USER MANUAL -1-

Introduction

TTS Marine AS
-2-
Main Data

-3-
Technical
Description

-4-
Preparation
Installation

Provision Service Crane -5-

GPK 115-3-16 Operating
Instructions
NAM CHEONG DOCKYARD SDN BHD
Hull Number: 703
-6-
Maintenance
50065
Copyright © by TTS Marine AS.
No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of TTS Marine AS. -7-
Data Sheets
Spare Parts

-8-
Parts List
Drawings
 TTS Marine AS
TTS Marine Machine Number:
50065

TTS Marine Project:

Provision Service Crane

NAM CHEONG DOCKYARD SDN BHD

Document Title:

User Manual
GPK 115-3-16

08.01.13 First Issue ZJL Roy

Author Approval, Project Manager
Date: Description:
Initials / Signature: Initials / Signature:
All information and data herein or herewith are confidential and proprietary property of TTS Marine AS
and are not to be used, reproduced or disclosed in whole or in part by or to anyone without the written
confirmation of TTS Marine AS.
TTS Marine AS

REVISION HISTORY

Rev Date Chapter Page Description

REFERENCE MANUALS

Manual doc. number Description

50065 User Manual

 USER MANUAL -1-
Introduction

Introduction
-2-
Main Data

-3-
Technical
Description

-4-
Preparation
Installation

Provision Service Crane -5-

Operating
GPK 115-3-16 Instructions
NAM CHEONG DOCKYARD SDN BHD
Hull Number: 703
-6-
Maintenance
50065

Copyright © by TTS Marine AS

No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of TTS Marine AS. -7-
Data Sheets
Spare Parts

-8-
Parts List
Drawings
TTS Marine AS 1-2

1 INTRODUCTION ................................................................................................................ 1-3

1.1 Structure and Contents ..........................................................................................................1-3
1.2 Operator Information ............................................................................................................1-3
1.3 Contact Information ..............................................................................................................1-4
1.4 Document Identification ........................................................................................................1-5
1.4.1 TTS Marine AS ............................................................................................................................ 1-5
1.4.2 Customer...................................................................................................................................... 1-5
1.5 Location of User Manuals......................................................................................................1-6
1.5.1 TTS Marine AS ............................................................................................................................ 1-6
1.5.2 Customer...................................................................................................................................... 1-6
1.6 Abbreviations ..........................................................................................................................1-7

50065 User Manual

TTS Marine AS 1-3

1 INTRODUCTION

This user manual describes the Provision Service Crane supplied by TTS Marine AS for NAM
CHEONG DOCKYARD SDN BHD.

1.1 Structure and Contents

The user manual is divided into eight chapters; each chapter taking care of each topic in accordance
with NS 5820 (Norwegian Standard).

All necessary information is implemented in this manual. The user manual main chapters are listed
on front page of each chapter. A chapter index is located on the second page of each chapter.

1.2 Operator Information

No personnel under the age of 18 years is allowed to operate the crane.

At the present time, there are no legislative requirements for certified qualifications for the crane
operator. However the operator is required to possess a good knowledge of the cranes safety
systems and method of operation.

If a training program for this crane type is required please contact TTS Marine AS.

50065 User Manual

TTS Marine AS 1-4

1.3 Contact Information

Company E-mail
Service & Spare parts: [email protected]

Telephone:

Department Telephone + 47 Telephone + 47 Fax + 47

Service 38 04 93 49 38 04 93 41

Spare Parts 38 04 93 47 91 19 92 35 38 04 93 41

Switchboard 38 04 95 00 — 38 04 96 06

Company Name Postal Code City Country

TTS Marine AS Service box 602 4606 Kristiansand Norway

50065 User Manual

TTS Marine AS 1-5

1.4 Document Identification

1.4.1 TTS Marine AS

1. Document Source TTS Marine AS

2. Document Type User Manual

3. Document Number UM 50065

4. Paper Format A4 and A3

5. Publishing Software Microsoft Word

6. Document File Folder

7. Document Files UMC 50065.PDF

(Adobe Acrobat )
8. Electronic Manual CD as per offer
Files

1.4.2 Customer

1. Customer NAM CHEONG DOCKYARD SDN BHD.

2. Project 50065

3. Contract Number PL10703

4. Hull Name

5. Document Title User Manual

6. Document Number N/A

7. Equipment Model GPK 115-3-16

8. Equipment Type Provision Service Crane

9. Equipment Tag 50065

50065 User Manual

TTS Marine AS 1-6

1.5 Location of User Manuals

1.5.1 TTS Marine AS

1 original user manual located at the documentation department.

1.5.2 Customer

Fill out the table below where the copies of user manuals are supposed to be stored.

Number of Location Note

Copies

50065 User Manual

TTS Marine AS 1-7

1.6 Abbreviations

Following is a table of abbreviations used in TTS Marine AS User Manuals.

Commercial

ABS American Bureau of Shipping

BV Bureau Veritas
CCS China Classification Society
DNV Det Norske Veritas
GL Germanischer Lloyd
KRS Korean Register of Shipping
LRS Lloyds Register of Shipping
NMD Norwegian Marine Directorate
NPD Norwegian Petroleum Directorate

Technical

COG Center of Gravity

CCW Counter Clock-wise
CW Clock-wise
NA Not Applicable
RPM Rounds Per Minute
w/o Without
GA General Arrangement (main drawing)

50065 User Manual

 USER MANUAL -1-
Introduction

Main Data
-2-
Main Data

-3-
Technical
Description

-4-
Preparation
Installation

Provision Service Crane -5-

Operating
GPK 115-3-16 Instructions
NAM CHEONG DOCKYARD SDN BHD
Hull Number: 703
-6-
Maintenance
50065

Copyright © by TTS Marine AS

No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of TTS Marine AS. -7-
Data Sheets
Spare Parts

-8-
Parts List
Drawings
TTS Marine AS 2-2

2 MAIN DATA ......................................................................................................................... 2-3

2.1 Technical Specification ..........................................................................................................2-3
2.2 Hydraulic Pressure .................................................................................................................2-3
2.3 Pump Capacity .......................................................................................................................2-4
2.4 El. Motor Data ........................................................................................................................2-4
2.5 External Connections .............................................................................................................2-4
2.6 Restrictions in Use ..................................................................................................................2-5
2.7 Restrictions in Guarantee ......................................................................................................2-5
2.8 Name Plate ..............................................................................................................................2-5
2.9 Certificates ..............................................................................................................................2-5

50065 User Manual

TTS Marine AS 2-3

2 MAIN DATA

The below stated speeds apply during maximum load and working radius against the stated heel
plus trim conditions. A speed tolerance of +10% to -5% is within the accepted range and should be
taken into consideration.

2.1 Technical Specification

TTS Marine AS- Provision Service Crane

Type: GPK 115-3-16

Machine number: 50065

Lifting capacity (SWL): 3T

Working radius - max: 16 m
Working radius - min: 3.2 m
Lifting speed at SWL: 0 - 10m/min
Lifting speed at no load: 0 - 10m/min
Lifting height: 30 m (Single hook travel distance)

Luffing time: 85 sec ( average up/down )

Slewing sector: 360°
Slewing speed: 0-1 rpm
Heel + trim conditions: 5°+ 2°
Weight of crane - theoretical w/o oil: ~6.8 T

2.2 Hydraulic Pressure

Main pressure: 240 bar
Winch up: 220 bar
Winch down: 90 bar
Main Jib up: 220 bar
Main Jib down: 70 bar
Knuckle Jib up 200 bar
Knuckle Jib down: 140 bar
Slew: 210 bar

50065 User Manual

TTS Marine AS 2-4

2.3 Pump Capacity

Pump capacity: Max ~42.8 l/min

2.4 El. Motor Data

El. data: 440 V / 60 Hz / 3 ph

Starter method: Y/D
Power rating continuous S1: 17.5 kW 30 A
Power rating S6-40% ID: 24.5 kW 42A
Starting Current: 266.9 A (DOL)

Rotational speed (approx.): 1770 rpm

Rotation seen from fan end: CW (See arrow-sign on fan end)

Enclosure: IP 55
Insulation class: F
Temp. rise class:

Heater voltage/phase: 220V / 1ph

Heater Power Consumption: 1x21W

2.5 External Connections

Electric connection - see drawing: 50065-8001

50065-8101

50065 User Manual

TTS Marine AS 2-5

2.6 Restrictions in Use

Subject equipment must only be used for the prescribed purpose and within the specified
limitations referred to in chapter 5.7. The operator must be qualified according to chapter 5.8.

Repairs and modifications must not be carried out without prior written approval from TTS
Marine AS, except for the minor corrections that are described in the maintenance chapter. If such
work is carried out by others; TTS´s procedures for this kind of work must be followed. Only
approved materials and original spare parts must be used.

2.7 Restrictions in Guarantee

TTS refuses all responsibility caused by breach of the restrictions described in the section above.
The guarantee for good performance is strictly linked to the correct and careful application of the
instructions in this user manual. If, during the warranty period, these restrictions are breached, the
warranty/guarantee shall no longer be valid.

2.8 Name Plate

The name plate is located at the main control platform.

Figure 2-1
Name Plate

2.9 Certificates

Certificates are enclosed as separate attachments after this page.

50065 User Manual

 USER MANUAL -1-
Introduction

Technical Description
-2-
Main Data

-3-
Technical
Description

-4-
Preparation
Installation

Provision Service Crane -5-

Operating
GPK 115-3-16 Instructions
NAM CHEONG DOCKYARD SDN BHD
Hull Number: 703
-6-
Maintenance
50065

Copyright © by TTS Marine AS.

No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of TTS Marine AS. -7-
Data Sheets
Spare Parts

-8-
Parts List
Drawings
TTS Marine AS 3-2

3 TECHNICAL DESCRIPTION ........................................................................................... 3-3

3.1 General ....................................................................................................................................3-3
3.1.1 Safety System ............................................................................................................................... 3-3
3.2 Design and Function...............................................................................................................3-4
3.2.1 Crane Control.............................................................................................................................. 3-4
3.2.2 Electro- Hydraulic Power Pack .................................................................................................. 3-4
3.2.3 Electric ........................................................................................................................................ 3-5
3.2.4 Hydraulic ..................................................................................................................................... 3-5
3.2.5 Jib Cylinders ................................................................................................................................ 3-6
3.2.6 Hoisting Machinery ..................................................................................................................... 3-6
3.2.7 Slew System ................................................................................................................................. 3-6
3.2.8 Control Platform ......................................................................................................................... 3-7
3.2.9 Structure ...................................................................................................................................... 3-7

50065 User Manual

TTS Marine AS 3-3

3 TECHNICAL DESCRIPTION

3.1 General
This crane is of electro hydraulic crane type. This means that an electric motor is used to drive a
hydraulic pump.

A flow of oil at high pressure is supplied, which is utilized as the transmitting force to propel the
hydraulic motors as the means to operate the hoisting winch, hydraulic cylinder, luffing the jib and
the slewing motion.

3.1.1 Safety System

The crane is equipped with following safety system:

• Emergency stop close to operator.

• All movements protected against overload by hydraulic relief valve.
• All control levers are of “spring centered” and goes back to neutral position automatically.
• Mechanical automatic stop of jib in upper and lower position.
• Winch and slew are equipped with a “fail-safe” brake. In case of hose or pipe failure the
brake will automatically stop the load.
• Hydraulic cylinder is equipped with a load holding valve. This valve is blocking the
cylinder in case of hose failure.
• Hook stop limit device in upper and lower position.
• Emergency winch lowering system

50065 User Manual

TTS Marine AS 3-4

3.2 Design and Function

Reference drawings: 50065-GA01

50065-7000
50065-8001

3.2.1 Crane Control

The crane is controlled from an open control platform on the side of the crane house
The control station normally consists of 4 levers(hoist-slewing-luffing-knuckle).
All motions have step less speed control from 0 to max.
Two motions may be operated at the same time with full lifting capacity, but with reduced speed.
Start/stop of pump motor is done from push button box on the crane pedestal.

The following is a brief description of each electrical unit related to crane operation:

[-A901] Starter cabinet

(See further details later in this Chapter)

[-A922] Remote control station for starter cabinet

(See further details later in this Chapter)

3.2.2 Electro- Hydraulic Power Pack

The crane is equipped with an electro-hydraulic power pack system, consisting of one electric
motor as the prime mover.

In the centre of the stationary part the electric motor is mounted with its rotating shaft extending
vertically upwards. The electric motor is equipped with a heating element which reduces its
moisture level and facilitates cold start.

As the complete power pack is mounted inside the crane king and pedestal adapter, a dry
atmosphere space is secured for carrying out service and maintenance.

The electric supply to the main electric motor and to the auxiliary equipment is provided from the
vessels electric source (chapter 2.5).

In the centre of the rotating part the hydraulic pump is mounted with its shaft pointing vertically
downwards.

The electric motor and the hydraulic pump are interconnected through a flexible coupling or a
shaft drive.

The hydraulic oil pump supplies oil to the jib, slew and winch system, enabling the crane driver to
operate at least two motions with full load simultaneously, but with reduced speed.

50065 User Manual

TTS Marine AS 3-5

When none of the control handles are operated, oil goes through the oil filters (where impurities in
the oil will be removed) and back to oil tank.

3.2.3 Electric

Reference drawing: 50065-8001

50065-8101

See also the section “Crane Control” earlier in this chapter.

Pump Motor
The electric pump motor is of marine type, with IP55.

Motor is provided with anti-condensation heater, Winding type of heating.

Motor is protected by thermal relays.

Starter Cabinet [-A901]

This cabinet has motor starter circuits for controlling electrical motor on hydraulic power pack.
The starter is of DOL type, supplied as a loose item for mounting in the deck housing, customer
specified area.

The starter includes the following features:

• Safety door switch
• Start button, Stop button
• Running lamp, green
• Source lamp, white
• Motor space heater control with control lamp, blue
• Thermistor / Thermal overload protection relay
• Hour-counter
• Ampere meter
• Emergency stop

Remote control station for starter cabinet [-A922]

Remote start/stop box for mounting on or near the crane pedestal, with the following equipment:
• Start button
• Combined stop/emergency-stop button

3.2.4 Hydraulic

Hydraulic oil tank is integrated into the rotating crane column and is accessible from a hatch. Tank
is fitted with drain valve, filter and a combined glass level indicator and temperature gauge. Filling
system through valve on return filter.

The hydraulic system is designed as an open circuit system. All external mounted pipes are of
stainless steel type.

Hydraulic fittings are of the EO 2 type of std. carbon steel.

50065 User Manual

TTS Marine AS 3-6

Hydraulic hoses are made from rubber types with special good resistance against sea environment.

Hydraulic hose fittings are of the EO 2 type of std. carbon steel.

3.2.5 Jib Cylinders

The hydraulic jib cylinders are based on a rugged well proven construction. The cylinder eyes
have bearings of composite type with high loading-capacity. Cylinder piston rod is
chromium-plated.

Locking valve is mounted directly on the cylinder bottom. This is opened by hydraulic pressure
when operating jib down and will control the jib in down motion.

When driving jib up, the oil pass through a one way valve. If oil pressure disappears the cylinder
locking valve will close and the jib motion will stop.

3.2.6 Hoisting Machinery

The winch is located on the main jib. It consists of a grooved steel winch drum with roller bearing
and brackets. The winch foundation includes a bolted-on gear box built into the drum with a
fail-safe brake and hydraulic motor.

The wire rope is of LOW-ROTATING galvanized type.

The wire sheave is provided with roller bearing and grease nipple.

When operating the winch the oil pass through a load holding valve. If oil pressure disappears, the
load holding valve will close and stop winch motion.

A flange mounted hydraulic hook stop (cam limit switch) is located on the opposite side of the
winch gear foundation.

3.2.7 Slew System

Slewing machinery consist of a ball or roller type slew ring seated on machined surfaces.

Slewing ring bolts and nuts are made from special alloy steel and tightened to an exact tension.

The slewing bearing used in the crane is of a high quality make and of the ball bearing type,
specially designed and calculated for use on deck cranes. The slewing bearings are all provided
with internal gear ring.

Each slewing gear box with brake and motor is built together to a complete unit. The slew gearbox
pinions are meshed with the geared innerring of the slew bearing.

The planetary slew gearbox contains a rugged disc brake immersed and working in the gear oil
bath. A positive pressure has to be applied to the brake unit to release the brake.

50065 User Manual

TTS Marine AS 3-7

3.2.8 Control Platform

The control platform is an open type with access leader. It is located outside the crane king on left
or right hand side. It consists of a main operator control console and three control valves.

Two motions may be operated at the same time with full capacity, but with reduced speed.

A safety railing is located around the operator platform.

3.2.9 Structure

The structural steel used in our cranes will be supplied with documentation according to the
chosen Classification Society’s requirements.

All primary steel materials are fully traceable.

The quality is selected in accordance with design rules or classification societies requirements, to
obtain necessary ductility for the lower temperature design limit.

Important welds are carried out in accordance with welding procedures and NDT checked before
painting.
Base column / pedestal
Lower end of the base column/pedestal is prepared for welding to customer’s structure.
It has a hatch for access to the electrical motor and for the coupling/shaft up to the hydraulic pump,
etc.

Slewing column/ crane house

The slewing column/crane house is a fully enclosed structure, containing the operator platform
and the hydraulic oil tank, accessible through a hatch.

The top of the slewing column is provided with brackets for connection to the jib. Connection is
made by plain bearings. The slewing column is connected to the pedestal through the slewing
bearing.

Jib
The jib is made as a welded box structure with necessary internal stiffeners.
A cylinder bracket is welded to the under side of the jib.

50065 User Manual

 -1-
USER MANUAL Introduction

Preparation Installation
-2-
Main Data

-3-
Technical
Description

-4-
Preparation
Installation

Provision Service Crane -5-

Operating
GPK 115-3-16 Instructions
NAM CHEONG DOCKYARD SDN BHD
Hull Number: 703
-6-
Maintenance
50065

Copyright © by TTS Marine AS.

No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of TTS Marine AS. -7-
Data Sheets
Spare Parts

-8-
Parts List
Drawings
TTS Marine AS 4-2

4 PREPARATION / INSTALLATION ................................................................................. 4-3

4.1 General ....................................................................................................................................4-3
4.1.1 Mounting of TTS Marine AS Cranes ........................................................................................... 4-3
4.2 Prior to Starting the Crane ...................................................................................................4-4
4.3 Start up, Idle Operation.........................................................................................................4-4

50065 User Manual

TTS Marine AS 4-3

4 PREPARATION / INSTALLATION

4.1 General

As a minimum requirement of the various classification organizations the substructure must be

designed to withstand the cranes max. bending moment with a 25% overload.

The crane base or counter base with bolting flange welded to the hull substructure is regarded as
part of the hull and is therefore a classification item. All welding and machining work on these
items at the yard are the responsibility of the yard. The same applies for the classification approval
work related to the above items.

The crane is normally delivered with the el. motor built into the crane base. The el. motor is
equipped with a heating element which must be “on” when the crane is not in use. The crane may
also be delivered without an el. motor, for connecting to an existing hydraulic system.

The crane is normally not delivered with el. motor starter, motor protector, electric cable, lower
flange mounting bolts, nuts and washers unless requested and purchased by the customer.

4.1.1 Mounting of TTS Marine AS Cranes

See the following section before installation of the crane:

• The crane is to be welded directly to the deck or some other type of support.
• As a minimum requirement (of the various classification organizations) the deck must be
designed to withstand the cranes max. bending moment with a 25% overload.
• To avoid distortion of the slew bearing, we recommend that the crane base be welded to the
substructure before the crane king with slew bearing is connected to crane base.

• Check adjoining welding grooves to obtain an even gap through the circumference. Also
an evenly distributed heat input is required to avoid distortion.
• The flange is obviously more exposed to distortion if the deck stiffeners, platforms etc. are
welded to crane base. All such welding has to be completed and the structure has to return
to normal temperature before the slew bearing support flange is measured for flatness.
• For optimal slew bearing life the base flange flatness has to be kept within given tolerances,
see the “Slew Ring Wear Test” section in chapter 6.

Before mounting the base and king with slew bearing together; check the following points:

• The flange machined surface is clean and free from paint and welding slag, etc.
• Check the bolt length. Only the bolt types indicated in the parts list are to be used.
• The bolt holes in the base flange must match so that the bolts go freely through the holes
and without resistance when rotated in the holes.

• Hardened washers as indicated in parts list and on the G.A. drawing are to be used under
bolt heads.

50065 User Manual

TTS Marine AS 4-4

• The tightening torque indicated on the G.A. drawing is based upon a lightly oiled bolt
thread surface. We recommend lubricating with MOLYCOTE 1000 because of its relative
stability between tightening torque and bolt tension with special consideration given to
re-tightening.

• MOLYCOTE 1000 is also a corrosion inhibitor.

• The crane construction is a complete unit with the el. motor built into the crane base.
• The el. motor is equipped with a heating element. This must be “ON” when the crane is not
in use.

4.2 Prior to Starting the Crane

a) Check that all hydraulic connections are in accordance with the hydraulic diagram.

b) Check that all hydraulic connections are tightened up firmly.

c) Check that all bolts are tightened with correct torque.

d) Check that all electrical connections are in accordance with the el. interface drawing.

e) Check and activate / deactivate emergency stop stations.

f) Fill up the hydraulic oil tank through the oil filling ball valve, located in front of the
return filter. It is of outmost importance that only pure clean oil is used. Under no
conditions must water, dirt or other foreign matter enter the tank. Impurities and moisture
will drastically reduce the efficiency and life span of the hydraulic system.

g) The crane have been operated and tested at the production workshop prior to delivery.
However, improper storage and handling during transport may result in oil leakage.

h) Therefore, check the oil level at gearboxes (winch/slew) and top up if necessary, making
sure to use an approved oil. (See the lubrication chart under the Chapter Maintenance).

All pressure control valves have been adjusted by the manufacturer and must not be altered.

4.3 Start up, Idle Operation

Start the motor for idle operation and check the hydraulic system for leaks.

NOTE:
Setting of El. motor rotation direction is depending on pump direction - see chapter 2 main data.
Check fan end on motor (ref. Arrow-sign). If motor is rotating in the wrong direction, interchange
2 phases and check again.

THE MOTOR MUST BY NO MEANS BE ALLOWED TO RUN IN THE WRONG

DIRECTION, AS THIS WILL ADVERSELY AFFECT THE LIFE SPAN OF THE PUMP.

50065 User Manual

 USER MANUAL -1-
Introduction

Operating Instructions
-2-
Main Data

-3-
Technical
Description

-4-
Preparation
Installation

Provision Service Crane -5-

Operating
GPK 115-3-16 Instructions
NAM CHEONG DOCKYARD SDN BHD
Hull Number: 703
-6-
Maintenance
50065

Copyright © by TTS Marine AS.

No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of TTS Marine AS. -7-
Data Sheets
Spare Parts

-8-
Parts List
Drawings
TTS Marine AS 5-2

5 OPERATING INSTRUCTIONS ......................................................................................... 5-3

5.1 Prestart ....................................................................................................................................5-3
5.2 Parking ....................................................................................................................................5-3
5.3 Normal Operation ..................................................................................................................5-4
5.3.1 Start ............................................................................................................................................. 5-4
5.3.2 Stop .............................................................................................................................................. 5-4
5.3.3 Main Control Console ................................................................................................................. 5-4
5.3.4 Portable Remote Control Unit..................................................................................................... 5-5
5.4 Emergency Stop ......................................................................................................................5-5
5.4.1 Deactivating Emergency Stop ..................................................................................................... 5-5
5.5 Emergency Procedure ............................................................................................................5-5
5.6 Disturbance of Operation ......................................................................................................5-6
5.7 Hazards and Protective Measures ........................................................................................5-6
5.8 Operators Qualification Requirements ................................................................................5-7

50065 User Manual

TTS Marine AS 5-3

5 OPERATING INSTRUCTIONS

5.1 Prestart

Prior to starting the crane / electric motor, always carry out the following inspections / checks:

Description

1 Check oil level in the hydraulic oil tank. It should be approximately middle of sight
glass.

2 Inspect all hydraulic hoses and connections for sign of leakage. Rectify immediately
if any are found.

3 Inspect the crane for signs of external damage. Replace or repair if any are found.

4 Start the electric motor.

Check that rotation of the El. Motor is in the CW rotation seen from the fan end. (See
arrow-sign).
If the motor is rotating in the wrong direction, interchange 2 phases and check again
for rotation in the CW direction.

5 Check that the by-pass indicator arrow on the hydraulic filter element is pointing to
the green area.
Replace filter element immediately if arrow is pointing to the red area.

6 Run all crane motions without load in the hook in order to check for normal
performance.

5.2 Parking

Crane jib should be parked in a jib rest when the crane is not in use. When crane is in parked
position , jib cylinder(s) shall be in completely retracted position. This is to avoid corrosion of
piston rod.

Height of jib rest must be designed according to this requirement.

50065 User Manual

TTS Marine AS 5-4

5.3 Normal Operation

5.3.1 Start

Reference Drawing: 50065-8401

The main starter cabinet is not installed by TTS

Marine, but the location is normally inside deck
house close to the crane.

Before entering the crane, the main switch at the

starter cabinet must be ON.

The crane may then be started by pushing the start

button. Then check that the RUN lamp illuminates.

If the main switch is on, the crane may also be

started from the remote start / stop box usually
located at the pedestal

5.3.2 Stop
Push the stop button on the main starter cabinet . Figure 5-1
Starter Cabinet (Typical)

5.3.3 Main Control Console

The main control console consists of an open platform located on the side of the crane king. On
this platform, the valves for controlling the main motions of the crane are mounted. The valves are
controlled via handles directly connected to the valve spools.

By operating the respective handles (joysticks), the required motion of the crane will be executed.
The control levers will return to neutral position when pressure is released.

The control functions are indicated by the instruction labels positioned directly in front of the
control levers.

During operation of the crane the levers must be operated slowly in order not to induce a swinging
motion in the hanging load or oscillation in the crane structure.

Extreme care must also be taken when operating the winch up and jib up motion simultaneously.
When the jib angle is nearing it’s maximum vertical value and the hook is close to the hook stop;
the load may hit the underside of the jib.

At normal operation; please avoid parking and shut down of the crane with load in hook or any
limit devices / emergency stop activated.

50065 User Manual

TTS Marine AS 5-5

5.3.4 Portable Remote Control Unit

No portable remote control unit for these cranes

5.4 Emergency Stop

The emergency stop system includes the following four options:

• Hydraulic emergency stop valve located on the main control platform.
• Electric emergency stop button at the Fixed Remote Control Station usually located on
pedestal.
Electric emergency stop button at the Fixed Control box for the Remote Control system
located at the main control platform
• Electric emergency stop button located on starter cabinet

Built in check valves and “fail-safe brakes” will ensure that the crane will not lower the load until
positive action is taken.

5.4.1 Deactivating Emergency Stop

Prior to deactivating the emergency stop, ensure that the reason for activating the emergency stop
has been identified and cleared up.

Deactivate hydraulic emergency stop by reset of (open) the valve lever / handle.
Deactivate electric emergency by pulling the button.
The electric mushroom type button must be turned to allow a reset.

5.5 Emergency Procedure

Reference Hydraulic diagram Drawing: 50065-7000

Lowering of winch
1. Check connect the emergency pump pressure side to POS 408, suction port to POS 409.
2. Close the switch of emergency pump as show in drawing.
3. Grab winch operation lever and keep that in position for lowering, or alternative use as small
rope to keep it in position.
4. Operate the hand pump continuous, and the load will start lowering.

NOTE:
Weight below 1 ton will not function due to hydraulic friction etc.
Reset above valves / switches to original after operation.
The POS in hydraulic diagram is different due to various designing, Skip the procedure for
which the POS is not showed in the hydraulic diagram.

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TTS Marine AS 5-6
Lowering of jib
1．Pull the control lever in jib lowering position or alternative using a rope to maintain the
position.
2. Open manual emergency lowering screw or shock valve adjusting screw on valve POS 204/B02
by turning it out until cylinder starts moving.
Open carefully and stand by with the tool ready to close the valve if the lowering speed has
tendency to increase. (Speed increase is most actually if the jib is lowered from a relatively high
position.)
NOTE:
Retighten emergency lowering screw to closed position adjusting screw to original position.

Slewing
1. Tie the jib head with ropes on to fix structure on deck to prevent un-certain rotation
2. Disassembly the slew motors and valves from the slew gears.
3. Connected the slew gears brake port C with hand pump only.
3. Rise pressure around 30 Bar from hand pump to release brake on slewing gears.
4. Pull jib into position on the rope by force from the jib head to make crane rotation.
In some case if jib is very big, a chain block is necessary to move the jib.
NOTE:
After operation, assembly the slew motors and valves onto slew gears.

5.6 Disturbance of Operation

If the hydraulic system oil gets overheated the loss of power will be reduced dramatically and
some crane movements may stop.
If the safe working load (SWL) is exceeded or the emergency stop / limit switches activated the
subject crane movement will stop.

5.7 Hazards and Protective Measures

The following points sum up the safety aspects related to operation:

• The equipment must only be used for the prescribed purpose.
• The safe working load (SWL) of the machine must never be exceeded. If the machine is
overloaded, construction damages may occur. This may not be noticed during normal use
of the machine. TTS is not responsible for damage caused by overload.
• The equipment is powered by high pressure hydraulic oil. Beware of the risk of pipe/hose
burst.
• If anyone gets hydraulic oil into their eyes or open wounds, wash at once with lots of fresh
water.
• No personnel under the age of 18 years is allowed to operate the crane.
• Do not under any circumstances operate the crane when the ships heel + trim exceeds
5o + 2 o.
• Do not operate the crane when wind speeds exceed 20 m/s.
• No tools or loose items must be left on the crane jib.
• The crane is not designed for ice or snow on the structure. Great care must be taken to
avoid ice falling down on personnel below the crane.
• Do not operate the crane with personnel other than the crane driver on the crane.

50065 User Manual

TTS Marine AS 5-7
• The crane driver must always be able to see the hook / load, or be in direct contact with
somebody who can see the hook / load.
• Do not adjust the various relief valve settings to other values than shown in the Hydraulic
flow diagram for the crane.

5.8 Operators Qualification Requirements

At the present time, there are no legislative requirements for certified qualifications for the crane
operator. However the operator is required to possess a good knowledge of the cranes safety
systems and method of operation.
Any intended operator of these cranes is required to gain experience in operating the cranes under
the supervision of experienced operators.
If a training program for this crane type is required please contact TTS Marine AS.

50065 User Manual

 -1-
USER MANUAL Introduction

Maintenance
-2-
Main Data

-3-
Technical
Description

-4-
Preparation
Installation

Provision Service Crane -5-

GPK 115-3-16 Operating
Instructions
NAM CHEONG DOCKYARD SDN BHD
Hull Number: 703
-6-
50065 Maintenance

Copyright © by TTS Marine AS.

No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of TTS Marine AS.. -7-
Data Sheets
Spare Parts

-8-
Parts List
Drawings
TTS Marine AS 6-2

6 MAINTENANCE ...................................................................................................................... 6-3

6.1 General ........................................................................................................................................6-3
6.1.1 Maintenance Log ......................................................................................................................... 6-3
6.2 Hydraulic System .......................................................................................................................6-4
6.1.2 Hydraulic Oil Change ................................................................................................................. 6-5
6.3 Lubrication .................................................................................................................................6-6
6.3.1 Typical Lubrication Points .......................................................................................................... 6-6
6.3.3 Oil Quantities GPK 115-3-16 ...................................................................................................... 6-8
6.3.4 Lubrication Chart GPK 115-3-16 ............................................................................................... 6-8
6.3.5 Lubrication Schedule ................................................................................................................... 6-9
6.4 Slew-/Winch Gear ....................................................................................................................6-10
6.5 SLEW RING .............................................................................................................................6-11
6.6 Slew Ring Wear Test ................................................................................................................6-12
6.7 Re-tightening of Slew Ring Bolts ............................................................................................6-15
6.8 Wire Rope .................................................................................................................................6-16
6.8.1 Method of Examination ............................................................................................................. 6-16
6.8.2 Summary of Wire Examination .................................................................................................. 6-17
6.8.3 Replacing the Wire .................................................................................................................... 6-17
6.8.4 Brilube Information ................................................................................................................... 6-18
6.9 Hook Stop Adjustment.............................................................................................................6-19
6.10 Appendices ................................................................................................................................6-20
6.10.1 Appendix A - Maintenance Log ................................................................................................. 6-20
6.10.2 Appendix B – Slew Ring Wear Measurement Table .................................................................. 6-21
6.10.3 Appendix C – Corrective Measures Report ............................................................................... 6-23
6.10.4 Appendix D – Major Repairs and Modifications Log ............................................................... 6-24

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TTS Marine AS 6-3

6 MAINTENANCE

6.1 General

The following points sum up the safety aspects related to maintenance:

• Only qualified and authorized personnel are allowed to carry out maintenance work.
• Use fall protection equipment.
• A warning sign must be placed at the control panel while maintenance is carried out.
• Ensure that all controllers are placed in the “off” position, and the main switches are open
and locked.
• The area below the crane must be cleared and a barrier erected to prevent injury from a
falling object.
• Beware of the risk of pipe/hose burst.
• No welding of lugs, brackets etc. must take place on the equipment.
• Only original spare parts must be used - this includes hydraulic hoses.
• Replace all guards and other safety devices before leaving a crane.
• Remove all stops, tools, loose parts and other material and dispose of them before
completing the repair job.

If there is any question about maintenance, please contact TTS Service Department. See “Contact
Information” in chapter 1.

6.1.1 Maintenance Log

It is recommended that a Maintenance Log be established for this equipment. All maintenance,
abnormal observations and repairs should be logged. Upon request, the log should be made
available to the TTS Serviceman.

A sample maintenance log is included in the appendix section back in this chapter.

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TTS Marine AS 6-4

6.2 Hydraulic System

The operation and lifespan of a hydraulic system is greatly

depended upon the quality of the hydraulic oil.

The lubrication schedule in the user manual indicates the type of oil
to be used and frequency of oil changes.

A hydraulic system when in use will always produce particles. The

amount and hardness of the particles varies dependant upon how
well the system functions and where in the system the particles are
produced.
Oil filter / Refill valve
Each type of pollutant entering the oil will reduce the quality. In order (Typical)
to avoid reducing the oil quality, or in the worst case, damaging costly
components it is of out most importance that the oil quality to be
maintained as close to that of new oil for the systems entire lifespan.

Therefore are the built in filters which function continuously while

the system is in use an important part of the hydraulic system.

The hydraulic system flow diagram with it’s parts list in the user
manual indicates the location and type of filter used in the system. Drain valve
Regardless of the filter type such as suction filter, pressure filter or (Typical)
return oil filter.

In many cases the filters are equipped with indicators that reveal the
condition of the filter. As soon as the indicator signals a dirty or
contaminated filter, the filter element is to be replaced immediately.

In larger units with system capacities of 1000 litres or more, the oil
should be laboratory tested at least every 6 months. The lab report will
help in determining the life span of the oil.

Under no circumstances shall a filter operate more than one year

without changing the filter element. A clogged filter element causes a
BY-PASS through the filter which result in the system operating with
un-filtered oil.

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TTS Marine AS 6-5

6.1.2 Hydraulic Oil Change

Before draining the oil tank all hydraulic cylinders must be retracted.

After the tank have been drained, remove access cover, hatch cover
and check visually for dirt inside the tank. Clean the tank thoroughly.

Replenishment must be carried out through the filling valve. This is to

secure that the oil is passing through the return filter before entering
the hydraulic system. In order to avoid contamination of the system oil,
this plug should always be used whether it is oil change or
replenishment of oil.

Oil level glass

and thermometer

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TTS Marine AS 6-6

6.3 Lubrication

6.3.1 Typical Lubrication Points

A lubrication chart and lubrication table is

included later in this chapter.

Cylinder and jib bolt have lubrication free

composite bearings. They are lubricated only
during installation with grease Kluber
Staburags NBU12K. (Grease including MOS2
or graphite shall never be used for greasing
composite bearings).
Winch gear sealing (12) Slew ring bearing (13)

The following grease nipple and lubrication

points is typical for most TTS cranes,
(lubrication chart references in parentheses):

• Slew gear box (11): oil change.

• Winch gear box (11): oil change.

• Winch gear sealing (12): grease nipple.

• Winch-end bearing (13): grease nipple. Winch end bearing (13) Internal slew ring /
• Slew ring bearing (13): grease nipple. slew gear pinion (14)

• Internal slew ring gear/pinion (14):

lubricate.

• Wire sheaves (16): grease nipples.

• Winch wire (16): lubricate.

Wire sheave (16)
Cardan shaft /
• Jib bolt sealing (17): grease nipple. El. Motor (17)
• Cardan shaft (17): grease nipples.
• Electric motor (17): grease nipples.
• Control platform gate (17): grease
nipple.

Jib bolt sealing (17) Electric motor (17)

Ctrl. Platform gate (17)

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TTS Marine AS 6-7

6.3.2 Standard Lubricants for TTS Marine AS

The following table shows the TTS Marine lubricant standard.

Oil Lubrication
CODE AND USE GENERAL EXAMPLE
OF OIL/LUBR. SPECIFICATION SHELL ESSO * FAMM MOBIL KLÜBER CASTROL
DIN 51517-
1) CLP 150 OR 220 SPIRAX AX 80 SPARTAN 150 MEROPA MOBILGEAR KLUBEROIL ALPHA
ISO-VG 150/220 OR 150 630 OR 629 GEM 1-220 SP 150
SLEWING GEARBOX (MINERAL OIL) OMALA OIL 150

1) DIN 51517- SPIRAX AX 80 SPARTAN 150 MEROPA MOBILGEAR KLUBEROIL

ALPHA
CLP 150 OR 220 OR 150 630 OR 629 GEM 1-220
WINCH GEARBOX SP 150
ISO-VG 150/220 OMALA OIL 150
Without spraque clutch (MINERAL OIL)

1) 2) DIN 51519 TEGULA 32 TORQUE FLUID RANDO HDZ MOBIL DTE 24

HYSPIN
ISO-VG 32 N 45 32 X AWH-M32
WINCH GEARBOX (MINERAL OIL)
With spraque clutch

1) PGLP SHELL SPARTAN PINNACLE MOBIL KLUBERSYNTH

DIN 51502-220 TIVELA OIL WB SYNTETIC MARINE GEAR GLYGOYLE 30 GH 6-220 ALPHASYN
WINCH GEARBOX (SYNTHETIC OIL) S220 220 HG 220
Continuous Operation
Seabed winches

1) PGLP SHELL GEAR OIL PINNACLE MOBIL KLUBERSYNTH ALPHASYN

DIN 51502-220 TIVELA OIL WB S220 MARINE GEAR GLYGOYLE 30 GH 6-220 HG 220
SPREADER GEAR FOR (SYNTHETIC OIL) 220
PUMPS

ISO-VG46 HV TELLUS OIL NUTO H 46 RANDO DTE HYSPIN

HYDR. OIL 46cST/40º VI˜150 T 46 OR HDZ 46 15 M X
ON SYSTEM AWH-M46
POUR POINT -40º UNIVIS N 46

1) Mineral and Synthetic oil are not to be mixed. See General Specification.
2) Oil used for gearbox with spraque clutch must not contain MoS2 or other low friction additives.
Oil must stand the FZG test A/8 3.90 DIN 51314, failure load stage, equal or better than 12.

Grease Lubrication
CODE AND USE GENERAL EXAMPLE
OF OIL/LUBR. SPECIFICATION SHELL ESSO * FAMM MOBIL KLÜBER CASTROL

GREASE WITH RETINAX MOLYTEX MOBIL- MS 3

MOLYBDENDI-S HDX EP 2 GREASE X or
PLAIN BEARING ULPHIDE, MoS2 SPESIAL LMM grease
BRONZE

3) GREASE WITH ALVANIA BEACON MULTIFAK MOBILLUX CENTOPLEX

LMX
EP ADDITIVES EP 2 OR 3 EP 2 N EP 2 EP2 2 EP
PLAIN BEARING grease
GREASE
COMPOSITE

GREASE WITH ALVANIA BEACON MULTIFAK MOBILLUX CENTOPLEX

LMX
EP ADDITIVES EP 2 OR 3 EP 2 N EP 2 EP2 2 EP
ROLLER /BALL grease
GREASE
BEARING
SALT WATER
RESISTANT ENSIS FLUID G Surett 4K Crater 1X MOBILARMA Rustilo 533
GREASE WITH 798
WIRE ROPE CORROSION X
PROTECTIVE
INHIBITORS

KLÜBERPLEX
AG11-462
OPEN GEAR

3) Grease used for Composite plain bearings must not contain Molybdendisulphid, MoS2

GENERAL: The products selected should be solvent refined, containing additives against oxidation, corrosion and foaming
Also anti-wear and/or EP additives should be included. For use of equipment in extreme hot or cold climate,
please contact TTS Marine AS for advice.
* FAMM (Fuel And Marine Marketing) is an organisation incorporating Chevron and Texaco.

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TTS Marine AS 6-8

6.3.3 Oil Quantities GPK 115-3-16

LOCATION Unit Unit QTY

Hydraulic System Oil 1 400 L
Slew Gearbox 1 7L
Winch Gearbox 1 2L

6.3.4 Lubrication Chart GPK 115-3-16

See the lubrication schedule for correct service and interval.

Pos No. Description:

11 Slew gear box, Winch gear box.

12 Winch gear sealing.
13 Slew ring bearing, Winch-end bearing
14 Slew ring - internal gear / pinion.
15 Hydraulic system oil, Return filter.
16 Wire sheave, Winch wire.
17 Electric motor, Jib-bolt sealing, Cardan shaft, Control platform gate.

Lubrication chart

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TTS Marine AS 6-9

6.3.5 Lubrication Schedule

If the yearly operating time is less than 1000 hours, please consider a separate interval for the
lubrication schedule. For an accurate estimate of lubrication intervals we recommend oil analyzes
once or twice a year.

Following is a lubrication schedule for the first 1000 hours:

Table description:

Cardan shaft, Control platform gate.

A = Check oil level.

Slew ring - internal gear / pinion.

B = Change oil.

Electric motor, Jib bolt sealing,

C = Lubrication.
(Ref.: Lubrication Chart)

Wire sheave, Winch wire.

D = Change filter.
Service / Pos No.

E = Clean and check

Hydraulic system oil,

Winch gear sealing.

Winch-end bearing.
for leakage.
Slew ring bearing,
Winch gear box.

F = Check torque tightness of

Slew gear box,

Return filter.
bolts / screws.

HOURS 11 12 13 14 15 16 17 Date - Notes - Signature

50 A C C* C AD C* C* *) Add. first-time re-lubrication.

100 A C CF* C A *) Slew ring only.

150 A C C A
200 B* CE C C A C C *) First 200 hours only.

250 A C C A
300 A C C C A
350 A C C A
400 A CE C C A C C
450 A C C A
500 AF C C C AD
550 A C C A
600 A CE C C A C C
650 A C C A
700 A C CF* C A *) Slew ring only.

750 A C C A
800 A CE C C A C C
850 A C C A
900 A C C C A
950 A C C A
1000 AF CE C C BD C C

Lubrication Schedule

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TTS Marine AS 6-10

6.4 Slew-/Winch Gear

The slew and winch gear needs an oil change

every 1000 operating hours or at least once per
year.

Oil quantity is marked on the nameplate. The

oil should be drained with the gearbox at
operating temperature.

To change oil, do as follows:

• Unscrew the filling plug, relief valve
and the drain plug.
• Once the oil has been drained, replace
the drain plug.
• Fill up the exact amount of oil or up to
oil level sight glass.
• After filling up, replace relief valve
and the filling plug.

It is essential that the relief valve is removed

during filling or topping up. Failure to do so
will result in trapped air giving a false oil level.
A period of 30 minutes should be allowed
after filling or topping up to allow trapped air
to vent through the relief valve hole and
stabilize the oil level.

NOTE:
FOR EXACT TORQUE TIGHTNESS OF
EXTERNAL SCREWS, SEE THE
SEPARATE SERVICE MANUAL IN
CHAPTER 7.

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TTS Marine AS 6-11

6.5 SLEW RING

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TTS Marine AS 6-12

6.6 Slew Ring Wear Test

1. General
During operation of a crane, the slew bearing will be exposed to wear in the raceway. This wear
will cause an increase in the bearing clearance, which for safe operation, only must attain a certain
value. For assessing the condition of the bearing at all time, the bearing clearance must be
measured, recorded and evaluated with frequent intervals. The first measurement has been done
before delivery of the vessel. This measurement shall be used as a reference for all future
measurements.
2. Measuring conditions
The measuring should preferably be performed with level ship in harbour or sheltered water.
It is also important, that the conditions are the same each time a measurement is done. The
required conditions are shown in the heading of the measurement report. The measuring points
shall be free of oil and dirt etc. while measuring, and the surface at the measuring points should be
free of any roughness.
3. Measuring method
The measuring method is shown in the sketch. The distance between the underside of pedestal
flange and underside of bearing outer ring shall be measured fore and aft on the rotating
crane house, with the crane positioned at every 90 deg. All measurements shall be done with an
accuracy of 0,1 mm, and can be done with standard measuring tools as slide calipers or depth
gauges. The pedestal flange is marked for each 90 deg of the circumference with a ø6 mm tap hole
drilled into the flange above the lower edge, and each stamped with a number 1-4.

Measuring type A:

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TTS Marine AS 6-13
Measuring type B:

4. Procedure.
• Apply the measuring conditions as stated in the heading of the measurement report.
• Slew the crane to a position where the crane boom is above mark # 1 on the pedestal, and
measure the distance between underside of flange and bearing, both fore and aft on the
crane, and record it into the measurement report, ref. E-16-081
• Then turn the crane to position # 2-3-4 respectively where the distances are measured fore
and aft and recorded accordingly.
• After all the measuring has been done and recorded, the results shall be compared with
the reference values, and the deviations shall be calculated and entered into the measurement
report. The deviation is always to be calculated as the difference between the reference – and the
actual measurement.
• Sign and date the report.
5. Evaluation of measurement
Max allowable deviation is shown in the heading of the measurement report.
When the deviation reach the max allowable value, the bearing has to be replaced. Due to the
normal
long delivery time for such components, TTS should be contacted in good time before this value is
reached.
TTS recommend an initial measuring frequency of 12 month. However, when the calculated
deviation
reach approx. 50% of allowable value, the frequency should be increased to about 6 month. If the
measured wear escalate, or comes near the allowable, the intervals should be shorten further.

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TTS Marine AS 6-14

SLEW RING WEAR MEASUREMENT TABLE

SPECIFIED CRANE MODEL 115
TTS STANDARD FOR ALL CRANE MODEL ARE BELOW
40/80/115/150 MAX. ALLOWABLE DEVIATION = 2,0 mm
260/380/400/410/630/680//710/735 MAX. ALLOWABLE DEVIATION = 2,6 mm
500/530/800/835/900 MAX. ALLOWABLE DEVIATION = 3,3 mm

Measurements to JIB POSITION

be made every 6 Condition for 1 2 3 4
measure
month from date Main Bom degree
of basic measure.
Slew degree from
park position
Outreach

Load in hook

1 1 2 2 3 3 4 4
FORE AFT FORE AFT FORE AFT FORE AFT
Date: Basic
Measure
Deviation 0 0 0 0 0 0 0 0
Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

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TTS Marine AS 6-15

6.7 Re-tightening of Slew Ring Bolts

Ref. Drawing: Mounting slew gear / slew ring drawing.

The safe operation of the slew ring (bearing) is depend on proper tightening of the bolts. It is very
important that the bolts are regularly checked and re-tightened if necessary.

The required tension / torque indicated is based upon lightly oiled bolt threads and nut / bolt heads.

For re-tightening of bolts (grade 12.9) use the following torque moments /tension:

Bolt size: Torque moment: Tension:

M16 340NM 124kN

M20 650NM 194kN
For re-tightening of bolts (grade 10.9) use the following torque moments /tension:
Bolt size: Torque moment: Tension:

M24 960NM 239kN

M27 1740NM 390kN
M30 1900NM 480kN
M36 3300NM 700kN

The first bolt check is to be made after the first 100 running hours, the following intervals are to be
600 running hours, or after 3 months, depending on the use frequency of the crane.

In the event that the bolts are loosening up between check intervals, increase the frequency of the
bolts checks.

50065 07 User Manual

TTS Marine AS 6-16

6.8 Wire Rope

A long history of examining returned ropes and those in service has clearly shown that internal
degradation, mainly by corrosion and fatigue mechanisms, can be a serious and unsuspected cause
of rope failure.

In several instances, a normal external examination could not have revealed the extent of the
internal degradation even in situations where a failure was imminent under normal working
conditions due solely to the extent of the internal degradation.

Based on this experience, it cannot be an overstatement to say that no rope examination is

complete until an assessment of the internal condition at appropriate positions has been made.

6.8.1 Method of Examination

By the use of simple tools used with care, a 6 or

8 stranded rope and Multi-Strand and
“Paragon” type rope up to at least 28 mm
diameter can be opened sufficiently to permit a
reasonable determination of the internal
condition.

The method consists of firmly attaching to the

rope two correctly sized clamps about 100 - 200
mm apart. By contra rotating these clamps in
the direction to unlay the rope the rope strands
will be lifted away from the core. Examination of wire rope

Extreme care is necessary during this operation to ensure that the strands are not excessively
moved such that they become permanently deformed.

With the small openings now presented, a small probe such as a screwdriver, may be used to
manipulate the strands and displace any grease or debris which may be obscuring the inner
regions.

Because it is generally impracticable to examine a rope internally over its entire length, suitable
areas have to be selected.

In the case of ropes working over drums, pulleys or sheaves, it is usual to examine those areas
entering or leaving the grooves when maximum loads, particularly shock loads, are experienced,
or areas which remain for long periods, in exposed places such as over a jib head pulley.

On some running ropes, but usually more relevant to standing ropes such as pendants, the areas
adjacent to termination’s should be given particular attention.

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TTS Marine AS 6-17

6.8.2 Summary of Wire Examination

• Lower hoist to unload rope sheaves.

• Unwind all wire rope from the hoist drum to expose all parts of a rope, making sure that the
rope does not rewind in the reverse direction.
• Inspect sheaves, sockets, dead-ends, thimble joints, and all wire rope hardware.

• During rope changes, check the sheaves for worn bearings, broken flanges, proper groove
size, smoothness, and contour.
• Inspect all parts of the cable, cleaning wire rope only as required to complete an inspection.
Excessive removal of lubrication will lead to damage.
• Re-lubricate rope to prevent corrosion, wear, friction, and drying out of the core.

• Check for ropes that may have been operated dry (unlubricated). Replace dry ropes. There
may be hidden damage that is not detected by visual inspection.
• Compare the rope length and diameter with the original dimensions. Lengthening
accompanied by diameter reduction is often an indication of interior core defects.

6.8.3 Replacing the Wire

In the maintenance log; establish a schedule of rope

replacement to change wire rope before it breaks. Periodic
replacements do not take the place of inspections. If rope Wrong
breaks or inspections reveal abnormal wire breakage or Note the kinks
defects, reduce the time between replacement. forming!

Handling and installation of the rope should be carried out in

accordance with a detailed plan and should be supervised by a
competent person.

When a new rope is fitted a variation in size compared with

the old worn rope will be apparent. The new rope may not fit
correctly into the previously worn grove profile and
unnecessary wear and rope distortion is likely to occur. This
may be remedied by machining out the grooves before the
new rope is installed.

Place the rope in a suitable stand which allows it to rotate and

be braked to avoid overrun during installation. Roll it out
straight ensuring that it does not get contaminated with dirt
moisture etc. Handling of wire

Always double check wire connection on winch drum and

block/ jib.

NOTE:
WHEN REPLACING WIRE – ALWAYS PROVIDE 5 – 10 %
BACK-TENSION OF ROPE SWL.

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TTS Marine AS 6-18
6.8.4 Brilube Information

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TTS Marine AS 6-19

6.9 Hook Stop Adjustment

Following is a procedure for adjustment of the hook stop (cam limit switch).

• Lower the winch until there is 3 (three) turns of wire on the drum.
• Loosen / remove the 3 clamping screws. Turn the cam so that it shunts against the roller on
top of the control point on the valve.
• Re-clamp the cam with a clamping screw.
• Raise the winch to its highest required position and adjust the other cam as described
above.
• To check the control accuracy raise and lower the winch several times. Re-adjust the
settings if required.
• After the final adjustment re-clamp the cams with all 3 of the clamping screws.
• Finally replace the cover and gasket and tighten all the bolts. Ensure that the connection is
correct and no water / dust can enter the unit.
NOTE
The valves inside the unit are not specified for a specific up or down motion of the hook-stop
system. The settings can vary from crane to crane depending on how the wire, winch or crane is
installed.

50065 07 User Manual

TTS Marine AS 6-20

6.10 Appendices

6.10.1 Appendix A - Maintenance Log

All maintenance, abnormal observations and repairs should be logged. Upon request, this log
should be made available to the TTS Serviceman. Please have a copy made of the sample
maintenance log and keep it as a separate document in this user manual.

Table description:

Cardan shaft, Control platform gate.

A = Check oil level.

Slew ring - internal gear / pinion.

B = Change oil.

Electric motor, Jib bolt sealing,

C = Lubrication.
(Ref.: Lubrication Chart)

Wire sheave, Winch wire.

D = Change filter.
Service / Pos No.

E = Clean and check

Hydraulic system oil,

Winch gear sealing.

Winch-end bearing.

for leakage.
Slew ring bearing,
Winch gear box.

F = Check torque tightness of

Slew gear box,

Return filter.
bolts / screws.

x 1000 Date - Notes - Signature

11 12 13 14 15 16 17
HOURS
___050 A C C A
___100 A C C C A
___150 A C C A
___200 AB CE C C A C C
___250 A C C A
___300 A C CF* C A *) Slew ring only.

___350 A C C A
___400 A CE C C A C C
___450 A C C A
___500 AF C C C AD
___550 A C C A
___600 A CE C C A C C
___650 A C C A
___700 A C C C A
___750 A C C A
___800 A CE C C A C C
___850 A C C A
___900 A C CF* C A *) Slew ring only.

___950 A C C A
___000 AF CE CF C BD C C

Maintenance log - Lubrication

50065 07 User Manual

TTS Marine AS 6-21
6.10.2 Appendix B – Slew Ring Wear Measurement Table

SLEW RING WEAR MEASUREMENT TABLE

SPECIFIED CRANE MODEL 115
TTS STANDARD FOR ALL CRANE MODEL ARE BELOW
40/80/115/150 MAX. ALLOWABLE DEVIATION = 2,0 mm
260/380/400/410/630/680//710/735 MAX. ALLOWABLE DEVIATION = 2,6 mm
500/530/800/835/900 MAX. ALLOWABLE DEVIATION = 3,3 mm

Measurements to JIB POSITION

be made every 6 Condition for 1 2 3 4
measure
month from date Main Bom degree
of basic measure.
Slew degree from
park position
Outreach

Load in hook

1 1 2 2 3 3 4 4
FORE AFT FORE AFT FORE AFT FORE AFT
Date: Basic
Measure
Deviation 0 0 0 0 0 0 0 0
Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

50065 07 User Manual

TTS Marine AS 6-22

1 1 2 2 3 3 4 4
FORE AFT FORE AFT FORE AFT FORE AFT
Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

Date: Measure

Deviation

50065 07 User Manual

TTS Marine AS 6-23

6.10.3 Appendix C – Corrective Measures Report

CORRECTIVE MEASURES REPORT

To:
TTS MARINE AS– After Sales Service, N-4606 Kristiansand , NORWAY
Telefax: + 47 38 04 93 41 - Telephone: + 47 38 04 95 00
From (Company):

Telefax: Telephone:
Installation / Vessel:

Product:
TTS MARINE Machine No.:

Contact Person: Sign: Date:

a) Symptom of Incorrect Function b) Source of Trouble c) Status Other Functions d) Corrective Measures

Person in Charge: Sign: Date:

50065 07 User Manual

TTS Marine AS 6-24

6.10.4 Appendix D – Major Repairs and Modifications Log

Date Performed: Contract Reference: Document or Drawing Reference:

Description of Major Repairs and Modifications:

Date Performed: Contract Reference: Document or Drawing Reference:

Description of Major Repairs and Modifications:

50065 07 User Manual

 USER MANUAL -1-
Introduction

Data Sheets / Spare Parts

-2-
Main Data

-3-
Technical
Description

-4-
Preparation
Installation

Provision Service Crane -5-

Operating
GPK 115-3-16 Instructions
NAM CHEONG DOCKYARD SDN BHD
Hull Number: 703
-6-
Maintenance
50065

Copyright © by TTS Marine AS.

No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of TTS Marine AS.. -7-
Data Sheets
Spare Parts

-8-
Parts List
Drawings
TTS Marine AS 7-2

7 DATA SHEETS / SPARE PARTS ...................................................................................... 7-3

7.1 General ....................................................................................................................................7-3
7.1.1 Spare Parts included in the delivery ........................................................................................... 7-3
7.1.2 Spare Parts Ordering .................................................................................................................. 7-3
7.2 Index - Data Sheet / Spare Parts ...........................................................................................7-4
7.2.1 50065: .......................................................................................................................................... 7-4

50065 User Manual

TTS Marine AS 7-3

7 DATA SHEETS / SPARE PARTS

7.1 General

Part lists for all components used in this TTS product are found as attachments in chapter 8.

Several of the components listed in chapter 8 consist of other sub-components.

Some of these components have sub-components that may be obtained as separate Spare Parts.
This will allow for substituting only one or more sub-components, instead of substituting the
entire component.

An index for these components is found later in this chapter.

7.1.1 Spare Parts included in the delivery

The following spares are included in the delivery:

SPARE PARTS PER. CRANE

Item No. Position Item Name Your Item No. Quantity
21868 FILTER ELEMENT 1,00

TOOLS FOR PER. SHIP

Item No. Position Item Name Your Item No. Quantity
66902 PRESSURE GAUGE 400 BAR 1
97101 TESTING HOSE 1

7.1.2 Spare Parts Ordering

For ordering of Spare Parts, please see chapter 8.3.

50065 User Manual

TTS Marine AS 7-4

7.2 Index - Data Sheet / Spare Parts

The following is an index for the Data sheets and component Spare Parts lists for the components
having sub-components that can be obtained as separate Spare Parts.

The Data sheets and component Spare Parts lists are included as separate attachments after this
page.

7.2.1 50065:

TTS MARINE AS
Data Sheet/Spare Parts Date: 2012/9/4
Tag Item Name Drawing No. Item No.
-A901 EL.STARTER 50065-8001 501512
101 GEAR PUMP 50065-7000 96451
102 CONTROL VALVE 50065-7000 109221
105 WINCH GEARBOX 50065-7000 112617
106 AXIAL PISTON MOTOR 50065-7000 112706
205 HYDR. CYLINDER 50065-7000 601383
307 AXIAL PISTON MOTOR 50065-7000 114029
309 SLEWING GEAR BOX 50065-7000 112437
402 RETURN FILTER 50065-7000 96582
505 HYDR. CYLINDER 50065-7000 601350

50065 User Manual

 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512 -A901

001 96451

002 109221

105 112617

106 112706

205 601383

307 114029

309 112437

402 96582

505 601350
SPARES MANUAL

EL.STARTER
TTS STARTER ,EYM42ES1A043 item.501512
STARTER -A901
Pos. Qty Unit Item.No Item name El.nr Technicl
-A901 1,00 PCE 501028 SWITCH CABINET 600x500x250mm w/mountpl
-A901.3 4,00 PCE 57498 WALLBRACKET F/AMC CABINET
-A901.4 7,00 PCE 57296 CONTROL NAME PLATE, ENGRAVED
-A901.5 7,00 PCE 57516 SIGNHOLDER TELEMEC.30x50mm
-F11 1,00 PCE 57572 CIRCUIT BREAKER 4A
-F12 1,00 PCE 57572 CIRCUIT BREAKER 4A
-F13 1,00 PCE 57572 CIRCUIT BREAKER 4A
-F14 1,00 PCE 57504 THERMISTOR RELAY
-H11 1,00 PCE 57512 LAMP COMPLETE w/GREEN LED
-H12 1,00 PCE 57514 LAMP COMPLETE w/BLUE LED
-H13 1,00 PCE 57511 LAMP COMPLETE w/WHITE LED
-K1 1,00 PCE 57849 CONTACTOR RELAY 50A/AC3
-K1.1 1,00 PCE 57868 AUXILLARY CONTACT BLOCK
-K2 1,00 PCE 57849 CONTACTOR RELAY 50A/AC3
-K16 1,0 PCE 58112 TIMER RELAY Y/D START
-K3 1,00 PCE 57849 CONTACTOR RELAY 50A/AC3
-P11 1,00 PCE 57590 HOUR COUNTER IP52 f/TS35 RAIL
-P12 1,00 PCE 52363 AMPEREMETER 0-100A
-S1 1,00 PCE 57577 MAIN SWITCH 63A/3ph
-S1.1 1,00 PCE 57490 MAIN SWITCH GRIP(panel mounted) IP65
-S1.2 1,00 PCE 57491 SHAFT BETW.GRIP AND SWITCH
-S10 1,00 PCE 57578 EMERGENCY STOP
-S10.1 1,00 PCE 57510 CONTACT ELEMENT 1xNC w/HOLDER
-S13 1,00 PCE 57508 PUSHBUTTON RED
-S13.1 1,00 PCE 57510 CONTACT ELEMENT 1xNC w/HOLDER
-S14 1,00 PCE 57507 PUSHBUTTON GREEN
-S14.1 1,00 PCE 57509 CONTACT ELEMENT 1xNO w/HOLDER
-T10 1,00 PCE 600464 TRANSFORMER 630VA
-T12 1,00 PCE 52369 CURRENT TRANSFORMER100A/5A
-XNNN 33,00 PCE 16823 TERMINAL 2,5MM2 White
-XNNN.1 6,00 PCE 57655 END PLATE
-XNNN.2 7,00 PCE 57947 END STOP f/Terminal
 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512

001 96451 001

002 109221

105 112617

106 112706

205 601383

307 114029

309 112437

402 96582

505 601350
 SPARES MANUAL

GEAR PUMP

SPECIFICATION ITEM NUMBER

96451
 SINGLE PUMP
PUMP DESCRIPTION : R1A4016H3A1C
ITEM NO : 96451
DRW REF : RL052722
POS NO QTY. DESCRIPTION PART NO.
001 1 MOUNTING FLANGE N/A
002 1 FRONT COVER N/A
003 1 BODY N/A
020 1 DRIVEN GEAR N/A
021 1 DRIVE GEAR N/A
030 1 WEARPLATE *
031 1 SEAL *
WEARPLATE BACK-UP
032 1 *
SEAL
035 1 WEARPLATE *
036 1 SEAL *
037 1 WEARPLATE BACK-UP *
055 1 SHAFT SEAL *
056 1 SHAFT SEAL *
057 1 MULTSTEP PUSH CLIP N/A
060 1 O-RING *
070 4 CAPSCREW N/A
080 4 CAPSCREW N/A
085 1 LOCATION RING N/A
090 4 PLAN BEARING N/A
095 1 SEAL N/A
110 1 KEY * N/A
111 1 CIRCLIP * N/A

ONLY SEAL KIT IS AVAILABLE AS SPARE PARTS

1/1 10 august, 2011

TTS Marine ASA
 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512

001 96451

002 109221 002

105 112617

106 112706

205 601383

307 114029

309 112437

402 96582

505 601350
 SPARES MANUAL

CONTROL VALVE

The “pos/tag” component for this project does not comprise a spare

parts list. For further details, please contact after sales dept.; Spare

parts contact information in chapter 1.3

 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512

001 96451

002 109221

105 112617 105

106 112706

205 601383

307 114029

309 112437

402 96582

505 601350
SPARES MANUAL
WINCH GEAR

SPECIFICATION ITEM NUMBER

112617
 WINCH GEAR

GEARBOX DESCRIPTION : WINCH GEARBOX

ITEM NO : 112617
DWRG REF :RL052537

POS QTY HL.NO DESCRIPTION

1 3 N/A PLANETARY GEAR

2 3 N/A SPACER

3 1 N/A PLANETARY CARRIER

4 1 117194 SUN GEAR

5 4 N/A INTERNAL SNAP RING

6 4 N/A PLANETARY GEAR PIN

7 4 N/A PLANETARY GEAR

8 4 N/A SPACER

9 72 N/A NEEDLE ROLLER

10 1 N/A PLANETARY CARRIER

11 1 N/A EXTERNAL SNAP RING

12 1 N/A DRILLED END PLATE

13 3 N/A INTERNAL SNAP RING

14 3 N/A PLANETARY GAER

15 54 N/A NEEDLE ROLLER

16 6 N/A SPACER

17 3 N/A PLANETARY CARRIER PIN

18 1 116651 SPLINED COUPLING

19
20 1 116650 GREASER

21 1 116519 EXTERNAL SNAP RING

22 1 116930 PLUG

23 1 116631 HOUSING

24
25 1 N/A O-RING SEAL

26 1 N/A ANTIEXTRUSION RING

27 1 116605 BRAKE PISTON

28 1 116538 INTERNAL SNAP RING

29
30 8 N/A SCREW

31 8 N/A HELICAL SPRING

32 1 116535 SPLINED COUPLING

33 1 117174 MOTOR FIXING FLANGE

1/3 Q:\AS\DELER\GEAR\W-K\PDF 24.02.09

 WINCH GEAR

POS QTY HL.NO DESCRIPTION

34
35 1 116602 INTERNAL SNAP RING

36 1 116589 INPUT SHAFT

37
38
39 1 N/A RING SEAL

40 1 N/A BEARING

41
42 4 N/A STEEL DISC

43 3 N/A BRONZE DISC

44 1 N/A SPACER

45 1 N/A O-RING SEAL

46 1 N/A ANTIEXTRUSION RING

47 1 N/A O-RING SEAL

48
49
50
51
52
53 1 N/A O-RING SEAL

54 1 117167 WHEEL MOTOR FLANGE

55 1 N/A SEAL RING

56 1 N/A DUST COVER

57 3 116537 WASHER

58 3 116536 PLUG

59 1 N/A BEARING

60 2 116557 EXTERNAL SNAP RING

61 1 116514 INTENAL SNAP RING

62 1 117166 WHEEL HOUSING

63 1 N/A END PLATE

64 1 N/A PLANETARY CARRIER

65 1 116652 RING GEAR

66 1 116894 SUN GEAR

67
68 2 N/A O-RING SEAL

69
70 12 N/A SCREW

2/3 Q:\AS\DELER\GEAR\W-K\PDF 24.02.09

 WINCH GEAR

POS QTY HL.NO DESCRIPTION

71 1 116654 INTERMEDIATE FLANGE

72 1 116505 RING GEAR

73 2 N/A O-RING SEAL

74
75
76
77
78 1 117099 INTEMEDIATE FLANGE

79 1 116852 RING GEAR

80 2 N/A O-RING SEAL

81 1 116546 DRILLED END PLATE

82 1 116549 EXTERNAL SNAP RING

1 117197 SUN GEAR
83 1 117173 SUN COUPLING RE110
84 1 116547 DRILLED PAD

85 54 N/A NEEDLE ROLLER

86
87 3 N/A INTERNAL SNAP RING

88 3 N/A PLANETARY CARRIER PIN

89 2 116655 PLUG

90 2 116595 WASHER

91 8 N/A SCREW

92 8 N/A WASHER

93 1 116503 COVER

94
95
96

3/3 Q:\AS\DELER\GEAR\W-K\PDF 24.02.09

 WINCH GEAR

ITEM NOT SHOWN

QTY HL.NO DESCRIPTION

3 116550 NEEDLE ROLLER
* ** SUN GEAR
1 116660 DOWEL
4 116550 SPACER
12 116657 WASHER
1 116657 EXTERNAL SNAP RING
1 116819
SHIM RING
1 116819
1 116659 SPLINED COUPLING
1 116658 SPACER
8 116634 SCREW
1 116898 FLANGE
1 116890 COUPLING
1 N/A RING SEAL
1 N/A O-RING SEAL
5 116595 WASHER
5 116596 PLUG
1 116597 INPUT FLANGE
1 116599 O-RING SEAL
1 116600 EXTERNAL SNAP RING
8 N/A WASHER
4 117176 SCREW
1 116638 EXTERNAL SNAP RING
1 117175 COUPLING

NOTE:

ALL ITEM MARKED WITH N/A IS NOT AVAILABLE AS SINGLE

SPAREPARTS, ONLY DELIVERED IN KIT SEE NEXT PAGE FOR
PART NUMMER

4/3 Q:\AS\DELER\GEAR\W-K
 WINCH GEAR

THE FOLLOWING PARTS ARE ONLY SUPPLIED AS AN ASSEMBLY

POS HL.NO DESCRIPTION

BEARING KIT
1 117199
COMPRISING ITEM:
SEAL KIT
2 117200
COMPRISING ITEM:
REP KIT BRAKE
3 117001
COMPRISING ITEM:
SEAL KIT BRAKE
4 117016
COMPRISING ITEM:
1 st STAGE PLANET CARRIER ASSEMBLY
5 116881
COMPRISING ITEM:
2 nd STAGE PLANET CARRIER ASSEMBLY
6 116864
COMPRISING ITEM:
3 rd STAGE PLANET CARRIER ASSEMBLY
7 116865
COMPRISING ITEM:

5/3 Q:\AS\DELER\GEAR\W-K\PDF 24.02.9

 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512

001 96451

002 109221

105 112617

106 112706 106

205 601383

307 114029

309 112437

402 96582

505 601350
SPARES MANUAL

AXIAL PISTON MOTOR 34CCM

SPECIFICATION ITEM NUMBER

112706
 AXIAL PISTON MOTOR
DWG. REF: RL052396
ITEM NR: 112706
IMPORTANT: ABOVE INFORMATION MUST ALWAYS BE GIVEN WHEN SPARE
PARTS ARE ORDERED
ITEM QTY HL.NO DESCRIPTION
1 1 SHAFT
2 1 KEY
3 1 WASHER
4 1 LOCK RING
5 1 SEAL
6 1 LOCK RING
7 1 TAPERED ROLLER BEARING
8 1 BEARING HOUSE
9 1 LOCK RING
10 1 PLUG
11 1 SEAL WASHER
12 1 TAPERED ROLLER BEARING
13 1 O-RING
14 1 PIN
15 1 GEAR RING
16 1 PISTON COMPLETE
17 1 SPRING PIN COMPLETE
18 1 ANGULAR HOUSING
19 1 CYLINDER BLOCK
20 1 O-RING
21 1 SHIMS
22 8 BOLT

23 1 COVER

24 1 PLUG

25 1 SEAL WASHER
26 1 PLUG

Q:\AS\DELER\kunde\PDF 12/3/2008
 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512

001 96451

002 109221

105 112617

106 112706

205 601383 205

307 114029

309 112437

402 96582

505 601350
 SPARES MANUAL

MAIN CYLINDER

The “pos/tag” component for this project does not comprise a spare

parts list. For further details, please contact after sales dept.; Spare

parts contact information in chapter 1.3

 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512

001 96451

002 109221

105 112617

106 112706

205 601383

307 114029 307

309 112437

402 96582

505 601350
SPARES MANUAL

AXIAL PISTON MOTOR

SPECIFICATION ITEM NUMBER

114029
DRWG. REF: RL05336
ITEM NR: 114029

IMPORTANT: ABOVE INFORMATION MUST ALWAYS BE GIVEN WHEN

SPARE PARTS ARE ORDERED

ITEM QTY HL.NO DESCRIPTION

1 1 122221 SHAFT
2 1 122222 BEARING HOUSING
3 1 122223 ROLLER BEARING
4 1 122225 LOCK RING
122226 HEXAGON SOCKET
5 1
O-RING BOSS RING
122227 TAPERED ROLLER
6 1
BEARING
7 1 122228 O-RING
8 1 12229 GEAR RING
9 1 12230 PIN
10 1 122231 PISTON COMPLETE
11 1 122232 SPRING GUIDE
12 1 122233 ANGULAR FOUSING
13 1 122234 CYLINDER BLOCK
14 1 122235 CONNECTION COVER
15 8 122236 BOLT
16 1 122237 O-RING
17 1 122239 SHIM
122241 HEXAGON SOCKET O-
18 1
RING BOSS PLUG
19 1 122238 SHIM
20 1 122240 LOCK RING
21 1 122242 SHAFT SEAL
22 1 122243 WASHER
23 1 122244 LOCK RING

Q:/AS/DELER/HYD.MOTOR/SUNFAB/OSS/RL052061 10/14/2008
 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512

001 96451

002 109221

105 112617

106 112706

205 601383

307 114029

309 112437 309

402 96582

505 601350
SPARES MANUAL
SLEW GEAR

SPECIFICATION ITEM NUMBER

112437
 OUTPUT DRIVE

RL052420
ITEM:

POS QTY HL.NO DESCRIPTION

1 1 PINION SHAFT
2 1 SPACER
3 1 NILOS RING
4 1 BEARING
5 1 GEARBOX HOUSING
6 1 SEAL RING
7 1 BEARING
8 1 SPACER
9 1 NUT

1/1 Q:/AS/DELER/GEAR/CUSTOMER/RL052420 01.12.2008

 MULTIPLE BRAKE

RL052424
ITEM:

POS QTY HL.NO DESCRIPTION

1 1 CIRCLIP
2 1 SPACER
3 1 DISCS RETAINER
4 1 BRAKE SHAFT
5 3 STEEL RING
6 4 SINTERED DISC
7 1 PLUG
8 1 OIL LEVEL PLUG
9 1 HOUSING BRAKE
10 1 BACKUP RING
11 1 O-RING
12 1 O-RING
13 1 BACKUP RING
14 1 SEALING BRAKE KIT
15 1 PISTON
16 11 SPRING
17 1 SPRINGS RETAINER
18 1 CIRCLIP
19 1 O-RING
20 8 SCREW

1/1 Q:/AS/DELER/GEAR/CUSTOMER/RL052424 01.12.2008

 REDUCTION STAGE 300

RL052423
ITEM:

POS QTY HL.NO DESCRIPTION

1 2 O-RING
2 1 REDUCT.ASSEMBLY
3 1 TOOTHED RING
4 1 SUN GEAR
5 1 REDUCTION STAGE

1/1 Q:/AS/DELER/GEAR/CUSTOMER/RL052423 01.12.2008

 REDUCTION STAGE 303

RL052422
ITEM:

POS QTY HL.NO DESCRIPTION

1 2 O-RING
2 1 REDUCT.ASSEMBLY
3 1 TOOTHED RING
4 1 SUN GEAR
5 1 REDUCTION STAGE
6 1 COVER
7 8 SCREW
8 1 O-RING

1/1 Q:/AS/DELER/GEAR/CUSTOMER/RL052422 01.12.2008

 REDUCTION STAGE 306

RL052421
ITEM:

POS QTY HL.NO DESCRIPTION

1 1 REDUCT.ASSEMBLY
2 2 O-RING
3 1 TOOTHED RING
4 1 SUN GEAR
5 1 REDUCTION STAGE
6 1 COVER
7 12 SCREW
8 4 SCREW
9 1 O-RING

1/1 Q:/AS/DELER/GEAR/CUSTOMER/RL052421 01.12.2008

 ADAPTOR

RL052425
ITEM:

POS QTY HL.NO DESCRIPTION

1 1 MOTOR ADAPTOR
2 1 BEARING
3 1 COUPLING
4 2 CIRCLIP
5 1 CIRCLIP
6 1 O-RING
7 4 SCREW
8 8 SCREW

1/1 Q:/AS/DELER/GEAR/CUSTOMER/RL052425 01.12.2008

 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512

001 96451

002 109221

105 112617

106 112706

205 601383

307 114029

309 112437

402 96582 402

505 601350
 PART LIST - RETURN FILTER

ITEM NR: 96582

ITEM QTY DESCRIPTION TECHNICAL

1 1 FILTER ELEMENT
2 1 HOLDER ASSEMBLY NA
3 1 SCREW NA
4 1 SPRING NA
5* 1 O-RING
6 1 END CAP NA
7 1 FILTER HOUSING NA
8 1 FUNNEL NA
9* 1 SEAL
10* 1 O-RING
11 3 PLUG NA
12 3 GASKET NA
13 3 IN SIX SCREW NA
14 3 WASHER NA

* SEALKIT: 104795 ARE THE ONLY PARTS THERE ARE AVAILIBLE

Q:/AS/DELER/FILTER/CUSTOMER 31.07.2007
 TTS Marine AS
Data Sheet/Spare Parts – Appendix:

Tag Item Number

-A901 501512

001 96451

002 109221

105 112617

106 112706

205 601383

307 114029

309 112437

402 96582

505 601350 505

 SPARES MANUAL

KNUCKLE CYLINDER

The “pos/tag” component for this project does not comprise a spare

parts list. For further details, please contact after sales dept.; Spare

parts contact information in chapter 1.3

 USER MANUAL -1-
Introduction

Parts List/ Drawings

-2-
Main Data

-3-
Technical
Description

-4-
Preparation
Installation

Provision Service Crane -5-

Operating
GPK 115-3-16 Instructions
NAM CHEONG DOCKYARD SDN BHD
Hull Number: 703
-6-
Maintenance
50065

Copyright © by TTS Marine AS.

No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of TTS Marine AS. -7-
Data Sheets
Spare Parts

-8-
Parts List
Drawings
TTS Marine AS 8-2

8 PARTS LIST / DRAWINGS................................................................................................ 8-3

8.1 Drawing List Index.................................................................................................................8-3
8.1.1 Mechanical / Hydraulic Drawings 50065: .................................................................................. 8-3
8.1.2 Electric Drawings 50065: ........................................................................................................... 8-4
8.2 General Explanation to TTS Parts List................................................................................8-5
8.3 Spare Parts Ordering .............................................................................................................8-6

50065
User Manual
TTS Marine AS 8-3

8 PARTS LIST / DRAWINGS

8.1 Drawing List Index

Part lists and drawings are included as a separate attachment back in this chapter.

See the following index of enclosed drawings:

8.1.1 Mechanical / Hydraulic Drawings 50065:

50065 GPK 115-3-16

Document No. Rev./Dwg. Description Remark

50065-GA01 4 GENERAL ARRANGEMENT

A3610a 2 PUMP DRIVE ARRANGEMENT

A2077a 4 SLEWING MACHINARY ASSEMBLY

A3166a 3 WINCH ASSEMBLY

A3361a 2 CYLINDER HINGE ASSEMBLY

50065-6001 1 JIB HEAD ASSEMBLY

50065-6002 1 KNUCKLE JIB HINGE ASSEMBLY

50065-7000 2 HYDRAULIC FLOW DIAGRAM

50065HL 1 HOSE LIST

50065
User Manual
TTS Marine AS 8-4

8.1.2 Electric Drawings 50065:

50065 GPK 115-3-16

Document No. Rev./Dwg. Description Remark

50065-8001 0 EL.BLOCK DIAGRAM
50065-8101 1 EL.CIRCIUT DIAGRAM
50065-8401 1 EL .PANNEL LAYOUT
EARAADP2 3 STANDARD CONTROL STATION PROTECTION
ASSEMBLY
EAR40DP1 1 STANDARD CONTROL STATION

50065
User Manual
TTS Marine AS 8-5

8.2 General Explanation to TTS Parts List

See the following sample parts list described below. Note the marked drawing MMBSTA03 and
tag no. S07/1 and S07/2.

Each component has a unique item no. or tag no.. If a component is specified with “REF” in parts list, you will find the unique
item no. in parts list for drawing specified in column for “Drawing Reference”.

Example:
Tag no. S07/1 and S07/2 have item no. “REF”. If you read parts list for drawing no. MMBSTA03, you will find the unique
item no. for tag no. S07/1 and S07/2.

50065
User Manual
TTS Marine AS 8-6

8.3 Spare Parts Ordering

Please use the following example when ordering spare parts:

Supplier: Customer:
TTS Marine AS
Service Box 602 Office Address:
N-4606 Kristiansand
Norway

Phone: (+47) 38 04 95 00 Delivery Address:

Telefax: (+47) 38 04 93 41

Contact Person:
Phone:
Telefax:

Machine Type: Notes/Customer Order ID:

Machine Number:
Main Drawing:

Qty. Item No. Item Name / Description Drawing Ref.

WARNING:
DURING THE WARRANTY PERIOD, ALL REPAIR AND MAINTENANCE WORK
MUST BE CARRIED OUT IN ACCORDANCE WITH TTS MARINE ASA’S
PROCEDURES AND APPROVAL. THIS INCLUDES APPLYING APPROVED
MATERIALS AND ORIGINAL SPARE PARTS.

50065
User Manual
TTS MARINE AS
CUSTOMER PARTLIST

Project :50065 GPK 115-3-16

Debtor :
Hull No : 703
Machine No. :50065

Drawing No. : 50065-7000 Drawing revision: 2 DATE:

Item No. : X50065-7000 Block Diagram 2013/1/8

Item group : DRAW Drawing

CustDocNo :

Drawing
Tag Qty. Item name Item No.
Reference
001 1 GEAR PUMP 27CCM 96451
002 1 CONTROL VALVE 109221
102 1 LOAD CONTROL VALVE 112625
105 1 AXIAL PISTON MOTOR 56 CCM 114030
106 1 WINCH GEARBOX 112616
110 1 HOOK STOP, ZOLLERN CAM LIMIT SWITCH 112619
111 1 SHUTTLE VALVE. Light.10mm pipe di 96501
204 1 LOAD CONTROL VALVE 601475
205 1 HYDR.CYLINDER, 180/110 601372
303 1 LOAD CONTROL VALVE 601510
304 1 FLOW CONTROL VALVE, SINGLE ACTION 21501
307 1 AXIAL PISTON MOTOR 34 CCM 114029
309 1 SLEW GEARBOX RE513/2 112437
400 1 HANDPUMP WITH HANDLE 64340
402 1 RETURN FILTER 96582
402.1 1 FILTER INDICATOR 19817
402.2 1 FILTER ELEMENT 21868
403 1 BALL VALVE 1", LONG THREADED 93376
404 1 LEVEL GAUGE W/THERMOMETRE 93345
405 1 BREATHER FILTER FOR OIL TANK 96591
406 1 BALL VALVE 11118
408 1 QUICK COUPLING 3/8" MALE 96660
408.1 1 DUST CAP 3/8" 104131
409 2 QUICK COUPLING 1/2" MALE 96661
409.1 2 DUST CAP 1/2" 104130
412 2 CHECK VALVE,25S 96540
505 1 HYDR.CYLINDER 601350
506 1 VALVE HOUSING, DOUBLE. 90162
506.1 2 LOAD CONTROL VALVE 68770
507 2 FLOW CONTROL VALVE 21500
 Refer
TTS Marine Shanghai Customer Hose List 50065-7000
Dwg
PYA/ 08.01.2013 Revision 2 Page 1 of 1

Tag No. Pos No. Qty Item name Item No.

14 1 HYDRAULIC HOSE 6 17 0110 22 35
19 1 HYDRAULIC HOSE 6 17 0125 22 35
49 1 HYDRAULIC HOSE 6 11 0110 20 33
64 1 HYDRAULIC HOSE 6 09 0050 17 30
74 1 HYDRAULIC HOSE 6 09 0130 17 43
79 1 HYDRAULIC HOSE 6 17 0120 21 34
84 1 HYDRAULIC HOSE 6 17 0120 21 34
89 1 HYDRAULIC HOSE 6 17 0170 21 34
94 1 HYDRAULIC HOSE 6 17 0170 21 34
99 1 HYDRAULIC HOSE 6 17 0150 21 34
104 1 HYDRAULIC HOSE 6 17 0150 21 34
109 1 HYDRAULIC HOSE 6 09 0060 17 30
114 1 HYDRAULIC HOSE 6 10 0120 78 79
119 1 HYDRAULIC HOSE 6 17 0130 22 35
129 1 HYDRAULIC HOSE 6 17 0165 22 35
148 1 HYDRAULIC HOSE 6 17 0125 21 34
158 1 HYDRAULIC HOSE 6 17 0170 21 34
172 1 HYDRAULIC HOSE 6 11 0120 20 33
177 1 HYDRAULIC HOSE 6 17 0125 21 34
182 1 HYDRAULIC HOSE 6 17 0170 21 34
187 1 HYDRAULIC HOSE 6 11 0130 20 33
194 1 HYDRAULIC HOSE 6 11 0070 20 33
199 1 HYDRAULIC HOSE 6 11 0090 20 33
311 1 HYDRAULIC HOSE 6 11 0080 45 33
317 1 HYDRAULIC HOSE 6 11 0060 45 33
328 1 HYDRAULIC HOSE 6 09 0180 43 30
333 1 HYDRAULIC HOSE 6 09 0160 43 30
338 1 HYDRAULIC HOSE 6 10 0170 80 79
343 1 HYDRAULIC HOSE 6 10 0120 80 79
348 1 HYDRAULIC HOSE 6 17 0130 46 34
353 1 HYDRAULIC HOSE 6 17 0130 46 34
358 1 HYDRAULIC HOSE 6 17 0170 46 34
363 1 HYDRAULIC HOSE 6 17 0170 46 34
368 1 HYDRAULIC HOSE 6 17 0080 46 34
373 1 HYDRAULIC HOSE 6 17 0095 46 34
378 1 HYDRAULIC HOSE 6 17 0160 46 34
404 1 HYDRAULIC HOSE 6 09 0160 17 30
409 1 HYDRAULIC HOSE 6 09 0180 17 30
 TTS MARINE AS
CUSTOMER PARTLIST
Machine No. 50065
Drawing No. 50065-8001 Drawing revision: 0 DATE: 2013/3/14
Item No. 50065-8001 Electrical block diagram
Item group: DRAW
Cust Doc No
Pos. Tag Qty. Item name Item No. Drawing Reference
-M20 1 ELECTRIC MOTOR HOYER 160L 14,0 501634
1 ELSTARTER STAR/DELTA 501512
1 REM. START & EM-STOP 502065
1 Handle AE FT 2767/68 w/cyl. 58669
1 Cabinet. Stainles Steel AE 100 58668