Lifeboat Manual

William Mills (Marine) Ltd

"TITAN"ON-LOAD QUICK RELEASE

SUSPENSION GEAR FITTED WITHHYDROSTATIC INTERLOCK AND

HOOK SAFETY INDICATOR'S

OPERATION MANUAL

mills

OPERATION MANUAL

"TITAN"

ON-LOAD QUICK RELEASE SUSPENSION GEAR

FITTED WITH HYDROSTATIC INTERLOCK

AND HOOK SAFETY INDICATORS

WILLIAM MILLS (MARINE) LTDManor RoadLevenshulme

MANCHESTERM19 3EJEngland

Telephone: 0161 224 6224Telefax: 0161 2242098

e:mail [email protected]

MARINE

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

ISSUE CONTROLissue level1

details offirst issue

change, sept 1997

1"TITAN" OPERATION MANUAL (WITH INDICATORS) issue 1 - SEPTEMBER 1997

millsMARINE

CONTENTS

SECTION

1 INTRODUCTION

2 OPERATING INSTRUCTIONS

2.1 Important Notice

2.2 Normal Release Procedure

2.3 Emergency Release Procedure

2.3.a Craft is Waterborne but hydrostatic release unit has malfunctioned.

2.3.b Craft is not waterborne but stuck at a height during launching.

2.4 Hook Resetting Procedure

2.5 Attachment of the Davit Falls*

3.0 Illustrations

3.1 Typical Arrangement of Titan Release Gear

3.2 Instruction Poster

3.3 Correct Location of Cam Release Pin and Hook

3.4 Cam Release Pin Position Indicators Hook Position Indicators

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

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* "TITAN" OPERATION MANUAL (WITH INDICATORS) issue 1 - SEPTEMBER 1997

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1. INTRODUCTION

The Mills TITAN on-load quick release suspension gear is a release mechanism for davit-launchedsurvival craft complying with the requirements of the 1998 amendments to chapter iii of SOLAS1974.

The on-load release capability of the equipment enables the bow and stern suspension hookassemblies to be opened simultaneously* even with the craft being towed by the parent vessel ordrifting due to wind or tide whilst still attached to the davit falls. The hook assemblies are openedby cables activated by a release handle unit which is sited at the helmsman's position for oneperson operation.

Accidental release is prevented by the inclusion of three safety devices namely safety pin, lockinghandle and a hydrostatic interlock device which ensures that the equipment cannot normally beoperated until the craft is in the water.In the unlikely event of a malfunction of this interlock, or if the craft is not waterborne** due tosome malfunction of the launching device, as the ultimate last chance of escape, the interlock maybe over-ridden for emergency launch of the craft by breaking the cover glass and using the safetypin to manually lift the hydrostatic locking lever.

The gear has been fitted with readily visible indicators showing the positive condition of the Hook'sCam Release Pin, so as to improve the ease of inspecting the gear to ascertain the gears safetycondition.Note: Should any of the indicators be found to be in the red/unsafe zone the craft must be takenout of service immediately and the matter corrected by adopting the prescribed procedures laiddown in this manual.

* This means both hooks opening by one full operational movement of the release handle. It doesnot imply absolute synchronisation of the opening instant of each hook, as exact synchronisation isnot required to effect a safe launch if the gear is set-up and operated in accordance with thismanual.

** Survival craft in which the twin fall Titan Release Gear are fitted are not designed to free fall intothe water, therefore this facility must be considered as the ultimate last chance of escape, where itis impossible to lower the craft normally to the water and in the full knowledge that serious damageto the craft and possible-fatal injuries to the personnel may be sustained due to this action.

The basic configuration T)f the equipment is shown in Figure 3.1.

1.1 CAUTION

Before this equipment is operated, this manual should be read and understood by all personsinvolved. This manual should then remain accessible at all times for future reference.

If there is any doubt concerning the correct functioning of the equipment when the scope of thismanual has been covered, then William Mills (Marine) Ltd must be contacted to remove any doubtbefore the equipment is put into service.

William Mills (Marine) Ltd. accept no responsibility if the scope of this manual is extended by anyinstaller, operator or service agent.

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2.0 OPERATING INSTRUCTIONS

2.1 Important Notice

The Mills TITAN on-load quick release suspension gear, as the name implies, is designed tooperate whilst there is load on the davit falls. This situation commonly occurs during the launchingsequence due to wave action, tide and possible towing forces. Although a hydrostatic interlockdevice is fitted to prevent accidental release before the craft is waterborne, a manual overridefacility is provided for use in emergencies. It is possible, therefore, to release the craft from thefalls from any height during its descent to the water.

Survival craft in which the twin fall Titan Release Gear are fitted are not designed to free fall intothe water, therefore this facility must only be considered as the ultimate last chance of escape,where it is impossible to lower the craft normally to the water and in the full knowledge that seriousdamage to the craft and possible fatal injuries to the personnel may be sustained due to thisaction.

Extreme caution should be exercised if the gear is to be operated when the boat is not waterborne.This should be considered only as an extreme last resort of escape, if the lowering operation hasbeen unable to make the craft waterborne. Careful consideration of the dangers and benefits mustbe made by the persons in charge of the craft prior to release, together with clear warnings beinggiven to the occupants to check their belts and brace themselves against shock landing andpossible break up of the craft.

For survey and test purposes of on-load release equipment it is recommended to test theequipment off-load or lightly loaded, as this is a more onerous requirement. The craft should bepositioned no higher than keel just above waterline. Frequent on-load operation also causes wearand tear to the hook tail and the cam face, so on-load operation should routinely be carried out assparingly as possible. Routine on-load testing is not only unnecessary, but detrimental to thecondition of the gear and craft.

2.2 Normal Release Procedure

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

ii) Remove the Button Headed Safety Pin from the Release Handle unit by holding the buttonin and withdrawing the pin from the sideplates.

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

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

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

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mills2.3 Emergency Release Procedure

Situation A

Craft is Waterborne but hydrostatic release unit has malfunctioned.

Take the following actions:-

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

ii) Remove the Button Headed Safety Pin.

iii) Use the Button Headed Safety Pin to break the glass access panel in the hydrostaticlocking lever cover.

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

v) Operate the release handle in one firm movement, with the other hand,

vi) Release hydrostatic locking lever.

Situation B

EXTREME CASE

Craft is not waterborne but stuck at a height during launching.

Extreme caution should be taken prior to this action being undertaken and it should beconsidered as the ultimate last chance of escape where it is impossible to lower the craftnormally to the water.

THE FOLLOWING ACTION MUST ONLY BE TAKEN WITH THE FULL KNOWLEDGE THATSERIOUS DAMAGE TO THE CRAFT AND POSSIBLE FATAL INJURIES TO PERSONNELMAY BE SUSTAINED.

A launch may be effected, If after considering the above and in the full knowledge of the possibleconsequences by taking the following action:-

After taking the decision to emergency launch, shout warning to the occupants to bracethemselves. Then follow through the same actions as for "Situation A".

Note:- The circumstances under which an emergency situation may arise is completelyoutside William Mills control or influence and William Mills disclaims any liability whichmay arise due to carrying out the above actions.

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2.4 Hook Resetting Procedure

Note:- This procedure should be followed as soon as practically possible after the release crt thecraft has taken place in anticipatory preparation of hoisting, with due consideration to seaconditions. The procedure should not be delayed to coincide with actual hoisting.

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

ii) At each hook assembly, by hand swing the hook bill to the closed position and thehook tail as far as it will go and lift the cocking lever upwards to its maximum extent in norder to return the cam release pin to its locked position. Place by hand the hook bill in the jposition it would take under the falls pull and look between the hook sideplates to confirm 1by sight that the hook tail is behind the cam release pin and that the cam release pin is in Jflat to flat contact with the tail of the hook_and that the indicators are registering the lockedposition and not in the red zone Fig 3.4 Check that the cocking lever has dropped backtowards the deck.Confirm that the hook is closed and locked by pulling the hook hard upwards twice, if thehook rotates open, then repeat the reset procedure ensuring that the tail of the hook isbehind the cam release pin.

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

iv) Replace the Button-Headed Safety Pin.

2.5 Attachment of the Davit Falls

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

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

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

iv) When the craft has been hoisted just clear of the water, Stop hoisting, thenvisually ensure that :-

a) Hydrostatic interlock has returned to its locked position.

b) Guard plates have both dropped back into the closed position. ]

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

d) Release Handle locating bars are located in the slots and the Button HeadedSafety Pin is in place.

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

Important Notes

1) If all or any one check is unsatisfactory it is unsafe to hoist the craft any further.The craft must be lowered back into the water and the gear made free for investigation andcorrection of the problem. If necessary expert advice should be sought. No adjustment ormodification is to be made which is outside the equipment's Maintenance Manual.

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

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3.0 Illustrations




3.4 Cam Release Pin Position Indicators Hook Position Indicators

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3. ILLUSTRATIONS


1 Hook Assembly2 Release Handle Unit3 Hydrostatic Unit4 Aft Operating Cable5 Forward Operating Cable6 Hydrostatic Operating Cable

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Load on Hook

Cock ing Lever

O p e r a t i o n

Pos i t i on of Hook Tai l When There is Load on Hook.

Fuily C o c k e d and C o r r e c t Cam Pos i t i on

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3.4 Cam Release Pin Position IndicatorsHook Position Indicators

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INDICATOR REFERENCE RING

INDICATOR

SAFE. ZDNEHDDK PDSITIDNINDICATOR

SAFE ZDNE


I N D I C A T O R

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William Mills (Marine) Ltd

"TITAN"ON-LOAD QUICK RELEASE

SUSPENSION GEAR FITTED WITHHYDROSTATIC INTERLOCK AND

HOOK SAFETY INDICATOR'S

MAINTENANCE MANUAL

millsMARINE

MAINTENANCE MANUAL

'TITAN"

ON-LOAD QUICK RELEASE SUSPENSION GEAR

FITTED WITH HYDROSTATIC INTERLOCK

AND HOOK SAFETY INDICATORS

WILLIAM MILLS (MARINE) LTDManor RoadLevenshulme

MANCHESTERM19 3EJEngland

Telephone: 0161 2246224Telefax: 0161 224 2098

e:mail [email protected]

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

ISSUE CONTROLissue1 sept 1997

details of changefirst issue

-1-•TITAN" (WITH INDICATORS) MAINTENANCE MANUAL issue 1 - SEPTEMBER 1997

millsMARINE

CONTENTSSECTION

1 INTRODUCTION

2 CAUTION

3 EQUIPMENT SCHEDULE

4 DRAWINGS

5 MAINTENANCEGeneralWeekly Maintenance & InspectionsMonthly Maintenance & InspectionsAnnual MaintenanceMaintenance Check List

6 OPERATIONAL TEST

7 HOOK TOLERANCES

8 HOOK PIN WEAR VERIFICATIONTemplate for recording Hook Pin Wear

9 HYDROSTATIC UNITHydrostatic Unit Cable Attachment and Adjustment.Procedure for Resetting Hydrostatic Unit.

10 OPERATING CABLESOperating Cable SpecificationsOperating Cable AdjustmentOperating Cable Replacement, Attachment and Setting

11 LUBRICATION PROCEDURES

12 SPARE PARTS

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

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1. INTRODUCTION

The Mills TITAN on-load quick release suspension gear is a release mechanism for davit-launchedsurvival craft complying with the requirements of the 1998 amendments to chapter iii of SOLAS1974.

The on-load release capability of the equipment enables the bow and stern suspension hookassemblies to be opened simultaneously* even with the craft being towed by the parent vessel ordrifting due to wind or tide whilst still attached to the davit fails. The hook assemblies are opened bycables activated by a release handle unit which is sited at the helmsman's position for one manoperation.

Accidental release is prevented by the inclusion of a hydrostatic interlock device which ensures thatthe equipment cannot normally be operated until the craft is in the water.In the unlikely event of a malfunction of this interlock, or if the craft is not waterborne** due to somemalfunction of the launching device, as the ultimate last chance of escape, the interlock may beover-ridden for emergency launch of the craft by manually lifting the hydrostatic locking lever. Thislever is enclosed behind glass, which has to be broken to gain access

The gear has been fitted with readily visible indicators showing the positive condition of the Hook'sCam Release Pin, so as to improve the ease of inspecting the gear to ascertain the gears safetycondition.Note: Should any of the indicators be found to be in the red/unsafe zone the craft must be taken outof service immediately and the matter corrected by adopting the prescribed procedures laid down inthis manual.

* This means both hooks opening by one full operational movement of the release handle. It doesnot imply absolute synchronisation of the opening instant of each hook, as exact synchronisation isnot required to effect a safe launch if the gear is set-up and operated in accordance with this manual.

** Survival craft in which the twin fall Titan Release Gear are fitted are not designed to free fall intothe water, therefore this facility must be considered as the ultimate last chance of escape, where it isimpossible to lower the craft normally to the water and in the full knowledge that serious damage tothe craft and possible fatal injuries to the personnel may be sustained due to this action.

The basic configuration of the equipment is shown in Figure 1.

2. CAUTION

Before this equipment is installed or operated, or before any maintenance is attempted, this manualshould be read and understood by all persons involved. This manual should then remain accessibleat all times for future reference.

If there is any doubt concerning the correct functioning of the equipment when the scope of thismanual has been covered, then William Mills (Marine) Ltd must be contacted to remove any doubtbefore the equipment is put into service.

William Mills (Marine) Ltd. accept no responsibility if the scope of this manual is extended by anyinstaller, operator or service agent.

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3. EQUIPMENT SCHEDULE

Each survival craft set of TITAN release gear comprises the following:-2 off Hook assemblies.1 off Release handle unit.1 off Hydrostatic unit and Cable.2 off Protective covers complete with Indicators.,2 off Set of protective cover screws and washers.2 off Keel pin spacers.1 off Forward operating cable.1 off Aft operating cable.1 off Set of instruction labels.1 off Set of instruction posters1 off Set of manuals

4. DRAWINGS

Reference should be made to the following drawings when using this manual:

Figure 1. Typical Arrangement of Titan Release Gear.

Figure 2. General Arrangement of Hook Assembly.

Figure 3. Details of Cam Release Pin Position

Figure 4 Cam Pin Positional Indicators

Figure 5 General Arrangement of Release Handle Unit

Figure 6 Details of Hydrostatic Lock Engagement

Figure 7 .General Arrangement of Hydrostatic Unit.

Figure 8 Recommended Label Fixing Positions.

Figure 9 Cam Pin Wear Indicator Reference Markings

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Figure 1. Typical Arrangement of Titan Release Gear.

1 Hook Assembly2 Release Handle Unit3 Hydrostatic Unit4 Aft Operating Cable5 Forward Operating Cable6 Hydrostatic Operating Cable

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Figure 2. General Arrangement of Hook Assembly.

Cocking Lever

Cam Release PinOperatfng LeverMousing Plate•Operating CableAuxiliary QuspEns'an Pol r>t

Keel Pm SpacerCoverCable Clamp

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

Load on Hook

Flat ro FlatC o n t a c t o f

Faces

Cocking Lever

Operat ion

Posit ion of Hook Tail When There is Load on Hook

With no Load on the Hook a Gap or Angle May Deve lopBetween Faces. This is of No Consequence During Set t ing .

However Falls Tension Must be Maintajned When Boat is

S towed to Prevent Gap Developing

Fully Cocked and C o r r e c t Cam Posi t ion With Re lease

Cable Disconnected. Release Cable Ad jus ted For SlightlyLonger Length (by 1 or 2 mm) A f t e r Alignment of Connect ing

Holes and Then Fi t ted wi th a Residual Compress i ve ForceOn the Cable ( and Never Tension )

Figure 3(b). Operational Setting Check

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Fig 4 Cam Pin Positional Indicators

Details of Initial Cam Release Pin and Hook Relative Setting showing indicator set up.

In order to permit the checking of the safe, face to face contact between the tail of the hook andthe cam pin, indicators, which are positively fixed in register with the cam pin face have been fittedto the hook units, to provide an easy reference with regard to the interface condition.If the indicators are found to be at any time, in the red/unsafe zone thus illustrating the "wrong"condition as shown in Fig 3 , the equipment must be taken out of service. Provision must be madeto safely take the load off of the hooks before the fault is investigated and corrected.

SAFE ZDNE


INDICATOR

HOOK POSITION'INDICATOR

SAFE ZDNE


INDICATOR


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Figure 5. General Arrangement of Release Handle Unit.

II

But ton Headed S a f e t y Pin

Opera t ing Handle

Detent Pin on Operat ing Handler

Operat ing Quadrants

Opera t ing Cab le

H y d r o s t a t i c Lever Cover

H y d r o s t a t i c Lock ing Lever

Clevis Fitting

C l e v i s Pin

H y d r o s t a t i c Unit Cab le

Spring

Stop Pin

Glass A c c e s s Panel

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Fig 6 Details of Hydrostatic Lock Engagement Positions

LOCKED

POSITION

Hydros ta t i c

Locking

Lever

Operat ing

Quadrant

RELATIVE POSITIONS - BOAT OUT OF W A T E R

FREE

POSITION

8 mm Maximum C l e a r a n c e

R E L A T I V E POSIT IONS - BOAT IN W A T E R

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Figure 7. General Arrangement of Hydrostatic Unit.

H y d r o s t a t i c Unit C a b l e

Vent Pipe

D iaphragm

Diaphragm C lamp ing Be i t s

P i s t o n P l a t e

Top F ix ing Nut & W a s h e r s

B o t t o m F ix ing Nur &• W a s h e r s

Top P la te & Neoprene Wasr .er

P is ton P la te A d a p t o r

C l e n c h P la te

Ven t Pipe C o n n e c t o r

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Fig 8. Recommended Label Fixing Positions.

2 X LB 3^

1 X LB 17

1 X LB 25 / 25A

1 X LB 95

1 X LB 135

1 X LB 136

1 X LB 97

IN POSIT IONS V ISABLE TO PERSON RESETT ING THE HOOKS

IN W A Y OF HELMSMAN

IN W A Y OF THE RELEASE HANDLE USE A P P R O P R I A T E LABEL

RELEASE HANDLE UNIT - A D J A C E N T TO THE BUTTON HEADED PIN

RELEASE HANDLE UNIT - TOP OF GLASS A C C E S S PANEL

R E L E A S E HANDLE UNIT - B O T T O M OF G L A S S A C C E S S PANEL

LABEL - A D J A C E N T TO G L A S S A C C E S S PANEL

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Fig 9 Cam Pin Wear Indicator Reference MarksHook Position Indicators

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HQQK PDSITIDNINDICATOR

REF DIMENSION

3 Tonne TITAN

= 3 nn DIA CENTRE PUNCH

REF DIMENSION

5 Tonne TITAN


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5.0 MAINTENANCE

IMPORTANT NOTICE

Regular maintenance in accordance with William Mill's instructions must be carried out to ensurethat performance and safety are not impaired.

IT IS STRONGLY RECOMMENDED THAT ANY MAINTENANCE WORK IS CARRIED OUT BYTRAINED SAFETY OFFICERS HAVING AN ADEQUATE MECHANICAL ENGINEERINGBACKGROUND TO UNDERSTAND THE OPERATIONAL AND MAINTENANCEREQUIREMENTS OF THE EQUIPMENT, AND TO CARRY THE CONCOMITANTRESPONSIBILITY OF PROFESSIONAL WORKMANSHIP ON WHICH THE SAFETY OF LIVESDEPEND.

IF THE CRAFT IS TO BE RETAINED IN THE DAVIT WHILST WORK IS CARRIED OUT, THELOAD MUST BE TRANSFERRED FROM THE FALLS AND THE MAIN HOOKS TO THEAUXILIARY SUSPENSION POINTS AND SUITABLE HANGING OFF PENDANTS AND LUGSON THE DAVIT. (SEE DAVIT MANUAL FOR CORRECT APPLICATION) FAILURE TO HEEDTHIS WARNING COULD PROVE FATALLY DANGEROUS.

William Mills operate Comprehensive Training Courses to certify personnel as competent in theOperation and Maintenance of their Equipment.

Note the transfer of load from the davit falls to the auxiliary suspension points must be carried outwith the minimum of shock loading.

5.1 General

The Mills Titan On-Load Release Mechanism is designed to have minimum maintenancerequirements. All main Pivot Pins are manufactured in Stainless Steel and run in self lubricatingbushes, any components not in Stainless Steel are supplied in hot dipped Galvanised Mild Steel.The operating Cables supplied by William Mills are manufactured from corrosion-resistantmaterials, and are sealed for life, requiring no periodic lubrication apart from the cable end rodsand swivels as defined in Section 11.

Note

Operating cables cannot effectively be repaired. Faulty cables (seized or kinked) render thecraft unsafe to use and must be replaced immediately if the craft is to remain in service.

Under no circumstances should any part of the equipment including cables, cable swiveljoints or ridged extensions be painted or coated with any other substance than thelubricant indicated in section 11.

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5.2 Weekly Maintenance & Inspections

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

i) At the hook assemblies:-

Check that the fall rings or links are kept under tension by the winch through the falls, andare fully engaged in the throat of the hook with the guard plates closed correctly.

Check that the hooks are fully closed, ie indicator arrows aligned, and that the cam pinindicators are registering the locked position and not in the red zone See Fig 3 & fig 4

Check that the cocking levers are in the lower position

Check that the protective covers are in place and protecting the operating cables frommechanical damage.

Check for any damage, corrosion, dirt, excessive salt deposits of foreign bodies likely toimpair the operation of the equipment and correct as necessary.

Check for damage and or corrosion to the operating cables,

ii) At the Release Handle unit:-

Check that the release handle is in the fully locked position with the locating bars fullydown in the side plate slots and behind the operating quadrants.

Check that the Button-Headed Safety Pin is in place.

Check that the hydrostatic locking lever is in the locked position See Fig6

iii) Check the security of all cable clamps,

iv) Check all operating cables for damage.

v) Check that all instruction labels are in place.

vi) Check that the equipment is adequately lubricated, and rectify as necessary (SeeSection 11.

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

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5.3 Monthly Maintenance & Inspections

Comply with the weekly maintenance schedule described previously and carry out the followingadditional work.

If the craft is to be retained in the davit whilst carrying out the monthly maintenance andinspection procedures hang the craft on the auxiliary suspension points and pendants.The transfer of load from the main falls to the auxiliary suspension points must beconducted with NO PERSONS IN THE CRAFT and in a way as to ensure that the auxiliarysuspension points and pendants are not shock loaded. Only when the main fall wires arevisibly slack should persons board the craft.Following load transfer, the main fall rings are to be removed from the hook by lifting themousing (guard) plate and pulling the ring free.

Only then test the operation of the release equipment as detailed in section 7 OperationalTest.

This monthly maintenance schedule tests all parts of the equipment except for the diaphragm inthe hydrostatic unit. Without dismantling the hydrostatic unit, which is an annual maintenancerequirement, the only way to check the operation of the diaphragm is to make the craft waterborneand observe the hydrostatic locking lever through the glass access panel. For this reason it isrecommended that the craft be launched as part of the monthly maintenance check wheneverpossible.

,*

This recommended launching offers the ideal circumstances for hook pin wear to be monitored bya measurement between the wear indicator reference points being taken as the craft is recoveredand suspended just above the water for final checks prior to lifting to the davits.(see section 8.1)

Record Monthly Check and any action taken in Ships Maintenance Log.

Following the completion of the maintenance schedule the craft should be returned to the mainfalls.


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5.4 Annual Maintenance

Comply with the monthly maintenance schedule described above and carry out the followingadditional work.

i) Inspect the hydrostatic unit diaphragm as follows. See Fig 7

Disconnect the operating cable at the release handle unit and the vent pipe at thehydrostatic unit.

Remove the diaphragm clamping bolts, separate the upper housing from the lowerhousing, and remove the diaphragm. Replace diaphragm with a new one.

Clean the lower housing and drainpipe of all dirt and salt deposits. Ensure that the matingsurface in way of the bolting pattern is clean, and wipe it over with a thin film of grease.

Dismantle the upper housing, and clean and inspect all the component parts. Reassemblein reverse order, ensuring that all fastenings are secure, and that no sharp edges are lefton the heads of the screws in the piston plate that are in contact with the diaphragm.

Locate the diaphragm on the lower housing and refit the upper housing. Ensure that theprojecting location lugs on the upper and lower housing are in line with each other, andreplace the clamping bolts.

Hand tighten any four bolts that are diametrically opposite each other, and then tighten thesame four bolts in the same sequence with a torque wrench set at 34 Nm (25 ftlbs).Repeat this operation on all the nuts and bolts around the circumference of the housing.

Reconnect the vent pipe.

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5.5 Maintenance Check List

RELEASE HANDLE

Visual on safety devices & hook indicators

Check for free play

Setting for lever lock

General Condition

HOOKS

Check covers / Indicators

Strip & Clean all parts

Check Bushes

Check gap

Check hook tail condition

Check cam / spiral pin

Cleck clevises

General condition

Check Hook Pin Wear Indicators

HYDROSTATIC UNIT

Strip & Clean

Replace diaphragm

Check adaptor / piston

Check top gasket

Check breather pipe

General condition

CABLES

Visual seals

Check clevises / locknuts

Check for free movement

Check for corrosion

General condition

GENERAL SETTINGS

Check flat to flat contact reference hookindicators, Set Cables

Check opening

WEEKLY MONTHLY YEARLY |

- 1 8 -"TITAN" (WITH INDICATORS) MAINTENANCE MANUAL issue 1 - SEPTEMBER 1997

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6 OPERATIONAL TEST

IF THE CRAFT IS TO BE RETAINED IN THE DAVIT WHILST WORK IS CARRIED OUT, THELOAD MUST BE TRANSFERRED FROM THE FALLS AND THE MAIN HOOKS TO THEAUXILIARY SUSPENSION POINTS AND SUITABLE HANGING OFF PENDANTS AND LUGSON THE DAVIT. (SEE DAVIT MANUAL FOR CORRECT APPLICATION) FAILURE TO HEEDTHIS WARNING COULD PROVE FATALLY DANGEROUS.

i) Remove the upper pair of bolts in the hydrostatic lever cover, slacken the lower pair, androtate the cover downwards to expose the hydrostatic locking lever.

ii) Remove the Button-Headed Safety Pin.

CONFIRM CRAFT IS SUSPENDED BY THE AUXILIARY SUSPENSION POINTS ANDPENDANTS NOT THE MAIN FALLS, AND THAT THE FALL RINGS HAVE BEEN REMOVEDFROM THE HOOKS.

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

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

v) At each hook assembly, check that the hook can be swung clear of the cam release pinwithout binding at the pivot and that clearance as shown in section 7 is correct. If notcheck again that the quadrants in the release handle unit are up against the stop pin, andif so, make small adjustments to the clevis fitting at the hook end of the operating cableuntil the clearance is correct.

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

vii) Check the operating cable end seals and ensure that the cable rod ends and swivels areadequately lubricated. Paying particular attention to the condition of the swivel jointbetween the cable end and the cable rod, also the cable fixing clamps.

viii) Reset the hooks and whilst doing so check that the operation of the cocking levers doesnot require the use of more than normal hand force. Excessive operating force normally isindicative of cable problems.

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

See section 10 for Cable replacement / Resetting Instructions

x) Replace the protective covers and indicators on the hook assemblies.

xi) Refit the hydrostatic lever cover on the release handle unit.

xii) Attach the davit falls.


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7 HOOK TOLERANCES

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

a. Check the tail of the hookand the face of the camrelease pin for signs of wearand damage. If wear of thehook tail is in excess of thatshown in Sketch 1 the hookshould be replaced.

If present this wear willnormally appear in the form ofa rounding of the hook tail andan indented line across thecam release pin. This conditiongenerally having been causedby:-

i) The hooks having beenunloaded from the falls when

the craft is stowed.This has allowed vibration tochatter the hook and cam facetogether causing theindentation and rounding.

ii) Frequent on load testreleases.

EXCESSIVE WEAR IS A RADIUS

GREATER THAN 1 MM

Sketch 1

b. Check the gap formedbetween the tail of the hookand the flat of the release pinby using feelers as shown insketch 2, lifting the hook as thisis done will take account of anywear in the bush or pin . If thegap is in excess of thatallowed, the gear must bewithdrawn form service and thehook replaced.

Changes in this gap can onlybe due to wear and should beprogressive rather thansudden.

MAXIMUM ALLOWED GAP0.070 INCHES 1.8 MM

Sketch 2


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8 HOOK PIN WEAR VERIFICATION

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

8.1 Calibration of Wear Mark Indicators.

When the craft is first received into service the under load dimension between the two referencemarks, on both fore and aft hooks, should be accurately established and separately entered inthere respective columns of a record table a template for which is shown below at 8.3

Determine and record the limit of wear allowance for each hook by adding 0.80 mm to thecalibration reference dimension. This figure which, if the ongoing measured reference dimensionexceeds, requires that the craft be removed from service and the causes investigated.

8.2 Ongoing measurement to check for wear,

With the hook under load, ie.

The craft is suspended just above the water after an operational launch test.

The craft is suspended from the falls with the maintenance pendants attached just prior tomaking the transfer from main falls to maintenance pendants.

Measure between the two points, with dividers or vernier and record the dimension.

Compare the dimension obtained with that noted as the maximum allowed wear figure for the gearin question on the record chart.

It must not be greater than this figure.

If a reading greater than this is obtained then the boat must be removed from service, thehook / hook pin assembly disassembled, checked and the worn items replaced.

Following disassembly and or part replacement a new reference dimension and maximum allowedwear figure must be established and recorded to allow the process of wear checking to continue.

8.3 Template of Record for recording Hook Pin Wear

LIFEBOAT No.

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

AFT HOOK FOREWARD HOOK DATE SIG


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9 HYDROSTATIC UNIT

9.1 Hydrostatic Unit Cable Attachment and Adjustment.

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

i) Ensure that the relative positions of the hydrostatic locking lever and the operatingquadrants are correct for the "locked" (ie. "out of water") position of the release handleunit. This requirement is illustrated in Fig 6

ii) Adjust the position of the clevis fitting on the cable until the pin can just be insertedthrough it and the hole in the hydrostatic locking lever.

iii) Ensure that the hydrostatic locking lever will lift against the spring to the "free" (ie."in thewater") position and return to the locked position when released. This will indicate correctfree functioning of the hydrostatic unit. If necessary, adjust the position of the clevis fittingon the cable until this requirement is met, then tighten the locking nut and secure the pinwith the clip provided.

9.2 Procedure for Resetting Hydrostatic Unit.

i) Undo and remove the four fixing bolts from top plate.

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

iii) Undo top and bottom cable fixing nuts simultaneously and proceed to unscrew bothnuts to their full extent.

iv) Place the top plate assembly back in its original position and replace two top platebolts.

v) By holding the end of the inner and outer cable (that is the opposite end to thatwhich passes into the Hydrostatic unit ) establish free movement of the inner cable bebefore next step.

vi) Press by hand the inner cable until resistance is obvious. This means that the pistonplate is resting on the diaphragm, hold this position and proceed to hand tighten top cablefixing nut.

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


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10. OPERATING CABLES

The Williams Mills Titan On Load Release Mechanism depends upon the operating cables for itssafe operation. Their ability to transfer compressive load to the release handle unit, withoutbuckling or premature failure is an integral part of the design of the equipment. Hence it is ofparamount importance that only the quality and type of cable as specified by William Mills be fittedto the equipment. Equally important is that they should be correctly fitted, protected frommechanical damage by the equipment covers and continue to be maintained in such a way as toensure their continued action by the prevention of corrosion.

Points to check

i) Corrosion on the extended ridged rod between the swivel andthe clevis.

ii) Corrosion of the swivel joint, this may need thedisplacement of the rubber seal to detect.

iii) Correct fitting, and continued tightness of the cableclamps.

iv) Kinks or sharp bends in the cable run within the craft,

v) Damage to the outer cable within the craft.

Under no circumstances should any part of the operating cable, swivel joint or ridgedextension be painted or coated with any other substance than the lubricant indicated insection 11.OPERATING CABLES CANNOT EFFECTIVELY BE REPAIRED, FAULTY CABLES (SEIZEDOR KINKED) RENDER THE CRAFT UNSAFE TO USE AND MUST BE REPLACEDIMMEDIATELY IF THE CRAFT IS TO REMAIN IN SERVICE.

10.1 Operating Cable Specifications

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

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

Application

End Rod

Travel

Min Load

Hydrostatic

1/4x28UNF

2

150 Ib comp

3 tonne

5/16x24UNF

3

210 Ibcomp

5 tonne

5/16x24UNF

4

170 Ib comp

12 tonne

3/8x18UNF

6

300 Ib comp


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10.2 Operating Cable Adjustment

ON NO ACCOUNT MUST ANY ADJUSTMENTS BE PERFORMED WITH THE CRAFTSUSPENDED BY THE GEAR, hang the craft on the auxiliary suspension points andpendants, or transport the craft to hard standing.

Only then carry out cable adjustment as follows:-

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

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

iii) Ensure the tail of the hook is flat against the cam of the release pin.

iv) PUSH through any slack in the release cable.

v) Adjust the clevis fitting to line up with its respective cam operating lever hole whilemaintaining a slight compressive force on each cable (and not tension).

vi) Put clevis pins in place to reconnect cables to cam operating levers, ensuring thatall clevis locking nuts are tight and split pins have been replaced.

•*

vii) Replace all protective covers and indicators .

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

10.3 Operating Cable Replacement, Attachment and Setting

ON NO ACCOUNT MUST THESE PROCEDURES BE PERFORMED WITH THE CRAFTSUSPENDED BY THE GEAR, hang the craft on the auxiliary suspension points andpendants, or transport the craft to hard standing. Only then carry out cable replacement asfollows:-

i) Install the fore and aft operating cables, making sure the correct lengths for the craftare used. The lifeboat manufacturer should be contacted with regards to the correct lengthof the cable and the correct routing in the boat, prior to removal or installation of areplacement. Take care to run the cables with the absolute minimum number of bends andwhen bends are necessary ensure that they have the largest possible bend radius. Forefficient operation the total amount of bend in any cable should not exceed 180 degreesand should be in excess of 205 mm (8 in) radius.

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

iii) Remove the protective covers and indicatorsjrom the forward hand aft hookassemblies and ensure that the hooks are in the closed position, i.e. with the cam releasepin (item 3, Figure 2 ) in flat contact with the tail of the hook. This requirement is shown inFig 3. Temporarily clamp the operating levers of each hook ensuring that the hooks andrelease pins are set in accordance with Fig 3a

- 2 4 -•TITAN" (WITH INDICATORS) MAINTENANCE MANUAL issue 1 - SEPTEMBER 1997

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

v) When fitting clevis forks to the cables, screw on for approximately 15 mm of thethreaded length. Refit clevis forks to quadrants and proceed to return the release handleunit to its closed or locked position, see Figure 5.Secure operating cables to the release unit sideplate with the cable clamps provided,ensuring that the groove in the cable fitting is aligned with the ridge in the clamp beforetightening. A pattern of six holes are provided in the release unit sideplates for theattachment of the cable clamps. From the top these determine the correct outer cablefixing for 3 tonne, 5 tonne gears.

Replace the Handle stop pin (Item 12, Fig 5) in the correct location for the size of gearbeing operated. Hole nearest the handle for 3 tonne, hole farthest from the handle forothers.

Check that the required length of cable travel, 3 inch on 3 tonne, 4 inch on others isavailable, by moving the quadrants by means of the operating handle.

Ensure that the clevis split pins are replaced and the under clevis'locknuts are tightened.

vi) Proceed to hook assemblies. Secure operating cables with cable blocks provided.(Item 4, Figure 5) ensuring that the groove in the cable fitting is aligned with the ridge inthe cable block before tightening.

Remove clevis forks from the operating levers, (Items 5 & 6, Figure 2), and fit clevis fork tothe threaded end of the cable above the locking nut.

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

Offer up the clevis fork to the operating lever and align the holes by rotating ftie clevis forkup or down ftie cable end until the pin can be inserted with a small compressive push ofthe cable.

Note residual tension in the cable should not be permitted as it may turn the cam towardsits opening position. Ensure that the clevis split pins are fitted and the clevis locking nutstightened.

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

- 25 -•TITAN" (WITH INDICATORS) MAINTENANCE MANUAL issue 1 - SEPTEMBER 1997

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11 LUBRICATION PROCEDURES

Item Cleaning Lubrication

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

Dependent upon condition the use of wirebrush or emery cloth, wiped clean withnon-fluffy oil soaked cloth.ANY PAINT IS TO BE REMOVED

Re-assemble with thinfilm of clean grease.

Stainless Steel pivot /cam pins in bushes

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


Cable clevis end / pins Use turpentine or paraffin based product toclean off.Use a light emery cloth on pins. Wipeclean with non-fluffy oil soaked cloth.ANY PAINT IS TO BE REMOVED


Cable end Rods Use turpentine or paraffin based product toclean off.Wipe clean with non-fluffy oil soaked cloth. -ANY PAINT IS TO BE REMOVED

Coat sparingly with athin film of cleangrease

Control Cables Cables supplied by William Mills areFactory Sealed for life and require nolubrication.ANY PAINT IS TO BE REMOVED.

Non Required.STIFF OR SEIZEDCABLES MUST BEREPLACEDIMMEDIATELY IF THECRAFT IS TOREMAIN IN SERVICE.

Lubricants suitable Shell Alvania GreaseR2 or G3B.P. LS" GreaseMobilux EP2LPSESA100


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12 SPARE PARTS

The following spare / replacement parts are available from William Mills (Marine) Ltd., for thefitting by the operator.

CablesForward Operating CablesAft Operating CablesHydrostatic Unit Cable

The length of all operating cables is to be advised by the operator.

TG55Hydrostatic Unit DiaphragmSet of Instruction LabelsProtective Covers and Indicators TG 3 tonne

TG 5 tonneTG 6 tonne


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