GUIDANCE MANUAL

for
Weatherdeck hatch covers

TTS
Dry Cargo Handling
18th Floor,3255 Zhou Jia Zui Road
Shanghai 200093,China
Tel: +86 21-65398257
Fax: +86 21-65397400
E-mail: engineering @ tts-huahai.com

Yard SHANG HAI

Hull no. S1139
Order No. 533
 Guidance manual

Weatherdeck hatch covers

Contents Page

1. Introduction & Warnings

1.1 Introduction 2
1.2 Safety notes 2
1.3 Copyright 3
1.4 Guarantee terms 4

2. Specification
2.1 Specification of the steel equipment 2
2.2 Specification of the hydraulic system and components 4

3. Manoeuvre instructions
3.1 Important notes 2
3.2 Opening of the holds 3

4. Troubles, Emergency Operation

4.1 Troubles 2
4.2 Emergency operation 2

5. Maintenance
5.1 Maintenance of hatch covers 2
5.2 Maintenance of hydraulics 8

6. Service & Spare Parts

6.1 Spare parts 2
6.2 Spare parts and tools list 3
6.3 TTS Service-stations world-wide 5
 Guidance manual

Weatherdeck hatch covers

Contents Page

7. Certificates

8. Drawings steel & fittings

8.1 List of drawings steel & fittings 2

9. Drawings Hydraulic
9.1 List of drawings hydraulic 2

10. Drawings Electric

10.1 List of drawings electric 2

11. Drawings Pneumatic

12. For Your Notes

 GUIDANCE MANUAL

Weatherdeck hatch covers

1. Introduction & Warnings

1.1 Introduction

This manual for TTS hatch covers contains information especially for this
equipment on technical data, installation, start-up, care and maintenance as
well as spare parts ordering.

The advanced design and the size of this plant requires experience, skill and
special attention for safe operation and careful maintenance.

Make sure the guidance manual instructions, especially the safety

instructions in this documentation are carefully observed!

∗ General notes on safety are listed in this first chapter.

∗ Special instructions are given at the beginning of the individual chapter.
∗ Safety instructions referring to actions are given before the action itself is
described.

1.2 Safety notes

The products of TTS Hua Hai have been designed and manufactured as to
reflect the actual technological state of the art. Nevertheless, it cannot be ruled
out that danger may arise to:
− life and limb,
− the product itself and the overall plant,
− other assets

In particular, dangers may occur:

− if insufficiently trained personnel manipulates the product,
− if the product is improper installed, operated and serviced,
− if the product is used for other than the intended purposes.

All persons operating the plant or product must:

− have definitely read and understood this chapter,
− know these operating instructions or at least be familiar with those parts
where the respective activity and associated dangers are described,
− be familiar with shut-down procedures, e.g. "Emergency-Off", relating to the
entire plant or to plant items important to the relevant activity,
− have adequate technical qualifications and be authorised to perform the
relevant activity,
− know their specific duties and authority.
 Moreover, it is mandatory that these persons:
− refrain from doing anything that might cause bodily harm or constitute a
danger to health, the product or other assets,
− inform their superiors in charge or the operator of any modifications made to
the product,
− inform their superiors in charge or the operator of any changes detected in
the operational behaviour of the product, for example unusual running
noises.

No modifications to the product are permitted unless the prior approval of TTS
Hua Hai has been obtained.

The user shall undertake to:

− ensure that the product and its surroundings are kept clean and in good
order,
− operate the product only when in perfect condition,
− use the product exclusively for the intended purpose,
− use the product only in the framework of the technical characteristics listed
below,
− safeguard rotating parts by means of suitable protective systems,
− instruct the personnel to wear protective clothing to the extent deemed
necessary,
− distribute these operating instructions among the personnel in charge.

Using the equipment for the intended purpose as set out above also includes
observing the instructions given in this operating manual.
In addition to the procedures and instructions outlined in this operating manual
all generally applicable statutory and other accident prevention rules and
provisions must be observed.

We reserve the right to implement technical changes for product improvement

purposes.

The figures shown in this manual may slightly deviate from the actual design.

1.3 Copyright

We reserve the right of origin for this guidance manual for the design as well as
for the technical information contained therein. Passing on to third parties
and/or reproduction of this guidance manual without our specific consent is not
permitted. All our records are to be treated as strictly confidential. They remain
our property and are to be returned on demand.
1.4 Guarantee terms

Begin and period of guarantee for the delivered equipment is laid down in the
contract.

The guarantee covers functional defects which are resulting from faulty design,
materials or workmanship.
Claims of the customers out of this guarantee can only be considered, if the
defect is advised to us immediately after it occurred stating exact details of the
damage. Guarantee-services will only be rendered if it concerns a definite
guarantee-case. The customer, therefore, will enable us to inspect the damage
and establish the necessary preconditions for our staff to carry out the repair
works.
We shall supply spare parts under guarantee terms only provided that the
damaged parts are put at our disposal.

Guarantee services will be carried out without charge. Included are the working
hours for our technical staff as well as their travel and living expenses. As far as
these services will occur in China, we will decide whether the damaged part will
be repaired or will be replaced by a new one.
Guarantee-repairs which have neither been arranged for, nor have been
ordered by us or to which we did not at least agree will not be paid by us.
In case a defect can be remedied in a foreign port only with assistance from a
third party we shall reimburse expenses only up to the amountment which
would be due if the repair would be carried out in a Chinese port.

The parts for replacements will be sent at costs and risk of the customer. Same
applies for the defective parts sent back to us.

We do not guarantee for :

− Damage which is caused by excessive stress, improper use, careless and

faulty maintenance, normal deterioration as well as neglect of the operation
instructions.
− Loss of profit
− All kinds of indirect damages (consequential damages)
− Damages which have been occurred by and with materials supplied from the
purchaser.

Manipulations in our installations undertaken by firms or persons being not

authorized by us will forfeit any guarantee claim.
 GUIDANCE MANUAL

Weatherdeck hatch covers

2. Specification
2.1 Specification of the steel equipment

2.1.1 Weatherdeck

2.1.1.1 Rules and regulations: BV (BV certificate) and

The International Load Line Convention
1966 With all amendments
SOLAS 1974 With amendments
IACS UR S21 Rev.3 April, 2003

2.1.1.2 Type of covers: TTS side-rolling AutoRoll system hatch

covers

2.1.1.3 Actuation: Handling: hydraulically

Cleating: Mechanical Automatically

2.1.1.4 Arrangement of covers: Hold no.1-7: two side-rolling panels,

(see also dwg. no. 533-1111; opening directions one panel portside and
1211; 1311; 1411;1711): one panel starboard

2.1.1.5 Hold dimensions: Hold no. 1/7: 17.290mm x 16,500 mm

Hold no. 2-6: 17,290mm x 19,000 mm

2.1.1.6 Structure design: Open girder construction, sloping top plate

2.1.1.7 Material: Steel plates of mild and high tensile steel

AH36 in ships quality
Axles and bolts of type stainless steel and
engineering steel. Bronze bushings with
greasing through readily accessible grease
nipples to be arranged where necessary.
Pipes in TTS equipment is of normal steel,
quality DIN 2391, if not otherwise specified.
Couplings of ERMETO type or similar.

2.1.1.8 Welding: Welding is continuously and according to

Classification Society

2.1.1.9 Wave loads: Vertical wave loads :71.10 kN / m² for No.1

H.C.;40.70 kN / m² for No.2 H.C; 34.30 kN
/ m² for No.3-7 H.C
Horizontal sea load: 175 kN / m²

2.1.1.10 Uniformly distributed load: Water ballast load: 0~72.5 kN / m² (From

side skirt of one side to another side)

2.1.1.11 Restrictions: proper function is guaranteed up to a max.

trim of ± 2,0° and max. ship's heel of ±3°.
Temperature range from -20°C to + 45°C.
2.1.1.12 Coaming deflexion: max. ± 20 mm

2.1.1.13 Weathertightness: Achieved by TTS SQUARE rubber

arranged in the split joints and on the
underside of the hatch covers against the
coaming and the adjacent panels coaming
profile. Drainage ball valves for the
coaming is arranged at the corners of the
hold and each of the drive recesses.

2.1.1.14 Cleats: The hatch covers are secured to the

coaming by cleats that automatically
engage / disengage through the operation
of the AutoRoll system. The ballast water
hatch covers will be secured with Anti-
lifting cleats by manually operated.

2.1.1.15 Wheels: With rolling bearings and nipples for

lubrication.

2.1.1.16 Anticorrosion preservation: Blasted SA 2 ½ and with approx. 20 μm

shopprimer.

2.1.1.17 Operation of covers: The hatch covers are left from the cleats
and moreover raised to the rolling position
in one operation through the action of
forward and aft wheel AutoRoll systems
driven in with two hydraulic cylinders at
each end. From this position the panels will
be driven into stowage by a rack and a
pinion driven system. This will consists of a
hydraulic motor driven pinion mounted at
the end side of the coaming. The pinion will
engage with a rack arm welded to the
underside of the panel. The hydraulic
operation system to be capable of
operating the two panels simultaneously.

2.1.1.18 Auxiliary operation In case of failure of one pump or electric

motor the remaining pump is sufficient to
proceed operating the covers.
For emergency operation, one portable
electric pump by to be used.
2.1.1.19 Single weight of covers: see drawing no. 533-1111 & 1211 & 1311
& 1411&1711
2.1.1.20 Shipping weight: abt. 615 t
Specification of the hydraulic system and com

2.1.2 Components

power unit

Power consumption : 2 x 12.7 kW

Power supply : 440 V/60 Hz, 3 phases
Rated current : 2 x 21.27 A
Insulation : class F IP 55
Pump capacity : 2 x 26 l/min
Nominal working pressure : 250 bar
Testing pressure : 375 bar
Classification : BV Register

hydraulic cylinder
The hydraulic cylinders are made for use on board of seagoing vessels and are
approved by the classification society.
Hydraulic cylinders are according to TTS standard.
control
All control valves are manually operated and made for use on board of seagoing
vessels.
One(1) control valve stand shall be arranged for each hatch at after of hatch
coaming 。
All name plate should be in English.

High pressure hoses

The high pressure hoses are to fulfil the class rule and are fitted with couplings
suitable for the pipes.

Hydraulic oil
Oil recommended by TTS will be used(mineral oil)
2.1.3 Opening/closing time
(Theoretically data without time for cleating/locking)

Time calculated for opening one adjacent panels of each hold is approximately
2 minutes.
Time calculated for closing one adjacent panels of each hold is approximately
2 minutes.
 GUIDANCE MANUAL

Weatherdeck hatch covers

3. Manoeuvre instructions
 Important notes
IT IS STRICTLY FORBIDDEN TO BE IN THE HOLD DURING HATCH COVER
OPERATIONS ! (DANGER BY OBJECTS FALLING DOWN !)

IT IS STRICTLY FORBIDDEN TO ENTER ONTO THE HOLD COAMING OR

THE STORAGE SPACE AS LONG AS THE COVERS ARE NOT FULLY
OPENED AND SECURED OR IN FULLY CLOSED POSITION !

OPERATING OF HATCH COVERS BY CREW MEMBERS ONLY !

OPERATORS MUST BE INSTRUCTED, WELL TRAINED AND FAMILIAR
WITH THIS GUIDANCE MANUAL !

General hints

All control desks for operating the hatch covers are arranged on
weatherdeck.
The hatch covers are operated from the control desks arranged on AFT. end.

Attention:
When the covers are lowered and secured to the coaming check following
points:

− when loaded, the covers shall rest on all supports uniformly

− all wheels must turn free, even with load on the covers!
− When No.4 hold is full charged of ballast water, the anti-lifting device must be
locked on the end of hatch covers.
− Before No.4 hold ballasting / de-ballasting must open all ventilator covers for
air free purpose.

3.1.1 Limitation of operation

The hatch covers are designed for operation under conditions up to

max. Trim of ± 2,0° and max. Ship’s heel of ± 3,0°.

Temperature range from –20°C to + 45°C.

3.1.2 Preparations before opening the holds

− Remove deck load from the hatch covers.

− Make sure that there is no cargo or other obstructions in the path and the
stowing space of the hatch covers.

− Check cleanliness of coaming top before operating the covers.

 − On weatherdeck, disengage “anti-lifting” pins of No.6 hatch cover of water
ballast hold.

3.2 Opening of the holds

At the control desks: Check all by-pass to be closed. (See drawing no.
533-9000.)

3.2.1 Start both pumps at both power units.

− Power unit no. 1,2 feeds oil for all hatches.

3.2.2 Opening the weatherdeck holds

Start the pump.

Release the locking pin of auto-roll assembly. Furthermore, release the

locking pin of anti-lifting device for water ballast hatch cover.

Open the ball valves in the control valve unit.

Push the lever for cylinders to “CLOSE” seconds, and to "OPEN" and remain in
this position. Until the cog segment touch the stopper of auto-roll assembly.

Push the control valve lever for the motor which is to be operated to "OPEN"
and hold it there until the cover has been opened.

Reduce cover speed before striking stopper by gently returning control lever to
neutral position.

Lock the panel with the pin of the end stopper for open position.

The opposite panel can now be closed or operated to outer position and locked.

After opening operation, push the lever for cylinders to "CLOSE" and remain in
this position. Until the double link touch the stopper of auto-roll assembly. And
lock the locking pin of auto-roll assembly.

Closing the ball valves.

Stop the pump unit.

3.2.3 Closing of the weatherdeck holds

Start the pump.

Release the locking pin of auto-roll assembly.

Open the ball valves in the control valve unit.

Push the lever for cylinders to “CLOSE” seconds, and to "OPEN" and remain in
this position. Until the cog segment touch the stopper of auto-roll assembly.

Release the locking pin of end stopper for open position.

Push the control valve lever for motor, which will be operated to "CLOSE" and
hold it there until the cover is stopped gently against the cog segment .

Reduce cover speed by inching control of valve lever before coming into contact
with cog segment .

Push the lever for cylinders to "CLOSE" to roll down the cover. Until the cover
has been closed completely.

After closing operation, lock the locking pin of auto-roll assembly.

Closing the ball valves.

Stop the pump unit.

 GUIDANCE MANUAL

Weatherdeck hatch covers

4. Troubles, Emergency Operation

4.1 Troubles

Reaching an oil temperature of 60°C the thermostat will switch off the
concerned power unit. Re-start after the oil has cooled down.
If the oil temperature is below 5°C the thermostat will switch off.
A level switch switches off the concerned power unit when the oil level is too
low.
An adjustable timer will switch off the concerned power unit after 30 running
minutes.
A pressure switch will be alarmed if the return line filter is contaminated.

4.2 Emergency operation

During operating, the covers will stop immediately in each position when putting
the hand lever of the related control valve back into neutral position.

By pushing an “Emergency off” push button(mounted in the pump room), the E-

motors of the related power unit will be switched off and all motion of the hatch
covers of the related hydraulic circuit will stop immediately.

If a pipe line between a control desk and a power unit should burst or if a power
unit should fail, all motion of the concerned hatch covers will be stopped
immediately.

If a pipe line between a control desk and cylinders should burst, the unsecured,
concerned folding pair will run downwards. However, speed is limited by flow
control valves incorporated into the cylinders and is about 1,3 of the normal
speed.
 GUIDANCE MANUAL

Weatherdeck hatch covers

5. Maintenance
5.1 Maintenance of hatch covers

5.1.1 Lubrication

Maintenance of the equipment is foremost systematic lubrication of the movable

parts for keeping them easygoing and to prevent corrosion. Lubrication shall be
done after every use, but latest after every two months and after heavy weather.

5.1.1.1 Lubrication of grease nipples applied with grease gun

WEATHERDECK
Part name Quant. Location
Bearing 70 AutoRoll system assembly
Wheel 56 Hold 1~7
Grease nipple 112 Oil motor bed
The pin of stowage stopper 14 Stowage stopper
Cylinder rod side 14 Link of AutoRoll system
Cylinder seat 14 The pin of seat
Rail flap 56 The pin of rail flap

5.1.1.2 Lubrication with open gear grease applied with swap

Part name Quant. Location
Touch block 28 Weatherdeck covers/coaming
Guide block 28 Weatherdeck covers/coaming
Locking pin of AutoRoll system 14 AutoRoll Mechanism
Pin for eyeplate of AutoRoll 28 Eyeplate of AutoRoll
Cog wheel 42 Oil motor bed
Oil nylon touch plate 14 Oil motor bed
…all movable parts

5.1.1.3 Lubricant – alternatives: please see next page

5.1.1.4 Maintenance of the sealing

The rubber sealing must be greased with silicon grease. This will essentially
lengthen its lifetime.
 Lubricants – Alternatives

Maker Gear Oil Open Gear Grease for Lubricant Grease for
Swab Nipples
Antar (Aral) Epona Z 150 Engrenage 1401 Multiservice
BP Energol GR-XP 150 Energol GR 3000-2 Energrease LS 3
Castrol Alpha SP 150 Grippa 60 S Spheerol LMM *
Rustilo 553 Spheerol AP 3
Chevron NL Gear Compound 150 Pinion Grease MS Polyurea EP Grease
(Pinion Grease 250 TCB) (Dura-Lith Grease 2)
Dow Corning Molykote 165 X * Molykote Longteam2*
Exxon (Esso) Spartan EP 150 ENL 55 * Beacon 3
Beacon EP 2
Fina Giran 150 Cabline Fluid 2750 Marson EPL 2
Gulf EP Lubricant HD 150 Spray Lubcote No. 1 Gulfcrown EP Gr. 2
Mobil Oil Mobilgear 629 Mobiltac 81 Mobilflex 47
Mobilgear 630 Mobilux EP 2
John W. Miller Black-Moly * Black-Moly *
& Son Ltd. Millergrease D-580-LC Millergrease D-180
Norus Sales Norus Plasticoat DC Black
Company
Shell Omala Oil 150 Cardium Compound D Alvania R3
Cardium Fluid F Alvania EP 2
Slip Products Molyslip MPG * Molyslip MPG *
Co. Ltd. Molyslip OGL *
Sunoco Sunep 1050
Sunep 1090
Texaco Merapa 150 Crater 1 X Multifax EP 2
Multigear Lub EP 90 Crater 2 X Fluid
Texclad 2
Valvoline Dipper Stick Lube Wheel Bearing Grease
EP 2

*) contains Molybdenum disulphide

Special grease for equipment and accessories arranged in reefer holds and when
temperatures below 0°C Celsius are to be expected: Zerolene DLF

Special silicon grease for rubber packings: Silicon paste P

…
5.1.2 Auto cleats

Check periodically that all hooks are firmly engaged on the weatherdeck hatch
covers.

If the clearance (0-3 mm is permissible) between hook and wedge on coaming

is too much, adjust it by the hexagon nut.

The elastic washer must be replaced when the rubber has lost its elasticity.
Replacing is recommended every second year.

5.1.3 External Painting

The hatch covers should be preserved according to the ship’s painting

specification.

Do not paint rubber seals, piston rods of hydraulic cylinders and flexible hoses.

5.1.4 Welding and flame cutting

− Do not damage rubber seals by heating. Dismount them when nearby areas
are being repaired.

− When large-scale repairs of the equipment are undertaken, call for a TTS
expert in order to avoid deformations and twisting by wrong welding
sequences which could avoid water-tightness.

5.1.5 Replacing damaged rubber seals

− Perform gluing as described in the enclosed instructions (see page 5.5 ff.)

− When replacing the complete rubber sealing, the corner pieces must be
glued first, then the straight line rubber strips –with an over-length of
abt. 2-3 mm per meter- have to be installed.

− For connection of moulded pieces and/or straight strips the ends have to be
cut accurately and in right or 45° angle.
5.1.6 Mounting instructions for TTS seals

5.1.6.1 The TTS SQUARE seal shall be glued in between the seal retainers
(L100x63x8).
Adhesive to be used: HAWE “Super S” or an equivalent glue approved by TTS.
Follow manufacturer’s instruction for use of the adhesive (JY-2).

5.1.6.2 Before installation of the seal strips make sure that:

a) they have been unrolled as a straight line and have

rested in this condition at least for 24 hours,

b) the seal dimensions have been checked carefully,

especially the height of the seal profile.

If the stated deviations exceed the allowable tolerances,

TTS must be informed immediately.

5.1.6.3 Cut the rubber profile accurately and in correct right angle in order to fit each
other. Prepare the straight strips by cutting with overlength (max. 2-3 mm per
meter) so that they will be slightly compressed longitudinally when inserted.
The rubber seal shall not be stretched during the installation.

5.1.6.4 The rubber seal has to be dry and free of dirt and grease. It is recommended to
roughen the contact surfaces and wipe them with thinner shortly before gluing.
Use therefore clean cotton waste only.

5.1.6.5 Mix the glue thoroughly and apply it without thinner.

5.1.6.6 First of all insert the corner pieces (use screw clamps, if necessary). Spread
rear of the rubber corners with glue by using a paintbrush. The glue is ready for
application when the surface still feels sticky but shows no threads by touching
with a finger. Fit the corner pieces into the retainers and hit them with a rubber
hammer.

Notice: It is advisable to make a test before beginning to work as the drying of glue
depends on the ambient temperature and weather conditions.
5.1.6.7 For gluing rubber to rubber (end pieces, corners and hoses) use the special
glue LOCTITE 495. Pay attention to the working instructions of the
manufacturer of the glue.

5.1.6.8 The three surfaces of the retainer channel for the straight rubber seal
(“L100x63x8”) must be painted with glue quite thickly by using a paintbrush.

5.1.6.9 Immediately after this, and before the glue has become dry, the contact
surfaces of the straight seal strips must also be painted with glue. Then press
the rubber seal into the angle bar-100x63x8. During the inserting the wet glue
shall fulfil the function as some kind of lubricant and it will act as sealing
material between steel and rubber.

5.1.6.10 Connect both profile ends (corner and straight line) with elastic rubber cement
(Loctite 495), press them together and make sure that the joint surfaces have
correct contact. If necessary, bend inwards the seal bars by hammering.

5.1.6.11 After finished installation all joining edges and gluing seams must be sealed
with elastic rubber cement (Loctite 495). Unevennesses have to be smoothed
and planned.

Caution:

The adhesive is highly inflammable!

All necessary precautions must be taken!

5.1.7 Description of the adhesive “JY-2”

The “JY-2” is a one-component high-performance adhesive. An excellent

attribute is gluing together rubber to rubber, rubber to metal, wood or plastics.

The adhesive is resistant against water and high temperatures, flexible and
qualified for high mechanical stress.

5.1.7.1 Directions for use

Before using, stir up well. The surfaces have to be BVolutely clean and dry. For
better adhesive power, smooth surfaces shall be roughed and the work should
be done at room temperature.

Both surfaces are to coat with a thin film of the “JY-2” glue. After about 8-20
minutes, as a normal time for ventilation, press together both parts.
Thickness of coating, time for ventilation, a second coating perhaps or one-time
wet-gluing depends on materials, expected mechanical stress and other
influences of the environment, for example temperature, dampness, working
rate and others.

5.1.7.2 After use

Remarks: Storage time at room temperature 10°C-35°C is about 12 months. Colour:

yellow.

Though the quality of our “JY-2” adhesive is always constant, it is indispensable

to make tests of gluing before use in order to test the environment conditions
and the mode of working procedure.

We will not be liable for damages caused by disregarding of our directions for
use.

Safety advises
Adhesive inflammable ! Keep box well closed!
Storage must be ventilated ! Avoid flames and sparks!
Cut off electrical devices ! Don’t let reach into
Smoking prohibited ! sewerage!
Take care of good ventilation of the room during and after working !
Take steps to avoid electrostatic charges !
5.2 Maintenance of hydraulics
As pumps are working in hydraulic fluid, maintenance is limited to keep the
hydraulic fluid perfectly clean. Cleanliness is achieved by the return line filter
which requires a systematic maintenance. After repairs of pipe lines, especially
during the first operation hours, keep an eye on the filter unit, because small
particles may flow in the circuit. Therefore, clean the filter at the beginning
several times.

5.2.1 Warnings

REPAIRS ON THE HYDRAULIC SYSTEM WITH CLOSED HATCH COVERS ONLY!

OTHERWISE THE COVERS COULD MOVE UNINTENTIONAL.

BEFORE DETACHING ANY CONNECTION MAKE SURE THAT THE HYDRAULIC

SYSTEM IS PRESSURELESS. THIS HAS TO BE DONE BY SWITCHING OFF THE
PUMP UNIT AND MOVING THE CONTROL LEVERS FROM THE “OPEN” TO THE
“CLOSE” POSITION SEVERAL TIMES. OTHERWISE PRESSURISED OIL COULD
HURT PEOPLE AND CAUSE SERIOUS INFECTIONS!

PAY ATTENTION TO THAT IT IS IMPOSSIBLE FOR UNAUTHORISED PEOPLE TO

START THE PUMP UNIT AS LONG AS WORKS WILL BE DONE AT THE SYSTEM.

USE ORIGINAL HYDRAULIC HOSES ONLY! PAY ATTENTION TO PROPER

DIMENSIONS OF HYDRAULIC HOSES!

5.2.2 Regularly

Before starting the power unit, check the oil level in the tank. Refill if necessary,
but only with closed holds.
Check the condition of the return line filter.
Check the function of the “Emergency stop” switches.

5.2.3 Every six month

Check pipe-lines, flexible hoses and units for corrosion, wear, leaks etc.

5.2.4 Every year

Consult your oil company’s representative and arrange for a check on the
condition of the oil. If necessary, change the oil of the system. Take care of the
regular removal of the wear up oil.

5.2.5 Hydraulic fluid specification

Hydraulic fluid requires a certain consistence of oil. To comply with this the
hydraulic system has been filled with a sufficient oil type. When refilling, use the
same oil or an approved equivalent (see “Characteristics for hydraulic oil” page
below)
Characteristics for hydraulic oil
viscosity index (V. I.)
pour point °C
flash point °C
viscosity cSt at ... °C
relative density at °C

Remarks:

146- Viscosity index is a measure of the relative

change in viscosity for a given change in
emperature.
A high V. I. Oil (abt. 180) shows less change
in viscosity for a given change in tempera-
ture than a low V. I. Oil (abt. 100). The
greater the temperature range, the higher
V. I. Is required.

146- Requirement concerning the flash point:

American Bureau of Shipping: 157°
Det Norske Veritas: 150°
U.S. Coast Guard: 157°

146- The viscosity in cSt at 40°C is always in

accordance with the related ISO-viscosity ISO
group. For instance, the viscosity of
32 cSt at 40°C is equivalent to (ISO) VG 32.

146- For oil changing prefer the „first filling“ oil

quality. If not possible pay attention to the
miscibility of the old and the new oil filling.

Hydraulic oils for drive machinery of

cargo access equipment
.... for defined weather conditions
Hydromotorantrieb Zylinderantrieb erforderliche ISO-Viskosit’sgruppe
Hydraulic motor Hydraulic cylinder required ISO-viscosity group
A – (ISO) VG 15
W – (ISO) VG 15
W&S A (ISO) VG 22
T W&S (ISO) VG 32
– W&S (ISO) VG 32-46
– S&T (ISO) VG 46

A = artic conditions
W = winter conditions in Central Europe
S = summer conditions in Central Europe
T = tropical conditions

Note:
Oils(ISO)VG15shouldonlybeusedduring
extremlycoldconditions.Flashpointinthisgroup
isverylow,therefore,theClassificationSociety
should be consulted in any case.
Necessary ISO-Viscosity group according to page „Characteristics for hydraulic oil“

Pour Flash ISO-Viscosity group Relative

Designation V.I. point point Viscosity cSt at Density
°C °C 0°C 20°C 40°C at 15°C
ARAL Visga 15 150 -45 190 15 0,860
ARAL Visga 22 160 -42 170 23 0,865
ARAL Visga 32 180 -42 190 32 0,870
ARAL Visga 46 180 -42 200 46 0,875

BP Bartran HV 15 148 -45 160 75 28 15 0,874

(BP Bartran HV 22) 152 -39 178 135 48 22
BP Bartran HV 32 152 -33 210 240 75 32 0,870
BP Bartran HV 46 153 -36 210 400 46 0,877

CASTROL Hyspin AWH 15 150 -51 162 75 15 0,869

CASTROL Hyspin AWH 22 94 -39 171 180 22 0,886
CASTROL Hyspin AWH 32 150 -33 163 200 32 0,876
CASTROL Hyspin AWH 46 150 -33 166 380 46 0,880
CASTROL Hyspin AWV 32 355 -53 111 30 0,876

CHEVRON Mechanism LPS 15 153 -51 160 15 0,860

CHEVRON Mechanism LPS 32 151 -48 200 32 0,870
CHEVRON Mechanism LPS 46 151 -42 210 46 0,870

DEA Astron Z HLP 15 150 -39 150 15 0,879

DEA Astron HLP 22 100 -30 196 22 0,873
DEA Astron Z HLP 32 160 -33 182 32 0,873
DEA Astron Z HLP 46 158 -39 175 46 0,879

ESSO Nuto H 15 100 -33 186 100 33 14 0,850

ESSO Nuto H 32 100 -30 210 340 82 30 0,872
ESSO Univis N 15 151 -45 189 77 30 14 0,862
ESSO Univis N 32 151 -42 212 250 75 30 0,870
ESSO Univis N 46 152 -39 221 420 118 44 0,873

MOBIL DTE 11 M 158 -42 168 85 16 0,871

MOBIL DTE 13 M 153 -45 195 251 33 0,874
MOBIL DTE 15 M 153 -43 200 404 47 0,877
MOBIL SHC 524 141 -60 230 30 0,851

Shell Tellus Oil T 15 150 -60 150 100 15 0,885

Shell Tellus Oil T 32 165 -45 190 260 32 0,867
Shell Tellus Oil T 46 180 -45 190 380 46 0,870
5.2.6 Oil exchange and pump bleeding

IMPORTANT NOTES:

OIL EXCHANGE WITH CLOSED HATCH COVERS ONLY !

ENSURE THAT THE WEARED UP OIL WILL BE REMOVED ACCORDING

TO THE RULES OF POLLUTION CONTROL !

5.2.6.1 Preparation

− Control quantity and type of the new oil (see chapter 1).

− Keep ready a new filter insert and a new copper sealing ring for the drain
plug.

− Keep ready a sufficient number of containers suitable for taking up the

weared up oil.

− To BVorb oil running over keep ready suitable means such as sawdust or
granules.

5.2.6.2 Draining the worn up oil

− Close the ball cock in the P-line and detach the pressure hose. Insert the
pressure hose into a suitable container and switch on pump no. 1 or 2 to
suck off the worn up oil until the level switch will stop the pump.

− Screw out the drain plug at the bottom of the hydraulic power station to
remove the remaining oil.

− Renew the filter insert of the feed back strainer.

− Attach the new copper sealing ring to the drain plug and screw it into the
tank. Attach the pressure hose, too.

Note: When exchanging by reason of worn up oil the remaining small quantity of oil in
the system (cylinders and pipes) shall not be removed. To bleed the whole
system thereafter could take a long time caused by remaining air in small holes
inside the cylinders and control desks.
5.2.6.3 Bleeding of the hydraulic pump

At first initial operation, and after every oil exchange, the pumps should be bled
in order to avoid suction problems or the penetration of air into the consuming
elements. Act as follows:

− Before filling the tank with hydraulic oil unscrew the vent screw of the pump
completely.

− Fill up the tank to the upper mark with new hydraulic oil. It may be efficient to
wait a few minutes until the oil has displaced the air inside the pump.

− Screw in and tighten the vent screw and switch on and off the pump for
several times.

− Allow the pump to run in an unpressurized cycle for a short period of time
(3-5 minutes) by acting as follows:

∗ Open the by-pass valve (if existent)

∗ Reset the pressure relief valve at the power unit to a pressure value of
zero by screwing it left.

∗ Close the ball cock in the pressure line P

− Start the pump. The pressure gauge shall show no pressure. Close slowly
the by-pass valve (if existent).

− Set the system pressure slowly up to 350 bar by screwing the pressure relief
valve right. In case the pressure gauge will show no pressure, open the by-
pass valve slowly, reset the relief valve to zero, stop the pump and bleed it
again by unscrewing the vent screw.

− Bleed pump no. 2 the same way as described above.

5.2.6.4 Adjusting the rated value

− Open the by-pass valve (if existent)

− Start both pumps.

− Slowly close the by-pass valve (if existent).

− Set the system pressure slowly up to the nominal value by screwing the
pressure relief valve right.
 − Secure/lock the relief valve and check pressure value again!

− Open the ball cock in the pressure line P. Keep covers closed and check oil
level again. Refill if necessary. Now, the power station is ready for use again.

5.2.6.5 Exchanging the oil by reason of emulsification (water in the system)

In this case the whole oil has to be exchanged. Empty the tank as described at
paragraph 5.2.6.2, open the tank by dismounting the cover plate and clean the
empty tank with a no-fluffing cleaning-rag. Thereafter act as described at
paragraph 5.2.6.3 and 5.2.6.4.

The remaining oil in the system (cylinders and pipes) should be removed by
scavenge with new oil as follows:

− Detach return line R and insert it into a suitable barrel

− Switch on one pump. The contaminated oil will be pushed through the pipes
into the barrel.

− Operating the hand levers situated at the control desks (opening and closing
of all hatch covers) the contaminated oil resting in the cylinders and their
pipes/hoses will be removed.

− During scavenging, refill the tank continuously with new oil.

 GUIDANCE MANUAL

Weatherdeck hatch covers

6. Service & Spare parts

6.1 Spare parts

6.1.1 Spare part list

The equipment has been completed with a number of spare parts according to
the recommendations of the classification society. These parts must be
available on board at every time (see the following pages “Spare Part List”).
Additionally, we recommend to establish a stock of other types of spare parts
available on board, which is a must if you wish to keep your ship in a proper
service condition and to be prepared against hazards.

6.1.2 Supply of spare parts

All important components of the equipment are shown on a respective

assembly drawing (see chapter 5). Each drawing has a drawing number (in the
below right hand corner) and the parts are marked with item numbers.

WHEN ORDERING SPARE PLEASE STATE:

1. Ship’s name, Yard, Hull No.
2. Title of assembly drawing.
3. Drawing no. of assembly drawing.
4. Item number of detail part.
5. Title of detail part.
6. Dwg.No. or DIN no. of detail part, if any.
7. Quantity required.
8. Delivery terms and forwarding address.
9. Customer and acceptor of the bill.

Attention:

− Note eventual right or left hand shape of the components.

− Don’t use part’s name only. This might cause errors or
delayed delivery.
− Clearly indicate complete description of the part as well as drawing no. and
item no.
− Use original spare parts only !
− Otherwise risk of malfunction, damages and hurts !
6.2 Spare parts and tools list

ITEM NO.
DENOMINATION DRAWING NO. UNIT REMARKS
NO. OFF
1 Auto-cleat-side M56 (40°) HCA.56.4000 set 1
2 Auto-cleat-end M56 (30°) HCA.56.3000 set 1
3 Auto-cleat M42 HCA.42.4000 set 1
4 Square Sealing 94x55 HRC.50.0000 m 27
5 Square Sealing 100x55 HRC.60.0000 m 17.5
6 Corner Sealing HRC.69.0101 piece 1
7 Corner Sealing HRC.69.0201 piece 1
8 Flat end joint 94x55 HRC.53.2001 piece 2
9 2-way Corner Sealing HRC.52.1021 piece 1
10 Corner Sealing 94x55 HRC.51.0101 piece 1
11 Corner Sealing 94x55 HRC.51.0201 piece 1
12 Glue(Jy-2) piece 1
13 Glue(Loctite-495) piece 1
14 Polyurethane Sealant piece 1
15 Weldox 30x80x200 piece 2
16 Weldox 30x80x300 piece 2
17 Hardox 10x110x220 piece 2
18 Hardox 10x110x330 piece 2
19 Hardox 10x110x452 piece 2
20 Wheel Cap Wrench piece 1
21 Wrench For Auto Cleat Nut 65 piece 1
22 Wrench For Auto Cleat Nut 85 piece 1
23 Tool box piece 1
24 Greasing Nipples PT1/8 piece 20
25 Greasing gun piece 2
26 Hose for Cylinder set 2
27 Filter element piece 1
28 Hose for power pack set 1 Per type
29 Seal kit for power pack set 1 Per type
30 Bearing for E-motor set 1 Per type
31 Control relay set 1 Per type
32 MCB set 1 Per type
33 Bulb of lamp piece 2 Per type
34 Overload relay with MCB set 1 Per type
35 Pushbutton piece 1 Per type
36 Lense piece 2 Per type
37 Hose for Hy-motor set 2 P line
38 Hose for Hy-motor set 1 Drain line
38 Seal kit for cylinder set 1
39 Seal kit for control valve block set 1 Per type
40 Wrench set 2
41 Wrench for wheel cap set 2
6.3 TTS Service-stations world-wide

Please turn over to find our small booklet

"Global Ship Service World Directory"
which lists world-wide addresses and the corresponding service
capabilities.

Should it be missing or outdated, please use the FAX form sheet

below for receiving a new one in return.

Make sure you receive immediate updates of your World Directory by

filling out this form and faxing it to us at TTS HuaHai Ships Equipment.
Please print your information with block capitals.

To: (Fax) ++86 021 65397400

From:

Name and Title

Company

Address

City

Country Postal Code

You will now receive your World Directory whether or not you choose to
provide us with the following additional information, which would be of help in
the updating of our database.

Which of the following areas is of interest to your company? (Check all

relevant areas)

‰ Pumps
‰ Cargo Access
‰ Gas Equipment
‰ Diesel Parts
‰ Integrated Bridge Systems
‰ Equipment Service Agreement with operational cost guarantee
 GUIDANCE MANUAL

Weatherdeck hatch covers

7. Certificates
 GUIDANCE MANUAL

Weatherdeck hatch covers

8. Drawings steel & fittings

8.1 List of drawings steel & fittings

8.1.1 Weatherdeck

533-1111 Fitting installation of No.1 H.C.

533-1112 Fitting assembly of No.1 H.C.
533-1211 Fitting installation of No.2 H.C.
533-1212 Fitting assembly of No.2 H.C.
533-1311 Fitting installation of No. 3&5-6 H.C
533-1312 Fitting assembly of No.3&5-6 H.C
533-1411 Fitting installation of No.4 H.C
533-1412 Fitting assembly of No.4 H.C.
533-1711 Fitting installation of No.7 H.C
533-1712 Fitting assembly of No.7 H.C.

8.1.2 Fittings weatherdeck

533-1050 Sealing Plan Of Hatch Cover

533-1061 Wheel (Plain)
533-1062 Wheel (Flange)
533-1063 Auto-Roll System Assembly
533-1064 Touch Guide
533-1065 Stowage Stopper Assembly
533-1066 Grain Loading Scuttle Assembly
533-1067 Air Ventilation Assembly
533-1068 Installation Bolt Assembly
533-1069 Name Plate And Number Arrangement
533-1070 Gas Sampling Assembly
533-1071 Stanchion Arrangement Of No.1-4&6&7 H.C.
533-1072 Stanchion Arrangement Of No.5 H.C.
533-1073 Oil Motor Bed Installation
533-1074 Gas Sampling Assembly
533-1075 End Stopper Assembly
533-1076 Drain Valve
533-1077 Sounding Cap
533-1161 Rack And Driving Arm Of No.2-6 H.C.
533-1162 Auto Cleat Side (M42)
533-1163 Auto Cleat End (M42)
533-1261 Rack And Driving Arm Of No.2-7 H.C.
533-1361 Landing Mark Of Helicopter
533-1461 Auto Cleat Side (M56)
533-1462 Auto Cleat End (M56)
533-1463 Antilifting Device Of No.4 H.C
533-1464 Caution Plate For Ballast
533-1465 Floating Ventilator Assembly
 GUIDANCE MANUAL

Weatherdeck hatch covers

9. Drawings Hydraulic
9.1 List of drawings hydraulic

9.1.1 Weatherdeck

533-9000 Hydraulic diagram for hatch cover

533-9100 Hydraulic pump station
533-9110 Transportable pump unit
533-9200 Control valve
533-9270 Ball valve
533-9300 Hydraulic cylinder Ø140/90-550
533-9350 Hydraulic motor
533-9400 Hydraulic hose for hy-motor
533-9401 Hydraulic hose for hy-motor drain
533-9402 Hydraulic hose for hy-cylinder
 GUIDANCE MANUAL

Weatherdeck hatch covers

10. Drawings Electric

10.1 List of drawings electric

533-9800 Circuit diagram of starter

533-9801 Terminal connection of starter
533-9810 Panel geometry of starter
533-9820 Circuit diagram for portable pump unit
533-9830 Stainless steel box for emergency stop button
533-9840 Socket for transportable pump unit
 GUIDANCE MANUAL

Weatherdeck hatch covers

11. Drawings Pneumatic

........no pneumatic drawings

 GUIDANCE MANUAL

Weatherdeck hatch covers

12. For Your Notes

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HuaHai
DESIGN

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DESIGN
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H ua Hai H ua Hai H ua Hai H ua Hai H ua Hai H ua Hai H ua Hai

HuaHai
DESIGN

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DESIGN
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H ua Hai H ua Hai H ua Hai H ua Hai H ua Hai H ua Hai H ua Hai

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DESIGN

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DESIGN
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H ua Hai H ua Hai H ua Hai H ua Hai H ua Hai H ua Hai H ua Hai

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DESIGN

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DESIGN

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 TTS Hua Hai Ships Equipment Co Ltd

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TTS HuaHai
 I J K

A B
L M N O

C D P Q R

E F T U V W

X
G H
 φ30x4 φ35x4

28 29

P T
21
11
G1" 10
G1 1/4"
20
P1'

22 25.1MPa
17.1 17.2
23

P1 P2 T1 NG25

18

27.1 27.2
G1 1/4“
FILLING

15.1 14.1 15.2 14.2

12.1 12.2
26L/min 26L/min 6
25MPa
M1 25MPa
M2
7
13.1 13.2

16.1 16.2

26.1 26.2
25.1 25.2 19 24
4

9.1 9.2

3
5

2 1
3kW 440VAC φ3

G1/2"
8
 A

16 17

2
15 9

P1
14

25MPa
13
11 12

P T

7
8
4 13L/min
25MPa M
10
5
6 18

1
 7.2 7.3 7.4 7.5 7.6 7.7
φ20x3 φ20x3 φ20x3 φ20x3 φ20x3 φ20x3
MA1 A1 B1 MB1 MA2 A2 B2 MB2 MA3 A3 B3 MB3

4.3 4.5

4.4 4.6

3.1 5 4.2 3.3

3.2
120bar 60bar

T 6.1 150bar
100bar 4.1 6.4 150bar

A1 A2 A3 80bar 250bar 80bar

6.2 6.3 6.5

P B1 B2 B3 12
2.1 2.2 2.1

7.1 1.1 1.2 1.3

MT QT

4-M10 13 9

QP

A B
P T

P T 10 11

A B A B
φ30x4 φ35x4

P T P T

MT QT
QP MA2 MB2
MB1 MB3
MA1
MA3
 TTS Hua Hai Ships Equipment Co Ltd

TTS HuaHai
± 10
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*
*
*
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*

填料函孔径范围列表
 I J K

A B
L M N O

C D P Q R

E F T U V W

X
G H
 插座

15"斜面

PG21 PG21