Light Weight Taut Wire MK 15B Operation and Maintenance Manual

Bandak
Light Weight Taut Wire Mk 15B

Volume 3 Maintenance Manual
Sagamoen, N-3825 Lunde, Norway

Phone +47 35 94 66 00 Fax +47 35 94 66 01
www. bandak.no
Light Weight Taut Wire Mk 15B Operation and Maintenance Manual
Document revisions
Written by Checked by Approved by
Rev.
Date Sign. Date Sign. Date Sign.
A 21/9-04 SL 25/9-04 HT 30/9-04 SL
B
C
D
2
Table of contents
1 INTRODUCTION .......................................................................................................... 6
2 ABBREVIATIONS......................................................................................................... 7
3 MAINTENANCE ........................................................................................................... 8
3.1 Spare Parts ................................................................................................................. 8
3.2 Ordering Spare Parts.................................................................................................. 8
3.3 Repair of faulty parts ................................................................................................. 8
3.4 Handling and storing of Spare Parts .......................................................................... 9
3.5 Returning faulty parts for repair ................................................................................ 9
3.6 Maintenance Guidelines ............................................................................................ 9
3.7 Replacing Parts .......................................................................................................... 9
3.7.1 Electrical System ............................................................................................... 9
3.7.2 Hydraulic and Pressurised Air System .............................................................. 9
3.8 Periodic Maintenance Procedures ........................................................................... 11
3.9 Recommended Hydraulic Oils ................................................................................ 15
3.9.1 Oil viscosity..................................................................................................... 17
3.9.2 Oil change ........................................................................................................ 17
3.9.2.1 Hydraulic tank .......................................................................................... 17
3.9.2.2 Transmission............................................................................................. 17
3.10 Wire Rope & Couplings .......................................................................................... 18
3.10.1 Wire Rope ........................................................................................................ 18
3.10.2 Maintenance..................................................................................................... 18
3.10.3 Storage ............................................................................................................. 18
3.10.4 Replacement .................................................................................................... 19
3.10.5 Replacement procedure ................................................................................... 19
3.10.6 Overhaul .......................................................................................................... 19
3.10.7 Couplings ......................................................................................................... 20
3.10.7.1 Swivel....................................................................................................... 20
3.10.7.2 Shackle ..................................................................................................... 20
3.10.8 Clamping.......................................................................................................... 20
3.10.8.1 Clamping with Eureka Clamps................................................................. 20
3.10.8.2 Clamping with Talurit Clamps ................................................................. 20
3.11 Fleet Angle Compensator ........................................................................................ 21
3.11.1 General information......................................................................................... 21
3.11.2 Initial Adjustments........................................................................................... 21
3
3.11.3 Adjustment chart.............................................................................................. 26

3.12 Pre-set Parameters ................................................................................................... 27
4 DRAWINGS ............................................... FEIL! BOKMERKE ER IKKE DEFINERT.
5 VENDOR DOCUMENTATION ................................................................................. 80
4
Document History
Rev A Initial Issue
5
1 INTRODUCTION
The Taut Wire is a position reference system intended for a
deck-mounted, starboard or portside position, on most surface
vessels.
The purpose of the Taut Wire is to give accurate input data,
related to vessel movement, to the vessel's data processing
system to calculate vessel position corrections.
The purpose of this manual is to provide the user information
concerning the maintenance of the system to ensure optimum
reliability and service.
A complete set of technical drawings covering all electrical,
mechanical, pneumatically and hydraulically aspects of the
system will be found in a separate section.
As these drawings contain all details of the different functions
and the mechanical construction, are no unnecessary technical
descriptions or replacement procedures given, as these are
clearly self-evident to experienced maintenance crew.
Note All technical description, information and specification given in

this manual are subject to change without further notice.
6
2 ABBREVIATIONS
Abbreviation Explanation
DC Direct Current
DP Dynamic Positioning
KM Kongsberg Maritime
LTW Light Weight Taut Wire
PLC Programmable Logic Controller
TB Terminal Board
TW Taut Wire
UPS Uninterruptible Power Supply
7
3 MAINTENANCE
3.1 Spare Parts

The Spare Parts List specifies recommended quantities of parts
which, if held onboard, enables fast correction of most likely
faults, in addition the requirements of parts for periodic
maintenance and normal operational wear-and-tear and/or
losses.
Note The items identified in the list relate directly to the same item
identified on the relevant drawing in this manual
3.2 Ordering Spare Parts

Spare parts can be ordered from Kongsberg Maritime (KM), by
utilising the drawings, which relate directly to comprehensive
production parts lists held by the manufacturer.
Assembly drawings with ringed item numbers - quote the full
5-digit drawing number plus ringed item number.
Electrical schematics - quote the 5-digit drawing number plus
the component circuit reference.
After using all onboard spare parts, order a new from:
Spare Parts Dept.
Kongsberg Maritime
Postbox 483
N-360l KONGSBERG
NORWAY
3.3 Repair of faulty parts

Note NEVER REPAIR A FAULTY PART without first consulting
Kongsberg Maritime. This could lead to severe damage to
equipment and/or injury to personnel in addition to possible
invalidation of guarantee.
8
3.4 Handling and storing of Spare Parts

Spare parts are expensive, and must be available in good
condition when required, therefore:
Extreme care should be taken when handling and fitting spare
parts.
Always store spare parts in a dry clean room.
3.5 Returning faulty parts for repair

When the new part is received, send the faulty part back to
Kongsberg Maritime for repair, using the same packing material
that was used for the new part.
3.6 Maintenance Guidelines

WARNING Never attempt to carry out maintenance with an unsecured
boom or raised depressor weight or if the air reservoirs are
not fully evacuated.
3.7 Replacing Parts

The procedures for changing defective parts are usually self-
evident when carried out in conjunction with the relevant
diagrams in the drawing section.
Although experienced maintenance crew will be familiar with
all maintenance procedures, the following points are provided as
a general reminder.
3.7.1 Electrical System

When carrying out procedures, which require the removal of
electrical or electro-mechanical items
SWITCH OFF THE RELEVANT POWER SUPPLIES to
the equipment.
Always MARK ANY WIRES REMOVED so that they can be
reconnected in correct locations.
3.7.2 Hydraulic and Pressurised Air System

When carrying out procedures which require dis mantling of
hydraulic or air system units, always:
9
CARRY OUT SUCH WORK IN A SCRUPULOUSLY

CLEAN ENVIRONMENT, ideally designed for the purpose,
to obviate the ingress of dirt and/or other contamination that
could lead to either a breakdown or a shortened life of the
equipment.
EXAMINE CONDITION of SEALS, GASKETS etc, for
damage and/or deterioration. Renew such items.
TIGHTEN FASTENINGS TO THE CORRECT TORQUE
in Nm according to table no. 3.1.
Table 3.1 Bolt Torque (Nm)

CLASS M5 M6 M8 M10 M12 M16 M20 M24
80 6,3 10,7 25,7 50,6 88,0 214,5 418,5 723,4
70 5,7 7,2 17,6 35,0 61,2 152,0 296,4 512,8
50 3,6 6,1 14,9 29,5 51,4 127,8 249,7 431,8
UNC
CLASS 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1
80 11,9 24,0 42,2 101,8 201,5 354,0 566,5 848,0
70 7,8 16,1 28,7 70,4 140,7 250,0 400,6 601,2
50 6,7 13,7 24, 5 59,8 119,6 211,7 341,2 511,6
10
3.8 Periodic Maintenance Procedures

The maintenance procedures should be carried out at the
intervals stated to ensure that the system continues to perform at
optimum efficiency.
Note The manufacturer may perform certain of these procedures

under a separate Service Contract, thus relieving the user of
responsibility
After the procedures specified for each interval (daily, weekly,
monthly, etc) have been carried out, the Log Book for the
system should be signed and dated as proof of conformance to
the periodic maintenance requirements.
Condition of the following are of particular importance
regarding the safety and reliability of the system:
Pressurised Air
Lubrication
Hydraulic Oil
Wire Rope and Couplings
Pre-set Parameters.
Note Before starting, it is advisable that the Log Book is examined for
any previous entries which could assist in the recommended
procedures
Table 3.2 Daily Maintenance

STEP PROCEDURE
1 Check condition of depressor weight, couplings and swivel.
2 Check hydraulic oil level and top-up if necessary (see table 3.8).
3 Drain air reservoir and air regulators for water.
4 Check oil level in air system lubricator. Top up if necessary.
5 Clean and lubricate all moving parts, exposed piston rods and shafts according to table 7.8
6 Clean fleet angle compensator shaft and lubricate fleet angle compensator sheave bearing.
11
Table 3.3 Weekly Maintenance

STEP PROCEDURE
1 Lubricate according to table 3.8
2 Visually inspect the hydraulic system for oil leaks.
3 Visually inspect the tension compensating system for proper movements and unnormal air
leaks.
4 Cut off approx. 5-10 metre of wire to prevent prolonged wearing of same wire length.
Record details of any length of wire removed in the PLC and System Log Book.
Table 3.4 Monthly Maintenance
STEP PROCEDURE
1 Lubricate according to table 7.8
2 Check connections and couplings of all moving mechanical parts for security.
3 Check all external surfaces, for damage, build-up of deposits, corrosion etc;
repair/clean/repaint if necessary.
4 Check all electrical components for corrosion, condensation, burning or other visible signs
of deterioration; rectify condition and cause.
5 Examine the operational length of wire rope for signs of wear, damage and fatigue. Cut of
any defective wire and record details of wire removed in the PLC and System Log Book.
6 Check position transducer to be +/- 9,95 volt by putting a voltmeter between TB176 and
TB204. Adjust on EM-9 if necessary.
12
Table 3.5 3-Monthly Maintenance

STEP PROCEDURE
1 Check conditions of hydraulic oil and take necessary action.
2 Check conditions of gear oil and take necessary action.
3 Using a digital voltmeter, measure in turn the voltage present on the terminal blocks of each
power supply unit, and check that they are within the following limits:
PSU 1 + 11,25 V + 0,05 V TB 161 / 162

PSU 2 - 11,25 V + 0,05 V TB 171 / 172
PSU 3 + 24 V + 10 % TB 179 / 180
PSU 4 + 24 V + 10 % TB 211 / 212
PSU 5 + 15 V - 15 v on EM9 TB 7 / 9
+ 15 v on EM9 TB 1 / 9
If the voltage of a PSU is out of limits and cannot be adjusted within limits: Verify that the
condition is not caused by excessive external loading. Replace defective PSU.
13
Table 3.6 6-Monthly Maintenance

STEP PROCEDURE
1 Overhaul the complete wire rope
2 Tighten all electrical terminal blocks, screws and connections.
3 Examine all electrical junction boxes internally, for ingress of saltwater, and for general
condition and security. Take necessary corrective action.
4 Examine the sensor potentiometer enclosures internally, for ingress of saltwater, and for
general condition and security; take necessary corrective action.
5 Check Fleet angle compensator, Guide-wheels, Gimbal head for general freedom of
movement, and for any signs of wear or deterioration and take necessary corrective actions.
6 Check Electric motor, Hydraulic pump, Boom cylinders plus any other moving parts, for
wear or noise that indicates wear and take necessary corrective action:
7 Verify that the pre-set parameters for Gimbal head potentiometer, supplies and angle are
within limits.
Inform Kongsberg Maritime both of the readings obtained above, in addition to details of any
malfunction; proceed with corrective action as advised.
8 Clean down thoroughly, both the complete installation and the surrounding area used for the
operation of the Taut Wire, to remove all traces of excess oil, grease and other undesirable
deposits.
9 Check quantities and condition of all spare parts designated for the Taut Wire installation.
10 Check Air Pressure Regulator Filters
Table 3.7 Yearly Maintenance

STEP PROCEDURE
1 Drain hydraulic oil tank and refill with recommended oil.
2 Drain gear oil and refill with recommended oil.
14
9 10
3
16 12
17
13
19
1 11
6
8
Figure 3.1 Lubrication, Ref. Table 3.8
3.9 Recommended Hydraulic Oils

The hydraulic system components are designed to operate with
conventional mineral-base hydraulic oil. Although the majority
of commercial mineral-base oil are suitable, its recommended
that only MOBIL DTE- 13M or its equivalent is used when
operating in the North Sea and DTE 15 M in tropical
environment. However, different viscosity as well as different
producers should not be mixed.
Note High operating temperature will reduce the life of oils, rubber
seals and gaskets. Recommended oil operating temperature
range is +30 to +55 C
15
Table 3.8 Lubrication

PERIOD REF. LOCATION PCS. LUBRICANT
Daily 6 Fleet angle compensator guide shaft 1 Oil
7 Fleet angle compensator sheave bearing 1 Mobilgrease MP
1 Hydraulic oil tank, top up Mobil DTE 13M
17 Air oil lubricator, top up 1 Mecman oil
Weekly Clean and lubricate all moving parts, Oil

exposed piston rods, shieves and
chromed shafts with recommended oil.
8 Fleet angle compensator sheave Mobilux EP 2&3
3 Hinges and latches 10 Mobilgrease SHC 460
10 Boom cylinder piston rods 2 Mobilgrease SHC 460
9 Wire rope operational length 1 Mobilarma 798
11 Boom cylinder bearing 2 Castrol Sperol SX2
12 Basket pivot bearing 2 Mobilgrease SHC 460
13 Boom upper pivot bearing 2 Mobilgrease SHC 460
3-Monthly 5 Gear oil, top up 2 Mobil Glycoyle
6-Monthly 19 Air press. reg. filters, check 2 Mecman filters
Yearly 1 Hydraulic oil tank, drain and refill. 1 Mobil DTE -13M
9 Wire rope: complete length 1 Mobilarma 798
Use lubricant type shown or equivalent
16
3.9.1 Oil viscosity

Note Recommended viscosity range when operating is 25 to 75 Cst.
The viscosity should under no circumstances be lower than 20
Cst.
Table 3.9 Oil temperature and viscosity
OIL TEMPERATURE VISCOSITY
OIL TYPE MIN. RECOMMENDED MAX. MAX. RECOMMENDED MIN.
DTE- 13M 15 38 55
100 35 20
DTE- 15M 23 48 64
For further information, see the liquid petroleum products temp

/viscosity card fig. 4.2.
3.9.2 Oil change
3.9.2.1 Hydraulic tank
STEP PROCEDURE
1 Drain oil from tank via filler plug.
2 Refill tank with new (recommended) hydraulic oil to the correct level via a filter unit.
3.9.2.2 Transmission
STEP PROCEDURE
1 Drain oil via bottom plug
2 Refill oil to level indicated by plug on end wall.
17
3.10 Wire Rope & Couplings

The following paragraphs discuss the importance which should
be given to both the wire rope as a "working" part of the system,
and the use and safety of depressor weight couplings.
3.10.1 Wire Rope

The min. breaking load of new wire rope is 18kN, and the
weight of the depressor weight is 350 / 465 kg. Consequently
the safe ty factor for a new will be 5 / 4. The strength of wire
rope is slightly reduced as rope have been used for some time.
Although this safety is completely satisfactory for its application
very careful treatment of the rope is required in order to avoid at
the worst, accidents, and at the least, unnecessary loss of
production time and expensive equipment due to wire breaks.
3.10.2 Maintenance
Like most other "machines" a wire rope is composed of many
movable components. The rope, therefore, should be subject to
periodical inspection, cleaning and re-lubrication.
The lubricant used should be a grease that is free from acid and
which can have no harmful effect either on the wires or on the
core, and must have a consistency that enables it to penetrate
into the rope. The rope manufacturer recommends Mobilarma
798. PROPER LUBRICATION IS IMPORTANT TO THE
SERVICE LIFE OF THE ROPE. The lubricant is serving both
as protection against rust and as a factor to reduce the friction
between strands in the rope.
3.10.3 Storage
Wire ropes should be stored at even temperature in a dry place.
For lengthily storage the rope should be particularly well
lubricated. Attention must be paid to the danger of condensation
in the case of outdoor storage under a tarpaulin.
A rope that has been used must be cleaned, dried and lubricated
before being put into storage. Ropes that have been exposed to
seawater should first be washed in fresh water before
lubrication.
18
3.10.4 Replacement
It is difficult to be precise about the point of time when a rope
should be replaced, however the following indications for
replacement are given:
If the rope has other defects making it unfit for further use,
for example: a kink, a single strand being brought out of
position, tendency to spiral formation etc. or any other defect
likely to cause jamming of the gimbal head.
If wire rope has been exposed to heavy wear.
It the wire rope has been exposed to corrosion.
It is imperative that the rope is replaced only with a
recommended type of the same quality and design as primarly
fitted.
3.10.5 Replacement procedure

Remove old wire. Wind on new wire keeping approx. 100-
150 kp tension on wire
Reset wirecounter by pressing F5 and hold for 2 seconds.
Press F4 and MOD
Punch in "7533" + ENTER
Press "MOD two (2) times
Punch in new wire length + ENTER
Press F12, Wire available on drum
Press F2 to go back to main meny
3.10.6 Overhaul
This should be performed at the 6-monthly period maintenance
or at a greater frequency if the use of the wire is excessive or the
local prevailing environmental conditions are adverse to the
wire rope.
Overhauling, as a rough guide, includes the following:
Uncoil the complete rope.
Examining the rope for the symptoms discussed above and
remove any length that falls into the category. Cutting must
be done from one end, ensuring provided length is left on the
drum.
Thoroughly cleaning, drying and re- lubricating the rope.
19
Checking security of couplings and if necessary fitting new

component.
Re-spooling the rope carefully, observing the correct "lay"
and handling procedures.
When uncoiling rope, follow the specified procedure given in
this manual.
3.10.7 Couplings
Apart from failing to observe all the necessary precautions
regarding care of the wire rope, the most likely cause of the wire
rope parting from the depressor weight is the incorrect fitting of
couplings or the fitting of unsuitable couplings.
3.10.7.1 Swivel
Check that the swivel rotates easily and examine for wear in
securing point.
3.10.7.2 Shackle
Use only high quality shackle in the coupling between depressor
weight and wire rope.
3.10.8 Clamping
Note Use only wire clamps of recommended type, preferably Eureka,
to secure thimbles to the wire rope end. Incorrect fixing or use
of non-recommended types will greatly increase the danger of
breakage under load
3.10.8.1 Clamping with Eureka Clamps

Note The clamp should be pushed so fare as possible against the
thimble without actually clamping the thimble and that the cut
wire end should not be longer than 5-6 mm outside the thimble.
One clamp is sufficient.
Note Eureka clamp for TW wire has two (2) bolts only.
3.10.8.2 Clamping with Talurit Clamps

Standard TW wires ( 4,9 mm) should have sleeve and clamp
jaw no. 6. Fit wire as shown and press firmly jaws together. One
sleeve is sufficient.
WARNING Do not use Talurit clamps on old and/or worn wire.
20
3.11 Fleet Angle Compensator

3.11.1 General information
A Fleet Angle Compensator is necessary for proper winding on
a drum if the fleet angle is more than 1-1/2 degrees. When the
fleet angle is less than 1-1/2 degrees, a Fleet Angle Compensator
will also improve wire rope life by reducing scrubbing.
The fleet angle can be defined as the included angle between the
rope, in its position of greatest travel across the drum, and a line
drawn normal to the drum shaft, passing through the centre line
of the lead sheave. (see fig. 3.2)
The fleet angle has an important bearing upon the change from
one layer to the next. If it is too large, the tendency will for the
rope to pull away from the flange to rapidly, leaving gaps into
which the rope on the next layer will fall. If too small, the rope
may not pull away from the flange soon enough. In this event, it
would tend to pile upon itself adjacent to the flange, for perhaps
two or three wraps, and then drop down with considerable force.
The resulting impact would be harmful not only to the rope but
to the equipment on which it operates. Without a Fleet Angle
Compensator, the fleet angle should vary between 1-1/2 degrees
to a minimum of 1/4 degrees for good spooling.
The Fleet Angle Compensator is capable of reducing large fleet
angles so that the resulting fleet angles are kept within even
narrower limits than those above. The Fleet Angle Compensator
tends to keep the rope spooling onto the drum practically
perpendicular at all times except at the flanges where a small
fleet angle is needed to prevent the rope from piling upon itself
as stated previously.
In operation, the Fleet Angle Compensator is completely
automatic and after the initial adjustments are made only a
minimum amount of inspection is necessary. During the
winding or unwinding, the fleet angle compensator shaft will
slowly oscillate allowing the sheave to float across the shaft
scribing an arc path.
3.11.2 Initial Adjustments

After installation, the Fleet Angle Compensator must be
adjusted before proper operation is obtained. Preliminary
calculations were used to design the Fleet Angle Compensator
as to length of shaft, end cap throws, etc., but a final adjustment
under actual spooling operations is needed.
There are two types of adjustments required. One is the
adjustment of the end cap throws (amount of offset of the
bearing journal from the centreline of the shaft).
21
The other adjustment required is the positioning of the set

collars. The set collars limit the travel of the sheave along the
shaft so the fleet angle is never smaller than 1/2 degree.
The end caps are adjusted first. In figure 3.3 you will note that
the end caps are marked in 10mm increments. These marks
measure the distance between the centre line of the end cap
journal and the shaft. Rotating the adjusting screw
counter-clockwise will reduce the throw and rotating clockwise
will increase the throw.
Note The Fleet Angle Compensator has two end caps. Both end caps
should be adjusted equal amounts in the beginning. In the final
stage of adjusting, the end caps may vary a small amount to
compensate for misalignment of pillow block centres, shaft
centres, etc.
To begin the actual adjustment of the Fleet Angle Compensator,

the throw on both end caps is set to about 25 mm. The spooling
of the wire rope begins and it improper spooling occurs, the end
caps are readjusted eit her to a larger or smaller throw, see fig.
7.3. Several settings may be tried before the correct one is
found.
It is important that the same spooling action is obtained at both
flanges. If the cable tends to stack up at one flange and pull
away from the other, this would indicate that the pillow blocks
are not mounted parallel to the drum axis.
The counterweights when used are mounted on arms attached to
the set collars. These weights, when properly adjusted, will
balance out the shaft assembly when the sheave is located at the
centre of the shaft.
To adjust the counterweights, place the sheave in the centre of
the shaft and release all the tension in the cable. The shaft will
hang down below the pillow block axis of rotation. In this
position, point both of the counterweight arms straight up and
tighten setscrew in set collars. By trial and error, the proper
number of weights at the proper distance out the arm will cause
the shaft to be balanced. The shaft should be rotated to be sure
it would stop at any position without seeking a heavy side.
In some instances, a Fleet Angle Compensator will be installed
on a drum that already contains misspooled wire rope. Before
the compensator can be adjusted, it will be necessary to unwind
the drum until every wrap is in its proper position.
22
If there is no rope on the drum, proceed to spool the first layer of

rope on the drum under sufficient tension making sure that every
wrap is in its proper place. The decision whether the
compensator is in adjustment or not is determined by observing
the spooling or action of the wire rope. In most cases, if the
corrector is out of adjustment, the wire rope will misspool as it
rises from one layer to the next at the flange.
The most critical area on a drum for spooling is that area next to
the flange. When the first layer is completed, the wire rope will
rise to the second layer. At this point if the wire rope pulls away
from the adjacent wrap leaving a gap, you may assume the end
caps settings were not large enough, If, on the other hand, the
rope spools nicely to the flange, rises as it should, and the then
the next wrap or two the rope piles upon itself adjacent to the
flange, the assumption is that the end caps settings were too
large. In short, misspooling will be recognised by the wire rope
either pulling away from the adjacent wrap leaving a gap, or by
pilling upon itself.
Excessive scrubbing of adjacent wraps may also be classified as
poor spooling, which may be reduced by setting the end caps to
a larger throw.
As soon as miss-spooling occurs while winding the rope on the
drum, the drum should be reversed so as to unwind the bad
spooling from the drum and then the tension in the rope
removed. By analysing the observation of the action created by
the rope, the end caps are readjusted about 10mm either larger
or smaller. The winding procedure is commenced again for
another try.
After finding the correct end cap setting which will allow the
wire rope to travel over to the flange completing the first layer,
rising as it should to the second layer, the rope is allowed to
continue spooling toward the opposite flange. The spooling
condition at the second flange must also be observed at the end
caps adjusted again if necessary.
23
Fig. 3.2 Fleet Angle Adjustment
Fig. 3.3 Throw Adjustment
24
In the majority of cases, the adjustment required for good

spooling at one flange will be the correct adjustment for the
other flange. Assuming this to be the case, the spooling
operation is continued for several layers. At this time the set
collars may be positioned on the shaft and set. The set collar is
positioned so that when the sheave is adjacent to the set collar,
the wire rope will have a fleet angle with the flange of about 1/2
degree. This will prevent the rope from piling upon itself at the
flange.
The set collars are most important when spooling at both flanges
cannot be accomplished by the end caps settings. This condition
usually means that the Fleet Angle Compensator is not in proper
alignment with the drum or the first fixed sheave is not in the
exact centre for the drum. To solve this problem, the end caps
are adjusted so as to have good spooling on one flange and a
piling up tendency occurs on the other flange. Then, as stated
previously, the piling up tendency is corrected by the proper
positioning of the set collar at the flange.
So, a tendency of the wire rope to pull away is corrected by end
cap adjustments only. Also, a tendency to pile up at both
flanges is corrected by end cap adjustments. Piling up at one
flange must be corrected by the set collar at that flange if the
other flange has good spooling because adjusting the end cap to
correct the piling up would only cause the good spooling to
misspool by pulling away.
Always adjust the end caps first, then position the set collars.
Adjustment of the end caps is less difficult when the end caps is
adjusted before set collars are positioned because the natural
tendency of the sheave at the flange gives an indication to the
correct end caps setting.
In severe cases, the wire rope may pull away or pile up in the
centre of the drum. Fig. 4.3 summarises most troubles stated
above and which are likely to occur while adjusting the Fleet
Angle Compensator. To read the chart, decide first when the
trouble started, then next, what happened to cause the miss-
spooling. The most likely cause will be at the intersection of
these two columns.
25
3.11.3 Adjustment chart
1. First determine by inspection where misspooling occurred.
2. Next decide if the wire pulled away from its adjacent wraps or stacked upon itself.
Misspooling occurred Wire breaks away from adjacent Wire stacks upon itself or
When wraps scrubs excessively
Spooling from centre of drum The throw (eccentric) is too large. The throw is too small.
toward flanges:
Reduce throw both ends by Increase throw on both

turning adjustment screw in the ends by turning
end caps counter clockwise. adjustment screw in the
end caps clockwise.
Spooling from flange toward The throw is too small. The throw is too large.
centre:
Increase throw on both ends by Reduce throw on both

turning the adjusting nut in the ends by turning the
end cap clock-wise. adjusting nut in the end
cap counterclockwise.
Fig. 3.4 Fleet Angle Compensator adjustment chart for fixed angle and adjustment
throw.
Note After making these adjustments, be sure to put the dowel pin in
position and reset the collars for the travel of the sheave.
26
3.12 Pre-set Parameters

The principal parameters of the system, which could cause
deterioration of system performance if out of limits, are listed
below:
Wire angle calibration (potentiometer supplies, null setting
and polarity).
Position Transducer
Wire tension.
Hydraulic main pressure.
The parameters above are factory set during the production and
pre-delivery check-out of the equipment, and then if necessary
"trimmed" to optimum with the system installed in its
operational environment. Therefore, it is not customary practice
to alter these setting unless it is suspected that malfunctions are
occurring as a result of one or more of them being out of tole-
rance, or following relevant parts replacement.
Note It is strongly recommended that such adjustments are carried
out by authorized personnel unless agreed otherwise.
Table 3.10 Calibration of potentiometers supply
STEP PROCEDURE
1 Connect voltmeter to terminals 161 and X 162
2 The voltmeter should show a reading of -11.25 V+/-0.05V. If not, adjust output voltage of
PSU 1 on multiturn trimpot accessible to a small screwdriver, through a hole in the PSU
front.
3 Connect a suitable voltmeter to terminals 171 and 172. Reading should be +11.25V
+/-0.05V. If not, adjust PSU 2 as described in STEP 2.
27
Table 7.11 Null setting of potentiometers and polarity check
STEP PROCEDURE
1 Tighten the Gimbal head locking bolts
2 For adjustment of ALONGSHIP axis potentiometer: connect a suitable voltmeter to

electrical cabinet terminals: 18 (GND) and 15 (SIG).
3 Slacken the potentiometer-locking clamp.
4 Rotate the potentiometer to give a reading on the voltmeter of 0V +/-0.025V.
5 Fasten the locking clamp.
6 Unscrew the Gimbal head locking bolt.
7 A positive (+) reading will be obtained when the Gimbal head is swung to the right (as
seen from vessel side).
NOTE
This relates to starboard-mounted installations, the reverse applies to port-mounted
installation
.
8 For adjustment of BEAM axis potentiometer: connect a suitable voltmeter to electrical

cabinet terminals: 18 (GND) and 17 (SIG).
Repeat STEP 3,4,5 and 6.

9
10 A positive (+) reading will be obtained when the Gimbal head is swung outboard.
NOTE
This relates to starboard-mounted installations; the reverse applies to port-mounted
installations.
28
Table 3.11 Calibration of Position Transducer
STEP PROCEDURE
1 For adjustment of position transducer: connect a suitable voltmeter to electrical cabinet

terminals: 176 (GND) and 204 (SIG). The reading should be +/- 9,98 volt depending on
piston position.
2 Adjust ZERO on EM-9 till equal + and - voltages are obtained (max. & min. stroke).
3 Adjust GAIN to max. voltage, 9,95 volt.

NOTE
Do not exceed 9,95 volt because the PLC will not accept voltage of 10 volts and above.
4 Check according to step # 1 and repeat procedure if necessary.
Table 3.12 Adjustment of Wire Tension
STEP PROCEDURE
1 NOTE!___________________________________________________________
Wire tension is adjustable in mooring. For safety reasons min. tension should not be
less than 150 Kp and max. 250 Kp (optional 350 Kp).
_______________________________________________________________________
2 With Taut Wire in mooring mode, adjust air pressure on compensating cylinder until
required tension is obtained.
29
Table 3.13 Adjustment of Hydraulic Pressure
Note The hydraulic pressure is pre-set from the manufacturer of the

hydraulic aggregate and should normally not be adjusted by
crew.
STEP PROCEDURE
1 Remove adjusting screw cap on pump flange.
2 Start hydraulic pump by a short touch on F7 or F8. The pump will run for 10 seconds. Do
not move Boom.
3 Adjust pressure to 170 - 200 bar.

Boom must travel to either end-stop to get correct manometer readings.
4 Lock adjustment screw and install cap.
30
4 Drawings
The drawing section contains the following drawings printed to
match paper
size, and with title section blown up to a readable size.
- 1-4897 Taut Wire MK15B General Arrangement

- 1-4905 Wire Angle Compensator
- 1-4312 Tension Cylinder
- 1-4757 Wire Sheave Arrangement
- 1-4906 Gimbal Head Parallel shaft
- 0-0531 Gimbal Head
- 2-5352 Weight Receiver
- 2-5356 Brake Arrangement
- 2-5358 Winch Arrangement
- 2-5139 Hydraulical Schematic
- 2-5359 Pressurized Air System
- 3-6998 Swivel
- 1-4915 Electrical Cabinet
- 3-7494 Wiring, Motors
- 3-7528 Wiring Diagram, Signals Part 1
- 3-7529 Wiring Diagram, Signals Part 2
- 3-7511 Wiring Diagram Part 1
- 3-7532 Wiring Diagram Part 2
- 4-0888 Wiring Diagram, Power Supply
- 4-0889 Wiring Diagram, Motor Cables
- 4-0890 Wiring Diagram, 220v Signals
- 4-0891 Wiring Diagram, 24v Signals
- 4-0892 Wiring Diagram, Operator Terminal
- 4-0893 Wiring Diagram, Computer Signals
- 4-0887 Wiring Diagram, Warning/Alarm Signals
- 4-0886 Wiring Diagram, Remote Operator Panel
31
Tegning nr.1-4897 LTW-MK-15B General Arrangement

32
33
Tegning nr.1-4905 Wire angle compensator

34
35
Tegning nr. 1-4312 Tension cylinder
36
37
Tegning nr. 1-4757 Wire sheave arrangement
38
39
40
Tegning nr. 1 -4906 Gimbal head Parallell shaft
41
42
43
44
Tegning nr. 0-0531 Gimbal Head
45
46
Tegning nr. 2-5352 Weight Receiver

47
48
Tegning nr. 2-5356 Brake Arrangement

49
50
Tegning nr. 2-5358 Wimch Arrangement

51
52
Tegning nr. 2-5139 Hydraulical Schematic

53
54
Tegning nr. 2-5359 Pressurized Air System

55
56
57
Tegning nr.583-6998 Swivel

59
60
Tegning nr. 1-4915 Electrical Cabinet 61

62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
5 VENDOR DOCUMENTATION
- Operating and Maintenance Instruction for Winch Drive Motor

- Operating instruction for LenzeGlobal Drive Power Supply
- Operating instruction for LenzeGlobal Drive Servo
- Quick Reference Guide for Telemecanique Micro PLC
- User Manual Magelis Alphanumeric Matrix
80
81

Light Weight Taut Wire MK 15B Operation and Maintenance Manual

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Light Weight Taut Wire MK 15B Operation and Maintenance Manual

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Bandak

Light Weight Taut Wire Mk 15B

Sagamoen, N-3825 Lunde, Norway

3.11.3 Adjustment chart.............................................................................................. 26

4 DRAWINGS ............................................... FEIL! BOKMERKE ER IKKE DEFINERT.

5 VENDOR DOCUMENTATION ................................................................................. 80

Note All technical description, information and specification given in

3.1 Spare Parts

3.2 Ordering Spare Parts

3.3 Repair of faulty parts

3.4 Handling and storing of Spare Parts

3.5 Returning faulty parts for repair

3.6 Maintenance Guidelines

3.7 Replacing Parts

3.7.1 Electrical System

3.7.2 Hydraulic and Pressurised Air System

CARRY OUT SUCH WORK IN A SCRUPULOUSLY

Table 3.1 Bolt Torque (Nm)

3.8 Periodic Maintenance Procedures

Note The manufacturer may perform certain of these procedures

Table 3.2 Daily Maintenance

3 Drain air reservoir and air regulators for water.

4 Check oil level in air system lubricator. Top up if necessary.

Table 3.3 Weekly Maintenance

2 Visually inspect the hydraulic system for oil leaks.

Table 3.4 Monthly Maintenance

1 Lubricate according to table 7.8

Table 3.5 3-Monthly Maintenance

2 Check conditions of gear oil and take necessary action.

PSU 1 + 11,25 V + 0,05 V TB 161 / 162

Table 3.6 6-Monthly Maintenance

10 Check Air Pressure Regulator Filters

Table 3.7 Yearly Maintenance

1 Drain hydraulic oil tank and refill with recommended oil.

2 Drain gear oil and refill with recommended oil.

Figure 3.1 Lubrication, Ref. Table 3.8

3.9 Recommended Hydraulic Oils

Table 3.8 Lubrication

7 Fleet angle compensator sheave bearing 1 Mobilgrease MP

1 Hydraulic oil tank, top up Mobil DTE 13M

17 Air oil lubricator, top up 1 Mecman oil

Weekly Clean and lubricate all moving parts, Oil

8 Fleet angle compensator sheave Mobilux EP 2&3

3 Hinges and latches 10 Mobilgrease SHC 460

10 Boom cylinder piston rods 2 Mobilgrease SHC 460

9 Wire rope operational length 1 Mobilarma 798

11 Boom cylinder bearing 2 Castrol Sperol SX2

12 Basket pivot bearing 2 Mobilgrease SHC 460

13 Boom upper pivot bearing 2 Mobilgrease SHC 460

3-Monthly 5 Gear oil, top up 2 Mobil Glycoyle

6-Monthly 19 Air press. reg. filters, check 2 Mecman filters

9 Wire rope: complete length 1 Mobilarma 798

Use lubricant type shown or equivalent

3.9.1 Oil viscosity

OIL TYPE MIN. RECOMMENDED MAX. MAX. RECOMMENDED MIN.

For further information, see the liquid petroleum products temp

3.9.2 Oil change

3.9.2.1 Hydraulic tank

3.10 Wire Rope & Couplings

3.10.1 Wire Rope

3.10.5 Replacement procedure

Checking security of couplings and if necessary fitting new

3.10.8.1 Clamping with Eureka Clamps