TJ-583-02A Allied Marine Crane Manual 80-1286.pdf
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- MO FY27 Thomas Jefferson Drydock REFERENCES and ATTACHMENTS Federal contract opportunity
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About this file
This is a technical manual for the Allied Systems Company DC-8600CTS boat davit (marine crane), a hydraulic-powered lifting system designed for launching and recovering rigid hull inflatable boats (RHIBs) in heavy seas up to Sea State 5. The davit has an 8,600-pound safe working load capacity, operates on a constant tension winch system with a minimum hoisting speed of 72 feet per minute, and is equipped with both standard and SOLAS (Safety of Life at Sea) emergency launching capabilities. The system is powered by a 75 horsepower electric motor (460 vac, 3-phase, 60 Hz) driving an axial piston pump that delivers 47 gallons per minute at 3,000 psi to a three-section hydraulic control valve managing winch, pivot, and constant tension functions. Key components include a 125-gallon hydraulic tank with return filtration, proportional and solenoid-actuated control valves, anti-2-block safety controls, wire rope tension sensors, and both manual emergency control handles and hand-crank recovery systems for powerless operation.
The manual provides comprehensive installation, operation, preventive maintenance, and troubleshooting guidance for the DC-8600CTS (Serial Number 2394). Installation requires connection to 440-volt shore power, filling the 125-gallon hydraulic tank, and mounting the remote control console within 40 feet of the davit. Operation requires trained personnel and covers pre-operational testing, launching and recovery procedures, and emergency protocols including SOLAS-compliant procedures operable from both deck and boat locations using manual control handles. Preventive maintenance is prescribed on daily, weekly, monthly, quarterly, semi-annual, and annual schedules, including hydraulic oil analysis, filter changes, and component inspections. The manual includes detailed hydraulic and electrical schematics, parts lists with over 40 subassembly tables, and specifications for the constant tension winch system with integrated safety features for preventing hook overtravel and load slippage.
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80-1286Rev: 5-2019
TECHNICAL MANUAL
BOAT DAVIT
MODEL DC-8600CTS
S/N 2394
Please check the Allied Systems website regularly for updates to the technical manual.
Important: Be certain to specify the serial number of your crane or davit when ordering parts.
MANUFACTURED BY
21433 S.W. OREGON ST., SHERWOOD 97140, OR U.S.A.
PHONE: 503.625.2560 • FAX: 503.625.7980
E-MAIL: cranes@alliedsystems.com WEBSITE: http://www.alliedsystems.com
Marine Crane
80-1286 Rev: 5-2019
INTENTIONALLY LEFT BLANK
0-1 80-1286Rev: 5-2019
Chapter 0 Front Matter Table of Contents.......................................................0-1 Abbreviations and Acronyms.....................................0-4 Safety Summary........................................................0-5
| Chapter 1 | Introduction |
| 1.1 | SAFETY PRECAUTIONS................................1-1 |
| 1.2 | INTRODUCTION.............................................1-1 |
| 1.2.1 | Scope...........................................................1-1 |
| 1.2.2 | Applicability...................................................1-1 |
| 1.3 | DAVIT DESCRIPTION.....................................1-1 |
| 1.3.1 | Davit Installation...........................................1-1 |
| 1.3.2 | Hydraulic Power Unit....................................1-1 |
| 1.3.3 | Remote Control Console..............................1-2 |
| 1.3.4 | Constant Tension Winch...............................1-2 |
| 1.3.5 | Hydraulic System..........................................1-2 |
| 1.3.5.1 | Control Valve.............................................1-2 |
| 1.3.5.2 | Pivot System..............................................1-2 |
| 1.3.5.3 | Winch System............................................1-2 |
| 1.3.5.4 | Emergency System (SOLAS)....................1-2 |
| 1.3.6 | Electrical System.........................................1-2 |
| 1.3.6.1 | Electric Motor............................................1-2 |
| 1.4 | REFERENCE DATA.........................................1-3 |
| 1.5 | WARRANTY....................................................1-8 |
| Chapter 2 | Preparation for Use |
| 2.1 | UNPACKING....................................................2-1 |
| 2.2 | INSPECTION...................................................2-1 |
| 2.3 | MAJOR COMPONENTS.................................2-1 |
| Chapter 3 | Installation |
| 3.1 | GENERAL........................................................3-1 |
| 3.2 | INSTALLATION................................................3-1 |
| 3.2.1 | Davit Installation...........................................3-1 |
| 3.3 | PREPARATION FOR OPERATION..................3-2 |
| 3.4 | PREPARATION FOR RESHIPMENT...............3-2 |
| Chapter 4 | Principles of Operation |
| 4.1 | INTRODUCTION.............................................4-1 |
| 4.2 | MECHANICAL SYSTEM.................................4-1 |
| 4.2.1 | Davit.............................................................4-1 |
| 4.2.2 | Winch............................................................4-2 |
| 4.2.3 | Control Console............................................4-2 |
| 4.3 | HYDRAULIC SYSTEM....................................4-3 |
| 4.3.1 | Hydraulic Power Unit....................................4-3 |
| 4.3.1.1 | Axial Piston Pump.....................................4-4 |
| 4.3.1.2 | Pressure Compensator..............................4-5 |
| 4.3.2 | Control Valve................................................4-6 |
| 4.3.3 | Pivot System.................................................4-7 |
| 4.3.4 | Winch System...............................................4-7 |
| 4.3.5 | Emergency Launch System..........................4-9 |
| 4.3.6 | SOLAS Emergency Launching System........4-9 |
| 4.4 | ELECTRICAL SYSTEM...................................4-9 |
| 4.4.1 | Wire Rope Tension Control...........................4-9 |
| 4.4.2 | Anti-2-Block Control......................................4-9 |
| Chapter 5 | Operation |
| 5.1 | INTRODUCTION.............................................5-1 |
| 5.2 | OPERATING CREW........................................5-1 |
| 5.3 | INSTRUMENTS AND CONTROLS.................5-1 |
| 5.3.1 | Control Console............................................5-1 |
| 5.3.2 | HPU (Hydraulic Power Unit).........................5-3 |
| 5.4 | OPERATING THE DAVIT.................................5-3 |
| 5.4.1 | Pre‑Operational Test.....................................5-3 |
| 5.4.2 | Initial Operational Test..................................5-4 |
| 5.4.3 | Launching Operation....................................5-4 |
| 5.4.4 | Recovery Operation......................................5-6 |
| 5.4.5 | Emergency Operation...................................5-7 |
| 5.4.5.1 | Emergency Control Valve Controls............5-7 |
| 5.4.5.2 | SOLAS Launch Operation from Deck........5-8 |
| 5.4.5.3 | SOLAS Emergency Launching Op. ..........5-8 |
| 5.4.5.4 | Winch Emerg. Recovery Hand Crank......5-10 |
| 5.5 | HAND SIGNALS............................................5-10 |
| Chapter 6 | Preventive Maintenance |
| 6.1 | INTRODUCTION.............................................6-1 |
| 6.2 | LUBRICATION SPECIFICATIONS..................6-1 |
| 6.3 | PREVENTIVE MAINTENANCE.......................6-1 |
| 6.4 | HYDRAULIC OIL MAINTENANCE..................6-2 |
| 6.4.1 | Storage and Handling...................................6-2 |
| 6.4.2 | In-Operation Care.........................................6-2 |
| 6.5 | SCHEDULED MAINTENANCE.......................6-2 |
| 6.5.1 | Daily or Every 10 Hours................................6-4 |
| 6.5.1.1 | Inspect Fasteners......................................6-4 |
| 6.5.1.2 | Inspect Hydraulic Hoses, Tubes, etc..........6-4 |
| 6.5.1.3 | Inspect Winch Drum..................................6-4 |
| 6.5.1.4 | Check Hydraulic Oil Level..........................6-4 |
| 6.5.1.5 | Inspect Anti-2-Block...................................6-5 |
| 6.5.2 | Weekly or Every 50 Hours............................6-5 |
| 6.5.2.1 | Wash with Fresh Water..............................6-5 |
| 6.5.3 | Monthly or Every 200 Hours.........................6-5 |
| 6.5.3.1 | Wash with Fresh Water/Detergent.............6-5 |
| 6.5.3.2 | Inspect And Lubricate Wire Rope..............6-5 |
| 6.5.3.3 | Inspect SOLAS Ropes.............................6-10 |
| 6.5.3.4 | Inspect Lifting Eye...................................6-10 |
| 6.5.3.5 | Inspect Hydraulic Cylinders.....................6-10 |
| 6.5.3.6 | Inspect Davit Structure............................6-11 |
| 6.5.3.7 | Check Accumulator Precharge................6-11 |
| 6.5.3.8 | Clean Hydraulic Tank Breather................6-11 |
| 6.5.3.9 | Inspect Electrical Boxes...........................6-11 |
6.5.3.10 Check Winch Housing Oil Level...............6-11
Marine Crane Chapter 0
Table of Contents
0-280-1286 Rev: 5-2019
| 6.5.4 | Every 3 Months or Every 500 Hours...........6-12 |
| 6.5.4.1 | Replace Hydraulic Return Filter...............6-12 |
| 6.5.4.2 | Lubricate Electric Motor...........................6-12 |
| 6.5.5 | Every 6 Months or Every 1000 Hours.........6-13 |
| 6.5.5.1 | Check Bolts and Fasteners......................6-13 |
| 6.5.6 | Annually or Every 2000 Hours....................6-13 |
| 6.5.6.1 | Obtain Oil Samples for Analysis..............6-13 |
| 6.5.6.2 | Change Winch Assembly Oils.................6-13 |
6.5.6.2.1 Change Winch Brake Oil......................6-13
6.5.6.2.2 Change Winch Gear Reducer Oil.........6-13
| 6.5.6.3 | Inspect Sheave........................................6-14 |
| 6.5.6.4 | Change Hydraulic System Oil..................6-16 |
| 6.5.7 | Every 5 to 8 Years or As Required..............6-17 |
| 6.5.7.1 | Replace Hydraulic Hoses........................6-17 |
| 6.6 | MAINTENANCE RECORDS..........................6-17 |
| Chapter 7 | Corrective Maintenance |
| 7.1 | INTRODUCTION.............................................7-1 |
| 7.1.1 | Maintenance Practices.................................7-1 |
| 7.2 | ADJUSTMENTS..............................................7-2 |
| 7.2.1 | Main System Relief Pressure.......................7-2 |
| 7.2.2 | CT Winch Pressure Adjustments..................7-3 |
| 7.2.3 | Anti-2-Block Control Adjustment...................7-4 |
| 7.2.4 | Wire Rope Tension Sensor Adjustment........7-4 |
| 7.3 | REPAIRS ........................................................7-5 |
| 7.3.1 | CT Winch......................................................7-5 |
| 7.3.1.1 | Removal.....................................................7-5 |
| 7.3.1.2 | Constant Tension Motor Replacement.......7-6 |
| 7.3.1.3 | Load Motor Replacement..........................7-6 |
| 7.3.1.4 | Winch Brake Replacement........................7-7 |
| 7.3.1.5 | Winch Brake..............................................7-8 |
7.3.1.5.1 Disassembly...........................................7-8
7.3.1.5.2 Assembly................................................7-9
| 7.3.1.6 | Winch Gear Reducer...............................7-10 |
| 7.3.1.7 | Winch Installation.....................................7-10 |
| 7.3.1.8 | Wire Rope Installation..............................7-11 |
| 7.3.2 | Lift Cylinder.................................................7-12 |
| 7.3.2.1 | Cylinder Removal....................................7-12 |
| 7.3.2.2 | Cylinder Disassembly..............................7-13 |
| 7.3.2.3 | Replace Cylinder Seals...........................7-15 |
| 7.3.2.4 | Reassemble Cylinder..............................7-15 |
| 7.3.3 | Control Valve..............................................7-17 |
| 7.3.3.1 | Remove Control Valve.............................7-17 |
| 7.3.3.2 | Disassemble Control Valve......................7-17 |
| 7.3.3.3 | Reassemble Control Valve.......................7-17 |
| 7.3.3.4 | Install Control Valve.................................7-18 |
| 7.3.4 | Accumulator................................................7-19 |
| 7.3.4.1 | Precharging The Accumulator.................7-19 |
| 7.3.4.2 | Checking the Precharge..........................7-19 |
| 7.3.4.3 | Precharging.............................................7-19 |
| Chapter 8 | Storage |
| 8.1 | SHORT TERM STORAGE...............................8-1 |
| 8.2 | LONG TERM STORAGE.................................8-1 |
| Chapter 9 | Troubleshooting |
| 9.1 | INTRODUCTION.............................................9-1 |
| 9.1.1 | Safety...........................................................9-1 |
| 9.1.2 | Problem Area Isolation.................................9-1 |
| 9.2 | PRELIMINARY TROUBLESHOOTING............9-1 |
| 9.2.1 | Pump Test.....................................................9-1 |
| 9.2.2 | Control Valve Test.........................................9-1 |
| 9.2.3 | Winch System Test.......................................9-1 |
| 9.3 | FAULT DETECTION........................................9-2 |
| 9.3.1 | Probable Mechanical Causes.......................9-2 |
| 9.3.2 | Probable Hydraulic Causes..........................9-2 |
| 9.3.3 | Probable Electrical Causes..........................9-2 |
| Chapter 10 | Parts Lists |
| 10.1 | INTRODUCTION...........................................10-1 |
| 10.1.1 | Major Subassemblies.................................10-1 |
| 10.1.2 | Special Notes.............................................10-1 |
| 10.2 | FORMAT........................................................10-1 |
| 10.2.1 | Item.............................................................10-1 |
| 10.2.2 | Notes..........................................................10-1 |
| 10.2.3 | ASC P/N.....................................................10-1 |
| 10.2.4 | Qty..............................................................10-1 |
| 10.2.5 | Description..................................................10-1 |
| 10.2.6 | Illustrations.................................................10-1 |
| 10.3 | SPARE PARTS LIST......................................10-2 |
| Table 10-1 | DC8600CTS...................................... 10-5 |
| Table 10-2 | Boom Assembly................................ 10-7 |
| Table 10-3 | Boom Weldment................................ 10-8 |
| Table 10-4 | Sheave Case Assembly.................... 10-9 |
| Table 10-5 | Bracket Assembly........................... 10-10 |
| Table 10-6 | Cylinder Assembly.......................... 10-13 |
| Table 10-7 | Power Pack Assembly..................... 10-16 |
| Table 10-8 | Motor/Pump Assembly.................... 10-17 |
| Table 10-9 | Starter Assembly............................ 10-19 |
| Table 10-10 | Accumulator Assembly................... 10-20 |
| Table 10-11 | Filter Assembly............................... 10-21 |
| Table 10-12 | Reeving Arrangement..................... 10-23 |
| Table 10-13 | Winch Complete.............................. 10-24 |
| Table 10-14 | Manifold Installation........................ 10-28 |
| Table 10-15 | Manifold Assembly.......................... 10-31 |
| Table 10-16 | Valve Shield Assembly.................... 10-32 |
| Table 10-17 | Constant Tension Winch................. 10-33 |
Table 10-18 Winch Brake.................................... 10-35
| Table 10-19 | Winch Lockout Assembly................ 10-36 |
| Table 10-20 | Haul Ball.......................................... 10-37 |
| Table 10-21 | Remote Console Assembly............. 10-39 |
| Table 10-22 | Control Box Assembly..................... 10-42 |
| Table 10-23 | Inlet & Return System..................... 10-47 |
| Table 10-24 | Control Valve................................... 10-48 |
0-3 80-1286Rev: 5-2019
| Table 10-25 | Ball Valve Assembly........................ 10-49 |
| Table 10-26 | Pivot System................................... 10-51 |
| Table 10-27 | Manifold Assembly.......................... 10-52 |
| Table 10-28 | Winch System................................. 10-55 |
| Table 10-29 | Electrical System............................ 10-58 |
| Table 10-30 | Anti-2-Block Assembly.................... 10-60 |
| Table 10-31 | A-2-B Switch Assembly................... 10-61 |
| Table 10-32 | Weight Assembly............................ 10-62 |
| Table 10-33 | Tension Switch Assembly............... 10-63 |
| Table 10-34 | Junction Box Assembly................... 10-64 |
| Table 10-35 | Power Box Assembly...................... 10-65 |
| Table 10-36 | Downstop Assembly....................... 10-66 |
| Table 10-37 | Davit Assembly............................... 10-67 |
| Table 10-38 | SOLAS Controls Installation........... 10-71 |
| Table 10-39 | Decal Installation............................. 10-73 |
| Table 10-40 | Cradle Installation........................... 10-77 |
| Table 10-41 | Pad Assembly, Stern....................... 10-78 |
| Table 10-42 | Pad Assembly, Stern....................... 10-79 |
| Table 10-43 | Pad Assembly, Bow......................... 10-80 |
| Table 10-44 | Stop Assembly, RH......................... 10-81 |
| Table 10-45 | Stop Assembly, LH.......................... 10-82 |
| Table 10-47 | Spare Parts List.............................. 10-83 |
11 APPENDIX A: Model 10 Drive
12 APPENDIX B: Oilgear Pump
13 APPENDIX C: Marathon Motor
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ABS................................. American Bureau of Shipping Adj................................................................Adjustment amp.................................................................... Ampere API....................................American Petroleum Institute APL.................................................Allowance Parts List A/R.............................................................. As Required ASC........................................Allied Systems Company Aux................................................................... Auxiliary AWG............................................American Wire Gauge bar.................................... 14.5 pounds per square inch Brg..................................................................... Bearing C..................................................... Celsius (centigrade) CAGE....................Commercial And Government Entity CFR.................................. Code of Federal Regulations cid.............................................cubic inch displacement CNTRL................................................................ Control CT....................................................... Constant Tension CTRL.................................................................. Control DIN...................................Deutsche International Norm EIPS................................. Extra Improved Plough Steel Elec.................................................................. Electrical Ext.....................................................................External F....................................................................Fahrenheit fpm.......................................................... feet per minute FSCM.............. Federal Supply Code for Manufacturers gal.........................................................................Gallon Galv.............................................................. Galvanized Gnd.....................................................................Ground gpm...................................................Gallons Per Minute hp................................................................Horsepower HPU...............................................Hydraulic Power Unit Hyd..................................................................Hydraulic Hz..........................................Hertz (cycles per second) ID...........................................................Inside Diameter IEEE......Institute of Electrical and Electronic Engineers ISO...................... International Standards Organization IWRC............................... Independent Wire Rope Core kPa................................................................. kilopascal kw...................................................................... Kilowatt lb...........................................................................pound lbs....................................................................... pounds LH................................................................... Left Hand lpm.......................................................Liters Per Minute LT..............................................................................Left
Max................................................................. Maximum m............................................................................meter micron....................................................0.001 millimeter Min................................................................... Minimum N.C....................................................... Normally Closed N.O.........................................................Normally Open NATO........................ North Atlantic Treaty Organization NC........................................................ National Coarse NEMA.... National Electrical Manufacturer’s Association NF..............................................................National Fine NLGI.....................National Lubrication Grease Institute N-m.......................................................... Newton-meter Nom...................................................................Nominal NPTF..............................National Pipe Tapered for Fuel NSS......................................... Not Serviced Separately NSTM............................... Naval Ship Technical Manual OD......................................................Outside Diameter PC..............................................Pressure Compensator Pl............................................................................Plate P/N..............................................................Part Number POS................................................................... Position Pot............................................................Potentiometer psi............................................. pounds per square inch PVB..................................................Pump Side Module PVE................................... Proportional Valve Electrical Qty.....................................................................Quantity Ref................................................................. Reference RH................................................................Right Hand rpm............................................ Revolutions Per Minute RT...........................................................................Right SAE............................ Society of Automotive Engineers SOL..................................................................Solenoid SOLAS...........................................Safety Of Life At Sea Spec...........................................................Specification SS........................................................... Stainless Steel SW....................................................................... Switch TEFC............................... Totally Enclosed, Fan-Cooled Thk......................................................................... Thick TMCR............. Technical Manual Contract Requirement TYP......................................................................Typical v................................................................................ Volt vac...........................................Volts Alternating Current vdc...................................................Volts Direct Current VOM......................................................Volt-Ohm Meter
Abbreviations and Acronyms
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Safety Summary
GENERAL SAFETY NOTICES
The following pages contain general safety warnings which supplement specific warning and cautions ap-pearing elsewhere in this manual. All electrical and hydraulic equipment is dangerous. You must thorough-ly review and understand the Safety Summary before attempting to operate, troubleshoot or service your equipment.
All possible safety hazards cannot be foreseen so as to be included in this manual. Therefore, you must al-ways be alert to potential hazards that could endanger personnel and/or damage the equipment.
The following symbols/terms are used to emphasize safety precautions and notices in this manual:
DANGER
The “DANGER” symbol indicates a hazardous situation which, if not avoided, will result in death or serious injury. Carefully read the mes-sage that follows to prevent serious injury or death.
WARNING
The “WARNING” symbol appears wherever incorrect operating procedures or practices could cause serious injury or death. Carefully read the message that follows to prevent seri-ous injury or death.
CAUTION
The “CAUTION” symbol appears where a haz-ardous situation which, if not avoided, could result in minor to moderate injury and equip-ment damage.
NOTICE
This signal word alerts to a situation that is not related to personal injury but may cause equip-ment damage.
NOTE: The term “NOTE” highlights operating pro-cedures or practices that may improve equipment reliability and/or personnel performance.
Obey the following cautions and warnings before using your machine to avoid equipment damage, personal injury or death.
OPERATING SAFETY
Qualifications
• This equipment must be operated and maintained by experienced and trained personnel.
• You must receive training prior to operating this equipment.
• If you do not routinely operate this equipment, refresher training is recommended. You must reac-quaint yourself with this manual and the equipment before starting, and then proceed slowly.
Do Not Operate Alone:
• It is essential that someone be on deck to watch clearances and hand signals. Ensure that the director is clear of the Davit or other moving parts and the load before you move it. Do not move the Davit or load if you cannot see this person.
Safety Regulations:
• Each country has its own safety legislation. It is in the operator’s own interest to be conversant with these regulations and to comply with them in full.
This also applies to local bylaws and regulations in force on a particular worksite.
• Should the recommendations in this manual devi-ate from those in the user’s country, the national regulations should be followed.
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Equipment Hazards:
• Do not operate this equipment if you know of mal-functions, missing parts, and/or incorrect adjust-ments. Any one of these situations can cause or contribute to an accident or damage to the equip-ment. Lower the load and stop the HPU immedi-ately if problems arise after starting.
• Do not start the hydraulic power unit if the “start” switch has been tagged-out with a “DO NOT START” or other red tag.
• Never allow anyone under the load. Ensure the area is clear before moving the Davit or the load.
• Never attempt to disconnect any of the safety devices installed on your equipment.
• When moving the load, always make sure that there is adequate clearance for both the boom and the load.
• Do not overload the Davit. Always operate within the rated capacity of the Davit and rigging. Refer to the load chart for this Davit’s lifting capacity.
• Always wear appropriate safety clothing and use prescribed safety equipment such as head, foot, hand, eye protection, etc.
• Accurately place the load, keeping in mind how you expect the load to respond when released.
• Lower and remove the load before leaving the Davit or securing the hydraulic power.
• Maintain proper clearance from electrically ener-gized equipment. If the Davit contacts energized equipment, stay clear and prevent anyone else from coming in contact with the Davit.
MAINTENANCE SAFETY
Unless properly serviced, this Davit can be extremely dangerous.
Qualifications:
• To ensure safety, each person working on this Davit must have the necessary skills, informa-tion, tools and equipment. Do not attempt to make adjustments or perform repairs unless you are authorized and qualified to do so.
Do Not Work Alone:
• Never attempt to service energized equipment alone. Make sure that someone capable of provid-ing aid is present in the event of accidental shock or other incidents.
Secure the Equipment:
• Do not rely on the hydraulic system to support any part of the Davit during maintenance or lubrication.
Never stand under a component that is supported only by the hydraulic system. Make sure that components are resting on their mechanical stops or supported with appropriate safety stands during maintenance or lubrication.
• Unless otherwise directed in this manual, never attempt service procedures when power is on. Tag the “START” switch and/or the disconnect switch with a “DO NOT START” sign when required.
• Never attempt to service the hydraulic power sys-tem or the Davit while it is moving or the hydraulic power unit is running. Lower the load and secure the power.
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Equipment Safety:
• Test Equipment:
xx Make sure that the equipment used to test the hydraulic power system and the Davit is calibrated and in good working condition.
xx If an instrument must be held while taking measurements, electrically ground the case of the instrument before energizing the equip-ment when appropriate. There are some kinds of measuring devices that should not be grounded.
xx Do not hold ungrounded measurement de-vices while they are in use.
xx Do not touch energized equipment or person-nel working on energized equipment while holding a multimeter.
• Heavy Equipment:
xx Use lifting devices with a lifting capacity greater than twice the weight of any objects to be lifted to prevent personal injury or equip-ment damage.
• Pressurized Equipment:
xx Wear safety goggles when working on or near pressurized equipment.
xx Lower all loads and relieve all hydraulic pres-sure before disconnecting hydraulic lines. If this is not done the load could fall or pressur-ized hydraulic oil could cause personal injury or death. Never try to stop a hydraulic leak with any part of your body.
• Personal Protective Equipment:
xx Always use personal protective equipment (PPE) appropriate to the situation. This may include the use of hearing protection, eye pro-tection, a respirator, a hard hat, leather gloves, steel toed boots, etc.
Electrical Hazards:
• An electrical shock could be fatal. Be aware that the hydrau-lic power unit (HPU) is typi-cally driven by a 440 or 450 vac, 3-phase, 60Hz motor. Make sure that the power is “OFF” before opening electrical panels.
• Never attempt electrical test-ing or repair while standing in water.
• Remove watch-es, rings or any jewelry that may contact ener-gized circuits.
Hot Oil Hazards:
• Burns from hot oil can be severe. Always allow lubricating and hydraulic oil to cool before draining or disconnecting hydraulic fittings and hoses.
Fire Hazards:
• Hydraulic oil is flammable.
Do not smoke when check-ing or filling the tank. Keep open flames and sparks away from the hydrau-lic power system and the Davit.
• Regular pres-sure washing is recommended for fire prevention and improves general safety by removing oil, and dirt.
• Never overfill the hydraulic tank because the over-flow could contribute to a fire. Immediately repair any hydraulic leaks and clean up any spills.
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Compressed Air Hazards:
• When using compressed air to dry parts, pressure should not exceed 30 psi (200kPa).
• Air pressure penetrating your skin can be fatal.
Never direct compressed air at anyone.
Pressurized Hydraulics Hazards:
• Be aware of the hazards related to pressurized hydraulics:
xx Wear personal protective equipment, such as gloves and safety glasses, whenever servicing or checking a hydraulic system.
xx Assume that all hydraulic hoses and com-ponents are pressurized. Relive all hydraulic pressure before disconnecting any hydraulic line.
xx Never try to stop or check for a hydraulic leak with any part of your body. Use a piece of cardboard to check for hydraulic leaks.
xx Small hydraulic hose leaks are extremely dan-gerous and can inject hydraulic oil under the skin, even through gloves.
xx Infection and gangrene are possible when hydraulic oil penetrates the skin. See a doctor immediately to prevent loss of a limb or death.
Falling Hazard:
• Due to the height of some lubrication points, it is essential to personnel safety that approved ladders, personnel lifts and/or scaffolding is used while servicing the Davit. Always put the Davit in it’s parked position before attempting to perform repairs or service.
• Always use safety treads and handholds where provided.
The Davit can be dangerously slick whenever oily surfaces are exposed to rain or frost.
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Figure 1-1. Component Identification
1-1 80-1286Rev: 5-2019
Marine Crane Chapter 1
Introduction
1.1 SAFETY PRECAUTIONS
Warnings and cautions appearing throughout this technical manual are extremely important to personnel and equipment safety. Before attempting to operate, troubleshoot, or service this equipment, you must thor-oughly review and understand the Safety Summary that precedes this chapter.
1.2 INTRODUCTION
This manual has been prepared to assist person-nel operating and servicing the Rescure Boat Davit- DC8600CTS. Chapters 1 through 9 comprise the in-stallation, operating and servicing instructions. Chapter 10 contains parts lists for all components of the crane.
1.2.1 Scope
This manual provides instructions for personnel to ac-complish the following:
1. Install the davit.
2. Prepare, operate, and secure the crane.
3. Detect, isolate, and correct malfunctions.
4. Remove, repair or replace, and reinstall parts.
5. Perform scheduled maintenance.
Intermediate and depot level maintenance, specifically inspection, operability tests, fault isolation, and over-haul of items such as motors, brakes, and winches, will normally be accomplished at more extensive shop facilities.
1.2.2 Applicability
This manual is applicable to the Rescue Boat Davit
DC8600CTS, S/N 2394.
1.3 DAVIT DESCRIPTION
See Figure 1-1. Model DC8600CTS davit was devel-oped for launching and retrieving rigid hull inflatable boats (RHIB’s) in heavy seas. Maintenance straps are provided to secure the boat in place when being stowed.
This davit is rated for a safe working load of 8,600 pounds (3900 kg) up to Sea State 5, and has the capability to raise and lower the hook approximately 80 feet (24.4 m) on a 5/8 inch diameter Endurance Dyform 34LR 3 wire rope, rated for nominal breaking strength of 56,400 pounds (25582 kg). Winch hoisting speed is a minimum of 72 feet per minute (fpm), [22 meters per minute (mpm)].
1.3.1 Davit Installation
The davit weldments, the structural members which support the load, are constructed of high strength steel with continuous welds. The winch is mounted to the davit, and a hook rated for 8,600 lb. (3900 kg) is rigged for one-part reeving from the winch line, through a sheave. The davit’s base assembly is bolted to the deck.
1.3.2 Hydraulic Power Unit
See Figure 1-1. System pressure is supplied by a hydraulic power unit (HPU) including a motor driven, pressure compensated, axial piston, variable displace-ment pump and a 125 gallon (473 liter) tank. Oil return-ing to the tank passes through a 10 micron return filter.
Delivery is up to 47 gpm (178 lpm), maintained at 3000 psi (20684 kPa) by a pressure compensator on the pump.
Figure 1-2. Constant Tension Winch
Constant Tension Hydraulic MotorWire Rope
Anchor
Drum
Gear Reducer
Hydraulic Motor
Main Winch Brake
Spring Brake
Winch Frame
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1.3.3 Remote Control Console
All controls required for operating the davit are located at the control console. System condition indicators are located here and are protected from the weather by a hinged cover when not in use.
1.3.4 Constant Tension Winch
See Figure 1-2. A constant tension type winch is mounted to the davit assembly. The winch consists of a load hydraulic motor, constant tension hydraulic motor, planetary gear reducer, spring applied/ hydraulically released friction brakes, frame, cable drum and shaft.
A sprague clutch in the main winch brake allows the load to be lifted without brake drag.
1.3.5 Hydraulic System
1.3.5.1 Control Valve
The control valve has three sections. The first (winch) section is a motor spool actuated by a control lever or proportional solenoid. The second (pivot) section has a three position cylinder spool actuated by a control lever or proportional solenoid. The third (constant ten-sion winch) section is a motor spool actuated by an electric solenoid.
1.3.5.2 Pivot System
The pivot system controls hydraulic power to pivot the davit. Hydraulic pressure from the control valve alters the pressure level within the hydraulic cylinder, causing it to shift. As it extends or contracts evening the pres-sure within, the davit pivots at the attachment points.
1.3.5.3 Winch System
The winch system controls hydraulic power to the winch for normal hoisting and lowering. Hydraulic power is applied to a load hydraulic motor. A counter-balance valve hydraulically locks the winch and keeps the load from dropping. A spring applied hydraulic release brake acts as a parking brake.
1.3.5.4 Emergency System (SOLAS)
The emergency operating system is designed to allow limited use of the hydraulically controlled functions of the davit (pivot and lowering) in the event of a loss of power. The system consists of the four accumulators, the pressure gauge and associated plumbing. The accumulators are pressurized when hydraulic power is applied to the davit and remains pressurized until discharged by the accumulator valve. The emergency system can also be operated when the davit is under full power.
1.3.6 Electrical System
Both power distribution and control functions are served by the electrical system. The electrical system consists of a starter, wiring to the motor, a solenoid, a proximity sensor, and the constant tension electrical system; constant tension electrical components, and constant tension proximity sensor.
1.3.6.1 Electric Motor
The hydraulic pump is driven by a 75 hp 460 vac 3-phase, 60 Hz electric motor. This motor is energized by a solid state soft start system.
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Characteristics Description
| Ratings: | PERSONNEL RATED | |
| Safety Factor, Wire Rope | 6:1 | |
| Load | 8,600 lbs (3,900 kg) | |
| Hoist Speed | 72 fpm nominal (Bare Drum Speed) | |
| Wire Rope | 5/8" (1.6 cm) Dia |
Test Weights:
| Dynamic (110% of Rated Load) | 9,460 lbs (4,290 kg) |
| Static (150% of Rated Load) | 12,900 lbs (5,851 kg) |
Electrical Power Requirements: 440 vac, 3-phase, 60 Hz, 95 Amp
Hydraulic System:
| Operating Pressure | 3,000 psi (20,684 kPa) |
| Relief Pressure | 3,200 psi (22,063 kPa) |
| Required Pump Output | 47 gpm (177 lpm) |
| Temperature Range | 0° F to 180° F (-17° C to 82° C) |
| Hydraulic Fluid | Mobil DTE 13M |
| Hydraulic Power Unit: | ||
| Pump | Axial Piston, Pressure Compensated, Variable Displacement | |
| Motor | 75 hp, 460 vac, 3-phase, 60 Hz, 1800 rpm | |
| Return Filter | In-Tank Type, 6 Micron Element | |
| Tank | 125 Gallon (473 Liters) Capacity |
Control Valve: 3-Section Lever/ Solenoid Actuated
| Winch: | ||
| Maximum Rated Load | 8,600 lbs (3,900 kg) | |
| Normal Hoisting Speed | 72 fpm (22 meters per minute) | |
| Drum Speed | 33.58 rpm | |
| Drum Capacity | 112 feet (34 meters) |
Environmental:
Atmospheric Davit and equipment will withstand frequent soaking by salt spray and ambient atmospheric conditions
Temperature Davit and equipment will operate within ambient temperature range of -40° to 120° F (-40° C to 49° C)
Humidity Davit and equipment will withstand effects of relative humidity ranging from 0 to 100% under operating and stowage conditions
Stability Davit can withstand horizontal force along longitudinal axis of at least 10% of rated load and function satisfactorily in Sea State 5
Table 1-1. Reference Data
1.4 REFERENCE DATA
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"Solas Pivot" (Back Corner Under Handle on Base)
"High Voltage" "Start" "Stop" (Decals on Starter Box)
"Allied
DC8600CTS"
(Both Sides of Boom)
"Allied
DC8600CTS"
(Both Sides of Boom)
"Hydraulic Oil" (Oil Reservoir)
"Warning-No Step"
(Oil Reservoir)
"Accumulator Drain"
(Oil Reservoir)
"Solas Winch" "Handle Reset (Left on Base)
"Warning:
Hands Off"
(Both Cradle Legs)
"Warning:
Hands Off" (Both Cradle Legs)
"Warning: High Voltage"
"Warning:
Hands Off"
"Hand Crank" (On PVC Tube)
SOLAS winch approval decal
SOLAS Structural Approval Number
Reeving Chart
Winch Serial Number Plate
"Warning:
Manual Handles"
Figure 1-3. Decal Location
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| Model......................................................... DC8600CTS |
| Nomenclature................................................Boat Davit |
| Rated Capacity.............................. 8,600 lbs (3,900 kg) |
| Overturn Moment.................... 155,000 lb-ft (17512Nm) |
| Davit Total Gross Weight................ 9,000 lbs (4082 kg) |
Note: Capacities shown in this manual make no allowances for such factors as freely suspended loads, operating speeds, or weights of any accessories.
Figure 1-4. Dimensional Data
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146.29 in (371.6 cm)
REMOTE
OPERATOR'S
CONSOLE
E D
G E
O F
H U
LL
108.13 in (274.65 cm)
5/8 DIA WIRE ROPE
INTEGRATED
BOAT CRADLE
107.26 in (272.4 cm)
HYDRAULIC
CONTROL VALVE
196.63 in (499.4 cm)
Allied CT10 Winch with SOLAS Capability
8600 (3,900 kg) Rated load
Figure 1-5. Dimensional Data
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172.88 in (439.12 cm)
44.52 in (113 cm)
188.53 in (478.87 cm)
54°
85°
Approximate Travel Path
Approximately 100”
Davit Range of Motion
Cylinder Extends from 70” to 116”
(177.8cm to 294.6cm)
Figure 1-6. Davit Range of Motion
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WARRANTY
ALLIED SYSTEMS COMPANY, referred to as the Company, warrants its products to be free from defects in material and workmanship under normal use in service for a period of twelve (12) months after being placed in service by dealer or user, or within eighteen (18) months from shipment from factory, whichever occurs first. Within the warranty period, the Company will replace, EXW Sherwood, Oregon, or allow credit at the current dealer net price, any part that shall be proved defective, to the satisfaction of the Company. Upon the Company's request, all parts claimed defective must be properly identified and returned to the factory, freight prepaid. This policy makes no allowance for freight, travel expense or labor. ALLIED SYSTEMS COMPANY will honor properly documented and described warranty claims only on units for which a completed Warranty Validation form is in the Company's possession at the time when such claim is filed.
This Warranty is expressly in lieu of any other warranties, expressed or implied, including any implied warranty of merchantability or fitness for a specific purpose, and of any other obligations or liabilities on the part of ALLIED SYSTEMS COMPANY. No person, agent, distributor, or dealer is authorized to assume, for or on behalf of the Company any different or additional obligations in connection with the product. The Company's liability under this Warranty is limited to treatment of parts as set forth in the above paragraph. All other liabilities expressed or implied, arising under statute, through neglect or otherwise, including any warranty or merchantability or fitness for a particular purpose are hereby expressly waived.
This Warranty covers only new equipment in the possession of its original owner, which after shipment from the factory has not been modified, manufactured upon, altered, fitted with parts other than those specified in the parts book, or improperly repaired in any manner whatsoever, without the written consent of the Company. This Warranty is restricted to use within the specified performance rating or capacity in effect at time of sale of the equipment and excludes equipment which has been abused, misused, or operated under conditions other than those specified by
ALLIED SYSTEMS COMPANY.
Hydraulic and electrical components, engines, batteries, tools and similar equipment not manufactured by ALLIED SYSTEMS COMPANY, are covered only by the standard Warranty of the manufacturers of such equipment. Such items are not warranted by ALLIED SYSTEMS
COMPANY.
79-10B 2 October 2017
1.5 WARRANTY
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Marine Crane Chapter 2
Preparation for Use
2.1 UNPACKING
Immediately upon receiving the DC8600CTS davit, the components should be unpacked, and an inventory taken. See Figure 2-1 and Figure 2-2 for a list of items that should be included. Report any missing items to Allied Systems Company (503.625.2560) immediately.
2.2 INSPECTION
Upon delivery of the system, inspect the shipment for lost items and any damage that may have occurred during transit. Refer to the shipping diagram and pack-ing slip for a list of items included in the shipment. If there is a package or crate that appears damaged, unpack the equipment for further inspection.
Some examples of damage:
• Scratched or scuffed paint
• Dents or cracks
• Broken or bent hydraulic tubes
• Leaking hydraulic components
• Corrosion
It is the responsibility of the person receiving the ship-ment to inspect all shipments for visible and/or con-cealed loss or damage at the time of receipt. Any and all loss or damage must be properly documented and reported to the carrier within the time limits and in the form and format required by the carrier, the tariff, or any related insurance or transportation regulation.
Documentation of visible loss or damage and/or short-ages are to be clearly noted on the freight bill and appropriately signed by representatives of the carrier and the customer/receiver BEFORE ALLOWING THE
DRIVER TO LEAVE YOUR DOCK.
Appropriate documentation of concealed loss or damage shall include, but not limited to, photographs showing evidence of loss or damage, evidence of the carrier’s subsequent inspection and findings and where appropriate, copies of the customer’s formal claim made on the carrier. The carrier may also insist that the original packaging (carton, pallet, box, crate, etc.) be saved for their inspection.
Allied Systems Company assumes no responsibility for any loss or damage, which has not been appropriately documented and reported.
Report any damage or claims to Allied Systems Com-pany Traffic Department immediately at: 503.625.2560.
2.3 MAJOR COMPONENTS
The major components (as shipped) of the davit are illustrated in Figure 2-1 and Figure 2-2.
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Figure 2-1. DC8600CTS - Approx 9,000 lbs
Figure 2-2. Remote Console - Approx 100 lbs
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Marine Crane Chapter 3
Installation
3.1 GENERAL
This chapter is provided to assure a smooth and sat-isfactory installation of the Rescue Boat Davit, model
DC8600CTS, S/N 2394.
1. Have a crane available that will safely lift the davit assembly including winch and electric motor and the hydraulic power unit (9,000 lbs).
2. �When installing the davit, check for adequate pivoting clearance between the davit and the ship’s structures or any other deck mounted equipment.
| 3.2 | INSTALLATION |
| 3.2.1 | Davit Installation |
Figure 3-1.
1. Remove all access covers from the davit and console.
2. �Lift the davit over the mounting flange so that the base assembly attachment points will be centered over the deck attachment points.
3. �Position the davit so that all attachment points are in the correct position with the deck. Install (22) 3/4” Grade 8 capscrews, (22) 3/4” Esna Nuts, (22) 3/4” flat washers and (22) 3/4” lock washers under each capscrew and tighten as indicated in Figure 3-1. If welding to deck, critical weld zones are the 1/2” material regions around the bolt holes.
4. Connect the shipboard powerline (440v, 3 phase) to the starter box on the HPU (See Figure 10-8).
5. Mount the remote control console in it’s respective position. Clearance along the deck must be made for the electrical line between the remote control console to the davit.
6. �Connect the electrical line from the hydraulic pow-er unit to the control console. Verify connections as shown the Figure 4-13, Electrical Schematic, and Figure 10-28, Electrical System.
7. �Fill the hydraulic tank with approximately 125 gal-lons of clean hydraulic fluid. Check the sight gauge on the tank for correct level—Do not overfill.
Figure 3-1. Davit Installation
DAVIT BASE
F
IG
-1
3/4” GR8 CAPSCREWS
CRITICAL WELD ZONES
AROUND THE 1 ” MATERIAL
BOLT HOLE REGIONS
or
/2
Torque 3/4" Grade 8 bolts to 340 ft-lb lubricated or 230 ft-lbs with anti-seize.
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8. To test if the motor is wired correctly, perform a “bump test”. Remove the access cover on the pump/motor adapter to observe the coupler be-tween the motor and the pump. Very briefly apply voltage to the motor while observing the rotation of the coupler. It must be as indicated by the red arrow. If the direction of rotation is opposite of what is indicated, a qualified electrician must rewire the motor to reverse direction.
3.3 PREPARATION FOR OPERATION
1. Check all lines and fittings for security.
2. �Start the hydraulic power unit by depressing and releasing the start button on the starter box. Allow the HPU to warm up, and purge any air from the system.
3. Inspect for hydraulic leaks, unusual sounds, vibra-tions, or other problems. Correct as required.
4. Perform preliminary checks described in Chapter 9, Troubleshooting.
5. Carefully operate the pivot control lever, and en-sure the davit stops at the correct points in its pivot arc.
NOTE: The winch should have at least 100 lbs (45
kg) of weight on the hook to perform its functions.
If the winch does not stop at the correct point, refer to Chapter 7 Corrective Maintenance.
6. �Carefully operate the winch lever to ensure that the winch stops at the correct point. When hoisting, it should stop just before the lifting ring reaches the sheave.
3.4 PREPARATION FOR RESHIPMENT
To prepare the davit for reshipment, perform the follow-ing:
1. Remove the lifting ring. Wind the cable neatly onto the drum and secure the end of the cable to the drum.
2. Secure power to the hydraulic power unit.
3. Remove davit and console service covers. Close the console cover and secure with a nut and bolt.
4. �Drain the hydraulic tank to prevent spills and cover the hydraulic tank breather to prevent contamina-tion of the system. Similarly drain the hydraulic power unit and console.
WARNING
Ensure that the power to the equipment is off before attempting to disconnect the cables. An electrical shock could be fatal.
5. Tag and disconnect hydraulic lines and electrical wiring between the davit, control console and HPU.
CAUTION
Disconnected hydraulic lines must be covered to prevent hydraulic system contamination.
Make sure open ports on hydraulic compo-nents, including hoses, tubing, and fittings, are either capped or plugged during installation, maintenance and repair procedures.
6. Support the davit with an overhead crane that can safely lift at least 9,000 lbs, and remove the davit base mounting bolts. Use care when the davit becomes free, in case it is not well balanced with the crane attachment being used. Move the davit to a safe location.
7. �Long-term storage recommendations are listed in Chapter 8.
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PRINCIPLES OF OPERATION
4.1 INTRODUCTION
The model DC8600CTS Davit provides the capability to launch or retrieve rigid hull inflatable boats (RHIB’s) in uneven seas.
The functions and capabilities of the davit are the result of several systems working together: Davit;
Winch; Operator Controls; Hydraulic System; Electrical System; and the Hydraulic Power Unit.
Figure 4-1. Component Identification
Chapter 4
4.2 MECHANICAL SYSTEM
4.2.1 Davit
The davit is the structural member which supports the load, and the winch is mounted to the davit. A hook rat-ed for 8,600 lb (3,900 kg) is rigged for one‑part reeving from the winch line, through a sheave at the end of the davit arm. The davit’s base assembly is bolted to the deck.
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Figure 4-2. CT Winch
Figure 4-3. Remote Control Console
4.2.2 Winch
See Figure 4-2. The boom mounted winch consists of a main winch motor, planetary gear reducer, spring-applied/hydraulically released friction brakes, frame, wire rope drum, and constant tension motor.
Brake
Gear ReducerFrame
Wire Rope Drum
Main Winch Motor
Constant Tension Motor
4.2.3 Control Console
See Figure 4-3. All instruments and controls are located in the control console which is mounted to the deck within 40 feet (12 meters) of the davit.
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4.3 HYDRAULIC SYSTEM
4.3.1 Hydraulic Power Unit (HPU)
See Figures 4-4 and 4-5. The hydraulic power unit (HPU) provides hydraulic power for all davit functions.
The axial piston pump draws hydraulic oil from a 125 gallon (473 liter) reservoir and delivers 47 gpm (178 lpm) at 3000 psi (20.7 Mpa) to the control valve. Pres-sure compensated control ensures maximum flow until the preset pressure is reached, and then regulates discharge to maintain pressure in response to system demands.
Pump
125 Gallon (473 liter) Hydraulic Tank
Control Valve
Accumulators
Hydraulic Motor
Figure 4-4. Hydraulic Power Unit (HPU)
Figure 4-5. Hydraulic Power Unit (HPU) Schematic
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MAXIMUM
PARTIAL
8 7 6 3 1 5
9 2 10 11
Legend
| 1. Control Actuator | 7. Cylinder Barrel | ||
| 2. Cylinder Bearing | 8. Valve Plate | ||
| 3. Swash Block | 9. Valve Ports | ||
| 4. Shaft | 10. Shaft Seal | ||
| 5. Shaft Bearing | 11, Housing |
6. Piston & Shoe
4.3.1.1 Axial Piston Pump
See Figure 4‑6. The axial piston, variable displacement pump is controlled by a pressure compensator which ensures maximum flow until it reaches the control pressure setting, and then regulates flow to match sys-tem requirements while maintaining control pressure.
As driveshaft (4) turns, piston and shoe assemblies
(6) held against swashblock (3) are drawn in and out of rotating cylinder barrel (7).
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