MAINTENANCE MANUAL

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

OPERATION AND

MAINTENANCE MANUAL

NDA DAVITS

NORSAFE AS

P.O. Box 115

N-4852 Færvik

Norway

Telephone: +47 37 05 85 00

Telefax: +47 37 05 85 01

E-mail: mail@norsafe.no

IMPORTANT NOTICE!

During the warranty period, all necessary spare parts must be supplied by NORSAFE AS.
The use of spare parts supplied by other suppliers violates and forfeits the warranty.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

Rev.

Reason for issue

Date

Chk

ISSUED FOR CONSTRUCTION

05-98

NHØ

WINCH MAINTENANCE / OIL TYPE CORRECTED

10-98

NHØ

TENSION SYSTEM / RENEWED DRAWINGS

04-99

NHØ

TECHNICAL SPECIFICATION

09-00

NHØ

DRAWINGS FOR NDA34

02-01

INSTALLATION INSTRUCTION

03-01

NHØ

CHANGING OF GEAR OIL IN WINCH GEARBOX

01-02

HDC

NHØ

REMOVAL OF CHAPTER 10

02-02

NHØ

GENERAL UPDATE CHAPTER 2.2, 2.3 AND 4.2

06-02

HDC

NHØ

HOT OIL FLUSHING OF HYDRAULIC SYSTEM 6.10

08-02

NHØ

NEW HPU DESIGN AND ADDITIONAL ACCUMULATOR VALVE

01-04

HDC

PAGE xx-xx REMOVED

2006-08

NHØ

UPDATED MONTLY CHECK LIST AND LIMIT SWITCH

2009-01

OIS

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

LIST OF CONTENTS

INTRODUCTION ............................................................................................. 5

1.1

Introduction/validity ............................................................................................... 5

1.2

Supplier information ............................................................................................. 5

TECHNICAL DESCRIPTION / SPECIFICATION .......................................... 6

2.1

Winch operating description ................................................................................. 6

2.2

General description NDA davits ........................................................................... 8

2.3

Technical specifications ....................................................................................... 9

OPERATING INSTRUCTIONS..................................................................... 10

3.1

Restrictions in use .............................................................................................. 10

3.2

Launching using the electric power supply........................................................ 12

3.3

Launching using the stored power system ........................................................ 14

3.4

Recovery of the rescue boat .............................................................................. 15

3.5

Boat stowage ...................................................................................................... 15

3.6

Manual hoisting of the rescue boat .................................................................... 15

3.7

Tension system (option): .................................................................................... 16

MAINTENANCE INSTRUCTIONS DAVIT AND WINCH ............................ 18

4.1

Maintenance instructions davit and winch ......................................................... 18

4.2

Maintenance instructions winch ......................................................................... 19

4.3

Maintenance of falls ........................................................................................... 21

4.4

Monthly maintenance inspection report. ............................................................ 22

4.5

Inspection log for monthly maintenance inspections. ....................................... 24

4.6

Lubrication charts ............................................................................................... 29

PARTS/SPARE PARTS INTERCHANGEABILITY RECORD .................... 33

5.1

How to order spare parts.................................................................................... 33

INSTALLATION INSTRUCTIONS ............................................................... 35

6.1

IMPORTANT INFORMATION - READ THIS WHEN RECEIVING THE

DAVIT ................................................................................................................. 35

6.2

Maintenance during storage .............................................................................. 35

6.3

Storage ............................................................................................................... 35

6.4

Long time storage ............................................................................................... 36

6.5

Check the following before installing: ................................................................ 36

6.6

Assembly instructions......................................................................................... 36

6.7

Installation instruction - winch ............................................................................ 36

6.8

ASSEMBLY DRAWING ..................................................................................... 38

6.9

First time start up of hydraulic system: .............................................................. 39

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

6.10 PRESERVATION / HOT OIL FLUSHING OF HYDRAULIC POWER

SYSTEM FOR NORSAFE DAVIT SYSTEMS ................................................... 40

ON BOARD TESTING DAVIT AND BOAT ................................................. 41

7.1

Test 1, 1.1 x SWL - Loaded lowering test ......................................................... 42

7.2

Test 2, Recovery test: ........................................................................................ 42

7.3

Test 3, Hand cranking ........................................................................................ 43

WARRANTY CONDITIONS - ORGALIME S2000 ...................................... 44

CALL FOR SERVICE FORM ....................................................................... 48

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

INTRODUCTION

1.1 Introduction/validity

This manual is valid for Norsafe NDA rescue boat davits.

1.2 Supplier information

Norsafe A/S was established in 1903 as Jørgensen & Vik in Grimstad. At first they

manufactured wooden lifeboats and during the 1. World war the first partially enclosed

lifeboats were delivered. Aluminium was used from 1952 to 1958. Since 1958 fibreglass has

been used as building material.

Norsafe A/S moved from Grimstad to Arendal in 1990, and delivers today a wide range of

different lifeboats; from small rescue boats, through free-fall boats to lifeboats.

Our market is ship owners and shipbuilders, and offshore oil field installations world-wide.

Norsafe A/S is headed by the company manager, and the organisation is divided into six

departments; Administration, Sales/Marketing, Research and Development, Contract,

Purchase and Production, which all are headed by a dept. managers.

Postal address:

Norsafe AS

P.O.Box 115

N-4852 FÆRVIK

Norway

Visiting address:

Nedre Tybakken, Tromøy, Arendal, Norway

Phone:

+47 37 05 85 00

Telefax:

+47 37 05 85 01

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

TECHNICAL DESCRIPTION / SPECIFICATION

2.1 Winch operating description

The hydraulically driven winch includes an incorporated planetary gearbox with a

hydraulically released brake on the input shaft. Further-on a centrifugal service brake is

included between planetary gearbox and the drum. Totally 4 methods of operation can be

selected via an externally fitted control lever. In case of emergency if no energy is available

an additional crack handle can be used. In case of supply lifting an additional cam limit

switch can be supplied to prevent the rope being spooled off.

Methods of operation

The 4 methods of operation are «lowering, running of motor " «at stand by», manual working

- empty hook and part load. Each switch position is locked by a locking bolt. It is possible to

shift from “stand by” position to “dead ship lowering” without opening the locking bolt. This

means that the operator in the boat can at all time lower the boat by the control wire. The

winch should always be left in “stand by” position.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

ATTENTION!

The control lever must be always in position «at stand by»!

When changing to “manual hoisting”: Rotate the hand crank slightly when changing.

0 - Running motor position (at stand by)

Switch the control lever into position «0» to select running motor operation. The service

brake is closed by springs and the crank handle is out of operation. The input parking brake

has to be released for lowering and lifting. This is done automatically when operating the

control valves.

1 - Lowering position

Switch the control lever into position «1» to select gravity lowering operation. The service

brake will then be released by the control lever so that the load can be lowered controlled by

the centrifugal governor. At position «1» it is not possible to run the motor and the crank

handle is out of operation.

«Stop & go»

On changing the tension at the remote control line it is possible to slow down the

lowering speed even to a full stop.

2 - Manual working empty hook

Switch the control lever into position «2» to select manual working (empty hook). The load

will then be held by the parking brake. Because of a sprag device incorporated inside the

brake it is only possible to lift the load. Lowering is not possible.

The control lever in position «2» will allow for fast lifting. In this position it is not possible to

run the motor.

3 - Manual working part load

Switch the control lever into position «3» to select manual working «part load». The load

will then be held by the parking brake. Because of a sprag device incorporated inside the

brake it is only possible to lift the load. Lowering is not possible.

Supported by an additional gear ratio, it is then possible to lift part load. In this position it is

not possible to run the motor.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

2.2 General description NDA davits

General introduction

The NDA davit systems is designed for the safe and efficient launch and retrieval of Norsafe
rescue boats.  The davit system is designed for long time operation in a tough and corrosive
marine/offshore environment.  The davit system is designed to fulfil all requirements as given
in latest SOLAS/IMO requirements.

The system will allow:
-Hoisting and lowering of the fully loaded boat up to 20° list and 10° trim.
-Gravity lowering of the fully loaded boat up to 20° list and 10° trim, completely independent
of any power supply.

The davit system is based on a hydraulically driven jib cylinder system with a cylinder and a
hydraulic driven winch.  Both the winch and the jib system are supplied with hydraulic energy
from one power unit.

A hydraulic power pack is included, and may be located in a suitable location on the vessel,
directly connected with hoses to the davit.
A separate control stand with a joystick and a start/stop box is also included.  This is
controlling two (2) valves in the power unit tank by hydraulic remote hoses. The control stand
has to be installed on deck in a suitable location where a good visibility over the davit and
boat is obtained.

All internal hydraulic piping is properly done and completed on the entire davit system.  The
only installation work of piping required is the connection of the delivered five (5) hydraulic
hoses between the power pack and the davit.

All selected equipment is chosen and installed to ensure the lowest possible emission of sound
and to give good access for maintenance.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

2.3 Technical specifications

NDA davit systems for Norsafe rescue boats

Capacities:
Lifting/lowering speed:

0-18 m/min at max load (Solas version)

0-50 m/min at max load (Ro-pax and NMD offshore
version)

Dead ship lowering speed: Max 60 m/min

Max list/trim for operation:

20° / 10°

Operation temp. range:

-20°C to 50°C

Winch data:
Wire type:

Non rotating

Corrosion protection wire:

Galvanised

Inner wire end:

Secured to drum

Outer wire end:

Wire rope thimble / Shackle

Power consumption:
Standard Power supply:

380/400 V 50 Hz or 440/460 V 60Hz

(May be changed to suit the vessel's power supply)

El. motor protection:

IP 56

Heating element in el. motor:

220V/40W in motor

Duty class:

S6-40%

Oil filter system:

Full flow 10 my nominal filtration

Hydraulic piping and fittings:
System type:

DIN 2353 (ISO 8434-1) Bite tube fittings

Materials; Pipes:

AISI 316 Stainless steel

Fittings and hose fittings:

Chromated

Scope of yard supply:

Assembly/Erection/all welding to deck

Deck foundations

Piping between power pack w/control valves and davit

All electric wiring

Testing acc. to regulations.

Packing/Shipment:

Packed in container for overseas transportation.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

OPERATING INSTRUCTIONS

IMPORTANT !

All crew members on the mother ship should be familiar with the operating procedures for
this launching appliance and lifeboat. Failure to follow the procedures detailed in this manual
may result in serious personnel injury or material damage.

CAUTION !

When operating the control levers, take care to move the levers smoothly, and avoid all abrupt
motions of the davit arm or the suspended boat.

3.1 Restrictions in use

Norsafe davit is only to be used in lowering/hoisting operation with boat connected to hook.

Norsafe davit is not to be used as a crane, meaning replacement of boat with e.g. cargo net is

not allowed.

Norsafe davit is only to be used with boat weight not exceeding S.W.L. for the davit

arrangement.

The davit is designed for use between -20 C and +50 C, (-4 F and +122 F).

For operation of the rescue boat, please refer to the relevant user manual for the boat.

Any violation to these restrictions may invalidate the guarantee conditions.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

3.2 Launching using the electric power supply

Before doing anything else, check that no persons or any obstructions will interfere with the

launch path. Check carefully that there is no vessels or any obstructions on the sea in the

rescue boat landing area. Make sure that the winch is in «stand by mode».

1. Start the hydraulic power pack

2. Tighten the winch wire

3. Remove the lashings and the electrical supply (if fitted) from the boat.

4. Swing out the a-frame enough to lower the boat to the boarding area, using the joystick.

5. Lower the boat to the boarding area using the joystick. Watch the remote control wire.

6. Swing in the a-frame so that the boat is resting firmly against the fender.

7. Connect the painter line to the painter release hook on the boat. The painter line should be

pre-arranged so that the length corresponds with lowering height to the sea level.

8. Board the boat. Make sure that the boat is boarded evenly so that the boat doesn’t tilt.

9. Please refer to the boat’s user manual for starting instructions

Please note that most engines only must be started when the boat is water born.

10. The operator will swing out the boat as much as necessary. The operator must at all times

have contact with the crew in the boat.

11. The crew in the boat will lower the boat, using the remote control wire. Pay carefully

attention to any signals from the operator on deck. Watch the painter line to see that the

length is sufficient until the boat is waterborne.

WARNING!

DO NOT release the painter line before releasing the winch wire!

As an alternative, the operator on deck can lower the boat, using the hydraulic motor.

The electric motor on the power pack must then be running. The operator must at all

times have contact with the crew in the boat. Pay attention to the remote control wire

on the winch drum. If the wire gets jammed on the drum, it may get stuck between the

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

winch drums. Check carefully that the wire follows the boat all the way down. The

best way to avoid the control wire to be jammed, is to use it frequently, and to let one

of the crew members in the boat hold on to the remote control wire at all time. This

will also avoid the weight and wire to start swinging. Please note that in order to

achieve correct lowering speed according to SOLAS, the gravity lowering method

should be used.

When the boat is waterborne;

Start the rescue boat engine

Release the winch wire

Release the painter line

Read carefully the user manual for the boat. Follow the operating instructions.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

3.3 Launching using the stored power system

Before doing anything else, check that no persons or any obstructions will interfere with the

launch path. Check carefully that there is no vessels or any obstructions on the sea in the

rescue boat landing area. Make sure that the winch is in «stand by mode».

1. At least one operator should embark the boat.

2. Remove the lashings and the electrical supply (if fitted) from the boat.

3. Swing out the a-frame enough to lower the boat to the boarding area, using the stored

power in the accumulator. Operate valve A located close to the accumulator, then the person

in the boat must operate valve B. Please note that it is not possible to swing the boat back in.

It is therefore important not to swing the boat too far out.

4. The person in the boat will lower the boat to the embarkation area.

5. As an alternative, all of the operators will embark the boat at stowed position in order to

avoid any unnecessary stops.

6. Connect the painter line to the painter release hook on the boat. The painter line should be

pre-arranged so that the length corresponds with lowering height to the sea level. Board

the boat. Make sure that the boat is boarded evenly so that the boat doesn’t tilt. Please

refer to the boat’s user manual for starting instructions.

7. If necessary, one of the operators will swing the boat further out, using the stored power

valve.

Please note that most engines only must be started when the boat is water born.

8. Watch the painter line to see that the length is sufficient until the boat is waterborne.

WARNING! DO NOT release the painter line before releasing the winch wire!

9. When the boat is waterborne;

Start the rescue boat engine

Release the winch wire

Release the painter line

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

Read carefully the user manual for the boat. Follow the operating instructions carefully.

3.4 Recovery of the rescue boat

1. Make sure that the dead ship swing out valve is closed. Make sure that the winch is in

«stand by» mode.

2. Start the hydraulic power pack.

3. Move the joystick to the «out» position. This will charge the accumulator. Hold the

handle in «out» position until pressure gauge on accumulator shows 200 bar. The

accumulator is now fully charged.

4. Connect the painter line to the boat (when necessary). Then, connect the winch wire. Lift

the boat. The operator on deck must at all times have contact with the crew in the boat.

5. The crew will embark the boat, either at the boarding area or with the boat stowed in the

davit.

3.5 Boat stowage

1. Connect the lashings and the electrical supply. Make sure that the boat is resting firmly.

If necessary, use some rubber plates or similar between the boat and davit.

2. After use, always drain the boat. If necessary, flush the engine with fresh water. Please

refer to the user manual for the boat for any further details.

3. If required, let the boat rest on the davit beams. Tighten the lashing so that the boat does

not swing in the davit.

4. ALWAYS leave the boat suspended from the winch wire, ready for immediate use.

3.6 Manual hoisting of the rescue boat

The winch can be hand cranked manually. In order to hand crank the winch, the mode

selector must be shifted to low speed hand cranking mode» indicated by a hand on the winch.

It is now possible to hand crank the winch.

For empty hook high sped hand cranking, the selector should be shifted to the next setting,

indicated by two hands. It is now possible to hand crank the winch.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

Make sure to ALWAYS return the selector to the «stand by» mode.

The winch can only be hand cranked up. To lower, shift the selector to «dead ship lowering

mode».

3.7 Tension system (option):

The davit may be equipped with a tension system.  This system will, when engaged, maintain
a constant tension of approx. 10-20 % of maximum SWL in the wire, following the waves by
2-3 m/sec.  This allows the davit operator to let the boat follow the waves, controlling it at the
same time.  The system will only be engaged with the boat water born (weight in wire below
300-400 kg) and when the hydraulic power unit is running.  The tension system has an
electrical interlock providing that the system will not be engaged if the weight in wire is
above 300-400 kg. This means that the boat is lowered with the normal speed.

When this system is running the oil will be heated, and therefor the system should not be in
engaged continuously for more than 15 minutes. It is important to follow the oil temperature
indicator when running, to avoid that the temperature exceeds 60°C.

See drawing on the next page

To activate the tension/wave compensating system – Push the button on joystick

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

MAINTENANCE INSTRUCTIONS DAVIT AND WINCH

4.1 Maintenance instructions davit and winch

This boat and davit installation is a life saving appliance and hence should always be

ready for use. Hence it should never be used for the attachment of lines or other

objects, nor should loose objects be stored on the boat or davit, or be so placed as to

obstruct the launch path of the boat.

Please follow recommended maintenance schedule. Apply grease on positions marked A on
the following drawing.

As a general rule, all paint damage will be repaired as soon as possible to avoid future
corrosion problems.

All hydraulic couplings (unless those made of stainless steel) will be protected by Densotape
or similar greasy protection tape, to avoid corrosion.

Check regularly that the hydraulic hoses are moving freely and are not exposed to mechanical
wear.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

4.2 Maintenance instructions winch

ZOLLERN

MAINTENANCE INSTRUCTION

Lubrication

The Zollern planetary gear of rope has splashed lubrucation.

Oil filling ex factory: AVIA FLUID ATF 86
Specification:

Dexron II D 21523

Attention: Only use above-mentioned oil!

In case of using other oils, the operating safety of the winch

will heavily be injured.

The oil quantity is marked on the nameplate. If the gear is delivered without oil,
this is indicated on corresponding label.

The clearance between lever housing (pos. 22/89) and flange (pos. 22/1) as well as
the two hollow sets of the lever (pos. 22/93) are filled with grease.

Grease filling ex factory:

AVIA AVIALITH 2 EP

Chice according to DIN:

DIN 51502

Description according to DIN: Grease, DIN 51825-KP2K

Recommendation for maintenance intervals

Greasing intervals: Renew monthly the grease at clearance between lever

housing (pos. 22/89) and flange (pos. 22/1): Put switch lever to position
“HEAVING MANUAL OPERATION” (operating pos. 3). Grease all around the flange. Put
switch lever back to position “STAND BY/MOTOR DRIVE” (operating pos. 0).

Renew monthly in both hollow sets of lever (pos. 22/93).

Grease monthly from outside the locking bolt (pos. 22/101) with fine
machinery oil.

Oil control: Weekly.

Control oil level only with non-running gear.

Oil change after 200-1000-2000 operation hours, but at least once a year.

Oil change only with service temperature condition.
We recommend to rinse with a pre-heated part of new oil when ambient temperature
is low, so that abrasion and contaminations can flow out.

The winch has to be inspected by authorized technicians after approximately
3000 service hours, resp. after approximately 5 years.

Test of load holding force and function

The winch should be tested with 10 % overload on regular intervals according to
SOLAS
requirements.

Load holding force test: Operating position “STAND BY/MOTOR DRIVE” (operating pos.
0).

Load the winch with test load = holding load + 10 % holding force
(holding force see installation drawing)

Attention: Testing load may not be raised by persons!

The test is ok when test load is kept definitely.

Function test: Test the winch to exact function in all 4 operation

possibilities (1, 0, 2, and 3) -
see “Functional Description Zollern-Multipurpose Crane Winch”.

Doc-No: 190000425.E/00

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

4.4 Monthly maintenance inspection report.

Use a copy of this report for each inspection.

Monthly maintenance inspection report.

Check no._____

Task description

Checked

by:

Date:

Yearly

A- Check Oil level in hydraulic power pack.

B- Start power pack & check that control levers winch
and A-frame functions as intended.

C- Inspect all hydraulic connections for leakage, wear
and tear.

D- Grease all grease points.

E- Grease the winch wire.

F- Check oil level in winch gearbox.

G- Change hydraulic oil in power pack.

H- Change oil filter.

I- Change gear oil in winch gearbox.

J- Inspect davit/launching path to ensure that the boat
can be launched safely, without obstructions.

K- Check shock absorber if applicable

L- Remove lashings. Swing the a-frame fully out.
Continue to hold the control valve in the «Cyl. Out»
position until the accumulator is fully charged (1 to 3
minutes)

M- Turn winch wire end for end.

Note: If the wire is fitted with a swaged eye,

this is not possible.

When required.

At least every 30

months.

N- Replace winch wire.

When required due

to deterioration.

At least every 5

years.

A- Check oil level in hydraulic power pack

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

The oil level indicator is found on the General Arrangement drawing of the

Hydraulic Power Unit. The oil should be visible in the level glass at all times.

D- Grease all grease points

E- Grease winch wire

Apply grease to wire every 50 hours of operation or at least once every month.

F- Check oil level in winch gearbox.

Please refer to the winch information pages for winch details. Check oil level at least

once a month. REFILL IF NECESSARY

G- Change hydraulic oil in power pack. A new oil filter cartridge is installed and the

oil reservoir drained prior to delivery. It is recommended that the hydraulic oil

should be changed after 1000 running hours or at least once a year. With large

quantities of oil an oil analysis may be profitable.

H- Change oil filter. The filter element should be changed every 500 hours of

operation or at least once a year.

I- Change gear oil in winch gearbox. To change gear oil, operate the winch until it is

warm.

K- Check shock absorber if applicable. Lower boat at full speed and rapid apply

brakes on winch and see if wire sheave wheel on shock absorber moves at least 10-

30 cm.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

4.5 Inspection log for monthly maintenance inspections.

INSPECTION LOG FOR MONTHLY INSPECTIONS.

Check. No:

Date:

Sign.:

Condition:

Actions taken:

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

INSPECTION LOG FOR MONTHLY INSPECTIONS.

Check. No:

Date:

Sign.:

Condition:

Actions taken:

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

INSPECTION LOG FOR MONTHLY INSPECTIONS.

Check. No:

Date:

Sign.:

Condition:

Actions taken:

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

INSPECTION LOG FOR MONTHLY INSPECTIONS.

Check. No:

Date:

Sign.:

Condition:

Actions taken:

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

INSPECTION LOG FOR MONTHLY INSPECTIONS.

Check. No:

Date:

Sign.:

Condition:

Actions taken:

115

116

117

118

119

120

After 10 years we assume that you will need a new manual. Please
contact Norsafe AS for a new copy.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

4.6 Lubrication charts

MAINTENANCE SYSTEM FOR NORSAFE PRODUCTS

LSS NO: 01

LUBRICATION NIPPLES, GENERAL

Last updated: 11.10.94

LUBRICATION INSTRUCTION:

Operate the equipment while applying grease. Use enough grease so that excessive

grease can be seen on the bearings.

LUBRICATION SPECIFICATION:

SUPPLIER:

LUBRICATION SPECIFICATION:

COMMENTS:

BP ENERGREASE LS EP 2

CHEVRON

DURA LITH GREASE 2

ESSO

BEACON EP 2

MOBIL

MOBILUX EP 2

STATOIL

UNIWAY C2N

CASTROL

SPEEROL AP2 / EPL 2

SHELL

ALVANA GREASE R3

TEXACO

MULTIFAK EP2

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

MAINTENANCE SYSTEM FOR NORSAFE PRODUCTS

LSS NO: 02

WIRE

Last updated:

LUBRICATION INSTRUCTION:

Operate the equipment while applying grease. Use enough grease so that excess

grease can be seen on the bearing. Apply grease to every 50 hours of operation or at

least every 2nd month.

LUBRICATION SPECIFICATION:

SUPPLIER:

LUBRICATION SPECIFICATION:

COMMENTS:

BP ENERGOL GR 3000 or GREASE OG

CHEVRON

PINION GREASE MS

ESSO

SURRET N5K

MOBIL

MOBILTAC 81

MOBILTAC D (Not for arctic)

STATOIL

GREASEWAY OG N

SHELL

CARDIUM COMPOUND D

TEXACO

CRATER 2 X FLUID

CASTROL

GRIPPA 60S

MOLYCOTE

165 LT

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

MAINTENANCE SYSTEM FOR NORSAFE PRODUCTS

LSS NO: 06

WINCH GEARBOX Zollern Winches (Stop and go system)

Last updated: 19 October 1998

LUBRICATION INSTRUCTION:

To change gear oil, operate slew gear until it is warm. Drain oil through plug on

lower part of gearbox. Fill until oil comes out of oil level plug.

LUBRICATION SPECIFICATION:

Dexron II D 21523

IMPORTANT: USE ONLY THIS SPECIFICATION!

SUPPLIER:

LUBRICATION SPECIFICATION:

COMMENTS:

Temp. over -10 deg C:

Temp. under - 10 deg C:

CHEVRON

Temp. over -10 deg C:

Temp. under - 10 deg C:

ESSO

Temp. over -10 deg C:

MOBIL

Temp. over -10 deg C:

Temp. under - 10 deg C:

STATOIL

Temp. over -10 deg C:

Temp. under - 10 deg C:

SHELL

Temp. over -10 deg C:

Temp. under - 10 deg C:

TEXACO

Temp. over -10 deg C:

Temp. under - 10 deg C:

CASTROL

Temp. over -10 deg C:

Temp. under - 10 deg C:

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

MAINTENANCE SYSTEM FOR NORSAFE PRODUCTS

LSS NO: 04

HYDRAULIC SYSTEM OIL

Last updated: 1

LUBRICATION INSTRUCTION:

The hydraulic system has been tested by NORSAFE. A new oil filter cartridge is

installed and the oil reservoir drained prior to delivery. We recommend that the

hydraulic oil should be changed after 1000 running hours or at least once a year.

With large quantities of oil a oil analyse may be profitable.

LUBRICATION SPECIFICATION:

SUPPLIER:

LUBRICATION SPECIFICATION:

Temp. over -10 deg C: ENERGOL SHF 46

Temp. under - 10 deg C: ENERGOL SHF 32

CHEVRON

Temp. over -10 deg C: AUTOM.TRANS.FLUID

Temp. under - 10 deg C: AVIATION HYDR.FLUID A or C

ESSO

Temp. over -10 deg C: UNIVIS N 46

Temp. under - 10 deg C: UNIVIS N 32

MOBIL

Temp. over -10 deg C: DTE 15M

Temp. under - 10 deg C: DTE 13M

STATOIL

Temp. over -10 deg C: HYDRAWAY HVX A46

Temp. under - 10 deg C: HYDRAWAY HVX A32

SHELL

Temp. over -10 deg C: TELLUS 46

Temp. under - 10 deg C: TELLUS 32

TEXACO

Temp. over -10 deg C: RANDO OIL HDZ 46

Temp. under - 10 deg C: RANDO OIL HDZ 32

CASTROL

Temp. over -10 deg C: HYSPIN AWH 46

Temp. under - 10 deg C: HYSPIN AWH 32

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

PARTS/SPARE PARTS INTERCHANGEABILITY
RECORD

5.1 How to order spare parts

Please quote the Norsafe davit build number and the boat build number when contacting

Norsafe. The numbers are given on enclosed certificates, and is also shown at the name plate

on the boat and davit. In addition, the davit build number is weld tagged to all structural

members.

IMPORTANT:

Direct all inquiries regarding spare parts and service to:

Norsafe AS

Postbox 115

N-4852 FÆRVIK

NORWAY

Telephone:

Int. + 47 37 05 85 00

Telefax: Adm:

Int. + 47 37 05 85 01

Tech:

Int. + 47 37 08 65 40

IMPORTANT!

Due to continuous development, we reserve the right to change our product

specifications and manuals without notice.

Regarding warranty claims:

Please note that all claims will be fully invoiced until accepted as a warranty claim by Norsafe

a.s. Please also enclose a copy of the relevant boat/davit certificate for all warranty claims.

The warranty period is normally limited to max. 18 months from delivery of equipment or 12

months from delivery of vessel to owner, whichever comes first.

All claims are handled according to "Orgalime S 92" which is enclosed in this manual. Please

fill in a copy of the "Call for service form" for all service or warranty claims.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

INSTALLATION INSTRUCTIONS

INSTALLATION / FIRST TIME START UP. INSTALLATION OF

NORSAFE HYDRAULIC DAVIT TO VESSEL

6.1 IMPORTANT INFORMATION - READ THIS WHEN RECEIVING THE DAVIT

When receiving the davit, please check carefully against material packing list
MPL). Any deviation between the MPL and the received goods must
immediately be reported to Your Norsafe AS contact person. When finished
checking, sign MPL and send one copy to Norsafe AS in order to maintain
warranty agreements.

Norsafe davits are normally delivered for welding directly to deck and bulkhead or some

other type of substructure.

As a minimum requirement the deck must be designed to withstand the davits maximum

bending moment with necessary safety factor. The requirement for this kind of life saving

equipment is a safety factor of 4,5 against the guaranteed material tensile strength.

6.2 Maintenance during storage

During storage, the boat and davit should be maintained as if installed onboard the vessel.

6.3 Storage

Structural steelworks may be stored outdoors prior to installation without any further

preservations.

Use anti-corrosion spray on bolts, chains, links, hooks and wire sheaves to obtain a water tight

film. All other parts than structural steelworks and the winch and the hydraulic cylinders

connected to the davit should be stored indoors.

IMPORTANT: ALL HYDRAULIC CONNECTIONS SHOULD BE RE-TIGHTENED

BEFORE INSTALLATION

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

6.4 Long time storage

If the equipment is stored for more than two months, the hydraulic power pack should be

filled completely with oil. All hydraulic components should be sprayed with anti-corrosion

oil. The hydraulic cylinder(s) should be completely filled with oil. It is recommended that all

parts are stored indoors.

6.5 Check the following before installing:

Deck structure must be free of cracks, rust, oil and other species that will inhibit welding of

foundation to surface.

The field welds are shown on the relevant Davit General Arrangement drawings.

Welding must only be done by certified welders. WPS and WPQ are subject to class approval

prior to start welding. The yard is responsible to carry out the installation and field welding as

required by class society. The hydraulic piping should be connected

according to the hydraulic flow diagram. Necessary flushing and pressure testing shall be

carried out.

Be sure that no dust or other pollution enter the hydraulic system.

Check if the preservation procedure is completed.

6.6 Assembly instructions

The installation instructions is made for the basic version of the davit. You may have a

customised system, with respect to winch installation, pre-assembly prior to shipment or sim.

If any of the actions shown in this manual are not required for your system, please skip that

item and go to the next step.

Use an area of at least 4 x 6 m., with solid and even foundation. Use a crane and soft slings to

handle the davit.

Install all the components as shown on the attached drawings

6.7 Installation instruction - winch

Please note the indications in the installation drawing. The rope winch is supplied completely

assembled. Clean all screw-on-surfaces at the winch support. Strength classes and torque

moments for screws, see installation drawing of the winch.

Put rope winch with winch support into steel frame. Fix winch support with screws.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

6.9 First time start up of electric/hydraulic system:

Connect the electric motor according to drawing the corresponding el. wiring diagram.

Check the power supply with voltmeter before connecting to electric motor.

Connect cable from junction box xjb1. to starter cabinet and adjust limit switch (LS1) on

winch as shown in description below.

Fill the hydraulic system oil tank with the correct amount of an approved oil. Fill oil until

level is on the top of the level glass. The oil level is to be visible at all times.

Refill if necessary.

It is of the utmost importance that only pure clean oil is used. Under no conditions must

water, dirt and other foreign matter enter the tank. Impurities and moisture will reduce the

efficiency and life span of the hydraulic system. The hydraulic oil shall be filled through the

systems oil filter.

The hydraulic system has been operated and tested at our workshop prior to delivery.

However, improper storage and handling during transportation may result in some oil

leakage's. Therefore, check the oil level in the winch gearbox and top up if necessary. Make

sure to use those oils recommended in the manual.

All pressure control handle valves have been adjusted by Norsafe and should not need to be

altered. However, due to the yard supplied pipes (when applicable), the transport, the oil

change, the hydraulic pressure should be corrected if necessary. The pressure is adjusted on

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

the hydraulic power pack. Correct pressure is given in the Hydraulic flow diagram. Connect

the electric motor.

As a final check before starting, check the rotation of the electric motor. Correct rotation is

marked on the motor. If the motor is rotating in the wrong direction, interchange 2 phases and

check again for correct rotation.

DO NOT start the hydraulic power pack without hydraulic oil.

The pump must not be allowed to run in the wrong direction or without oil for an
extended period of time (10-15 seconds), as this will adversely affect the life span of the
hydraulic pump.

Upon completion of initial test run, check the oil level in the system oil tank, top up if

necessary.

When the system is started the first time there will be air in the system. Let the power pack

run for a couple of minutes without pressure and shut down for 10 minutes before restarting.

The winch will automatically let out air from it's system when operated. To let out air from

cylinders on A-frame, swing the a-frame out. Stop at approx 1/3 of full stroke of the cylinder.

Repeat this at least 10 times before fully swing out A-frame. Be sure that all air in system is

ventilated before lifting any load or swinging out the A-frame of the davit.

6.10 PRESERVATION / HOT OIL FLUSHING OF HYDRAULIC POWER SYSTEM

FOR NORSAFE DAVIT SYSTEMS

To carry out flushing / hot oil flushing use the following flushing / hot oil flushing procedure:

Required cleanliness for systems subject to hot oil flushing shall be in accordance with:

NAS class 7 This procedure is to be achieved before mechanical completion of yard supply
pipelines, and connection to Norsafe supply pipelines.

If NAS class 10 appears, it is too poor quality for the system.

ALTERNATIVE FLUSHING (Summary of norsok standard) :

SYSTEM

SYSTEM
DESCRIPTION

PIPE
MATR.

FLUSH
WATER /
AIR

TEST W /
PRESERV.
FLUID YES/NO

CHEM.
CLEAN.

DRYING

PRESER
VATION

FINAL CLEANING/
REQUIRED
CLEANLINESS

HYDRAULIC
POWER SYSTEM

AISI
316

WATER

YES

NORMAL

HOT OIL FLUSH
ISI 44O6 15/12

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

Detailed procedure for hot oil flushing:

To be prepared by yard acc. to yard supply pipelines.

(Connection of loops etc. )

Filters used for hot oil flushing shall be:

3µm ABS for hydraulic systems.

Flushing and sampling to verify cleanness shall take place at turbulent flow, upstream any filters.

The Reynolds number shall be min. 4000.

The level of cleanness shall be documented from an automatic particle counter or a membrane
checked in a microscope before a flushing operation is considered finalised.

A flow meter shall be installed to verify flow used during flushing operation.

Maximum water content in oil used for flushing shall be less than 500 ppm.

The Norsafe pipelines are already cleaned acc. to above mentioned cleanness qualities.
If the sealing of Norsafe pipelines is broken before connecting to the hydraulic power system, Norsafe
will not guarantee the cleanness to be in accordance with required cleanness class.

On board testing davit and boat

This testing procedure follow the requirements of Chapter III, SOLAS 1974, 1983

Amendments.

Using IMO resolution MSC.81(70) "Part II, Production and installation tests, Chapter 6,

launching and stowage arrangements" for guidelines to the procedures.

Should the approving authority have different requirements, or never IMO resolutions be

amended, these should be followed and the testing procedure altered to suit.

Warning !

These procedures should be performed as instructed below, other procedures may result in

damages to the davit structure, or result in problems with the approving authority.

Therefore if you have any doubt about how to carry out the tests, please contact Norsafe AS

in Norway for assistance.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

7.1 Test 1, 1.1 x SWL - Loaded lowering test

IMO, MSC.81(70)part II. § 6.1.5

"The survival craft or rescue boat loaded with its normal equipment or an equivalent mass and

a distributed mass equal to that of the number of persons, each weighing 75 kg, it is permitted

to accommodate + 10 % of the working load should be released by the operation of the

launching controls on the deck. When the craft has reached its maximum lowering speed, the

brakes should be abruptly applied to demonstrate that the attachments of the davits and the

winches to the ships structure are satisfactory. The maximum lowering speed established by

the Administration should not be exceeded."

Test procedure

Please find your correct Safe Working Load from the nameplate on the boat, or on the boat

certificate.

Use a concrete / steel / some other suitable weight to test the davit. Before the full load is

applied, the davit shall be tested with a smaller load, 10% to 20% of the full load. Move the

A-frame in and out. Run the winch up and down several times with the smaller load before

connecting the full test load.

When the system is working properly, you may connect the test load (1,1xSWL). Now lower

the load at maximum speed, and let go of the winch lever so that the winch brake stops the

boat automatically. Repeat the brake test two or three times before the load reaches the water

surface.

7.2 Test 2, Recovery test:

IMO, MSC.81(70)part II. § 6.1.11.

Warning !

Do not under any circumstances attempt to lift or lower more than the certified Safe Working

Load of the davit ( + 10 % ) by using the winch and the davit arm.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

In the case of rescue boat launching appliances, it should be demonstrated that the fully

equipped rescue boat when loaded with a mass equal to that of the number of persons it is

approved to carry can be recovered by means of a winch at a rate of no less than 0.3m/s

Test procedure.

Load the boat to 1.0 x SWL. Connect the boat to the davit. Measure the lifting height. If

necessary, use guidelines on the boat. Lift the boat by the winch at full speed.

Measure the time. Recover the boat to its stowed position and adjust the upper limit switch

(LS1). Follow the procedure outlined in this operation manual.

Take care to handle the loaded boat gently.

7.3 Test 3, Hand cranking

IMO, MSC.81(70)part II. § 6.1.8. says that it shall be possible to recover the boat by means of

operating the hand gear.

It should be demonstrated that at least the weight of the empty boat can be hand cranked.

Test procedure.

Make sure that the hydraulic power pack is switched off. Enter the winch platform. Switch

the selector on the winch to «Manual hoisting». Operate the hand crank to lift the boat. It is

normally sufficient to demonstrate that it is possible to lift the boat. In case it is required to

lift the boat all the way up, several people should alternate to hand crank the boat.

Rev. 12 – 2009-01-19 Operation and Maintenance Manual – NDA Davits w/Zollern winch

CALL FOR SERVICE FORM

Please use a copy of this form, and fill in as much as possible of the following
information. Please fax this form to: Int. +47 370 58501.
All sales and service are acc. To Orgalime S92. All warranty claims must be accepted
in writing by Norsafe AS prior to dispatch of parts or service personnel.

Davit / boat build no:

Davit type:

Voltage/frequency
onboard:

Ship is built at (Yard):

Date of receipt of
equipment:

Date of delivery of ship to
owner:

Name of vessel:

Ship owner:

Contact person:

Shipping address for parts:

Telephone number:

Telefax number:

Signature:

Type of service (please tick):
Spare parts only Service only

Spare parts and service

Quote price first Send parts immediately without quoting

Warranty claim Ordinary service call

Description of problem (please add more sheets if necessary):