oil drain.
~ ..;; lt. 6) Take off stop hose.
2.0il. CHARGING .
1) Prepare the-2oot drti~ on deck house top or on uper deck.
} 2) Prepare the charging punp. ·
_}· 'l - 3) Connect the hose to th~ ch~rging pump.
4) Insert the.hose· to tho oil inlet.
'\ 5) Energize the charging PU•P·
\ 6) Pure the nev oil up to the level betYeen.
\
H and L marks of oil gauge.
,, 7) 'foke off the hose after oi 1 .charging.
I "
:'-
...
~.n;f;-A ~~"..20~) ::.-..:-.-_
DRA //\/ tiO§t

\
....,..___ b:=====f======f==;:::====jf======t
1)200 g t7bffit:1.,iMl...l::~ t:. ~'hi.l:t<:.f$flt1"-?i o
) .·
_;
2):t1'.t~'i"f O)A~'11J\,t,1ti:.;j;-:l. ~ ~*ltT -?i o
I
l CUSTOMER 3):1:-~t:200.e f7kfij3: "t:~ ': 0
I
... I
I
I (PR~: alot~a. dVt ·')lot~)
. I •
.SUPfL T.
~~ftr1_
4)::t~'71J(,t,j:f JHl <
0
5) ff ih1dJ»'~:i"ti::~ t7 t.: t.:. ; ~:lb1.M.1~ f,.i ~-°!> o

6) ;-:l-t: ~ "tJ 1J. To
I
I
I
~
~ 2. *~ fdr
1>200 1 i-=n m~ '1'1i M :t1::. ;t: r.: ti :;.,~...t tt:: it! m-r ::i o
... 2) ~?dl~!tj.~ !i!flf 1".:, 0

3) ;-;t·~ *~hktJ1 t: ~ttf T .:;, 0
4>t.-::tt- ~mot\::~ t,;6t· u

5) ~idlt!!7t ~lfrt.:, o
e} imiiiHO)H ~ L~~O)*Mirril ~ ~fFll11W ~ A.n ~ o
.' .! ; :; ~
7) Mii!fint~,n., t.: tr ~,;t;-A~ Jt2: ~~To
• :. ,: r I
. :• I~ • ' I
. ;.:;~: ;~ > :· --
.· . !1· ll ~1 ~-1.l! ,; i; I
I ·:.!;! !. ·.
:HE. ~""".!: 'iE13 EE. {"): !WJ mi
1-- 1) ;:::r... c-1
7. TABLE OF HYDRAULIC FLUID
.. 1)1e recommend ihc following producta or those of proven equivalent quality
~E~MX~,~~~M~~~~~m~Li~o
Z)for hydraulic fulicl ouantitier and maintenance intervals. see instruction manual.
1d3£Ei'FlhnhA c~!\T,i, ~~ ~~~~(J)~t#Jt«"f ~ l 'o
SHOWA SHELL NIPPON OIL COS HO IOEMITSU JAPAN ENERG)
© ~
Outside
Temperature
Sh•ll
~ ~
~
from +35t SB ELL COSMO DAPHNE JOMO
to -15t TELLUS '.·OIL Byrando HYDRO ·super BYDRC HYDLUX
(ISO VG 32) !32 fide 32 HV~2 IR32 ES32 .
from +45t SB ELL DAPHNE JOIO
to -1ot TELLUS OIL Dyrando HYDRO Super HYDRO BYDLUX
(ISO VG 46) T46 fide 46 HV46 JR46 ES46
SHELL
from +45t
to -20t'
TELLUS OIL
T32
- - - -
MITSUBISHI FUJI KOSAN
Outside
'). (~
Temperature
from t35t DIAIOND
~
FUUOL-SUPER CASTROL '• 9 M@bil
to· -15t HYDROL
Bydrofluid HYSPIN AlB UNIVIS N32 Mobil
(ISO VG 32) 132 F32 32 DTE13K
from +45t DIAKOND l<'UXKOL-SUPER CASTROL
~o -1ot Bydrofluid BYDBOL BYSPIN AJB UNIVIS N46 Kobil
(ISO VG 46) 146 F46 46 DTE15X
from +45t - - - - --
to -20t
Ir----·
Lil
Outside Ch1vron
Temperature
from +35t
@§c] ~ ===
to -15t RANDO OIL BP BARTRAN Mechanism elf
(ISO VG 32) HD AZ32 HV32 LPS 32 VISGA32
from +45t
to -1ot RANDO OIL BP BART.RAN Keehan ism elf
(ISO VG 46) BD C-46 HV46 LPS 46 VISGA46
from +45t RANDO OIL - - -
to -20t RD AZ32
H - 1
8. MANAGEMENT POR NORMAL RUN
1) Hydraulic Operating Fluid

[Quantitj af f~~id]
The pre&cribed fluid level shoul·d·;be maintained.
If the fluid quantity is insufficient, leakage

. .
is.::a:.~·Pl'.::C?s.uma.ble cause· .On .the· o~~er ha.no·, ·if the
fluid quantity iS" CXCCSSiVC I intrUSiOO Of Water iS
a p~esu~able cause.
IDiscoloration]
·Whitening of the fluid may· be attributable to
the intrusion of water~ while blackening may be

attributable . to the oxidation.
. .
.IFluid temperature J·
The £1uid temperature.must be .within a range
from + ~o·c to + 5o·c
When starting the oil hydraulic pump at a range

from·- 1o"c to+ 1o·c , make inching undet·no
load.
H -2
2) Oil hydraulic pump
Running sound
A change of the running sound takes place in

.case of occurrence of :the clogging of the filter
on the suet ion line pf the oil .hyc11·aulic pump or
when component parts are b~ing abnormally worm or
·.:about· to ...be. :broken.
It is important to remember the normal running

sound and .quickly detect the abhorrnal sound.
3) Leakage
Leakage even of the order of blot from weld
joint of line, oil hydraulic pump or other oil

hydraulic uni ts .woul°d cause a .grave.
•"
ace iden t , · so
make scruprous checking.

4) Fil tcr
Be careful of the clogging of suction filter,·

line filter, air breather and so forth and make
prompt cleaning.
I -1
9. TROUBLESHOOTING AND MEASURE
Trouble area Cause Counter-measures

Pump 1. Loadins of the Check and wash them ·
pump intake pipe with good quality
and section wash oil and light
filter oil.
"\
2. Air leaks from Coat the joint with.
intake side pipe grease and check how
or pipe joint. the sound changes.
If the sound becomes
smaller, tighten up
the joint or change
the seal.
3. Air leaks from Listen carefully to
shaf't packing of the sound while run-
pump. ning the device.
Coat the outside of
the shaft with
grease. If::·the
sound becomes small-
er , change the
.Noise packing.
Occurs
- 4. Fitting bolt Tighten up the bolt.
of the pump
becomes slack
Relief Valve 1. Piston slot Disassemble and
catches, or check. If the flow
operates defec- is small, lap it
i vely. again and observe
the results.
2. Abnormal wear Exchange, and check
of needle valve. the hydraulic oil
for dirt.
3. Resonance of Extract the air from
spring board, the circuit. Check
bent board and the· spots where air
;:\ i l" enters.
Others 1. Clarnpirng bolt Tighten up the bolt.
of a component
becomes loose
I -2
Trouble Area cause Counter-measures

Others 2. Pipe aupporting Check and tighten up.
fitting become loose. '
Pump 1. Quantity of oil Check the oil level

in the tank is small. and immediately add
the necessary amount
(be sure to use the
same kind of oil)
2. Pump intake port The oxides in oil

and filter which has been used
are blocked. too long, sink and
cause the blockage-
wash filter and oil
tank.
Press- 3. Air enters from Check and repair.
ure is intake pipe.
lost ~. Pump is in bad Check the above-men-
condition. t ioned items, and if
no abnormality is
·YI detected, check the
pump.
Relief valve 1. Setting pressure Reset the pressure.
is low.
2, Valve is in bad
condition.
2.1 Loading of Wash.
piston orifice.
2.2 Damage of valve Change (change also
seat. needle valve)
2.3 Permanent'strain Change
of spring
2.~ Damage or catch If piston catches, la~
in piston again. If damaged,
replace (Replace
also piston seat).
l-3
-....
Trouble Area .cause Counter-measures
Others 1. Del:mage in piping
.. Check piping and re-
pair
2. According to the Check and change
Press- damage in the packing
ure is . of an element.
lost \
3. Damage in pressure Change
gauge (if pressure
rises an estimate can
be made .from operating
sound)
4. Bent solenoil valve Change the coil or

•) operates difectively valve.
Breakdown 1. Pump discharging Change the coil or

pressure is lost. valve.
Cylinder
Opera-
tion
3. Cylinder catches Check. If it catches
again, replace it.
4. Hitch in electric Check the electric
control system circuit.
1. Pump discharge Refer to counter-
quantity is insuff i- measures under Press-
cient. ure is lost section.
Refer to count~r
measures under
Breakdown·section.
. . 1-4
T!'ouble Area Cau~e Counter-measures

Read just or checl
the sliding part
Cyl~nder ·
\
Opera-
4. Leaka,ge from valve Check and repair.
ti on (change depen8ing
cylinder, or piping
to outside . on damege).
. ....
y
. '
. i
I'- 5
Trouble shooting(Single crane)
_, dill
-I>\•• Uj
:::.. IMPOSSiblP. CO lilt load is regular Hover .load pressure switch is act. I
-?;i Electric trouble --3' Check ite1 on electric trouble
HJ> Oil pressure doesn't rise ~ Check i te1 on pressure down
I Can not lift load oad weight . ' Ra red ~oati - IPressure rises.but pressure is low.
rake doesn' c release
r-?> Sa1e as above
~ Check ite1 on brake trouble
~
L:;:. Pressure rises.bur can not lift load. ~ Inclined angle oft'ID1ocor shows 1in.1
Return che handle to neutral and take a~ in
~ Electric trouble --? Cited i te1 on elet:tric trouble
Middle lo.ill -?;i Oil pressure doesn't rise -? Check i te1 on pressure dc;.m
-
~
or
Ho-I oacl
--?;i
~
Pressure rises.but pressure is low.
Brake doesn't release
-?
f--7
Sa1e as above
Check ite1 on brake trout. le
Pi I01 pressure is ToV ~ Heas~re pi I ot -ores sure :--o t~
--~ated loai Set pressure of relief valve goes down Ove rhau I, inspect. wash or replace relief valve· (2)
Abnor1al or COllpensator valve - Overhau I, inspect and wash co1pensator valve @
ilOi SI ing speed Pilot pressure is low - Measure pilot pressure <O
is slow iddle loa Inclined anole of(ll)aotor doesn·r 1in. , Solenoid ·sot H ·tor inclination is energized 0
Abnor1al of C01pensator valve overllau I, inspect and wa:sn co1pensator valve @'
Pilot pressure is low Heasure pilot pressure @

l.iuht loat Inclined angle ot R>aocor doesn't •in. - Solenoid ·sol Ii" tor
O\'erbau I, inspect
inclinalion is eneroized @
or Abnor1al of co1pensator valve and wash COlr>ettsator valve ®
No- I oad Set pressure of rehef valve goes down O\•er•au I. i nsoect wash or re~lace relief va Ive 0
~ Pilot pressure is low f--7 Heascre pilot pressure
~ Inclined ano~)Motor doesn't 1id.1 '--? Solenoid ·sol l .. tor inclination is energized
Eowerino soeelf is slow
I ~
,- Abnonal of co1pensator valve ~
Set pressure of ref ief valve ooes down ~
overbau I. i nsoect and wash co1per1utor va Ire
Overhau I. inspect, wash or replace relief valve
."
I
~
·.'ii
~... '
1-6
SINGLE CRANE
_l!Q_t~T OPf P.AllOH
HOISTING OPERATION re:::--11-"" sr....IH...G_ _ _ _~

01.....
NO
Heasure t e Pl lot pressure at ull andle

lt is nor111a I if the va I ue is more than 22K.
Check if the incl ned angle o motor is min.a
Solenoid "SOL II" tor inclination is ener ized. 110
easure the Pl Iot pressure at u11 a e

It is normal if the value is more than 22K.
Check t e inclined ang e o motor is min.'
Solenoid "SOL H " for Inclination is ener ized.
Set pressure of relie valve goes do~n.
Re-set to correct value
tlO Heasure the pilot pressure at ul and e YES
It i normal ;r the value is more than 22K.
c ec 1 t e mc1ined anple ot®motor is mi .a
Solenoid "SO L .. ror Incl inaeion i~ enar iZed.
et oressure o re 1e valve goes down.
Re-set to correct value tlO
P ease 1n orm trout e to manu acture
. '. " ' ~

NORMAL
I- 7
SINGLE CRANE
lUFFING OPERATION
OOWH
Cec by test c1rcu1t

s er lectr' ircuit trouble shootin
set va ve o re 1e pressure 1s c anoe .

Re-ad'ust as er drawin.
Ovenhauf, inspect and wash re 1ef va ve
NO and or re lace relief valve.
Check the SPOO 1 it 1s sric e or smot NO
after overhaul of com ensator valve.
robl o pump & motor.
Parts re lace or com lete re lace
) ON (c Iose)' HO
Soc at starting
Ad'ust the micro switch on luffin controller
Shock at stopp no
Adjust the proximity swith will act
whenthe s ool i returned neutral osltion.
et pressure o re 1e va ve 1s a norma y 10
Re-setto correc value
Air intake noise o ,pump (cab1tation)
Che k I re air the suction i &remove the air
Troub e o pump & motor.
Parts re lace or COii lete re lace 110
loose o t1ohteninp .bQ[t
Re-ti hten the bot t: -,,
e
2K.
Set pressure o re 1e va ve • goes dourl
Re-set to correct value.
lease 1n orm trou e to manu acture
i '._ ,,; 1.,,/,
::~~.>.. .. -
• ·. r·::::.,., . .•
.:;·::~:.;,:.:'::··.· .
. . ·.
I- 8
SINGLE CRANE
SlHllHG OPERATIOll
I SLEWING lEfT OPEllATIOH }~<:-l E_FT_ _ _...::::::_ ...

, I
ec y test c1rcu1t
~s er electr!r circuit trouble shooti
Set va ue o rel1e pressure JS changed.
Re-ad'ust as er drawin.
ovenhau . !n~~ect ~n wash re ie valve
NO and or re lace iel ief valve.
C ec t e SPOOi J Jt JS sticked or smoth
after overhaul or com ensator valve.
et pressure o re 1e valve 1s abnorma ly igh

) Re-set to correct value
Air 1nta e noise o ll\lmD (cab1tation)
Check &r air the su tion i &remove the air
rou e o pumn motor.
Parts re lace or com lete re lace
loose o tJU ten1ng bolt.
Re-ti hten th bolt.
easure t e p1 ot pressure at u an
lt is normal if the value is more t
NORMAL NORMAL
.' .
..,.7·rJ
....... •.. ...
_., -~._;... ...... .
., ..... .. ' '· . . ..··: ....:··.. .
·~
~~~:;;~~'.~-· '
',. '" ,·· " ":'". I " .,\, ~. . ,
MAINTENANCE AND INSPECTION STANDARD
Maintenance Ha111e of check Check ite111s Check 111ethods P.eriod Maintenance Repair (replace) Jlema.rka
.:
Systems C0tnponents Standards Standerds
1. 1110tor insul.ation condi- measure at soov one - MOre than lO"'lbe-
tion 111e99er - year t:ween 9rounds :
.... . ..
control circuit do do : ii.Ore, than· lOHt'Sbe'"'. ..

Related
2. Ol'le'. f
year tween .. 9rounds
to
Electricity 3. electric vi re ·do . do one miore than lOHObe-
cord year tween 9rounds
,_ el~ctric vi re do do
pipe L:e
-
. ar
.. I
-----
,.
pipin9 condition
-
check the pipi.nq
in 9ene.re1l
lI
J
one
:r:ear
I no loosene5s at
1i
screw joigts l.. ti9h~er. UF
1. hydraulic oil : quantity of oil 111easure hy level one I qu.antity of oil chan9e the oil in
9'aU9e 111<>nth should be within the tank ev'!ry r«XJ
regulated r•nge A.«.IN'
Hydraulic purity of oil. ask the sa11a9le ••le:
oil-111alc:er tor
oil 1aaker replace-nt
system
chain couplin9 dis.assenbly and one existence of when heavity worn - i f heavity worn
check year abAOrw.al sounds
we.ar of chain
replace vith
one ..
new
..
.. in a short period
rec he cl:: the cent,..ri11
2. hydraulic pump abnormal sound check by listeninq four usually 97-lOJ
measure by decible dirtiness of hyd-
IM>nlh declbel.s raulie oil. load-
"'"'ter inq of filter, valve
the rlllOll\e te r f i t ther1110meter to one .axi•Uftl z~·c vhen te111perature ch~tterin9
the pump •ain body ye.ar rises rapldl.y • chect:
by joint t.he ~u•p and other
pressure Deasure by pressure t"IO ..aintain the regu- related collll'.'.>onents
gauge months 1.ated pressure
oil leakage check visually and two without •1ariation
ch~nqe pack:in9 look out for •9in9
by touch -.onth in pu•p shaft seal
air sution put grease, etc., two
on intake pipe eon th
(_
Ha.in t:.enace Name of check 0-=k it.ens Oieck trethod Period Maintenance Repair: (replliioe) Aemaxk..e
systems ~b 1t:anderds standerds
IU LULCl.IJ11 Illa t:t:.el:S 111 case ot tOre.LCJlll ~r usie dirty
). filter for:eiCJl'l llM tter: t.ak:e out and c:hedc. attached b> the -tt:er att:.ac:hlnent, oil.
•tucment visually. •cx:oc:ding surfa.oe and no dant- c:hano}e ~ oi 1
bo indi.catoc
~-spots
lvellOJl
- ---
0 -
,•
....., pr:essu:re can CJe ~ 1 f t:IIE prt!Ssua!l
'· pre Mure control
valw
pressun oontrol check: by presNr:e
9auqe • c:ontrol froni
NJC.i.- to .W...bull
. aont.hs vi tilolM;... ~ ,--4
cont.xol is possible
~in 9reat.
d-=k the i..ns ide I
repl&aed bo P.llt>
~other~
l"loel>'"\ts
.. if ~. c:ht"Je
. 7. flow O'.Jllt.rol
val Ye
flow oon tro l
pressure
c:ne
~ -.
... WllPft q>e.r:ation ls
defect!-. c:herdt
.. inside: u <llbn::w...&.l.,
"
~- .
.. 6'a.nge
: ~
~---
one acioord.ing t.o the U there is lealcaqe;

' -
8. stop val~ int:.eral le.alt shut the valYe and
check outs i.de leaks year pou:pose for· Use., m · m..nr,,e . .
int.eEnU. lealt .. -· .
'. solenoid valyoe insulatim con-

d.ition
well.SUl'.f! at
111e9a
SOOY - c:ne
year
llOl:'e
-~
than lOKlbet-
'
voltaqe -•sure- . with ~l" 11et.ec. two be i.n pane.able ~ -lta<Je cNnoJe ooila bur:n it
llydr•u.llc irent . 111ea.sure the ~ ~ rolrYJe of rated i• big, recheck elec- vol tac}e b out
vol taqe duci"'J cipe- woltaqe tric equipnent of pemeabl.e
catiOI'\
- operation sound chedc by lht.enincJ one
Systeml year
wear of bush rod chedc the shape b.o no h.srr en .:lqe dwin9e the W>rn
and looseness of looseness of screw llU'\tN surfaoe. no l0011e- parts. Lcos.e screws
scre.111 of termillal pied!! ~9 ;at any part &e<e a cause of e»il
and casing burnincJ
opntlon c:ondition pt:essw:e CJ"UIJe, b«> tel{ierablre rise WvJ'l openation iA doependinq Oil
a:>il CDYer: p;art. -ths at c::ontl~tion detect.iw, change the .qpe. llOl':e
tsnpertun! ooi 1 pu:l: \lllder part9: oc. ~inq tJ\&ft ~1.atie:l
.•· S'WitdU..ng oondition on the content. ,chnge flaw -.Jces operat:i.c:n
is less than 1s•c the ..note &o.fecil..,...,
10.• c::hedc v d ve internal leak increase pressure according to the in case of lealc..a<JI!.
outside, renove, pur:poee for use. ~ change, ~ on
and d\edc leak internal leak the oontent
11. pressure sw:1 tch insulation condi- 111easure at 500V one ~ than lOHbe-
ticn aer;r;ier year tween CJTClUnds
(_
I
(\.)
Main t:enanoe N.vre of chedc: ~ il:e"'9 Oieck 11ettois Puicid Maintenance Repair f repl.a.a! l ltemarks
Sy3teml cxrrpcnents standaxds •t:.artdesds
11. pressure Mitcti insulation con- ineasun by pressure two oonfim ciperatim
ditim gauge llOlths within setting
- pressure ranqe
12. hydraulic cyliroer c;peration ex>n- chec:k for SlhX>th bolo 1n ~ of qieratlon related to~.
dit.ion qieration llonths defect, insi3e valve; etc.
oil lealage c:hedt visually and b«>
-·
no external lealcac]e
- dlarlge p9c*inq
(external) by l:otJc:h ll'Onthlli
.-
ll oil leak.ac]e
: one
---- --
oil leakage bcJ ~
11Ptttu; d
-- H. piping vibcation sarre a.s aboue boo pipe ~·t f------ ------.·~i'
llO\ths vibcate qreaUr "~

-· d.lrinq svi t.chi"9 !
pipe ~t same as above

;1.x nol~•.,...
--
ur;.-. up
-
fitti'""9'1
-ths nothi.n'J aissinq
15. HYORAUL_IC BRAKE Splint' of Apply "'MOLY-COAT approx. Apply"' NEW GREASE .. •ft~r remoVat of liOLD
-GREASE,. to tht' every 500-
brake hub GREASE " dS the "'MOLY-COAT-GREASE" hds
800 hours
teeth of the spline tendt-ncy l>t'ing stiffen ye•H by year.
period
providt>d inside of the
h11h nf brc:lkt'
K-
CHECK METHOD FOR HOSE
1) Checking procedure
Hydraulic hose is manufactured so that it has same life time

as other hydraulic equipments, but depends on service conditj
and circumstance.
For example:
(l) If there is a crack on the surface of hose, sea water
enters into hose and reinforcement rayer rusts, and life
time of hose becomes extremely short.
(2) If hose cramp loosens or put off, movement or vibration

of hose is not stopped, and hose may touch or interfere
with construction, etc. and life time of hose becomes
extermely short.
2) Checking interval and checking item
By every 6 months: -~Loosening or putting off of hose clamp

Interference of hose during operation
{with other hose, with construction)
By every 1 year Loosening or putting off of hose clamp
Interference of hose during operation
(with other hose, with construciton)
Oil leakage from jointing part of hose
and hose fitting
Loosening of joint, Oil leakage from
joint
Damage or peeling off of hose surf ace
Loosening of bolt for hose fitting
"1"
Crack of hose
3) Judgement of hose change
(1) Crack on ho~e (rust)

(2) Damage and peeling off of hose
(3) Oil leakage between hose fitting and hose
Please judge according the aboves.
L-
HO.SE ORDER LIST
1. KIND OF HOSE FI'I'l'ING
.
5100 TYPE 5200 TYPE 2100 TYPE. 2300 TYPE
(SCREWED UNION) (SCREWED UNION) (SOLIT FLANGE) (SPLIT FLANGE)
" 6300 . 6400 .

2400~TYPE 2600 · 'l'YPE 6100 'l'YPE 6200 TYPE
( SPLI1' FLANGE (SPLIT Fl.ANGE
FUR S2DOK HOSE) FOR S280K HOSE)
2200 '11YPE 2500 TYPE 6600 '11YPE

. (SPLIT FLANGE) ( SPLIT FLANGE)
2. EXAMPLE OF HOSE ASSEMBLY
I~ HOSE
B
. ii;. .
L. L'
·®;1 If- I di
.2J --.._.._.........\_\_HO_S_E--~ ~
...
.... . "~
~ . \.HOSE
3. HOW ID ORDER
·For ou~ comfirmation please advise of.hose' type, kind of hose fitting, overall
· length of existing hose to be .replaced.
· EXAMPLE
HOSE TYPE . u:tt~(L) HOSP t•'l 'l'f IN!': A HOSE FITI'ING B O'TY
·WP105-9 . 1000 . 5100 .- 9" . 5100 - 9 ' 1
OMB20-20 . 1500 · 24po,.- ~O-OMB20 · 2600 - 20 .::oMB20 1

SHIPYARD OSIMA 0 SHIPBUILDING CO . . LTD.
SHIP NO. 10221. 10222
FINISHED DRAVVING
(HYDRAULIC EQUIPMENT)
ELECTRO-HYDRAULIC DECK CRANE
30/25 TON X 22/23. 5 M/R
TSUJI HEAVY INDUSTRIES CO . . LTD.

- CONTENTS -
PAGE
1. OUTLINE VIEi OF HYDRAULIC UNIT
1) PUMP UNIT ASSEMBLY ------------------------------------------- A- 1
2) AUX.PUMP UNIT ASSEIBLY ---------------------------------------A- 2
3) OIL TANK ----------------------------------------------------- A- 3
4) OIL COOLER UNIT ASSEMBLY ------------------------------------- A- 4
5) HOISTING CONTROLLER UNIT ASSEMBLY ---------------------------- A- 5
6) LUFFING &SLEJING CONTROLLER UNIT ASSEMBLY-------------------- A- 6
7) VALVE UNIT ASSEMBLY (1/2) ------------------------------------ A- 7
8) VALVE UNIT ASSEMBLY (2/2) ------------------------------------ A- 8
9) HYDRAULIC PARTS ARRANGEMENT ---------------------------------- A- 9
10) HYDRAULIC SYSTEM ARRANGEMENT ------------------;--------------- A-10
11) HYDRAULIC PIPING ARRANGEMENT --------------------------------- A-11
12) HYDRAULIC PIPING ARRANGEMENT (FOR VALVE UNIT)----------------- A-16
2. OUTLINE VIEi &SECTION DRAYING OF HYDRAULIC PARTS

1) MANIFOLD BLOCK (1) ------------------------------------------- B- 1
2) MANIFOLD BLOCK (2) ------------------------------------------- B- 2
3) IANIFOLD BLOCK (3) B- 3
4) MANIFOLD BLOCK (4) ------------------------------------------- B- 4
5) MANIFOLD BLOCK ------------------------------------------- B- 5
.,~~ ''},,..,c;:::------
6) PISTON PUIP
7) PISTON PUIP . , , .. ,...;. . t•z,•Ji- 7
6
8) GEAR PUMP (~1 l.o\ ~ \H11>J GSP2 --------------------------- B- 8

9) PISTON IOTOR UViOO ·- tfJLL~J.Hi.k ______ ~* B- 9
10) PISTON IOTOR A2Jil8 . . .. t"'~~~s;~'.'.;~d~;'i-10
11) PISTON MOTOR A2FK180 ~~::~~~l-~-~~------ 1-11
12) COUNTER BALANCE VALVE RF1C32 ------------------------- B-12
13) COUNTER BALANCE VALVE RF2B25 ------------------------- B-13
14) PILOT OPERATED CONTROL VALVE DDP40 ------------------------- B-14
15) PILOT OPARATED CONTROL VALVE DBP32 -------------------------- B-15
16) PILOT OPARATED CONTROL VALVE DHP32 -------------------------- B-16
17) JOYSTICK VALVE 2RE7L05 --~--------------------- B-17
18) JOYSTICK VALVE 4TH7Z -------------------------- B-18
19) RELIEF VALVE DBlO --------------------------- B-19
:20) RELIEF VALVE 107005 ------------------------- B-20
21) RELIEF VALVE DA30 --------------------------- B-21
- CONTENTS -
PAGE
22) SOLENOID VALVB 41E6D ---~-----------------·---- B-22
23) SOLENOID VALVE 41E6J -------------------------- B-23
24) CBECI VALVE RB ----------------------------- B-24
25) CBECI VALVE CA-16F ------------------------- B-25
26) CHECI VALVE FIC-03 ------------------------- B-26
27) LINE FILTER GI04 -----------------------~--- B-27
28) LINE FILTER FB441-24 ----------------------- B-28
29) OIL COOLER OA2827-------------------------- B-29
30) FAN 710 ---------------------------- B-30
. 31) RELIEF VALVE ZDR6 --------------------------- :B-31
32) LOGIC BLEUNT LC32 --------------------------- ·.B-32
33) LOGIC· COVER LFA32 -------------------------- ·B-33
34) DISK ~W:E BNBD8051 ----------------------- B-34
35) DISI BRAIE BHBD7031 ------------~---------- B-35
3. HOSE LIST
1) BOSE LIST FOR GENERAL ---------------------------------------- C- 1
2) BOSE LIST FOR VALVE UNIT ------------------------------------- C- 6
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1sl I I 027008 00 SPRING WASHER 3 2X8S
16 I 0 2 3 2 16185
HEXAGON SOCKET
HEAD CAP SCREW 6 M16X85
17 I 0270·16!00 SPRING WASHER
!
HEXAGCl'l SOCKET
6 2X15S
...,
16 I 02410516 HEADLESS SET SCREW 2 M8X15
.. - ) 19. 000001loa DRAIN 1 AL 12315
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CHl(O (}/( ' f6.
OWN HISTORY .. CUSTQ.IER
N.Morila DATE Dec.01'94 TSUJI HEAVY INDUSTRIES en L.
ISSUE NO Fl.ANT NAME DRY TYPE NEGATIVE Ol MOOEL
1 PRESSURE MUL Tl-DISK BRAKE '·"'' Hl\JBD 703M-04
ISSUE DATE DWO NO ~T.
.. .,~327 010 57.6 1/
UOSE LIST D. No. 197223 C-1
(B)
NO. DOSE TYPE LENGTU DOSE FITTING DOSE FITTING LENGTH OF

L(mm) A B DOSE ONLY
4 011820-24° 1796 2400-24-1 1/4-01820 2600-24-01820 1600
5 IP210-38 1808 2400-38-1 l/4-IP210 2300-38-IP210 1610
6 011820-20 1529 2400-20-0KB20 2600-20-011820 13JO
7 IP210-32 1521 2400-32-lP210 2600-32-IP210 1360
8 IP210-32 2190 2400-32-l-IP210 5014A-32-IP210 2010
9 IP210-32 2250 2400-32-l-IP210 5014A-32-IP210 2070
n OKB20·20 2400-20-0IB20 2600-20-1.-0MBZO
1
.LV 1689 1530
11 011820-20 1269 2400-20-011820 2600-20-011820 1110
84 IP35-38 989 2100-38-IP35 2300-38-IP35 800
85 IP35-38 1019 2100-38-IP35 2300-38-IP35 830
\__,··
HOSE LIST D. No. 197223 C-2
(B)
NO. HOSE TYPE LENGTll HOSE FITTING HOSE FITTING LENGTH OF

L(11m) A B HOSE ONLY
12 JP105-9 4233 5100-9 5200-9 4160

13 IP105-9 3123 5100-9 5200-9 3050
14 JP105-9 3143 5100-9 5200-9. 3070
17 IP105-9 2703 5100-9 5200-9 2630
18 IP105-9 2693 5100-9 5200-9 2620
19 IP105-9 3263 5100-9 5200-9 3190
20 iP i05-9 3213 5100-9 5200-9 3140
23 JP70-12 2933 5100-12. 5200-12 2850

24 IP35-19 3375 5100-19 5200-19 3270
25 IP35-12 2233 5100-12 5200-12 2190
26 IP35-12 2583 5100-12. 5200-12 2500
27 IP35-12 1183 5100-12 5200-12 1100
28 JP35-1Z 823 5100-12 5200-12 740
29 IP35-12 1433 5100-12 5200-12 1350
llOSE LIST D. No. 197223 C-3
(A) (B)
NO. HOSE TYPE LENGTH HOSE FITTING HOSE FITTING LENGTH OF

L(mm) A B HOSE ONLY
72 JP105-9 963 5100-9 5200-9 890
79 JP105-9 1173 5100-9-116 5200-9 . 1100
80 1Pl05-9 1143 5100-9-Ml6 5200-9 1070
(B)
NO. llOSE TYPE . LENG TU IIOSE FITTING llOSE FITTING LENGTll OF

L(mm) A B IIOSE ONLY
15 IP105-9 3236 5100-9 5100-9 3170

16 IP105-9 . 3216 .5100-9 5100-9 3150
21 1Pl05-9 4086 5100-9 5100-9 4020
22 IP105-9 2836 5100-9 5100-9 2770
31 IP105-6 2-810 5100-6 5100-6 2750
71 IP105-9 886 5100-9 5100-9 820
73 IP105-9 1006. 5100-9-IH6 5100-9 940

74 IP105-9 966 5100-9-116 5100-9 900
75 1Pl05-9 996 5100-9-1(16 5100-9 930
76 1Pl05-·9 986 5100-9-116 5100-9 920
77 IP105-9 1966 5100-9:.IHG 5100-9 1900
78 1Pl05-9 2006 5100-9-1116 5100-9 1940
llOSE LIST D. No. 197223 C-5
(8)
NO. llOSE TYPE LENGTH llOSE FITTING HOSE FITTING LENGTll OF

L(mm) A B llOSE ONLY
30 IP35-32 1093 2100-32-IP35 1001-32-IP35 980
IIOSE LIST D. No. 197223 ·
(A) (8)
NO. HOSE TYPE LENGTH llOSE FITTING llOSE FITTING LENGTH OF

L(mm) A B llOSE ONLY
32 IP35-19 843 5100-19 2200-19 730
82 IP70-12 1498 5100-12 2200-12-3/4 1400 '
(VAI,VE UNIT)
( I3)
NO. HOSE TYPE LENGTH HOSE FITTING HOSE FITTING LENGTH OF

L(mm) A B IJOSE ONLY
1 IPZl0-38 795 2100-38-tP210 2300-38-1 l/4-IP210 630
3 IP35-50 917 2100-50-IP35 2300-50-IP35 090
llOSE LIST D. No. 197271

(VALVE UNIT)
(A) CB)
NO. llOSE TYPE LENGTll llOSE FITTING llOSE FITTING LENGTIJ OF

L(mm) A D UOSE ONLY
5 IP105-9 1173 5100-9 5200--9 1100
6 IP70-12 1133 5100-12 5200-12 i050
7 IP35-12 853 5100-12 5200-12 770

8 IP105-9 523 5100-9 5200-9 450
9 IP105-9 473 5100-9 5200-9 400
10 IP105-9 623 5100:'-9 5200-9 550

49 IP105-9 323 5100-9 5200-9 250
I PAGE
ME ssRs :OSHIMA SHIPBUILDING co. ,LTD.

SHIP No. =l=fJ~ 10222
30/25TONx22/23. 5M/R
ELECTRIC PARTS
TSUJI HEAVY INDUSTRIES Co., LTD.

ENGINEERING DEPT.
MANAGER
ASST.MGR.
CHIEF
SUB CHIEF
y
CHECKED
DRAWN
DATE
DWG. No. M65030-1
CONTENTS
NO NAME DWG. NO
MAIN PUMP MOTOR AS862199
2 PILOT PUMP MOTOR AS850083
3 OIL COOLER FAN MOTOR AS850084
4 CONTROL PANEL M64965 11
5 SLIP RING M65026
6 TRANSFORMER HM100242
7 THERMOSTAT(TNS-C1100P) P60275
8 THERMOSTAT(TNS-C1070CP) P60277
9 PRESSURE SWITCH(TDZ-4) P60167
10 PRESSURE SWITCH(TDZ-7) P60168
11 FLOAT SWITCH P60135
12 SCREW TYPE LIMIT SWITCH S0.420164
13 LIMIT SWITCH(WLD-2) M64450
14 FLOOD LIGHT P60217
15 BALLAST BOX P60157
16 FLUORESCENT CEILING LIGHT P60027
17 MARINE W. T SWITCH P60266
18 CABIN LIGHT P60269
19 RECEPTACLE P60265
20 HEATER P60283
21 SW. BOX FOR EMERGENCY STOP P60293
?2 JO INT BOX (1 MO) P60261
23 JOINT BOX(2MO) P60264
24 HORN BUZZER(D-11) P60037
25 BLOCK DIAGRAM 161434 Lb.
26 ~0~~MAT10
V V I IL.Ill/"\ I
IV
nlA~RAM
VI Y \ H60916 ;~
27 CONNECTION DIAGRAM 161566 &
28 TEST REPORT(MOTOR)
29 INSTRUCTION MANUAL FOR
THREE PHASE INDUCTION MOTOR TTE3-282
PILOT & COOLER MOTOR K60103
SLIP RING ASSEMBLY K60127
STARTER K60025
33 TROUBLE SHOOTING K60076
34 =tEI~¥1J~l1.J#.!Uf:izt&L \~BJHi TTE3-250
35 JitB ffi ~ ¥1J ~ 11.J tilf:iz t1H \ ~ BJli= K60132
36 *'i:~~jf)( t& L'.f.:l. U ,~ ~ 1

) .A t- K60127E
37 t1JfitlH~ If:iz t1H \ ~ BJJ :fl: K60222
38 1-- 5 :::f JL.- ~ .:i.. --T 1' '_,/ :/ K60076E

ROTATION !
SPECIFICATION
-------- 515
847
1.Ru1E: ON\/.I AMF3. rFMr-.: 4SC
I)
481
i------- - - ---· ·-- - - · · -
2.GL/\NtJ NO. & . CASI E NO. : ..
----· --·-· 100 100
GLAND NO.
--·- --·~--
. N0.40ex2
MOTOR
-SPACE
- - 1-IEATEH
-··- -··--
-----·- N0.20cx1
THFT<MOS rAT
---· --·-·-
4-~24
I
...... -
.3.TYPE. OF COUPUN.G : DIRECT (l="LEXIBl.F.)
HOLES
4. MEl I !Ol)S 01- STARTING : STAR-OF.LTA
F3
5.CONNLCI ION (INTERNAL ) ·:.
;_,. ·1v ~{ ' r l

y 'c,W
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r o-r
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_
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406
1/0
311 168
Q........l'V'v' .o H1 H2 TH 1 SPARE TH2 I ·---
THERMOSTAT
I 49C:. 410
U X SPACE HEATER 1- "A". VIEW
6.GREASE (SHELL ALVPNIA No.3)
I•
LIMIT OF ALLOWANCE BEARING TF.:MP. RISE IS ss·c 2-PF12 PF3 4 ..
AT SUHFACF ON BEARING CAPSULE.
~
<j·
(MAX. AM~. TEMP. 45 ·c) lO .I. - - - I'"'")
\{)
I ./\CCESSORIE!S :
SI IAr r E:NO KEY (JIS-8-1301-·-76 FLAT KEY)
: .... : iV6_~m~ I
. TERMINAL
8.TOLERANCC: (JIS-8--0'101-65) -
...-i
GLAND "'A" V\EW
I ..
l secTION "B .. g .. SECTION "A-A"
PROTCC ilON
IP2.2
r . 9.PAIN I ING COLOR MUNSELL : 7~5 BGy'2
1 a.THRUST . rROM
.
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440
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HL
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SUSTAINED ON MOTOR BEARINGS TYPE INS.CLASS RATING FRAME" I-LANGE

OPP .L.Sll)E 460KGS
11.AOOITION/\L r~CQUIREMENT : FBOr F 40%t.U 2505 6313
® ..r·r~ove:n nY n11.1::
1) TAKE CARE NO I TO LEAK OIL FROM 1-------··
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$1-IM. I LX r£N"Sl ON
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>.IOOIF"r CONTE~T
=i< 4) GLAND (CUSTOMER SUPPLY)
V ..
450
10 ~!
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;:;: L .. ·;' 1-Ml2X25 ROTATION
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Sf'ECIF!CA llONS ltlU.H mw. ; •,s·c

IRUl i : . PNV
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lRULE: DNV MAX.AMS.TEMP. :45"C lP-44

2 GLAND NO: 20C (CUSTO~ER SUPPLY) OUTPUT POLES VOLTS rREO. R.P.M. BEARING APPROX 'M:IGH T
!--~~~~~~~~~--.
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AMP TERllAINAL 6306ZZ
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CONTENTS 0::
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l 0 CABIN LIGHT COS2
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TSUJI HEAVY INDUSTRIES CO., LTD. (A 4) ( I J{>
23
"'E rTING- J-<OLE S 2 - 7 •
RATING: 250V 20A
TYP.E : 2MO
WElc;HT: 0.45 Kg.
C\'1:11"'1NG SC~ ·'...I f11'{1)5S

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NO. NAME. lvlATERIAL Q'T NOTE. NO. NAME. MATE.RIAL o·r NOTE.
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CHECKER DATE TITLE

DRAWN r-v:;,R.INE JOINT eoxt W.T) D.NO
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P60264
TSUJI HEAVY INDUSTRIES CO., LTD. (A4) I Ju
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TSU~I INDUSTRY CO., L,fD.

CONTROL PANEL
@) L-DPYC-l.25 ---[[KJ SLACK OVER LS.

@ L-DPY~::L2,...._5_ _ _~ OIL I.DI LEVEL (Fl.DAT SI.)
_@__ L-DPYC-1. 25 ---GiiCJ OIL TEIP. SI. (35"C)
@ 1.-DPYC-l._25 GlliD OIL TEIP. SI. (85"C)
@ ll:If¥C::2. OLJ PILDT PIJKP IOTOR 3. 7ll.
@ L-DPYC::L25 CffiD PRESSURE SI. (SPEED CllANGE)
@ L-DPYC-L25 CfSD PRESSURE SI. (OVER WAD)
@
L-llPVlLC-_'J../_ _ _ _ _ _ _ _ _ [Ls:J LIIIT SI. BOX) [ DIFFEiENT
LUFF. OOIN. LS.
UP. REST. LS
(SCREI TYPE HOIST. UPPER. I.DIER. LS
_@__ L-llPYC-5
@ SPECIAL CABLE Ir x I HOIST WIER NEUTRAL
®@ SPECIAL CABl4PIJ
LUF:1 UP OOJN NE'JTRAL
L@___ L-lifr~C-_!.1_5_ _ _ _ _ _ _ _ _ _ 1IKJ
CONTACT FOR HOIST
@ 1,-llPYC-5 ---[[KJ
CONTACT FOR LUFF
@ L-IPYC-5 ---[[KJ
CONTACT FOR SLEW
@ 25~----{S[[]
L-DPYC::L.....
SOL.FOR HIGH SPEED
@ L-DPYC:l•. 25 [Sfil.iffi]
SOL.FOR HOIST BRAKE
@ ~YC-L 25 l:sfiiTI SOL. FOR LillIT
@ L-DPK:L25 [SOiiilJ
SOL.FOR LUFF BRAKE
@ L-DPY~L25 ---fSfilIJ
SOL.FOR WIER
@ 1.-DPYC::J~?-!l_, B SPECT Al r.Am R FAN (IN CABIN)
'3r L-IPYC-5
~~=--~'-'=--"'----·--i:==i EIERG.STOP SI.BOX
.~~~8~~Lu-D~PY~C~-1,~.2~.5--------@) CABIN LIGHT
_@2 H-TPNP-1. 25 ~
--.o@"""'g-~L-_~DP~Y~~ 11-TPNP-l. 25 c:::::::::J Fl1l00 LIGHT 4001
FLOOD LIGHT 4001
0
~
@ JcIDCd. 25 _____· - - - - 0 D
CAllIN HEATER lKI
Q
z
·--"®"""-4_ _.,l~,-D~PV~L25 0
-
.......... 0 RECEPTACLE
@ L-DPY.QY:.L2ti._ _ _ _ _ _ _ c==J WARNING llORN
L @ ~
L!_ L-DPYC-1. 25 _j1
@ @ @ @
2J_ L-DPYC-1. 25
MACHINE ROOK LIGHT
PflESSURE Sw. (2510ti)
.,
5
7 a 9
SOURCE FOR.
SOURCE SPACE HEATER
AC4~0Y, 60H::, 3• AV! lOV. 50Hz. l •

11cBD I
G//\
SC p-., 0 =-
EF0 1
lOA
.I SLIP RING
RING
I EFO:l
lOA
~CONTROL SOURCE
C2
SA102B/lSA
MC807 a
-:--..
~-+--+~~~~~~~~~~~~~~~~-Q I ()....~~~~~~~----,
1.-~~~~~~~~~~~~~~~--0....-:::-.~~~~~~~~
TRANS. SOX
t.1CBO 1 3KVA 1'
SA 4 0 3 R/ 30 0 A 44.0V/1 l av
l.4CB02 EF07 AY2

- EA53B/15A lOA (Cl25)
I
l
SC f""/ N SC1 N SC-4-0 sc-o I
~-jMC805 Il
_ !.!C03 ~~~MC04 }..«CO 5
l
~~C02 ~ ....i.... ......
( 024) (0 2 3) ( 04 8) (027)
51P
TR 8 N-N
SlF
TR.5-lN 9A
5lu
TRON 6A
'I F52B/1 OA r
--) t.ICB05
F52B/l OA
COS2
SET 10. SA SET 6.7A
SETl08 A
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u v "'
l. l E
I
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I
w1
SCSN
MCO 1
(022)
.L ___ _J
. I
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o
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lOOW lOOW
OIL COOLER AUX.MOTOR FLOOD LIGHT HEATER FAN RECEPTACLE LIGHTING LIGHTING MAIN
HYDR.AU l IC
PUMP MOTOR FAN MOTOR 3.7KW,4P (t.AERCURY LAMP) IN CABIN IN CABIN lOOW IN CABIN IN MOTOR. PANEL F
l !2 KW. 4P. ED40~ 5. SKW. 4P CONT 6.7A 400WX2 lKW 48W 60WX1 MACHINERY
CONT 10. SA ROOM SPACE HEATER
20WX2
• NON SPECIFIED CABLES TO BE SY-1. 25sq
IAPP CHK DRAWN ... >(j I{'.) • 1q· TY

Iow~. NO."
l SEQUENCE DIAGRAM . '
TSU J I HEAVY INOUSTR!ES CO .. LTD

I ~ . ~: -...}.) I _,J 1: I FOR SOURCE i :H:
I
' ' 6:rj:
' l.· '
c
i
'
.~'
.o.-.
' '
'
0:1
:: 3 5 7 8 9
.':"""'"-
-~ .
C1A . NON SPECIFIED CABLES TO SE SY-l. 25sq
Cl ci -,
I
r· lo•ERG.
25 TON
PRESSUAE I
OVH
?RE.SSUR'E'
-·----
~IPS3 l ;
... ------~-- I STOP
I
L P83
....,
N
o TF02
MC.,r!ij1
1 co I I
~ ;
~NOJ rY4 rX 1 rX2
~
23J1 (028) 031)(""'\ (031)
, r ( 0 2 8)
· I I
u (046)
l _: l I
.J
L .J ~r,
6
~ - - _ .... - -~ ~ l
AY8
9
(04 l>
EMERG.
STOP 0
It\
P83 N
0
STOP
r?84- P8:2
I
LL.
,......
----------f>~~~ ~) IMC02 I MC 0 l \W\RNI~

Ho RN
w
"'
N
AY5
(034?
('\J
~II AY6
( 0 24) ( 0 2 2) 0
~TART
PBl AX c
3
~
(036)
~I
MC03 MC 0 l
( 0 23} ( 0 2 2)
AY7 AXl AX2
(0 3 9) 1(031) ( 0 3 ll
I
<.:i<(
.
AY 5
(034)
. r' r
~ l, ~ 0
a::i <
I.{\
A Y6
( 0 3 6)
jTF6 J
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0
0
n,AY7
(03 9)
~.
E
TN MC AX MC Gl · TN AY TF
2 !
02 02 \j}_) l 2 05 Q.3 4 03
lOSEC O.SSEC I 2SEC 2.SSEC
C2
C2
_J
L J_ ....,_.;,.._.,......,_._,HHS4P-L ·S N SRCSCl_U X A HH 54 P-L I.A
MC03 AYl MC02 AXt3 l AY2 AXl 2 l.ICO 5 TN03 AY4 TF03
011 1!1048 0 1l tl. 011 I a 0 26 6 033 0·13
TC
a. 0 2 a. 028
TC
a O3 F
0 1l 011 a046 01l 0.. 017 ! a 0 21 a. 013 b b 035 b

I
0 t l 0 1l 0 l l ()... I b 019 a. 013 a. a
4
TCi--+----! i TC TC a
024
0 2 :2
b 027
036
024 0.
b
- b 0l 9 a.
b 046
b b
b 0 2 2 b b ' b
b -b~~~
MAIN MOTORA.-t,C!RCU[T CONTROL SOURCE AUX.MOTOR OVER LOAD
APP CH'l< OR.AWN jQ' TY
SEQUENCE D[AGRAM '
o: 2:
' '
TSUJ ( HEAVY I NOUSTiUES CO .. L TO FOR SOURCE : H:: 6:0: q.
I
'
f C-.. '
I_ 1
'
I : : ' I ' I....._ I I
'
•NON SPEC!FIE.D CABLES TO BE SY-l.25sq
cl
c1
A
AY4 TF04
( 0 2 8) (03 6)
TF03
~ (029)
0
rn CONTROLLER
TN04
pco31)
LTNOS
r(031) r{ TN06
o 3 2)
rn
0
AX l l
(0 5 2) I
AX4
( 0 3 7)
AY11
8
AXlO {042)
( 0 5 l)
CONTROLLER<
N
rn
0
AX3
·1I
I.)
If\
('\
( 0 3 3)
m
('\
rn
t---
AXl
(0 3 1)
1
A-x 8
039Aco 4 7)
0
0
035C c
.J <
~
rn
--o--.:,_·-+--. <( 0
037A
0 AX9 '°rn '°rn DOWN
Eru~~
u <a 4 7l 0 0
~ TFO l
u CD
< al
rn "'
..., N
(Tl ( 0 31> . .
(1'"0 (1'"0
L_ __J
qi~~;;,
0 0 0 0 0
AX2 _J
r--- ( 0 3 1)
I. al f' AX7 D
L co44>
J
"<f'
rn
~~!7)
0
- - OJSE AX8
0--
(0 4 7)
BRAKE
HOIST
BRAKE
035G
E
H H 5 4 P- L S.,....................."4" X LIMITTING HH54P-L

x x HH54P-L
AX4 HllS~!'-L AY7
AYS TF04 AY6
TN04 TN05 TN06 AX3
a 025 036 Al' 10 a 025 F
a 033 033 I a 025
a O3 TC TC ~ 027
TC ia 027 a 027
b b
b o~7
a a a TC t-4+ - - - t Q. o.3%
TC 1--+---< TC TC b
b b b
b b
b 034
b
b
LUFFING CIRCU[T SLEW C!RC!J[T
HO!ST C!RCU[T
JAPP ICH K \DR.AWN MFG NO.

I ! SEQUENCE DIAGRAM
: /"_ 0:3:
II , ~, I I A -
!~ -I F"OR. SOURCE .'O
TSUJf HE:,O.VY lNOUSTR.!E:S CO .• LTD
)-r • ..bl
SCREW lYp~ UMIT SW
I SLACK QV~R • NON SPECIFIED CABLES TO SE SY-1. :?Ssq
THERMOSTA
[ N MO
r
ro R.
!
·1 I (Q4 l) I
OIAX6
(04.3)
l
r TN07
(043)
IAX7
(044)
TF02
(0 4 5)
MC05
( 0 2 6)
l AYl
I <o 2 3 l
L. .J KS-1 8
L BYPASS
l SW [ TCH FLOAT SW
(WITH KEYJ
w w
,.
I
I
AYl 1/1 ·1
t~;"
c
'~ ~
(0 2 3)
<
L. .J 'THH
8 5 •
I
L. J
I THC
35.
8
N FF at
<:;J"
8 s ·c
AX6 AX8
~ ( 0 4 7)
~ 51U
(0431
I
..q 0
~ I
TN
A y
07
8
HHt;4P- L
MS4SA S
AYS TN07
a 044
a. 025 TC
b 0 4 l b
TC a
b
b 048 b b
b
b a3 s b b
OIL LOW LEVEL 0£L HIGH TEMP. Q[L COOLER

SLACK OVER
t..tOTOR. OVER LOAD
CHK DRAWN MFG/'10. 1owc. NO.
SEQUENCE. O[AGRAM I I I l I ! I
' '
FOR SOURCE I ~H~6~0~~: I ~6:-~0:4~ ' A\ '

'l.!...l '
TSUJ [ HEAVY !NDUSTR!ES CO .• LTO I I I I I I
~
- - - -,
.
I ~·1 HOIST
I ~·1 LUFF
KS2
I
I
NEUTRAL I
I
_J
NEUTRAL AY
d o 23.SWR
L .J POS!T!ON L_ POSITION
. ([J3)
4
22tfi
e
; AX AX
I 14 15 -
~!
co co a::i ~
N r() '::c ~ 0
~
L0 L0 L0 CJ
0 0 0 ~
.\
AX
11
AXlO AXl4-
F
b 03 3 Q. OH
Q. 052
CA.
0.
b o3> b 0 35
• NON SPECIF!ED CABLES TO -BE SY-l. 25s«
b b
I HO[ST NEUTRAL LUFF 'NEUTRAL

IMFG NO. IQ' Ty OWG. NO.
SEQUENCE OfAGR.AM . .
I :_:0:5:
TSUJ[ HEAVY !NOUSTR!":S CO .• LTO
! I
I
::-oR. SOURCE
'·t'
't :o' ' ' '
~--------··----
1
-----
I.
II
I
l
[
I
I
I
I
I
1·
i
Il
I
!I
I l
I
- I iI
i i
I' i
I
I; I
I
I
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I
.I
I
I
I
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ii
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II
II·
I -!l E 3-.282.
o-( /
/1:?
c :J :J l - \f "T' s
?:::.ge
Chaor.er l. . ............... .
Z. Insnec~ion before the LttS~allat~on
2-l ScatoT Wiring 1nci inside oi ~otoT
1
'
'
Z-3 ~easurement of axis cieviacion ..I.
~- Connection with Companion Machine .................. l
~ - .L In c ::.s .e oi 9utting bell: ~=--=- -:=:e :::::i n.::. e-=-:: :_a r.
3-2 In case 0 :r di rec: .::onnec~ :..on .
--
' '
-'
In CJ.Se of Gcaration . .
In C3Se oi Cha in
.' - - Othe-rs
3 - ci Attention ta install driving part
-
4. Others .J
- .................. -
~ -1 Cannec:ian oi Wiring . . .)
:l. - z Confirming or installation Re s i s t a.n c e . .

..1- 3 ~a load operation ........ .
Chapt:e:- 2. Start, Operation and Stop
Z. Operai:ion
J. Stop the motor ... - - ........................ - .......... - . . . . . . . . 6

'
v
1. "I a ::. n I ~ '.1 3. n c e 3. n ci : J s u e c ~ i. on a r

5LatoT :1i.:-ing 1 ....................
0
Loose~:ng or :~ste~ed boles ~nd nut5
Orie~ to disa~semoic
.)'
:a ·:le:.rn 3
, ,
ov :leaning cloth ................... '
..,
hv comnressed air
av emnloving Solvent . . . . . . . . . . . . . . . . . . . . .
~. Inspec-:ion of Rot:or ..... .. ....................... . 9
Insnection at Bearing . . . . . ...

J
1 .:., ....
;. Brie: Re~airing of each part L :;_
~-l Oeterioration of winding ~ire ~an:~~
S-2 Oe~e=ioration o~ winding wire
insulation resist~nce
.-:: - -
...) E~c~anging of bearing
Outline ~o pulling bearing out 12
6. Ho~ to order the par~s -

1 -
..)
Chapter Count:eTmeasure foT Condition and (3use
of Defee-:
Chapt:.er 6 . Limit. oi Temuerat:.ure ~ise L6
1~ -I
Chapter i Sec:t.ional Dwg. tor ..l.ss'Y
Chapter 3. Others
~a.
' ' - 1-.~-~
./
?3.qe
l. Di~e~sions and Tes~ ~esult ........... .
2. Inc:ui:y anc Gi.;t ................ ~ ...... . L7
o-4/
No. T'I'E 3-282 /1:?_
J(J!--HO
Inst3.llation
l. Handling oi Cargo
~ny dar:i.ages by trans9or~ation exis~ or not, as soon as t~e
motor ar:::-i '7es. Furt~er, a~tention should be 9aid Ear no
detec-:.s and shocks, for the trans?ortation of t.~e ~ocor in
Also, when ?Ut the mocor in c~stody for tem-

?Oral:"'] or long-ter~, damps and vibrat~ons snould be
s~=~~~~y ?rohi~ited.
2. I~speccion before the Installation
2-1 Inspec-:. ""het.~er the.!'.'e is such crags as wate.:::- cascade
or dus~ and ot.~ers in the stator wiring or inside
t..ne ~otor. (Especially, in the case of open type
water ~roof motor)
2-2 Turn t.~e axis of the illotor by hand,. and conf~rrn it to
ce rocated slightly.
If it turns very heavy, or it rotate grately, ins9ect
it whether there is any defect or not.
Also conf~rming should be done for 'the loosening of
each fixed Darts.
2-J Confirm the deviation of axis is under the soecified
value or not ..
J. Connection with Com:::ianion C-iach..ine
J-1 In c~se of ?utting belt Ear the connection, too much
belt tensity causes the decrease of transmission
No. 'r:'E 3-262

;;
ing unreasonable ?Ower to the =otor axis.
Sy :u.aking the contac~ surface between 9ulley and jelt
extended, through the lower :::;ar:: tighten and 1199 e.::-
~ar~ loose~, the sli~ will Je le~5.
In c~se of em9loying V belt, should 8e drawn
~oosely ~~an flat belt.
:' ..i.::--tb.er, cent:.e!:" lines of the axis of mot:.or and c::::im-

1
pan1on macb.ine shall be.9aralleled e~ch ocher, and
the center lines of both 9ulleys shall i:Je st=aighc.e!1.
3-2 In case of direct connection
!n case of direct connection, .careful considerac.ion

/
shall be ?aid for st=aightening of axis cores by
careful ~iecing u9 of both axis cores of motor anci
corapanion machine.
:ur~her, flexible coupling shall be·e~ployed for i t
to ?rotect the juggling.
3-3 I<l case of G2aration
The cange between centers 0£ gears shall be decided
+-n <e~p the suitable backlash (module x 0.05 -0.lmrn)
unifo.nnly through the cogs of gears by making both
axis 9ar3.lleled.
rurther, install it by adjusting not to give any
inclination by inspecting gears em9loying red lead

etc.
No. TTE~]-282 2,1.3

iC;-11~
J-4 In case of C~ain
Ins::.all the motor to be the chain r=ignt anglt:: .,,.i::.h 2.:<:is
bv me~ting the ce~~er 9ositions of cogs of s=rccket
bv making ~at., axis ~aralleled after careiul inst2.lla-
t~on of s~rocxet on swinging of side and oucer
c:!.rcular of it..
J- 3 0 t!"le!:"s
Install ~he mocor making ~alance i::.self as ?Ossi~le as

.,
you can, and GD- also equi??ed by spec~=~ed 5~yle, to
couple with such svnthetic machine as the case of
installi~g such rotating part as ?ressing rolle!:" to
~,e motor shaft end.
J-o At::.ention to install driving ?art
At~ention shall ~e ~aid for shock or benci to the axis
not to !:;)e loaded unreasonably, in the case of
installing of such at:Ove said driving oart as ,..,ullev

.. .
or cou?ling.
Fu.::-ther, in case of shaft end of t.J..ie motor Ls
tapered, insert it after confirming t.J..ie rabbing
rate wit., boss side is over 80%.
!n case of tighcen 4nd fixed the driving part by bolts
anci nuts, fixing device for them should be considered.
4. Others
4-L Connection of Wi=ing
Connect the wiring correctly to ?Ower source through
i'lo. TTE3-262 J/13

In c~se of ~nder 3.7 ~1 oi gen~ral ~otor, connect~on
of 'vi..:-ing is . .:. .__ type anc. ::.:ie ter:ninal ma.!:"k.s are U,'1,
-
~
r."JI
- a.nC. ~er ave:: 3 . 5 K:'1 is ~
marks are u,v,~, and also for
are a , v, :·1, ~~, '!. s. z.

curther, Ear such special type motor as nurn.ber or ~ale
conver3~on type, wir~ng c~rc~it ?late is s~icked co
the wotor itself and the connection should ::e done
fallowing this indication.
S?ecially, confir.:n whether there Ls error or not to
t:.he rotating direction for ~~e connection in the
te!::ninal box.
:asten tightly the terminal bolts, not to contact
tne bared ?arts of terminal each other, or not to
'°_o.- __
,,..._;,....... (Loosen fastening causes the defects of over-
neating) .
In case of earth terminal attached, ground wiring
shall be done.
4-2 Confi.::ning the insulation resistance
After installation, insulation resistance should be
confirmed by measuring it to make sure.
There will be no trouble if it i.s over lMO by
measuring SOOV t~ga.
In case of too much decreased, refer to the item of
No. T':'E 3-2rJ2 -l /L3

.- _j , ...
tre3. t.."1en t.
4-J L1a load operation
9efore actual oper~tion, tuI"!l tae motor ':::;v no load, and
c::m:fi.!::n t...1-te ampere of eac~ ?hase, sound of bear:..:ig.
direc-:::ion of rocacing, swing of shaft, and ot...>-ier
abnor:nc.li ty.
St~r~, Oneration and Stoo
Usually, starter is em9loyed for operation of motor.
A.f ter confirming the ?OS l. ::.ion of s tapt:Jage, close the :::iower
.:;wit::::. (c::rndit.:..on 0£ "ON") and bv moving the handle of
starter or pushing the button for operation, the motor
starts to rotate.
(tl.3.) In ca.se of A-!:::. star-::ing tY9e or voltage
cie~=ease starting type, cl1e operation is differ~~t by

starter. Therefore, start and operate the ~otor without
any mistake aiter i:::ead the inst::::-uction of starter well.
2. 09era tion
~the voltage and,
A£ter finished t...~e starting, confirm'the frequency to ce
rated value, ·and the ampe.::e to be ·under rated value by
:--io. TTE 3-2132 S;I..8

Ooe;:-acion condition, chen obse!:''Te t.he a.!::nor:nal ts:!119erat:'...!.re
c~se, abnor:nal t~r~iag sound anci aonor~al vi0r~t:icn ouc-
Sreak ear a ~hile.
J. S tcp c:ie r:to tor
t~e aperacion visa verse or S .... ~r-.;

~..::.
"'g
-...l....i.J. ..
Iz t~e ~o~or stops due to the 80wer cur=ent shut-orif wh~le
oper.::.ting, handle should be returned to t.!"le s-.:op :;:iosit:ion
manually Eor such st:uctured starter as no-cecurn auto!11a~ic~l-
~v t:o tje stop ~osition.
-~
I
C~reful at~ention shall be ~aid Ear such type as .........
star~ type for t.he operation of full voltage start when
t~e ?Ower car::::-ent cecavered with t.>-ie state or nae: re':.ur::l.e'J..
Chanter 3. Maintenance and Insoection
1 Maintenance and Inspection of stator wiring
l-l Maintenance, Inspection of wire end. Serie~ ooservation

shall be done for sticking of dust or oil, loosening
of binding string of wires each other, abnormality
of contact parts of wiring, and deterioration of
finishing vanish or tapes on the surface of wiring,
especially for open type structure.
~hen van{sh deteriorate too much, apply or spray

I I
:inishing vanish (suitable ~or eac~ insuiac~an classi
after cleaned it enough ~nd d~reci (c.~-

ChaDt:;!;.- 1 on
met~od) .
1-2 Insulation resistance CTeasure
Insulation resistance of wind w~re should be ~easured
?eriodic.3.lly.
~he decerioration of insulacion !'.'esistance is the
signal for danger of insulation, ~~erefore, com?aring
S ::all be done with :.."'le for.ner :::i.easured r:-esul t, by
recording the measured value of i t for eac~
measuring.
Advice is done for the measure under the same condi~ion
oi te.rnSJerature, imEJressec voltage and time to corn;:ia!'.'e
t.hem.
Desirable condition is generally over lMQ ~y ~easur-
ing of SOOV Mega.
2. Loosening of fastened bolts and nuts
Observe whether bolts and nuts of ~ach part loosened by
vibration of operation or not.
C::-taote.r 4. Disassembly and Reoair
Clean a.nd repair the motor after dis~ssembled i t at least
No. T'I'E. 3-282 7/13

!2
one:: d ·rear a.:Cte.?: beginning of 09era1:.ion and i..f nec:essar:y,
mendi:ig should be done :or it.

l. Order or disassemble
At first, disassemble the motor r=om ~~e cornganion

i.,.
mac .. ine.
The!l take of:: t:ie tightened bolt. for aracxet and ::::u out
the rotor from the simple substance of motor.
furtli.er, for t:..he d..isasse...rnbling, a little diffe.!:"e!1ce is be..:.:iq
existed bv each types of motor on tli.e binding sys~e~ of
br~cket etc., and refering the attached Dwgs., do it wit~out
any mistakes.
7he!1, obs e.!:"~Je, clean and repair the motor care.:fcill~r on the
each par~ as follows.
2. How to clean
2-1 av cl~aning cloth
I~ is enough to wipe ou~ by dried cloth when dried dust
piled on it, but waste cloth shall not be em9loyed.
E.mploying waste cloth causes to ?ile dusts, dam9s
and oil by stacking the flue to ins.ulation 1?art.
2-2 By comQressed air
Ganerally, it is effective to blow-off using compressed

...,
air of al:xJut 5 - 10 Kg/cm-, especially . this method
is l:ene.titable to wi9e out t.he dust which i.s not
able to take out by cloth.
In this case, the dust may be piled on other Qarts
,'fo. ;'"'r:' 3-262 3 / l. 8

---
13
again, and it should ~e wi2eci out oy cloG~.
cur~~er, in case of this ~et~od, t~e o~erai::.or should
employ the dust ?roof eye-glass to prot~ct his ~adv,
especially his eyes.
2-3 ay em9loying ;olvenc
Wipe grease or oil out emEJloying any oil sol•re!:'lt:. sold
in market.
The solvent is unflemrnable and ~at so ?Oisonous, but
anyt-1ay, use che neoolane gloves to 9 ro i::.ect:. :::-om act
by t.:.'le solvent.
3. Inspection of Rotor
Observat~on shall be done for being off from the connec~ed
?ar~ of end =ing and bar, or for any breakage.
Ccnfir~ whether there is any scar of overheat par~ly or
any scar of touch with stator / by observing the condition
of surface of rotor.
4. Inspection of Bearing
for general use motor, closed type ball bearing is em?loyed
Ear, and no use to supply any lubricating grease.
riowe•1er, renewal shall be done for the almost life e...'ld wnen
obs2rvation is done.
On the other hand, open type ball bearing is emoloved for
t:be special use motor, in this case, new grease Ls eut in
t.be bearing roller and the old grease LS put OUL Erom
there. ..
No. TTE. 3-282 9 /13

I ti.
;; l 1 up new grease for c.he ti~e of disassarnbly, target
LS aimed to fill about l/J oi s=ace of bearin~ box. Beari.-:g
box shall be assembled bv filling new grease to t~e spac2
OL one side of bearing anci by filling new grease only co
inside of bear~ng br3cxe~ or outside.
J. aric£ Re2ai=~ng of each ?art
~-L De~ericration of. wincing wire vanish
Iron core and winding wi:e is covered by most highest
Janish to withstand sufficiently against dust,
darno anci. salt. \1hen the cover deteriorateci, treat
again it by vanish of our recommendation.
·5-2 Deterioration of winding wire insulation resistance.
Insulation resistance may deteriorate in case 0£
remarkable high of ci=cumstance dame or uncier cus~ody
of :1 itilout long term ope:?:"ation. Hhen insulation
resistance deteriorated, dry the winding wi=e by
any method to blow dry hot ai= by about ao 0 c.

In this case, attention should be oaid for the over-
heat locally.
5-3 Exc~anging of bearing
'I'li..:: bearing burp t or come to life shall l.le exchanged by
the following order.
The bearings to be used shall be those of 1st class of
i.hppon Seiko (USK) or Toyo Bearing (HTN) made.
S9ecified detail of bearing and· grease shall be provided
:lo. 'I"::'.'.:. 3-262 lO/l.8

i•:-.na
It;
following na~e 8lata on ~otor or dimension Dwg. under
2urt~er, do not hesitace to incruire on the unknown
9roblems, by same way wit~ order of oarts.
\l) After disassembling by above wav
Ln c.::.se of .closed ball. bearing
!Jull bearing With f?I:'Otec::.ing :;?late om: C'f
bearing t:JUlli.ng t:.ool witb. CJrOtecting :;Jlate.
in c~se of 09en type bearing
Pull only bearing out by bearing ~ulling
tool, clean the inside end· cover with
benzine or ~et=oleum and again assemble it .
. ( 2) PU"t:. the new bearing in the oil oan and heat it

("\
until 90 - 100-C, take ou~ and wipe i t out on

. ,_
inside and outside surface and ?USh L '- to the
shoulder of the axis.
Do not push.it unnaturally when joggle or gra~e
exists;
The bearing can be inserted by k~ocking the all
circumference slightly for small type of bearing.
Further, fill the indicated grease refering
"Inspection of bearing" of Eo.r:mer i te.rn 4 :or the
open type bearing.
(J) Assemble it by G~e order of visa versa of the
disassembling.
No. ~TE. 3-262 Ll !l8

unrc::.=.s.::ir:..:i ble shock t:.o da..~ge or ·:enci t'.":e ~a:::- -
i.ng or sha£~ i~ c~se of disasserr~l~~g ~nc
c:.sse~cli.ng.
S-~ Outline to ?Ulling ~ear~ng out

F • 1 .
To ::mll bearing out, oo i~ as -0.L~OWl:-lg Ow<;.
special tCJol.
Dwg.l - i~ case of gene~al motor.
Dwg.2 - use at~ac:-i.ment wheo it ~an not be ~ulli~g
out as it ~rovides cooling olade.
Dwg.J - ?ull out ~ith ~rotec=ing :) le::. te •.-1hen
is ?rcvided.
l ~ l"f~,-,------.
-~
D"~.l
I I
.·-10.
!.
I,
'
'
'
. I
•· .
6. aow tc orC.er the ?art:;
To excjanse t~e ?ar~s, t3ke can~ac~ to o~r sales office ar
agent.
c.::i.se, ·r1e shall ce ver'! happy you let '.lS know
:~e desc=:..~ed mat~er on name ~late (No. of motor, t~?e,
c.:=.pac:.. r::::f and :nanu:fa.ct:ured da c:2 etc.) anC. d.esc=-:..-;rc:..:;r., ;:;:::.arr::;:.-::.i·.
Counter~easure Ear Condition and Cause oi De£ecc:
Cunaicion o(
Cause Count:e'!:1lleasure
De rec c
:la- *Wire break.Ear over 2 phases ~emove the ~art: ac

s c.:i. rt: No oi scacar Yire broken Yire Or Oad
sound ~or:: ion
* Wire break Ear aver 2 phases

oi connect: cable
* Deiec:s of svi:ch or cont:ac:

or starter (over 2 phase~)
* Fuse melted (over .2 phases) :...'<change che Euse blaun

and e.~amine che cause
* 2oYer cur~enc shuc oif I. After

I
power
confirmation of
;,-ecove:::-;, ~e-
operate
I
?.11zz * 1 phase break oi scacor ~ire C3.n oe turned co boch
direccian by aia.nual ~s
* l phase break oi conneccing mocor b~com~ single.
cable. phase
~ Def ec:s or svitch or concact

of scar~:r(l phase only)
; Fuse me.lcea (1 phase only) Exchange Euse, e.x.am.ine

cause
L 4/ '. . 3
/'I
(.JcH.ii ::.on .Jc

DeEec: C.u.use
:lo-
·I
3u;::.:: "' :·fec:C.J.nicJ.l cor.c.:ic: oc sc.:icor Disa"'s~~a·
~ ""~ "'
.L, " , "' 0 "ai·
__ ,, :: -·
1..'1e
anci ro cor cad porc2.on, anci as-
~e~ole Ln re?ai:: shoo
·· Connec: conversely oucsec i\e.:Jair i.n shoo for cri.i:;-

anci insec oi ~lagl~ phase connec=ion oi Yire
·" 2.i~ iJeeling o(f be.C',;een cocor, Disassem.Dly, i.n reoai::

oar ~ t::!nci ring shop
S c.:ic:s Tun "' :!is-·:onnecc oc illocor and ~xc::i..:tnge Eree ~ ;Jnases

:-everse. s Carce-::: (power) among J phases
"' ~lis-connecc or te.r.:i.inal I

mar ks o f mo co r i
'
I.nsui- "' Defect: of bearing Afr.er confir.neci, r~pair

ticienc in shop c.J.se. by ~ase
co c.:i.ce. "' ?eeling off or rocor bar
iJOl..le.r and end cing
R;se che iJOWer co
~ Orop of power volcage
raced vo i cag~_e________
I By curning mo co r by anci
k ?.J.r:ly short cut of scar.or •1
·.<iring !· by, inpuc cun:en c

I ·:=:::.r..;;-=·..:.
, I
• Same wich insufficienc Same wit~ insufficient.

Sudden
ro cace power roe.ace. powet:
drop of
, cocac.ion
Re.turn ca prope~ loaci
(check by inpuc current.)
.!
Ove'!: "' Over load ! tze.c.urn co proper loaci
1
h~ac ·(check by inpuc c.urrenc)
k Single phase operacian Afccr confirmed, =epair

.!~--~-~-~~-~~~~~~~-~...;.-~-~-~~~~~~~~--~'"7'
I
I
I* Drop of power volcage Return pow~r to raced
value
I
No. T'I'E 3-2t2 l.S / l 3

---------------
C.:rndic:::..on oi
Cause Coun cec-:IJ.e::i.s u ce
')e(ec;:
.:5C3.C':S Sucicien ... Ccogs inse::-;:ad oec.;een 5C3.COt': By ciisasse.mol:r taKe o[f
:; cop and ::ocor c:-ogs.
I Usually scops ~y ~c:ion
! I QC procec:~ng c:.ccUiC
.I • (fuse i!t:c. )
I
I
~ Oerec: oc beacing Exchange :~ear:.::1g by '.:i.::1d

che c.::i.use
~ ?owe:: snuc oif A.fcer con.Cir.:ned recovery

or: po<.>er, ::eoper::ice
,-
Chaoter 0 . Limit of T~~oe~ature Rise
7he mo~or is designeci and manufactured under c~reful
consideration Qn insulation and tem9erature cise value
to be able to emolov under bad condition of ci=cum-
stances.
However, after long time 09eration, or over loac or
under bad condition of operation, the temperature
cise value of stator 'cecomes extremely high, and ~n
the ~orst case, c~t off t.he li£e of i t or stator
coil will be burnt.
Therefore .. if any abnormali"tyfind out, check ir- by-
measuring. At the time, cefering specified value is
shown below.
1"'<0. L6/ :_3

_____________________________:::'t.- --~/_
" dee
E a E' H
Mechanic~! ?arts sue~ as 60 75 30 100 125

iron core closed to
insulated wire
Stator wire 60 75 90 100 125
3earing 40 Heat resis~ lub. oil 55
~emar ~~s: * Limit of !:'"isi.ng 'Talue bv resistant met:.hod.

k We use onlv he~t cesistant lubricator.
C~a.moer 7 _ Sec~ional Dwg. for Ass'y
Outlines of Sectional Owgs. for ~ss'y of each ty~es
of ~1otors are shown bellow.
Available for disassembly, overhaul and inspection.
c::i.aote:!:" 8. Others
l. Dimensions and Test Results are sent to you under
sepa-rated cover.
2. Please take ~ontact to our Sales o£iice or agent to
Na. TTE'. . 3- 2 8 2 l 7/ l 8
11
de-:3.ils of our :1otor.
In t~is case, we shall be ve:::'J happy L~ you let us ~now
::..'1e desc::-i::ed matt:e::::- on name ?late (No. of Motor, Ty?e,
C3.paci t.y anci ~~anufac::.ur:=d data 2i:::.c.) · and Dwg. No. ,
~1fg. No. on Dime!'l.sion Dwgs.
LB/18
m .~ ~ .:i: ~ ~ ~ :SJ
CONSTRUCT!ON OF OPEN DRIP PROOF, SELF VENTILATED TYPE
SHINKO F'R, fu 330

. goo~~ f5- m co 0
fl; ,.;,.
-Q :t I: tr ~
PART ~ DESCR!PTION QUANT ITI MATERfAL
,;; 1-" 7 r- . ~
1 l
Srt.AFT STEEL
--<T 'J :; '/ ;e;:-.::t
2 l
BEARING S?EC1AL STEC:.L FOR BEAR[({G
771r'7r ~ ~·
3 l
BRACKET CAST fRON
;r_j--? ;J -{ JV ~
4 1
STATOR COCL COPPER
7v-t.. ~.~
s FRAME l CAST r RON
,. - ~ -t' 1i.- ~"T1;::.. 77-':/7' 1} Jl~IH:;S;
6 l
TERMINAL SOX ASSEMBLY STEEL OR CAST CRON
;r_f--11 :::: T ii~:ax
1 l
STATOR CORE SICCCON STEEL
a-? ::JT ~~:ii
8 ROTOR CORE l SILICON STEEL
7 T / Tw~.:.r;J..
--
9 1
F A.N ALUMINIUM
7 T / ~~c~~
lO FA.1'i l STEEL AND CAST CRON
11
--< T ') / '/ /l ,.,
l
Sf .a
BEARtNG COVER CAST !RON
12 7777 l- ~ ~
8 R:\CKET I CAST [RON
13
--< T 'I :; '/ il5~~
BEAR!NG L SPECIAL STEEL FOR BEARl:--lG
l4 ""'T 'J ;;r JJ ,,
l
!JI(
SEARfNG COVER STEEL
lS 7 :=..-/ 7 7 './ 1"
l
1< *·'A
WA.VE WASHER '
SPR!NG S7EEL
I
~1~ ·J I
'"""'v ~ 1!3
INDUCTION M·OTORS
.Instructions
Pl LOT PUMP MOTOR
OlL COLLER FAN MOTOR
D!,/G.NO. K60!03
1
/13
1 ·Introciuc::ti.on
Marin Induction Motors are the pr-

oduct o~ our excellent technology and sev-
ere qual i tY control. and they are designed
to meet special marine SPecif ications in
every way down to the smallest part.
These instructions apply to these motors
which are suited for use on the upper dec-
k·s1 w hi ch are ex Posed to the action of the
waves.
standards applied
marin induction motors are manuf a-
ctured in accordance with the standards of
the organizations and with the standards
laid down bY. JIS. JEC. JEM and others. as we-
1.l as t he s h i P s s a f e t y a c t.
Insulation class and temperature rise lim-

it
marine inauction motors adopt thr-
ee classes
.-·"" ..... -.---·-:---·--
... . .. . . of insulation:
. ..
class E. class B
·.an d c l as s · F.
·, ·-· · - ·A 1 t ho u g h t he re i s n o s P e c i f i c 1 i m i t o n t h e
rise in temperature of the motor casing,
the following values are usually accepted:
Class E insulation-Maximum rise in temp-
erature of casing: about 45· c
Class B insul~tion-Maximum rise in temp-
erature of casing:about 50· " '-.J
Class F insulation-Maximum rise in temp-

erature of casing:about 55· c
The limit of the rise in temperature of
the bearings measured on the surf ace of
the axle box is:
55· C for class E and class B insulation
55· c for class F insulation.
- 2 -
-------
2 and Stora.
These motors are shipped as comolete units

from the factorY .. Check the name Plate to
verify the sPecifcations and make sure th-
at the motors have suffered no damage dur-
ing shipment. If you do not Plan to use the
motors immedi.atelY. take adequate precauti-
ons to Protect the motors durinQ storage.
Place covers over the motors and~store in
a clean. dry location.
Measure the wincing insulation resistance
regularly while the motors. are being stor-
e d. rn a k i n g s u r e t h at t h e v a l u ·e s a r e c o r r e c t
since corrective action is required when
the value of the insulation resistance dr-
ops suddenlY. The motqrs are coateo with a
p r e s e r· v at i v e a t t h e f a c t o r Y t o P r e v e n t c o -
r~r-osion. If a motor is to be stored for an
e x t e n d e d P e r i o d. r e at:> P l Y P r· e s e r v at i \J e a t
t 11 e n e c e s s a r Y l o c at i o n s .
For motors stored in clean. dry locations.
turn the shaft about once every three mon-
ths to check the rotation.
When storing outdoors or in location subj-
e c t t o rn o i s t u r e. u s e a w at e r ~ P r o ·o f c o v e r. i f
you intend to use a Packaged motor which
has been exposed t.o low temoeratures. be
sure to unpack after the ambient temperat-
ure has risen to that of the installation
site. otherwise rnoist.ure will condense. When
transporL.ing the motors. use suspension
bolts o:-i the frame.
- J -
3 I N S -r A L. L A I I O N
Instcllation Procedure
Qont install the horizontal motor by a sp-
ecial mounting method, aoart from the hori-
zor1tal. for the bow or stern. Check the mo.t-
or base carefullY. The motor and the dr1v.en
equipment centers must be accurately alig-
ned. or elsethis will cause vibration and
bearing wear.
For motors Y-.'hich have flange mountings, in-
stall carefully on the companion equipment
Gnd tighten .firmly with bolts.
couoling drive
A flexible coupling is recommended to cou-
ple the directcouPled motor to the load.
Accurate mechanical alignment is the most
important requirement for direct coupling.
echanical vibration generated during ope-
r at i o n i s a n i n d i c at i o n o f P o o r· . a 1 i g n me n t ·
It is·reco~mended that the alignment be
'
checked using the dial indicator and .othe-
r S.
End Play adjustment

Bearings used in motors having no special
specifications are usually designed to th-
at there is no external thrust load. There-
fore. with couoling drive. i t is imoortant
to install these bearings in the motor so •·I
that they are not subjected ~o this exter-

nal thrust load.
Installation trouble
Check the following items if there is tro-
uble while the motor is operating.
1. Bearings:for smooth rotation and Proper
lubricai::.ion.
- ~ -
2. Interference : m.e ch a n.i cal 0 b,j e ct s W,h i ch
i mP e d~ r o t at i o n.
3. Tightness of all the nuts and bolts.
Checks related to electrical trouble nece-
ssitate a comparison of the motor conditi-
ons to actual SPecif ications.
1 . v o 1 t a g e o f e a c t1 P h a s e a t mo t o r t e r m i n a l s .
2. Line voltage and frequency (must conform
to those shown on motor data Plate).
3. Operation of overlo;:..j Protective device
(when used) .
.::J. Circuit connections between control dev-
ice and motor and contac~ conditions.
5. Motor load (checked by comparing line cu-
rrent ~o full-load current shown on data
Plate).
6. Grounded motor (checked by disconnecting
power and measuring power circuit resis-
tance to ground with a megger).
Terminal box
The direcxion of the terminal box outlet
can be on the top. bottom. or l e f t or right.
Ch9nge as desired by removing the mounting
bolts and reorienting the terminal box.
Operation
Before s-r.arting the motor for. the first

time. read through the following instructi-
ons carefully and take the app~oPriate ac-
tion.
Moisture
When it appears that moisture has entered
the motor during ~hiPment or storage, the
St3tor winding insulation resistance must
be measured wit::h a megger. The actually me-
asured value mus~ no~ be less than ~hat:
- 5 -
b
shown below:
Rated voltage
----------------- = Megohms
(KW rating)+ 1 ooo
If the insulation resistance is less than

t h i s v a l u e : p e r f o rm· o n e o f t h e f o l 1 ow i n g
steps to eliminate the moisture.
1. Place the motor in an oven whose temper-
ature does noL.: e.><c2ed go· c and dry until
·the insulation resistance reaches 2 c=n-
...-
stant value.
2 . C o v e r t h e mo t o r 1,y i t h c a n v a s o r s i m i l a r
material and leave a hole on .toP through
which the moisture can escaoe. PlCJ.ce a
heater or lamp inside the canvas to eff-
ect drying.
3. Lock the rotor and aPPlY opwer to the
motor. current at this time shoufd be li-
mited to .one-tenth of that when the rat~
e d v o l t a g e, i s a p P 1 i e ·d t o t h e s t at o r. w i n -
d i n g .. G r ad u a 1 1 y i n c r e a s e t. h e ·~ u r r e n t u n .t -
i 1 the windin·g temperature reaches go· c.
D o n o t . e x c e e. d t h i s t e mp e r at;. u r e .
Voltage and line frequency

Make sure that the power source voltage
and the line frequency are identical to
those appearing on ~he motor and control
unit name Plates.
Ini'tial starting
1. Make sure that the parts are carefully
secured. and that dir:-t or dust has noL.
accumulated inside the motor.
2. I f P o s s i b. 1 e . t u r n t h e mo t o r r o L. o r b y h a n d .
an d rn a k e s u r e · t: h a t i t r· o 't'. a t e s s mo o t h l y.
3. If problems are presented QY the Possib-
- 6-
le. rota.ti on of the mo -r or in the reverse
direction. start t:he motor initially alone
and check the direction of rotation. If the
direction of the rotation has to be chang-
ed. swith two of the Power leads ... For equip-
ment designed to turn in ong direction on-
lY. make sure that the motor turn in the
correct direct.ion by checking the equipme-
nt data Plate or drawing Which come with
the equiPmen-c. The connection data Plate
attached to the motor indicates the corre-
ct rotation.
4 After check.in g all the Parts of the equ-
iPment. Proceed according to.the starting
method at the control device and star-c
the motor.
5 Maintenance
If the inspection and maintenance are car-

ef u l 1y p 1 a n.. n e d. t h e e q u i P me n t · w i l l o P e r at e
at-."the· maximum. ef.iciency .
and the costs re-
quired· for· maintenance will be··~inimized.
·T·he .f8llow1hg items must be check~d in ad-
dition .to daily observation ·of physical
op e r at i o n a n·d o v e r a l l con d i t i on s :
i: overall cleanliness
2. Insulation and windings
3. Lubrication and bearings
Insulation
It is necessary to conduct a complete che-
ck of the windings when disassembling the
motor. If the windings are dirtY. or the in-
sulation resistance is less than that pre-
scribed in section ~.·clean as follows:
1. I f all the oil and foreign matters adhe-
ring to the windings can not be removed by
h o t \'I a t e r o r s t:. e a m · u n d e r· l o w o r e ::: s u r e o r a
- 7 -
cleansing agent. clean with a volatile
solvent such as gasoline or carbon t e t r -
ach lode applied to a cloth or brush.
When using a solvent. make sure that the-
re is adequate ventilation otherw.ifse you
may inhale too·much vaoor.
2. use one of the methods ln section 4 to
dry the insulation.
3. If Possible. varnish processing should be
performed. This is done when the winding
are dry, or Preferably. s t i l l hot. APPlY
t 1·1 e v a r n i s h b y b r u s h i n g. s p r a y i n g o r d i P -
Ping. Dry for six or seven hours. but do
not allow the temperature to exceed go· c.
The use of rapid air~drYing varnish will
eliminate the n e c es sit y for an oven.
D e P e n d i n. g o n t h e w i n d i n g c o n d i t i o n s . mo r .e
than one varnish Processing may be nece-
ssary.
4. clan the w l n dings and do n o·t fail to ch-
eek the insulation resistance before OP-
era.ting ·the motor .
. RePlacernent·parts
When ordering parts. always include inform-
at ion on the data. plate ratings .. the seri al
number and equipment model. as well as the
quantities desired.
Coupling fitting/removal
l.v h e n f i t t i n g o r r e mo v i n g t h e c o u P l i n g a n d
Pulley. be careful not to aPPlY thrust Ca
+orce parallei to the axial direction) to
"Che bearings. Do ri,ot hit the bearings when
moving the couPling or Pulley along t:.he
s h af t b Y t .a P P i n g 1,-y i t h a w o o d e n m a l l e t . A l w -
ays support the OPPOSite end of the shaft
with a solid obje~~ when a~Plving force .
.. a -
sealed ball bearing .maintenancP.
e
wi t h ·s e a l e d - b a r· 1 n g mo' t o r s . ·a l . i t h. i u m b a s e
grease with superior moisture-resistant
aging-resistant and lubricating capabilit-
ies is used. There is no lubricant leakage
and so it is not necessarY·to add grease
or. conduct bearing maintenance. At the same
time. the service lif·e of the bearings \{"5
extended.
1. If i t appears that something has gone
wrong with the sealed ball bearings, dis-
assemble the motor and replace the faul-
t y ball bearings.
2. Prepare to replace the sealed ball bear-
ings if there are ch a fl g es· in the i.r o P e·r -
ating sound.or there is an abnormal sou-
nd. or i t the temperature of· the housing
rises ab°normallY. The service .life of se-
a1·ed ball bearings depends on their app-
lication environment. the use of the mot-
or ·and other factor~.
under normal conditions. they·will last
'
for aqout 20. ooo hours.
Be·ar in9 removal

when .disassembling the .bearings. make abso-
lut.ely ·sure that dirt does n·ot· fall onto
the area sorrounding the bearings or into
the bearing box. Always remove the dirt be-
forehand. The bracke"t. and the bearing box
are detached by removing the bolts.
The rotor can be extr.acted after the brac-
ket has been removed.
Extract the sealeo ball bearings by extra-
cting tool.
Bearing reassemoly
8 e t- o r e f i t t i n g t r1 e · b e a r l n g to t h e s il c f t .
remove d i rt -f r om the s 11 a Ft. :surface 1r-1 h i ch.
- 9 -
will come into contact with the bea~in9:
smooth scratches and burrs.
\
Wilen sealed ball bearings are usep for mo-
tors. coat the inner surface of th~ ball
be a r L n g an c1 t 11 e s h a f t w i t h l u b r i c a n t an d
position the bearing so that i t is square
with the shaft:. u:se a sleeve that will come
into contact with the inner race onlY and
carefully force the bearing into position
\.•;ith a Press.
If a Press is not available. strike the sl-
eeve lightly and evenly with a suitable
ool to force the bearing into Position,
Regardless of the method used. the bearing
must remain square with· the shaft and for-
ce must not be applied to the outer race.
- l 0 -
//
6. Trouble
.µ
L
ru 1. control unit trouble due to overload.
.µ
(f) . 2. Blown puse or fuse not inserted.
.µ 3. wi r i ng e r r· o r (c o n t r o l uni t )
0
c 4. Bind in driven equioment.
(f) 5. 0.P en stator or o Pen rotor winding
Ql
0 -
circuit.
D
6. Grounded winding.
o 7. Bind in bearing .
.µ
o 8. Loose terminal or le ad co n.n e ct ions.
:L
Ql
(f)
·.-1
0
c
1. OPerating under sins le-Phase power.
U)
Ql 2. Electrically unbalanced load.
.µ
C\J 3. Vibration.
L
Ql 4. Non-uniform air 9 aP.
c
c:::
.....) . InherenL.lY noisy bearing us ed.
6. Rotor and stator conL.actins.
0 I
µ
0
:L
- l. l -
L
Q)
L
::; 1. overload.
µ
C\J 2 . I n c o r- r e c t v o l t ag e or 1i ne f r e q u e n c Y.
L
UJ 3. s ho r t e d o r g r ounde d s t at o r· w i n d i n g .
0.
E 4. Excessive moto1 reversal operation.
Q)
µ
.... \
I
01
I
C·
......;
µ
C\J
J. . Incorrect. centering.
Q)
.!:.:.
2 . Excessive end thrust.
L
Q)
3. Excessive vibration of driven equipm-
> ent.
0
\Jl 4. Generation of shaft current.

c
• .....i 5. Damaged bearing .
L
C\J
Q)
m
m iii t¥. 11 ~ ~ a ~
CONSTRUCTION OF OPEN DR[P PROOF. SELF VENTILATED TYPE
l I ::;,,..7 !-
SHAFT
m £ :g ~
DESCRIPTION
tt I:
QUANTITY
1
··
•STEEL
SHINKO FR.lb 330
~ .
MATERIAL
2 I --<7 1) "/ '/ .

BEARiNG I, fill~:=
SPECIAL STEEL F'OR BEARING :
3
77'1"7 r l
Jf it:
BRACKET CAST CRON
I ~OPPER
I
4 ~-f-"J ::i., '" 1 '

STATOR COIL
.s 7 v-i..
FRAME
,_!., ;t!.,.?
l i ~AS~ IRON
!
I
'
I
-j-1v ;%. / 7 .<z;/"J'IJ il~IUU~ I
6 STEEL OR CAST IRON i
TERMINAL BOX ASSEMBLY I
;t.f--_, :::JT ii~•.l!i

7 STATOR CORE . 1 SlLlCON STEEL
a-? ::i·f ~=1§ .
8 ROTOR CORE· SILICON.STEEL
7r/
9 1
FAN
7r/ il-!lic~.a.
10 FAN STEEL AND CAST lRON
--<T 'J "/1' tJ,{ ~ ~
11
BEARING COVER I CAST IRON
/77".,. ~ ~ ii;
12
BRACKET G:AST tRON
13
--<7 •J
BEARCNG
"/'J'
I fill~,.
SPECfAL STEEL FOR BEARING
I
. 14
,-.r,7 ') :t 1'
BEARING COVER
tJ ,.<
l •STEEL I
? :I:.- -:f ry 7 ',/ ,. ,o(:j'.~
15
WAVE WASHER SPRING STEEL
~h AP N3 - l 5 3 9 7
------
...,
j
I
I -v.4
INSTRUCTION MANUAL
FOR
SL!PRJNG ASSEMBLY
-/- DWG.NO. K60127

1. Preface.
In order to use this collecting apparatus safely and efficiently.always pay caraful
attention to the condition of the machinery parts. Avoid operating the apparatus beyond
its power and prevent accidents from happening.
2. Mounting of the apparatus.

At the time of installation: don't damage the case.
The damaged part causes rust and becomes a cause of losing the benefit oi its paint coa-
-ting. Therefore be very caraful.
If by any chance damage occurs to the paint coating, apply a supplementary coat of
paint. In the case of machines which have a high vibration, use a vibration protecting
rubber at the place of fixation. Pay attention to the fact that this very apparatus is
not made vibration-proof.
3. Inspection.
Because the rubbing surface of slipring and brush of this collecting apparatus are
very important, see to it that no dirt or oil of any kind adheres to the ring surface at.
the time of inspection. As for the inspection of each separate part: perform inspection
with scrupulous care, consulting the maintenance inspection list which is indicated below.
4. In case the impossible happens.

We deliver this apparatus being produced at a thorough supervision.concerning its
quality. Nevertheless, if an accident occurs, be sure to let it know to our factory or
to one of our business offices. In case of trouble, please let us know the following
facts:
1. All particulars which are on the inscription plate.

(especi a1 r:1·· ttie manu fac ti.ire number a 1SO don t forget the date•)
I
1
2. Place of trouble and circumstances.

3. Usage conditions and surroundings.
-2-
I NS PE CT I 0 N L I S 'I'
Places to be inspecled Items of inspeclion Countermeasures Time
Hing and brush parls l. Is lhe rubliing surface in In case a spnrk exceeding Jue N0.5 is once a monlh
good Condi ti on? genera led.
11
Rubbing adjusting with 240 sand imper
has to be done.
2. I sn' l there any carlwn In this case lake powder away wilh a once a month
" powder sticking lo lhe clean c..:loth.
ring surface?
----------------
.
(.v 3. llow is abrasion condi lion f1ep I ace l>rush. with a new one. once a man ll1
t
of brush?
"
Each part of terminal lsn' t there any loosening Tighten parts. once every 3 months
of l~. compressed parts?
INSPECTION LIST
Places to be inspected Items of inspection Countermeasures Time
Electric wire parts 5. Isn' t there any coating Repair or replace lhe damaged parts once every 3 months
damage? with lapinR.
Each bearing part 6. Isn't there any noise or In case of continuous noise or vibra- once every 3 months
vibration? tion replace the parts.
I
Coating of paint ? . l sn' t there any damage,or !lave it repaired. once a month
rust coming out?
f-----------------+----------------- -·--------------------- - ---- ----------
Isolation fracture 8. Between each interval and Measure at l,OOOV. once every 3 monlhs
damage ground contact. over 3011.Q .
All right.
------------------11----------------r-----·-·------------·-- --------------<
__ ,
~-'
II
-~ I -- -
JN~, rRUCTION MANUAL

FOR
STARTER
_( MAI_~I.E.N.ANCE)
-2
C.011tacrs
dote: For inl<irmntion 011 contm:t on replacernn1 ,t and proper valuu ol contact pr~!ruro, 50'(l
t11.• DUrticulru l!jC.:tlon c.,[ thia in11trui.:tion with ~10 devko in deta!I.
01n1r;I
--
Cont.acta urc U1c baaic fonctinn.nl purls of nl I motor cont•ol und proper orern.tion c..\open<ls
urivn their lieing m;iint:ain.od in llOOJ o~ratini:r condition,.
···-~--
Every tuna cor.t1ct3 open or clo!le they a:e :;ubiect to mechanic.at wear nnd electric.al
burning. Contact' parts,· therefore, are items th.at rntty require considerable maintenanc..e
depend:,1g upon operating conditions of devices.
Often a small cnntact will operate depe11t!.ably wilh a heavy electrical loo.d, where la.r):{er
contact!! 1r.ade of inferior m..1terial would fail. No one rL'<.lUirt!ment Q\n li:ited for goo<l con·
met material, a' good i.:ontact mutcriul must meet each nt sevcr<tl te'lta.
The first requirement ot ;1 satisfactory contact material is high electrical conductivity.

Muterinls excellent in other resµect;i will fail a::i a cont.act material if the:y aiford high
e 1ei.:lrical resistance. High resistani.:c r~ults in excessive hcatini; and eXce>!3iVo heating
lead:-i to failure.
Copper Contacts
Copper conlai.:ts are inexpensive and are widely used as contact materi;i.l for most heavy
duly c.ircui•.s and. in r;,any cases. in pilot circuits ( rdays and interlocks) on shipboard
rnntrollen!. Cnp!J<.; has a high me Itin{{ point and high dectical and the.·nial i.:oml\1ctivity.
\V ht:11 rlet•n, ccpper has low contact res1:;taoce but doe:> form highly re'li~tance coatin:;s of
oxi<lf" purtic11larly wr ~n closed or .. hot" for long period;i of tim~. Tht:refore. it is often
neCC":U..Lry tc. remove tl.c· oxide coating with a fine file. For this reason copper cont.acts arc
oft· n ),lated with C'ldrnium or silver, instead of .Plain coppt:r, to reduct: the effect of copper
oxide, w:1ich may cause overheating. These cadmium or· silver fa~C'd contacts require no
C'.leaning or periodic filing. The platin!! assures a good electric<>! wntact on the mountin~
s•irfoc~ of the conwct tip. On .the cont.a<.:t surface •. however, the platine doM nut we.ar !11ntc
aml it is r,ec~sary° to arrange th~ contact·J to be self-cleaning.· Th;s acc;ompl:Jh(.d by ·irrang·
ing them so that they strike first at the tip and. as the cr..11tactor closes, they c..;me to::eth<!,..
with ,_ roll:ng sliding motio• nnd finally re-st. tol{ether at the heel of the cont.act. The rolling
sliuin~ motion i:i sufficient to wear through a thin film of cop[)<!r oxide an<l present a
comparatively dean contact surfact:. howt!ver, on apµlication~ where contacts are o~ ·.q:itcd
inireQuent!y it may lle necesS<Jry to operate the cont:ircc.r a number of times to obtain this
ef(ect.
p. ·:tinn of 3elf·cleaniri,. cont.Jct
M cu.rr~nt
r~~-
Closin~
Oncninrr
K60025 - 2
i'l'oUbln Shooting Chart f~r Contacts
I Cau;g l Correct/011
!---------------- ---------··---------·----------------!
Burnouts 1. Short circuits or ground::i." 1. Remove grounds ·or -;11orted
conditions.
~. Overheating.
2. Increa~ low contact pr~uro,
remove dir~. oil or ~re.ase. re·
move ox1d~ or sulfides ..
J. Slow "breaking". 3. Eliminate bind.
4. Low le.ad dimension. 4. Renew contacts.
5. Excessive lead dimen:'lion. 5. Redllce lead dimension.
Excessive Wear l. Ex.ce"'-Sive iogging or inchinis. 1. Do not iog or inch cono-ol len1
unnecessari I y.
i. Faulty blowout assembly or ::!. Replace or repair blowout coil,
arc :ihield. eliminate shorted turns.
J. Excessive oveloat.!:i.• :J. Eliminate cause - check current
reading:!.
~- Slow '"breaking", ~. Remove bind ol parts.
G. Excessive filing. 5. Do not dress or file the con·

tacts unneci:ssarily .
- - - - - - -· .
----·-·----· ----------------------i
Overheating 1. Oil or grease. l. Remove with carbon tetrach·
loride.
2. Copper oxid~. 2. Remove with a fine file or
sandpaper.
3. Low spring pressure. 3. Increase pre3<Jure or replace
spring.
4. Silver sulphides. 4. Remove u5ing fine sandpaper
or a fine tile.
5. Loose cont.acts. 5. Tighten.
Weldinl! or l. Ground or excessive over· l. Elimin;lte cause-check cur·

Sticking loa.ds.• rent readings.
2. High spring pressure. 2. Reduce pres.qure.
3. Low vol t:ige. 3. l ncrease.
ii. Slow "making" or bind. il. Remove bind.
------· -· ···---------------------------·- - ·----------
Excessive Arc- l. Shurt circuit or ground. I. Remove grounded or shorted
ing or Sputter- circuit.
iaz 2. !3inding parts. 2. Eliminate bind of parts.
3. f'uuily \Jtow·out. assembly. 3. Renlacc or repair blowout coil.
eliminate ~hart~ turns.
4. Exl:essive le:id dimension. 4. Reduce to increase contact gap.
•Warning: Short circuits or grounds in the associated eqipment necesaitates a thorough

inspection of the controller, a5 th~ conrnct.q may be damaged by this condition.
K6002.S - 3
-----------·---·-
Tho contact:i. coils nnd other parte of cnntuctora and relay 8 thnt may re<iuire replace·
n~nt.o ar" arrungcd to pr.rmlt quick and ea~y nccoM for such replacements. Deftigrll!l nre
complete unit IS99ombl iot 110 thtst an ontire Unit may be QUiC\([y replncetl by another one,
The Jam.1gctl unit then can ue put in good condition in the reJ)l\ir ehop.
Conl:lctqrs and relay!'\ should be cared for in :iccorclaoce with tho General .M.aint'l(nance
instructions in p.1rabrraph II o( this section. In acldition, operation of the individual devices
9houlc.l be checked during each. inspection and the fol lowing observation:s ma~.
Excessive slam
Excessive slam on closing. particularly on a.c. magnet oper.ited devic~. will eventuall;i:
d3rro).(e the laminations at the magnet fuce.s, will result in short magnet life, an<l may
darrot;e the sh.1ding coil.
a High voltage on the coil or the incorrect coil for the voltage i!t a possible cause of
eJlcessive slam. Check the line voltage on the coil and if too high, correct it at the
power source. If voltage is correct. check the coil number a-"'1inst tho service plans
for the device and ~~ if they ngr~ with the nmneplate voltage. . Insert proper coil it
11cce~1ry.
b lnsufficleot mecbaalcal load on the magnet mechanism is usually the re~mlt 'of weak con·
tact springs. worn out cont:aJ::t.s or both. Check th<'! .,.;ear · ailowa~c in accordance with
instructions or.i the individual d~vice instruction sheet. If this is not the cause, ch~k
the 1.:ontact springs and replace any weak or burned springs.
H'oi sy magnet
:i Magnet cbatter on a.c. magnets may be! c-...iused by an open circuit in' the shading coil.
Check th~ shading coil rarefully and rcpl<1ce if broken. (Temporary em~.rnency reP<Jirs
,·;in usually be m<:Jde by soldering a iw111>€r over the bre;.ik.)
A ma1,rnet chatter. very sirnilar to that l."3used by a broken shading coil may also
re::.ult fm111 an_v of the co11rlitio11:i which \4.\lse hum, :is listeJ below.
b. Magnet hum on 3.C. magnets 1:; an incticution that the rnabrnct nrrroture has not st>".iled
rirnperl v on closing.
Co111:\ctor~ nrcrntc<l uy n.c. 111<1~11cts will usu:tlly h;we ;1 low hu~~ing ·noise. But.
i( the m;;-;nct procha:cs :.in 0::xccs~ive noise or r:hatter, the moving Dal-t or nrmatl1re rnay
noL he rrnpcrly seated ~gainst the stationary ma~net surface. Improper ~ling c:rn he
c:111~P.d by oli!'tructions in !lie air ).(.Ip, et.c. This should be checked and correcteil irnme·
di:Hcly :19 it m::iy r:lltiiO burnnut of the m:1gnet coil. Any of the followinf! conc1ition!i
m:iy be the Cluse.
(a) Dirt. ~rease or otll.cr foreign matte• on the rn•11,.TT1et fac.~ should be wiped off with
a dry doth.
Mlst11lignment ot the.: arm.'\tl.!re is usually the re<>ult of ex.ce::;sive wear on the arma·
ture. or phy:1ical d·~r!"l<'~~t: to th~ i:n;1tact0r. Replace worn ur Llamaged flUl"t.
KE0025- 4-
( c) Ma~net surfaceS'that are excessively ,..• om.· p r e v ent p roper magnet sea 1·1ng. ll ow·
ever o.nly in eKtreme C.'1Se9 ghoulJ the magnet surface be filetl or. ground. All work
of this type should be done by a skilful mechanic. .The rnu1t11et may be closed
upon a piece of corbon Jllper to dotoct and mark pointa of unovon 1e:aiing.
' ' ,
( d) Blndlni muy be rauseu by a bent armatur~ 11hntt or by nccumulutlonis ot dirt anit
grens" around tho :\huft. Replace tho shaft It dan111l{ed •. Keep thc...operating parta
free of accumulation:i of dirt. Alw-.iys wipe oft ex.ees!l oil when lubricating.
(e) low voltafs will result in a weak magnetic flux which may not be sufficient to
seal the armature against the wntact aprini;: pressure. Line volta!;:e should be
checked Immediately and corrected.
('f) Too much sprl111 pressure muy prevent proper se.ali11g of the armature. On adJust·
able uevice'3 checlc inJiviJual inspection sheet for proper adjustment. On all
devices, after replacing contact springs. make sure th.at armature seala properly.
Ma111etlc Stlckl11i
When opernting coils are ue·energizeJ, some residl!lll magnetism remain:s m the m<lgnetic
circuit. This residual magnetism wmctimes is strong enough to hold the device closed
after the coil is decnergizeJ. This co11Jition occurs most frequently ·on small <levic~ on
which contact spring pressures and moving µarts ure light. J\fai,rnetic sticking c:au~ err.Hie.
un&itisfatory. nnd sometime!l dangerous operation. To avoid ·this situation. therefore. qm·
tactor and relay openlting magnets usually <lo not hav~ a cornpletly closed magnetiG circuit
unless the residual nWlgnetism is neutralized by reversal of the magnetic field. Most magnets
have an air gap or a non-magnetic shim in. the core or frame, on . the. armature, or on one
of the pole face3. Sticking or failure of. the armature of these cont:actors· or relays to
return to its normally open position afrer the previouRly energized i.:oil is de·energited may
be. c::lused by rna!,!netic dust in the air i;<tp, loss of the shim. welding of the contacts •. exce33
1
1.iearing friction by cnrrosion, etc., uccurnul::ition of dirt in the ma1>rnet guides, or mechanic:il
~isaligment or binding. Readiu3tment of parts and cleaning will usually correct arm;iturc
sticking.
Magnet Coll
a. General
for purpose of rnuintcnance, coil!! rn:JY, be cla:!sificd as "ther J.c. sh11nt, 11.c. ahunt or•
:1e1 ie::s tyf">C9· Mo::it (ailure3 of d.c. shunt coil:l uro "open::;"; mo~t failure3 ol a~. ahunt coils
are of the nmure of hlirnouts. whi!~ 1rn1st seri~ cr'lil failure3 are those ot ahort~d cir in
effective tum';!.
\Vith few e:-tceptions. coil f:•i 1ure·.l can he tr:icetl to fault in the ussociato equipment.
'This thou8ht ::1houl<l be kt!pt in ninct whr:n coil~ are replaced, so that the ClU5C ot u coil
!allure c:::m be dcteri111ined :md corrncted. When repeated burnou~s or failures occur. it i!! a
clL"ar indic.ition that tl~e eq11i1)(11c11t. in addition tn the cuil. ghoutd be chcckc:d and correct...--rl. I
-j
... A.C. SbuAt Coils

The most vital point to be con::1idcreJ when ~intainini;! a.c. shunt coil:! ifio that. due to
the n1<1gnetic air gap and the characteristics of a.c. circuits. tJ1e current in the co!! ;L fi;·:
'.
:11
ten t1me3 higher when the armature or plunger begin to clo90 and the air gap is lar._:.,~ cJ,:111
after the armature or plunger ha11 closed and the air j,rnp 'is zero.
-- - - - ----4 -··-·- -- -
-l
Since the clcr.3ing time is ,;hart. a.c. !'lh•mt coils are designed to with:itand to clofleu
conditions. The coil ct1rrent in a.c. magnet:s ia determined primarily by. the reacta11co o{
tho circuit which h1 lower when 11 lur~e. uir .unn exi!lt3 in tJ10 rrnignetic clrcttit. A11 the ::iir
Qap dl!cteat:)(l~ (plun131:1r 11/"fTUl.turo clo~s), ll,!t coil current a!oo decte4.!.Cs until tho plunger
ar
or Hl'>nature prot:c:l'fy seal.. At µ-.1. point thtt doll Ill carrying normttl current.
Tho high coif current when Lhe coif is fir:H ener1<i.:a1I~ thi:refore. if 11uscainer.J for lenxth
o{ time, will le:td to overhe;tting and eventu&llly, to u burnout of the coil.··- · -
Tltu::1 coi I burnout::! ure duo l.)rimar i !y to bindin8 or :itickin~ P,.Lrt!5 or nny restrictions
which prevent the magnet {rn~ and the movable plun~er frnm c!o:iing and their gr_ounc.l
surfaces from sealin!l properly. Dirt or fi!ing:i nn the g:round t:1urface.:1, exces:iive wntac.r
pri::ssure, or low voltage tluit is too low tn close tho magnet and t11~ t:oil remains energized
with the large air gan. arc contributing factors to wi I burnou LS.
Noisy cont::lctors or co11wctur::1 which vibrate ext.:essive!y may also leud to overhc::itlnt.:
t:oi l::i ;rncf burnouts.
(!J.C. coil:! are not ~ubiect to t11ese condition::i bec.111se the coil currents are cn11st.a11t ::it all
tirnes.)
Uefore a coil is reµlaccrl after a burnout occurs, it is important _to .clean ::ill tlle 1x1.n:..s
(plunger. frames etc.) thoroughly to remove the burned varnish., Failure to clean all pu.rcs
may result in subgequent burnout,. Sec "cleaning".
Keep coib d;y-While our method coil impregnation practically eliminates the possi·
bility of moisture penet:r.:lting into the coil they should nevertheless. be reasonable
care. D.c. shunt coils are most liable to failure due to moisture abaorbtion because
of the pos!'ibi I ity of electrolytic action between parl:3 of different potentia !. Spare coils
l'lhould be kept in a dry place. Coils which have become wet shoulri be thoroughly
dried out he fore using hy baking them in an oven at o temperature of from 1 lO"C. to
125 •c. The length of time in the oven wi It depend upon the size of coil and the degree
of exposure or absorption of moisture. Sm:1ll coil:'l which ha.ve been submerp;ed for a
short period shoulct be baked at lea!'lt eight hours. Large coil!il should he baked pro·
_portionary longer. Coils that have been :'lubnierged for some time may r~uire .::i·s much
as fifty hours to dry them out completely.
fuses
Fuses are installed as a protection against short circuits and continuous overload. Pre·
mature blowing of fuses may be the result of undue heating caused by. low contact pressure
or copper oxide at the ferrule'!! and fuse clips. This may he eliminated by keeping the con·
tact cli~ ::inc.! ferrules hright and clean and by ~uring that the contact clips give good
contact pressure on the fuse. Should fuse clips become annealed due tn heating, replace
with new clifJ' preferably of the positive pre-3Sure type. When blowin~ is too slow. check
for wrong sizetl fu5e for applic:ttion.
K60025-6
- 1/
I
MOTOR START~R C~~CK C~ART

Trouble Ca1110 What tn do
·-
-·
Cont:ictor or relay No Supply \'oltige Cl11rck fu11e1 and di3alnncct 11witch.
doe3 not cl~e
·-·-
' Low Voltage Check po~r aupply.
.Wire :siui may ~ too !!mall.
--- -.
Open-Circuited coil Replace.
Pushbutton, interlock. ur relay Adiu3t forcC!rrect .movement. ~

not making contact. of operation, and · proper contact
pressuri:.
Loose connections or broken Check circuit with fla:shlight (turn
wire. power otf fir.st).
Pushbutton not connected cor· Check connections with wiring dia-
rectly. gram.
Overload relay contlet open. Reset relay.
Dama~ed, worn of poorly ad· Clean and adjust mechanically.

iusted mechanical part!!. Alii:tn bearing:5 and free the move-
ment.
Repair of rep!~ worn or damaged
parts.
Cont:actor or relay Pushbutton not connected cor· Check connections with wiring dia-
does not open rectly. gram
Shim in mai:tnetic circuit* worn. Replace shim

Allowing re3idual mai:tnetism to
hold aimature closed.
Pushbutton. interlock. or relay Adfost for correct movement. ease

contact not opening coil circuit. of operation. and proper opening.
"Sneak" circuits. Check apparatu.s and wiring for in-

sulation failure.
C-Ont:acts weld shut s~ "conract9 weld shut"
Dama~ed. worn. or poor! y ad· Clean and adiust mechanically. Align

iusted mechanical parts. hearinRS and Cr~ the movement.
Repair or replace worn or damaged •
____ ..;_
.-
parts.
----··----··
Excessi\'e corrosion Insufficient contact spring pre· Adiust, increasing contact pressure.
of contacts · Contact9 ssure causing contact:! to over· Replace spring or wom contacts if
WE ld shut · Contact:l heat or draw an arc on closing. necessary.
overheat ....
Roui;(h contact surface causinp; Dres.~ up contnct9 with sand paper
current to be c:a.rried by too or fine file.
small an area. Replace if ba<lly worn.
Abnormal operating conditiorn. Check rnting agaioot load.

ll conditions are too severe for open
type cont:actors. replace with oil·
immersed or <lwt·tighl epuipment.
- Instruct operator in proper manipu·
lation of manuul\y operated device.
s{)C only
K.6C02S- 7
------·---·----- -
Trouble Cau1e . What to tlo
Exce?Utive corrtJ:jlon Chnttoring oi contacts 112 a ro. Check control 1witch contact prc1·
at cont.ncta · C-Ontact'!I sujt ol vibrations OUtlllcJc Of aura and rep!~ isprini il it doc"J
weld shut · Contact.'J controller cabinet. not givo ratod ~UDL.. _
overheat Tighten all connectiom.
I! this doeJ oot holp. mount or move
control. so th.at vibrations are de-
creased
•
'' Slugll:ish Op<:!r.ition Clean and adiU3t mochanically.
Align bearing, and tree_ movement.
Arc lingers
cont:;ict!!
acr033 If blowout i:i series it may be
shorted.
I Look .. at wiring diagram ind sec
kind of blowout. and then chock to
II blowout is shunt it may be ~ if circuit through blowout i:s all
open circuited. right.
Inetfoctive blowout coil Q1eck ·rating and i! improperly ap-

plied replace with rorrect coil.
Chock polarity and reverse roil if
~333.l")'·
If no blowout is used. note I~ing travel of cont:act:s will

travel of contacts. increase rupturing capacity.
If used. arc box might be left Se~_ th.at arc box i:s fully in pl.ace.
oa ·or not in correct position.
Overload. Check rating against load.

..
Creepage or voltage breakdown
over or through arc box wall.
I Cl~-dr~ out in oven, or rep~
Noisy A-C magnet [mproper seating of the arma- Adill!lt mechanical parts and clean
ture. pole face3.
Broken shading coil. Replace.

..
Low Voltage. Check power supply.
Wire size may be too small.
Abnormally short Hight Voltage. Cheek supply voltage againat ratinii

coil life of controller. ·
Gap in magnetic circuit. § Check 'travel of armature and ad·

just :so that magnetic circui~ ia com·
-·
pieced.
Clean pole tacco.
Too high an ambient tempera· Check rating of controller a~inst

tu re. ambient temperature. Get coil of
higher ambient rating from ma.nu·
factw"Cr if~·
Pnnel :ind apparatus Motor being- started too fre· Uae rc:sistor ot higher rating.
burned by heat from quently.
st:J.rting re:si5tor -
~AC only
.. ·--·-· ·- ·-·-------7
' f:· •.
' ..
\.
. .'r
'I '
::
- ./
I
~otor Stqrtor ChecH. Chnrt

1. A-C /v\OTOR CJ,,.lf:CK CHART
TrotJble Cause W!u1t to do
Motor :-it..-ill::s W;onK a~~li~~;t::·--- --!Chani::e type O'I' :iize. Cansult manu-
1· facturer. ·-----·
~;;;~:d•:d_;;,;oc- --=]"·d'"' ~~- --------· -·· ---

Low motor voltage. . t:ained.that.
See name plate voltage i::s main·
·----~--·-·-------+--------------
! ·
Open circuit. Fuse!! blown, chC(;k overload' relay,

. starter and pushbutton.
/
Incorrect control resi:-itance1f -Cb f1t!{;k·k. control . seq~Re_n_c_e_:--=u-=-e_p_l,_a_c_e-1
wound rotor. ro en re3.1stors. ep.a1r open cir·
cu1ts. ..
--------· --
Motor connected but One phase oµc11. Motor may bo Sec that no µhase i:t open. Reduce
t.loes not start ov~rloadcd. load.
-------···· ···--··- ----1----------------··
Rotor deft:ctive. Lock for broken bars or rings.
--------·--------- ------·---------------<
Poor ~t.ator coil connection. Remove. end bells, locate with test
------------··-----------------
r-Iotor ruM and then Power f4ilurc.
,_...____________________
lamp.
Che~k for louse connectia~ la line,

dies down to fu~ and to control.
------------t--·----··--.. -...... -----··~···--·-··--·------·----'-------I
Motor does not come I Not applied µroper! y. 1

Consult ::iuµµ! ier for proper type.
up to speed
-- ---·-. ····--·--------;-----------------~
voltagti too low at motor termi- u~ high~r volt<:ige on transformer

nal~ because uf l inedrop. terininals or r~duco load.
· #1f"WOuf1d rotOr, in1proper con:- ····-·--·-
Correct secondary control.
trot operation ut secondary re·
sistance.
----··-------------r--------------------
Starting load too high. Check load motor i11 ~upposed to
c:::.irry at start;
---- ···--------!·---- . _____________
Low pul1·i11 torque of synch· Change rotor starting resistance or
ronous motor. change rotor design.
,______ -- ----------··· ·---- ---· .. ·-------------
Check that all· brushes Check secondary connections. Leave
are
riding on r1n5::1. no I eads poor I y connected .. ·
- ·-------------- Lock for-cracksnear the I
rings. A
Broken rotor bars. new r.otor may be required as re-
P._8_ir5. ~~e _us.uaJ I y_!._e:!:!JOrary.
------------·---
Open prim;,iry circuit. Locate fault with testini; device and
repair.
.. •··------!-----------------
l\fotor takes too lnng Exce:is loatling. Reduce load.
to <lccelerate
· - - - - - - . ---------+-------------··-··· ----- ·--
Pnor c1rc111t. Check for high re:5istance.
- ··-·---------+------------------·
Detective Squirrelcaf;e rotor. Replac~ with new rotor.
---------------+--------------------
Appl iod voltage too low. Get power company to increase vol·
tage tap.
•-----------'-----------------J.....----------------
-; J
Trouble Cau110 What to do

Wrong rotation Wrong sequenca of phn~. Reverse connectiorns of motor or at
awitchboard.
Motor overheat3 Check Cor overloud. Reduced load.
while running under
load
Wrong blowers or air shields, . Good ventilb.tion 1:\ manit~~)li.ben a
may be clogged with dirt uod pre· continuous stream of air leaves the
vent proper ventilation of motor. motor. If not. check manufacturer.
Motor may have one phase open. Check to make :iure that all lea&,
are well connected.
.
Grounded coil. Locate and repair.
l
Unbalanced terminal volt:Ige. Check for faulty leads. connections

and transformer.i.
Shorted stator coi L Re0air and then check wattmeter
reading.
Faulty connection. Indicate by high re3istance.
High voltage. Check terminals ot motor with volt·

meter.
,___
Low voltage.
Rotor rubs stator core. If not poor machining, replace worn

bearings. ·.
-
Motor vibrates after Motor misaligned Realign.
correction9 have been
made -
Weak foundatiorn1. Strengthen base.
'
Coup! ing out of balniico. Balarn:e coupling.·
Driven equipment unbalanced. Rebalance driven equipment
Defective ball hearing. Replace hearing.

..
Rearing not in line. Line ur:i properly.

•
Balancing weights shi{te<l. Reba!:ince rotor.
Wound rotor coils replaced. Reha lance rotor.
Pol yphase motor running singlo Check for open circuit.

phase. . . ..
_Exc~iv~ end play. /\diust bearin~ or ndd w:1'3her.
..
vnbnlan~ed line cur·
Unequal terminal volt9. Check lend,, and cnnnectiom.
rent on pol ynhJse '
;.
rr.otors during normal
operati9'2_ __ .
----···
--------·--
-i·· / .. ,·, o.
K0·0025-~/0.
TroulJle
Unhulancad Jina cur·

--~~ .
Cause
- -·---------·---- -
Si"gte ph""" ooeratlon.
What tn dn
Check for op.on c.'ontact...

rent on µolyphail!'I
motnnt during normltl ·- ---···--- -----··
uµor.itiun f'oor roe or coc;tacr.a in CJJntrol Ciu:ck cuntrol dovicC3 •.
wound rotor re:lilitance.
...
Brushe:s not in proper position Seo that brushe!I are proper I y seat·
in wound roto;·. ed and shunts in i:;ood condition.
Scraping noise Fan rubhing air shield. Remove interference.
-
Fan striking insulation.
I Clear
I
fan.
!
Loo::ic on bxlµiatto. Tik>ht"n holding bol ta.
Magnetic noise Air gaµ not uniform. Check an<l correct bracket fits or
bearing .
.
'
Loo:se bearings. Correct or rllncw.
Rotor unbalance. Rebalance.
~~60 025-1 I
DECK CRANE
TROUBLE SHOOTING
( SINGLE CRANE )
TUJI HEAVY ·IHDUSTRIES CO .. LTD.
K60076
I ELEC-.::: iC i-lOTOR
I DOSE ~OT START
SHIPS PO\IER
"OH"
MA lH HCB lH TIIE
STARTER IS"OH"
1
_J, YES
OTllERfiCBl "HCB02"
"OH.. I "HCB03"
RESET TilE EACH THERMAL RELAY

OR REPLACEHEHT A FAULT
TIIERHAL RELAY
SlP:HAIH HOTDR
Slf:HOTOR FOR OIL ClXlLER
IS COHTACT OF SlU:AUX.HOTOR
P.B. SWITCH FOR HO REPLACEHEHT OF COHTACT
OR COHPLETE P.B.S~ITCH
0 ILLOI' LEVEL S'J. RELAY "TF02"

'JASACTUATED
:;(OHFIRH A ALARH LAHP OH
COHTROL PAfl EL
THERHOSTAT IH HA!H RELAY "AYS"
HOTOR 'WAS ACTUATED
YES ~COHFlRH A ALARH LAHP OH
mo lCATIOtl BOX
COHTROL LEVER IS RELAY
HOT HEUTRAL POSISIOH "AXl"
IF RELAIES ARE ABHORMAL. .. AXJ. ..
REPLACEHEHT HO REPLACEHEHT A FAULT RELAY. "AYS"
A FAULT RELAY RELA Y"TilO l" "AY5"
-~01 • "A YT
"Til02"
'"HC03"
"HC02"
"HCOS"
HO
110 !ST IS HORMAL 1

IHFORH TO HAKER
1 HOISTING OPERATIOH !HPOss!BLE]
I
,fl_Ol_ST_I_HG_ _ _ _ -</ D!HEHTf OH LO\JERIHG
I ~
OPERATE COHTROL ---.. OPERATE COIHROL
LEVER TU HOlSTIHG LEVER TU LO~ERIHG
OH THE HO !ST!HG
,__H_o____J REPLACE A 111cRo I HO

CLOSE? I :S'm'Cll i'>+------<
TFOl HO REPLACE A FAULT HO

>----~ ~-~--<
AXl RELAY
AY5
Til04 YES
IH CASE OF ABHORHAL OF
PRESSURE S\J. & SO LEHO IO
VALVE FOR SPEED CHAHGE.
HOISTIHG rs RATED SPEED.
REPLACE THE FAULT HO
PRESSURE S\J. &
!SOLEHOID VALVE
R;:rLACE A FAULT HO
>----~
SOLEHOID VALVE
REPLACE A FAULT
___
...,__ ~
MICRO S\J.IH THE HO
SCRE\J TYPE LIMIT
S\JITC!I BOX
HO
HOISTIHG OPERATIOH l HFORM ABHORMAL

IS CORRECT COHDITIOH TO MAKER IS CORRECT
I LUFF IHG OPERATIOH rnross IBLE i
I
LUffIHG UP DIRECTIOH LUFF IHG DH
OPERATE COHTROL OPERATE COHTROL

LEVER TO LUFFIHG UP LEVER TD LUFFIHG DH
OH TIJE LUFF & OH TIJE LUFF &
SLE1J COHT.
HO
HO REPLACE A Fi\ULT HO
'-~~~~ ~~~~-<
SOLE!IOID VALVE
REPLACE A FAULT
HO
>-~~~~
MICRO S\I. IH THE ~~~~<
HO
SCREW '.YPE LIMIT
S\IITCH BOX
LUFFIHG UP HO HO
I YES
LUFFING UP OPERAT!OH IHFORH ABHORMAL LUFFIHG DH OPERATlOH
IS CORRECT COHDITIOH TO MAKER IS CORRECT
\ SL.E'JIHG OPERATION IMPOSSIBLE !
SLE!JIHG RIGHT SLE11 IHG LEfT
OPERATIOH CONTROL OPERATION CONTROL

LEVER TO SLE~ING RIGHT LEVER TO SLE't'IHG LEfT
OH ntE SLEW ~ LUFF OH ntE SLE'J ~ LUFF

CONTROLLER CONTROLLER
HO
>------4
I REPLACE A HO
MICRO SWITCH I
HO HO
INFORM ABNORMAL
OPERATION IS CORRECT COHDITIOH TO MAKER OPERATION IS CORRECT
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OSHIMA SHIPBUILDING Co .. LTD.
H. No. 1 0221, 1 0222
ELECTRO-HYDRAULIC
DECK CRANE
N1 -CHRS3022(2523. 5)
SPARE PARTS & TOOLS LIST
SCALE I JOB NO.

MANAGER DWG. NO. F- 00 600
SUB CHIEF J<_ ~-""· ,,,::v/',~._-- -- TSUJI HEAVY INDUSTRIES CO .. LTD

CHECKED BY
IN CHARGE SASEBO · JAPAN
DRAWN BY -r.·
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DESIGN DEPT. MACHINERY SECT.

DATE Sep. 10. 1997
PAGE 1
SIJIP NU.
SLEWING GEAR ·GENERAL USE BOX NO.
SUPPLY -
NO. NAME SKETCH MATERIAL PER SHIP REMARKS
WORK- SPARE
IHG
OIL SEAL
a· 2 3 O
023027020 b' 2 70 NBR 8
c. 20
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TSUJI HEAVY INDUSTRIES CO .. LTU.

MFR'S NAME AIHOURA WORKS DESIGNING DEPARTMENT.
& ADDRESS SASEBO. JAPAN.
l SHIP HU.
l PAGE 2- 1
HOISTING & LUFFING WINCH BOX HO.

SUPPLY -
HO. NAME SKETCH MATERIAL PER SHIP REMJ\RKS
\r'ORK- SPARE
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OIL LEVEL I:'-
(T) - - - 8 2
5 GAUGE
CM N -3/4)
16 -

MFR'S NAME AIHOURA WORKS DESIGNING DEPJ\RTHEHT.
&ADDRESS SJ\SEBO. JJ\P AN.
I IpAli E 2- 2
SHIP HU.
HOISTING g LUFFING WINCH BOX HO.
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7 T810012513 b = 12 5 NBR 4 1
c = 13
TSUJI HEAVY INDUSTRIES CO .. LTlJ.

MFR'S NAME AINOURA WORKS DESIGNING DEPARTMENT.
PAGE 3
SHIP NU.
BOX NO.
SUPPLY
WORK- SPARE
ING
I
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Ob
··1· ·:
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b=105 FOR
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<ISPlD 80.105.7)
a= 50
b= 72
2 c= 7 NBR 4 l FOR
A2Fl07 (PUMPJ
<ISP10 50. 72. 7)

&ADDRESS SASEBO. JAPAH.
PAGE 4
SHIP NO.
BOX NO.
SUPPLY
WORK- SPARE
ING
0-R ING n D~
a :
a=169.3 FOR
1 b= 5.7 NBR 4 1 A6V500(MOTORl
(JIS 82401 18 G170)
FOR
a=29.4 . A6V500(MOTORJ
2 b= 3.1 NBR 28 2 DHP32<M.O.C. VALVEJ
PF1C32(C.B. VALVEl
(JIS 82401 lB G30J
a=l5.8 FOR
3 b= 2.4 NBR 4 1 A5V500(MOTORJ
(JIS 82401 lB Pl6l
a=9.8 FOR
A
'f: b=l. g NBR 12 2 A6V500(HOTOR)
(JIS 82401 lB PlOl
a=44.4 FOR
5 b= 3.1 NBR 4 1 AGV500(MOTORl
(JIS 82401 lB G45)

'
PAGE 5
SHIP NO.
BOX NO.
SUPPLY
WORK- SPAR£
ING
1' b
OIL SEAL
1"1·
LXJ
'i ·1·1=+
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b=85 FOR
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A2F172 CPUMP)
' USPlD 62.85. 7)
0-R ING h
a : D~
a=l39.07 FOR
2 b= 5.33 HBR 8 1 A2FM180(MQTOR)
,AS568A 357 1115-70)

& ADDRESS SASEBO. J/\PAH.
PAGE 6
SHIP NO.
BOX NO.
SUPPLY
HO. NAME SKETCH MATERIAL PER SHIP REMARKS
WORK- SPARE
ING
0-R ING n
c~ : r)
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a= 113. 89 FOR
1 b= 3.53 NBR 4 1 A2FIO 7{PUMPJ
(AS568A 2461115-70J
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4 1 A2F10 ?(PUMP>
<FYE 050/050/00 >

MFR'S HAME AIHOURA WORKS DESIGNING DEPARTMENT.
&ADDRESS SASEBO. JAPAN.
PAGE 7
SHIP HO.
BOX HO.
SUPPLY
li'ORK- SPARE
ING
.Pb
OIL SEAL 1·,. ·11·1=+

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a=l8
b=30 FOR
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(TCV 18.30.8)
IE: cpq -.!

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<l I
a=34.52 FOR
2 b= 3.53 NBR 28 2 DA30(RELIEF VALVEl
<AS568A 220 1116-90>
a=l2.3 FOR
3 b= 2.4 NBR B 1 DA30(RELIEF VALVE>
<RN181. 01 12. 3 x 2. 4>

HFR'S NAME AINOURA WORKS DESIGNING DEPARTMENT.
PAGE 8
SHIP NO.
BOX HO.
SUPPLY
HO. NAME SKETCH MATERIAL PER SHIP REMARKS
WORK - SPARE
ING
0-R ING
0
M D~
:
FOR
RF2B25(C.B. VALVE)
a=39.4 RF1C321C.B. VALVEJ
1 b= 3.1 HBR 64 2 DHP32tM.D.C. VALVE>
OHP401M.D.C. VALVE>
(JIS B2401 lB G40J PIP IHG FITTINGS
a=49.4 FOR
2 b= 3.1 NBR 8 1 RF1C32 (C. B. VALVE>
(JIS 82401 lB GSOJ
a=13.8 FOR
3 b= 2.4 HBR 36 2 2RE7L(JOY. VALVE>
GM-04tFILTERJ
(JIS B2401 lB P14) PIP ING FITTINGS
a=25.7 FOR
4 b= 3.5 NBR 8 1 2RE7L(JOY. VALVE)
(JIS 82401 lB P26)
TSUJI HEAVY INDUSTRIES CU .. LTD.

-- - --~-------
PAGE 9
SHIP NO.
BOX HO.
SUPPLY
UORK- SPARE
ING
0-RIHG ~
a i D~
FOR
a=24.4 RF2B25(C.B. VALVE)
1 b= 3.1 NBR 32 2 DHP32CM.D.C. VALVE>
DHP40<M.D.C. VALVE)
(JIS B2401 lB G25> PIP ING FITT IHGS
a=34.4 FOR
2 b= 3.1 NBR 16 2 RF2B25(C.B. VALVE)
(JIS 82401 18 G35)
FOR
4WE6D,4WE6J
a=9.25 (SOLENOID VALVE)
3 b=l. 78 NBR 48 2 ZDR6D
<REDUCING VALVE>
(AS568A 012 1116-90)
4 SOLENOID a-
~
15 1
FOR
4WE60.4WE6J
(SOLENOID VALVE>
(ACllOVJ

MFR 'S NAME AINOURA WORKS DESIGNING DEPARTMENT.
PAGE 10
SHIP NO.
BOX NO.
SUPPLY
WORK- SPARE
ING
0-R ING n n1
<J :
FOR
a=54.4 OHP32(M.O.C. VALVEJ
1 b= 3.1 NBR 40 2 DHP40(M.O.C. VALVE)
CA-lBFlCHECK VALVEJ
(JIS 82401 lB G55) GM-04ffILTERJ
TSUJI HEAVY INDUSTRIES CO .. LTV.

&ADDRESS SASEBO. JAPAH.
PAGE 11
SHIP NO.
BOX NO.
SUPPLY
WORK- SPARE
ING
0-R ING
a=64.4 FOR
1 b= 3.1 NBR 8 1 DllP4 0 ( M. D. C. VALVEJ
(JIS B2401 lB G65J
1= ~6 ·il.2000., FOR
~~
2 PROXIMITY SWITCH 8 1 OHP32(M.D.C. VALVEJ
OHP40(M.D.C. VALVE)
M18/
(E2F-X5YU
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16 1 LUFFING 2-. SLEWING
~rt.
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49.2 -
CONTROLLER
(Z-15GQ22-8)

PAGE 12
SHIP NO.
BOX NO.
SUPPLY
WORK- SPARE
ING
td
BACK UP RIHG I~
IXJ
!
·11~
IXl
a=24.5
b= 1. 75 FOR
1 c= 0.6 NBR 8 1 M0-7005
(RELIEF VALVE>
(24.5X28XQ,6)
J., .p Q. •I
d : L~
0-R ING
a=l5 FOR
2 b= 2 NBR 4 1 M0-7005
tRELIEF VALVEl
(RH181.0l 1116-90)
a=34.59 FOR
3 b= 2.62 HBR 4 1 M0-7005
<RELIEF VALVE>
<AS568A 126 1115-90)
a=23.47 FOR
4 b= 2.62 NBR 4 1 M0-7005
(RELIEF VALVEJ
(AS568A 119 1116-90)

R. AOORF.SS SASEBO. JAPAN.
PAGE 13
SHIP NO.
BOX NO.
SUPPLY
WORK- SPARE
ING
0-RING
(l
M l)~:
a=53.57 FOR
1 b= 3.53 NBR 4 1 LC32
(LOGIC ELEMENT>
(AS568A 227 1116-90)
1·
1' d . , ,.. b
BACK UP RING I
IXl
! W=t
a=51. 36
b= 3 FOR
2 c= 1.2 NBR 4 1 LC32
<LOGIC ELEMENT>
(52x58x1)
0-R ING
Cl
n : D~
a=39.34 FOR
3 b= 2.62 NBR 8 1 LC32
(LOGIC ELEMENT>
(AS568A 129 1116-90)
TSUJI llEAVY INDUSTRIES CU •• LTD.

MFR'S NAME AINOIJRA WORKS OESlGNING DEPARTMENT.
- &ADDRESS SA.SF.BO .IAPAN
PAGE 14
SHIP NO.
BOX NO.
SUPPLY
WORK- SPARE
IHG
+a
BACK UP RING I~
IXI
l
·11~rxl
a=40.16
b= 2.18 FOR
1 c= 1. 60 NBR 16 2 LC32
(LOG IC ELEMENT l
(40x44x1)
k 1id. ,j
L~
0-R ING
(J :
a=l0.82 FOR
2 b= 1. 78 NBR 4 1 LFA32
(LOGIC COVERJ
<AS568A 013 1116-90)
a=21. 89 FOR
3 b= 2.62 NBR 12 2 Lf A32
(LOGIC COVERJ
(AS568A 118 1116-90) PIP ING FITTINGS
a=14. 0
4 b= 2.0 HBR 20 2 FOR
4TH7ZCJOY. VALVEJ
<RN181. OU
TSUJI HEAVY INDUSTRIES CU .. LTD.

&ADDRESS SASEBO. .JAPAN.
PAGE 15
SHIP NO.
BOX NO.
~UPPLY
WORK- SPARE
ING
rfi cl
G~D~
0-R ING
a=17 .12 FOR

1 b= 2.62 NBR 8 1 DBlO<RELIEF VALVEJ
<AS568A 115 1116-90)
a= 14.0 FOR
2 b= 1. 78 HBR 28 2 DBlO<RELIEF VALVE>
PIP ING FITT IHGS
(AS568A 015 1116-90)
TSUJI HEAVY lHUUSTR ms co .. LTO.

r. Anni? r<<\.s C'"AC"'r.nn, . ....
,,....
PAGE lS
SHIP NO. I
BOX NO.
SUPPLY
WORK- SPARE
ING
\< 11s·-::i.J FOR

1 FILTER ELEMENT
-·-E3J-"J¢45 PAPER 4 4 GM-04 (FILTER l
(P-GM-2-10 t.t >
O-RING ~
a l !>~
a=21.8 FOR
..
? b= 2,4 HBR 8 1 GM-04(f ILTER>
(JIS 82401 lB P22>
a=24.99 FOR
3 b= 3.53 NBR 4 1 GM-04 <FILTER> j
! AH6227-19) r
'

MFR'S NAME AINOURA WORKS DESIGNING DEPARTMENT. i
&ADDRESS SAS EBO. JAPAN.

PAGE 17
SHIP NO.
BOX NO.
SUPPLY
WORK- SPARE
IHG
tE 280 71
FOR
1 FILTER ELEMENT -·-0·-·-···- -·&]~118. 7 PAPER 4 4 FH441<F ILTERJ
(EP820 020N) .20 µ.
0-R ING
~
a : D~
a::144.1 FOR
2 b= 3. 1 NBR 4 1 FH44l<FILTER>
(J IS 82401 18 Gl4 5)
a=84.6 FOR
3 b= 5. 7 NBR 4 1 FH44l <FILTER>
(JIS 82401 lA P85)
8 ::27.7 FOR
4 b=3.5 NBR 4 1 FH44T (FILTER>
(JIS B2401 lA P28)
1· 28 • 1 SYNTHETIC FOR
B~ :Jj
5 DRAIN PLUG RESIN 8 1 DISK BRAKE
CHOISTING.LUFFINGJ
\M16 x 1
TSUJI HEAVY INDUSTRIES GO .. LTD.

MFR'S NAME AIHOURA WORKS DESIGNING DEPARTMENT.
Q A 1\1\Dt'~~ <"A<"rnn Y.ln&ll
PAGE 18
SHIP NO.
BOX NO. I'
SUPPLY
1:
WORK- SPARE
ING
0-R ING n
Cl : D~
-
a=l0.8 FOR
1 b= 2.4 NBR 2 PIP ING FITTINGS
(JIS B2401 PlU
a=59.4 FOR
2 ,.,(..
b= 3.1 NBR PIPING FITTINGS
(JIS 82401 G60>
.
a=28.7 FOR
(JIS 82401 P29l
TSUJI HEAVY INDUSTRIES CO .. LTO.

MFR'S NAME AIHOURA WORKS DESIGHIHG DEPARTMENT.
-
PAGE 19
SHIP NO.
BOX NO.
SUPPLY
WORK- SPARE
ING
¢ d. .
0-R ING
J7l~
-
a=6.07 FOR
1 b=l.78 NBR 2 PIP ING FITTINGS
(AS568A 010 Hs90° J
a=7.65 FOR
.
? b::l. 78 NBR 2 PIP ING FITTINGS
<AS568A 011 Hs90° l
a=4.47 FOR
3 b=l. 78 NBR 1 PIP ING FITTINGS
(AS568A 008 Hs90° )

PAGE 20
SHIP NU.
BOX NO.
-- --.....--·---- SUPPLY
WORK- SPARE
ING
. ¢> a.
l'- ""I
0-R ING
a=;-- I~
I. __u-
a=69.44 FUR
(AN6230-iOJ
a=24.99 FOR
(AN6227-19l
a=32.92 FOR
( AH6227 ~z1 l
a=37.69 FOR
(AN6227 -'i.7 >
a=47.22 FUR
<AN5230-3l

MFR'S NAME AIHOURA WORKS UESIGHING DEPARTMENT.
&ADDRESS (' AC'r:'Ofl r An 111
PAuE 2l
SHIP HO.
BOX NU.
SUPPLY
NO. NAME SKETCH MATERIAL PER SlllP REMARKS
WORK- SPARE
ING
¢ d.
O-R ING
!7l~
a=56.74 FOR
(AN6230-6J
TSUJI llEAVY INDUSTRIES CO . . LTD.

&ADDRESS SASEBO. .JAPAN.
PAGE 22
SHIP NO.
BOX NO.
SUPPLY
WORK- SPARE
ING
PINCHERS
1 (150mm) l.io~~ SK7 1
~
MONKEY WRENCH
2 (200mm)
~ (
101 S45C 1
3
GREASE PUMP
(WITH HOSE)
~- 1
abt.200
~ ~
(p IN TYPE)
.
~, , 1.
1· ."'
Q
PIN PUNCHES
4-L-
0
4 1
'a. .
<(. 31
.,._
~ 1--
1--
5 PLASTIC HAMMERS 0
- 1
-- .._
- --- 290 I
6 TOOL BOX
r1 :
~·
~~ STEEL 1
~
0
~

MFR'S NAME AIHOURA YORKS DESIGNING DEPARTMENT.
PAGE 23
··-
SllIP NO.
BOX NO.
HEXAGON WRENCH KEYS(JIS 84648)
I
/;
I ~
I L
NOMINAL B L l ADAPTATION WEIGHT

SIZE (mm) (mm) (mmJ HEAD HEADLESS (kg) Q'TY REMARKS
,, i::
L.. v 2.5 60 15 M3 M5 1/1 ship
3 3 65 20 M4 M6 JJ
4 4 72 25 M5 M8 JI
5 5 80 28 M6 MlO ,,
6 6 90 32 M8 M12 (14)
8 8 100 36 MlO Ml5(18>
"
II
10 10 112 40 H12 M20 JJ
(12) 12 125 45 <Ml4J )}
14 14 140 55 M16<18l II
17 17 150 60 M20(22J
19 19 175 70 M24(27l
"
II
22 22 200 80 H30 111 ship

TSUJI HEAVY INDUSTRIES CO .. LTD. T. \{= Kg
MFR'S NAME AlNOURA llORKS DESIGN ING DEPARTMENT.
PAGE 24
0. TYPE SKETCH Q'TY REMARKS
400
PRESSURE GAUGE
1 400bar 300-42.000 /SHIP
L• 1000 llOSE(l)
200-16.100
. ·.· . . ..
PAGE 25
~o. TYPE SKETCH Q'TY REMARKS
1
SPARE PARTS BOX
(.JIS F 0902 >
t I~ \~\ l/SIHP
300-~ -"\.. j l
-a-
48-30
r- ·aoo -
.
•,
'
I
'
TSUJI llE/\VY ltiDUSTRIES CU •• LTD. i
MFR 'S NAME AINOURA WORKS DESIGNING DEPARTMENT.

&ADDRESS SASEllO. JAPAN.
I PAGE
ME ssRs :OSHIMA SHIPBUILDING co. ,LTD.
30/2 5TON x 22/2 3. 5M/R
ELECTRIC PARTS
(SPARE PARTS LIST)
TSUJI HEAVY INDUSTRIES Co., LTD.

ENGINEERING DEPT.
MANAGER I
ASST.MGR.
CHECKED
DRAWN
DATE
DWG. No. M65030-2
SHIP NO. SPARE PARTS LIST FOR USE SETS PER
VESSEL
INDUCTION MOTOR HYDRAWLIC DECK CRANE 4

QUANT! TY REMARKS
ITEM WORKING
NO. NAME OF PART OUTL l NE PER PER SPARE
SET VESS
~ ~
LD
1 BEARING (6313) ID
33
1 4 1 112 KW MOTOR
""I 1-E
'
2 BtARING(6313)
LD
U)
~ u ::;,.1 IE
33
1 4 1 112 KW MOTOR
3 SEARi NG (6308Zl)
~~ 3ilol
u23
IE
I 4 I 5.5KW MOTOR
4 BEAR! HG (6208Zl) =r{QB ~ 18

'"I#' ' 00
;. i i-E
1 4 1 5.5KW MOTOR
5 BEARING{6306Zl) =r(QB
('""'> c--
;i.1
u 19
IE
1 4 1 3.7KW MOTOR
6 BEAR! NG (6206Zl)
=~
('""'> • ....o
~IE
u 16 I 4 1 3.7KW MOTOR
10
TSUJI HEAVY INDUSTRIES CO.,LTD. DWG.NO. F61258 D
2 -}
SH[P NO. SPARE PARTS LIST FOR USE SETS PER
VFSSFI
r~~rn~~ I b~N~bx& ~YDRAULIC DECK CRANE 4

QUANTITY REMARKS
ITEM WORKING
NAME OF PART OUTLINE
H~ VP(RSS
NO. SPARE
1 MAGNETIC CONTACTOR
I ~
..ij
1 4 1 SW7N,ACllOV.60HZ
85A
~
111
13 1 4 1 SC7N.ACllOV.60HZ
..~ 111
-ir
'
Ll 1 4 1 SCSN,AC110V,60HZ
4 MAGNETIC COHTACTOR
B~ 1 4 1 SW-O.AC110V.60HZ
6A
I
5 AUXILIARY RELAY
;!LJ LJ 7 28 3 HH54P-L.ACllOV.60HZ
6 AUXILIARY RELAY
~37.~<
.I . r.I 1:J 14 56 6 SRC50-2U/X,4a2b,

ACllOV,60HZ
7 TIMER
;no D
le 48 >t
1~48-..1
7 28 3 MS4SA
8 TIKR
~na
I~
50
D
>I
5 20 2 MS4SF
9 FUSE
o==o~ 4 16 16 UC-1 lOA
10 ELECTLIC LAMP
bib 12 48 48 0~9~13S.b.3V,lW
TSUJI HEAVY INDUSTRIES CO.,LTD. DWG.NO. F61248-1 D

2-2.
SHIP NO. SPARE PARTS LIST FOR u:sE SETS PER
' VESS£ L
1~~i~~r1b~Nebx& HYDRAULIC DECK CRANE 4
QUANT{ TY REMARKS
ITEM WORKlNG
NO. NAME OF PART OUTLINE
PE~ SPARE
_)5
n~ YES:
11 GLOBE r]
'-- '&.
1 4 1 DR9C 001-W
l5
;-r
~
12 G\.OBE 2 8' 1 DR9C 001-G
'--
y·
15
13 ;- 8 32 4 DR9C 001-R
G\.OBE
\
'-
]
SPACE HE,c.JER
14 LIGHT
{IQ} ~ ,..,,__ 705 ~!
1 4· :
1 AH30ZVOH
!~
{[:] -
5
ILLUMINAiED PUSH 1 AR30EOL-11H4G
15 BUITON S ITCH 1 4
-. -
.
1 6 PUSH BUUOH SWITCH {[] ( ] 2 8:

:
2 AR30FOR-11R
63
~~ dID
:
17 SElECTO~ SWITCH 1 4 1 AR30PR-220B

-- 84 -
~~
-
18 SUECT°'I- SWITCH
WITH KEY
~-
1 4 l AR30JR-2l1A
\.._.../_
.
a ~
SW-4, AC 1lOV,
19 watt:TIC CONfACJQI 1 4 1 60HZ, 9A
~
,\
STEEL
20 SPARE PARTS BOX ~i i: COLOR:7.5BG7/2
TSUJI HEAVY INDUSTRIES CO. ,LTD. DWG.NO. F61248-2 L

5 sheets with cover
Test result No. 10-013
TEST RESULT
FOR
30Tx22M/R ELECTRO-HYDRAULIC DECK CRANE
Mfg. No. 973821. 973822

(No. 1 & No.2 CRANE)
J\IIESSRS
OSHIMA SHIPBU£ DfNG LTD
SH I P No_
l 0 2 2 2
DATE
23 r d. J a n u a r y 1998
Chief of Inspection Section

Tsuji tteavy Industries Co .. Ltd.
Sasebo Japan
SH I P No. l 0 22 2 No. l CRANE Page\ 1
1. LIMIT SWITCH TEST (No load) Result

Upper limit Ill= 6. 28 DI Good '
f'
'
Upper limit 112= DI ~ '
iR3 I '
Hoist in! Slowdown l iwi t
Rope slack over
Lower limit (Drum end)
Upper limit
w before stop
R3= 4.5m A2=abt. 79. 2 deg

~
Good
*
Good
,___; ' 02
I
I
Upper Slowdown limit R2= m ~
'
: I l A~ Rl
t
Luffing m . Al= 25 deg
~Al
Lower limit Rl= 22 Good ~
Drum end : A3= -5 deg. Good lll
llost upper limit R4= ~
J, v I
Slewing Right & Left limit ~
'I
'
'
~
'
I
* llark is to be confirm onboard. ///:/ I
2. BRAKE TEST ( 30 ton: fu 11 notch ->-stop)

1st. 2nd.
Hoi s t i n g I Lowering s1 ip I lleight (11111) 660 710
3. EMERGENCY PROOF TEST ( 30 ton)

Hoisting
Emergency s t 0 p (No y 0 l t a g e) Good
B r a k e manua l r e l e a s e Good
4. OVER LOAD T E S T ( 35 ton)

Hoisting Luffing Slewing
Strength & w o r k i n g c o n d i t i o n Good Good Good
*Judgment Good Sub Chief

In Charge
SH [ P No. l 0 2 2 2 No. l CRANE I I
5. VARIOUS LOAD TEST P i a n Re s u l t
I inch Speed Main Slew

Load Di rec- lo tor Voltage Current
Speed
CJ ib tion
Notch power (11/111in) Press. Speed
(tons) (v) (A)
radius) (r/min) (Kg/cl) (11/11in. ) (r/11in.)
No Up Full 44 440 99 40 46. 7 I
load Down Full 40 440 95 40 39.8 I
6
Up Fu! I 44 440 172 105 45. 0 I
llo is tin!!
Down Ful I 40 440 86 30 40. 1 I
1 8
Up Ful I AC 17 440 151 210 17. 0 I
Down Fu 11 440V 40 440 84 30 40. 4 I
3 0
Up Fu! I 184A 11 440 155 230 11. 2 I I
Down Fu 11 112n 40 440 84 25 40. 6 I
No Up Fu 11 40~E[ abt. 440 100 90 50. 6 I
Luffing
load Down Full 47sec 440 74 70 51. 0 I
3 0
Up Full 47.3 440 113 115 49. 9 I
I
Down Full m/mi!l 440 75 90 51. 6
No Right Full 440 87 50 I 0. 71
Slewing
load Left Fu! I ave. 440 87 50 / 0. 71
3 0
Right Fu! 1 0. 7 440 94 60 /. 0. 71
Left Full
-~·
440 94 60 v 0. 71
6. fNSULATION RESISTANCE TEST

(Unit MQ)
llose Main Motor light &
test Date leather Circuit llyd.Pu11p Pilot Pu11p Oil Cooler heater
Before 22-1-98 Cloudy 100 100 100 100 100
After Do. Do. 100 100 100 100 100
*Judgment Good Sub Chief J~

/V' .
fn Charge
SH I P No. l 022 2 No. 2 CRANE Page I 3
l. L IMIT SWITCH TEST (No load) Result

Upper limit Ill= 6. 28 m Good '
' r
~ I
I
Upper limit 112= m '
:R3
~
,~,/
llois tin!! Slowdown limit m before stop
Rope slack over Good
Upper limit R3= 4.5m A2=abt. 79.2 deg
*
Good I H2
l Rl /-~
I
Up~er Slowdown limit : R2= II

~ ~ I
Luffing
Slewing
Lower limit
Drum end
Most upper I imi t
Right & Left limit
Rl= 22 m • Al= 25 deg
: A3= -5
R4=
deg.
~
~
Good
Good
t ~Al
~
....... 1-; I
Ill
j,
* Mark is to be confirm onboard. ///:/ '
2. BRAKE TEST ( 30 ton: ful I notch -?Stop)

1st. 2nd. ;
Hoi s t i n g I Lowering s I ip I Ileight(mm) 650 630
3 . EMERGENCY PROOF TEST ( 30 ton)

Hoisting
Em e r g e n c y s t 0 p (No v 0 I t a g e) Good
Br a k e manua I r e I e a s e Good

lloisting Luffing Slewing
s t rength & work i n g c o n d i t i o n Good Good Good
I

In Charge
SHIP No. l 0 2 2 2 No. 2 CRANE I Page j 4
5. VARIOUS LOAD TEST P l a n Re s u l t

finch Speed Ila in Slew
Load Di rec lfo tor Voltage Current
(Jib
ti on
Notch power Cm/min) Press. Speed Speed
(tons) (v) (A)
radius) Cr/min) (Kg/cnf) (11/11in.) (r/11in.)
No Up Full 44 440 100 45 47. 4 I
load Down Ful I 40 440 95 40 39. 9 I

6
Up Fu 11 44 440 173 110 45.5 I
Hoisting
Down Full 40 440 86 30 40. 0 I
l 8
Up Fu! 1 AC 17 440 152 220 17. 2 I
Down Full 440V 40 440 84 30 40. 2 I
3 0
Up Fu! I 184A ll 440 155 230 11. 5 I
Down Fu! 1 112Kt 40 440 84 25 40. 4 I
No Up Fu 11 40%EI abt. 440 100 95 51. 7 I
Luffing
3 0
Up Full 47. 3 440 116 120 50.4 I
Down Full m/min 440 75 90 51. 6 I
No Right Fu 11 440 87 50 I 0. 71
Slewing
load Left Ful I ave. 440 87 50 / 0. 71
3 0
Right Full 0. 7 440 95 60 / 0. 71
Left Fu! l 440 95 60 v 0. 71
6. INSULATION RESISTANCE TEST

(Unit MQ)
Hose Main llotor light &

test Date leather Circuit llyd.Pu11p Pilot Pump Oil Cooler heater
Before 22-1-98 Cloudy 100 100 100 100 100
After Do. Do. 100 100 100 100 100

[n Charge
5 sheets with cover
Test result No. 10-013-1
TEST RESULT
FOR
30TX22M/R ELECTRO-HYDRAULIC DECK CRANE
Mfg. No. 973823. 973824

(No. 3 & No. 4 CRANE)
MESSRS
OSHIMA SHIPBUILDING CO .. LTD.
SH I P No_
]_ 0 2 2 2
DATE
28th, January 1 9 9 8
Chief of Inspection Section

Tsuji Heavy Industries Co .. Ltd.
Sasebo Japan
SH I P No. l 02 2 2 No. 3 CRANE Page I l
-
1. L IMIT SWITCH TEST (No load) Result
Upper limit 111=6.28 m Good '
r
' r
~
Upper limit 112= m ' I
: R3
Hoisting Slowdown limit m before stop ~
Rope slack over
Upper limit : R3= 4. Sm A2=abt. 79.2 deg
Good
*
Good
~I '' 112
Upper Slowdown limit : R2= m ~ '
' I l Ar Rl
Luffing
Slewing
Lower limit : Rl= 22
Drum end
Kost upper limit
Right & Left limit
m . Al= 25 deg
: A3= -5
R4=
deg.
~
~
Good
Good
t ~Al
-tr.
~
Ill
J, "
'
* Mark is to be confirm onboard. '//:/
' :
I
2. BRAKE TEST ( 30 ton: foll notch -+stop)
1st. 2nd.
H v i s t i n g I Lowering s i ip I lleight(mm) 640 650
3. EMERGENCY PROOF TEST ( 30 ton)

Hoisting
Erne r g e n c y s t 0 p (No v 0 l t a g e) Good
B r a k e manua 1 r e l e a s e Good

Hoisting Lu_ff ing Slewing
Strength & w o r k i n g c on d i t i o n Good Good Good
*Judgment Good Sub Chief // Lo ,.hfpt

In Charge
SH I P No. 1 0 2 2 2 No. 3 CRANE I Page I 2
i
5. VARIOUS LOAD TEST Pl an Re s u I t
finch Load Di rec- Motor Speed Voltage Current !lain Slew
(Jib Notch power Cm/min) Press. Speed Speed
(tons) ti on (v) (A)
(Kg/cnf)
radius) Cr/min) Cm/min.) (r/min.)
No Up Fu! l 44 440 97 50 44. 6 I
load Down Full 40 440 95 35 39. 5 I
6
Up Ful I 44 440 170 110 44. 1 I
Hoisting
Down Fu! l 40 440 85 35 39. 8 I
18
Up Fu! I AC 17 440 150 220 17. 1 I
Down Fu! l 440V 40 440 83 30 40. 0 I
3 0
Up Fu 11 184A 11 440 155 240 11. 2 I
Down Fu 11 112K'I 40 440 83 30 40. 2 I
No Up Full 40%Ef abt. 440 97 90 50. 9 I
Luffing
3 0
Up Full 47.3 440 115 120 50.3 I
Down Fu 11 m/min 440 74 90 51. 6 I
No Right Fu 11 440 85 45 I o. 71
load Left Full ave. 440 85 45 I 0. 71
I Slewing
3 0
Right Fu! I 0. 7 440 92 55 I I
o. 71
Left Fu 11 440 92 55 v 0. 71
6. INSULATION RES I STANCE TEST

(Unit MQ)
Hose !lain Motor light &
test Date feather Circuit llyd. Pump Pilot Pump Oil Cooler heater
Before 27-1-98 Clear 100 100 100 100 100
After Do. Do. 100 100 100 100 100

In Charge
SHIP No. 10222 No. 4 CRANE Page 3
1. L r M I T SW r T CH T E ST (No load) Result

Upper limit Ill= 6. 28 m Good
Upper limit H2= m
Hoistin Slowdown limit : m before stop
Rope slack over Good
Lower limit (Drum end) *
Upper limit : R3= 4. 5m A2=abt. 79. 2 deg Good
Upper Slowdown limit : R2= m
Luffing Lower limit Rl= 22 m . Al= 25 deg
Drum end A3= -5 deg.
Kost upper limit R4=
Slewing Right & Left limit
* lark is to be confirm onboard.
2. BR AKE TEST ( 30 ton:full notch --stop)

1st. 2nd.
Ho s t n g Lowering s 1ip Height (mm) 770 730
3. E ME R G E N CY P R0 0 F T E S T ( 30 ton)
Hoisting
Emergency stop(No voltage) Good
Br a k e ma n u a r e l e a s e Good
4. 0 VER L 0 AD T E S T ( 35 ton)
Hoisting Luffing Slewing
S t r e n g t h & wo r k n g c o n d t o n Good Good Good

In Charge
SHIP No. 10222 No. 4 CRANE
5. VARIOUS LOAD TEST P l a n Re s u l L

l -
-
finch Load Di rec- llotor Speed Voltage Current llain
(Jib Notch power Cm/min) Press. Speed
ti on (v) (A)
(tons) (r/min) (Kg/cnf) (m/min. )
radius) (1
No Up Full 44 440 98 45 45. 9
load Down Fu 11 40 440 93 35 39. 6
6
Up Full 44 440 170 105
·--
44. 3 I -
'
l
Down Full 40 440 84 35 40. 1
-
!Ioistin~
Up Fu 11 AC 17 440 150 220 17. 6 _j__'
18
Down Fu 11 440V 40 440 82 30 40. 3 I __
3 0
Up Fu 11 184A 11 440 157 235 11. 6 I
Down Ful I 112K1 40 440 82 30 40. 5 I
No Up Full 40%EI abt. 440 100 90 50.8 I
Luffing
load Down Fu 11 47sec 440 73 70 51. 4 I
3 0
Up Fu 11 47.3 440 114 120 50. 5 I
1 Down Fu 11 m/min 440 74 90 51. 6 I
No Right Full 440 85 45 I 0. 71
Slewing
load Left Full ave. 440 85 45 I 0. 71
3 0
Right Full o. 7 440 93 55 /, 0. 71
i. Left Ful 1 440 93 55 v 0. 71
t. INSULATION RESfSTANCE TEST

(Unit MQ)
- Hose Kain Motor light &
.e :t Date Weather Circuit llyd.Pump Pilot Pump Oil Cooler heater
~
Be If 27-1-98 Clear 100 100 100 100 100

Af ~r Do. Do. 100 100 100 100 100
fudgment Good Sub Chief

In Charge

O-01 Deck Crane - Voc Daisy

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M/V "VOC DAISY"

TO: J.P. SAMARTZIS MARITIME ENTERP. Co. S.A.

FR: CH. ENGINEER

SUBJECT: DECK CRANE PUMPS/ MOTORS PARTICULARS

MAIN ELECTRIC MOTOR

HOISTING HYO.MOTOR LUFFING HYO.MOTOR SLEWING MOTOR

30//25 TON X 22/23. 5 M/R

TSU.II I !FAVY li'.JDUSTRIES CO., LTD.

TO: J.P. SAMARTZIS MARJTIME ENT ERP.

FR: MASTER I CH. ENGINEER

RE: DECK CRANES MOTOR SPEC!f

DECK CRNE No. 1

DECK CRN'f. No.2

SL.EWING MOTOR -REXROTHi

DECK Cll,,}.,JE No.3 ..

SLEWING MOTOR iv~_,niufi --.,_,...,_,,._, .."',

SHIP YARD OSHIMA SHIPBUILDING Co. , LTD

HULL NAME 10222

CRANE TYPE Nl-CHRS 3022 (2523. 5)

SLEWING MOTOR (UCHIDA ·-fi.J:o.l'\..I'\.~.J

RESPEC ffULLY YOURS,

2. SPARE PARTS & TOOLS LIST

3. From section to section, this Instruction Manual describes the specifications,

4. If you have any question, please contact the offices below:

Tsuji Marine Services, Main office:

177-2 Hikari-machi , Sasebo-city , Nagasaki-pref. 858 , Japan

Tsuji Marine Services, Tokyo Branch Office:

Nihonbashi Saruya Bldg,, 16-1 O Nihonbashi-Koamicho, Chuo-ku,

Tsuji Marine Services, Osaka Branch Office:

Osaka-ekimae Dai-ni Bldg., 1-2-2 Umeda, Kita-ku,Osaka,530,Japan

There is possibility of death or serious injury

Wrong operation may cause injury and/or

2. Confirm safety within the crane operation area before operation.

4. Keep out of the area of slewing post during operation.

5. Maintenance operation may require working at a high place.

3. If abnormal noise or motion is found during operation, stop the machine

5. The hydraulic devices on the crane use high fluid pressures. If

7. Before inspection and maintemance, be sure to switch the power off,

8. Do not start the motor during inspection/maintenance.

1. Periodically inspect the following devices/instruments:

1) Mechanical and structural sections :

3. To repair and replace any major component/part, you must obtain

4. Always keep clean the plates indicating "Warning", "Caution", "Operation",

1) Be sure to execute inspection before and after operation and record

3-1) Range of warranty

1) The period of warranty shall be twelve(12) months after delivery at the

3-2) Changing the application

1) If using the crane for other applications (for example,

1) For the specifications/items of the deck crane and the applied/

2) Changing these specifications/items may cause a serious damage to the

3) To change the specifications/items and applied laws and regulations,

(3) Section 2 of the Instruction Manual describes the specifications/iems

Reduction No crack on gear box. Visual check. Every 6 voyages.

Slackover No abrasion on rollers. Visual check. ditto

Bearing conditions. ditto ditto

Machinery No water entering from entrance door. Visual check. ditto

~oper setting of microswitch & roller. Visual check. ditto

Exhaust Confirmation of rotating direction. Visual check. ditto