INTRODUCTION
This section defines the procedures used by Ram Winch and Hoist’s Technicians to evaluate a customer’s base mounted drum hoist, perform the level of service (as defined in this document) requested by our customer and return the unit to service. This document is not intended to alleviate the responsibility of the operator from determining the safe working condition of the equipment at the point of usage. Proper installation of the winch and associated rigging is critical to the overall safe working condition of the lifting system.
Air Winch Remanufacture / Overhaul consists of the following operations:
REMANUFACTURE/OVERHAUL
Initial visual inspection – The winch is subjected to a visual inspection of the components that can be seen with limited disassembly.
Check conditions of fluids – This step is used to verify if grease and oil levels are at the proper operating levels and if lubricants show signs of contamination (moisture/dirty/metal particles) or have been run at excessive temperatures.
Function Test – If the winch is capable, the unit will be function tested to further diagnose a potential problem. Excessive motor noise or blow-by will be noted along with any other abnormal mechanical noise.
Complete Tear Down – The winch is completely disassembled and a full visual inspection of all parts is conducted. All wear parts are subjected to a dimensional inspection comparing to original manufacturing tolerances.
Estimate – Based on steps 1 thru 4, the items requiring repair/replacement will be determined. A repair estimate is compiled. This estimate includes a list of required parts and the labor hours required to make the observed repairs. This list will include all bearings, seals, gaskets, wear parts such as bronze bushings, piston rings, etc. Additional labor will be added for the blast, and application of Ram’s 3-Part Paint System (Ref: PS-100001 for a complete paint system description).
Estimate Approval – The estimate is presented to the customer along with an anticipated delivery date based on the delivery time of the required parts and the back-log at the time the estimate is prepared.
Blast and Paint – After customer approval of the estimate, the main structural components of the winch, will be blasted to remove all loose paint and rust. The parts will then be visually inspected for signs of excessive wear, cracks, or damage. The parts will then be prepared for paint which will include an inorganic zinc primer, a polyamide epoxy tie coat, and a aliphatic
acrylic polyurethane top coat.
Assembly – A Ram trained technician will re-assemble the winch and make the necessary repairs replacing any removed fasteners with new one, using new seals and gaskets as required, and replacing any bearings removed during the course of the disassembly. All fluids are replaced.
Load Test – After the winch is repaired the unit will be subjected to a load test equivalent to the bare drum rating of the winch and an overload test of 125% or the rated load to ensure proper brake holding and structural integrity. A Load Test Certificate will be provided.
Winch Tags – Winch tags and safety decals will be replaced as possible.
Other Items – If during the course of performing the repair or load test, other items requiring repair are found, the customer will be notified and an additional estimate will be provided and customer approval obtained before additional work is performed. Any safety equipment missing from the winch will be noted for the customer to address before returning to service.
INTRODUCTION
This section defines the procedures used by Ram Winch and Hoist’s Technicians to evaluate a customer’s base air chain hoist, perform the level of service (as defined in this document) requested by our customer and return the unit to service. This document is not intended to alleviate the responsibility of the operator from determining the safe working condition of the equipment at the point of usage. Proper installation of the winch and associated rigging is critical to the overall safe working condition of the lifting system.
REMANUFACTURE
Air Chain Hoist Remanufacture / Overhaul consists of the following operations:
Initial visual inspection – The winch is subjected to a visual inspection of the components that can be seen with limited disassembly.
Check conditions of fluids – This step is used to verify if grease and oil levels are at the proper operating levels and if lubricants show signs of contamination (moisture/dirty/metal particles) or have been run at excessive temperatures.
Function Test – If the hoist is capable, the unit will be function tested to further diagnose a potential problem. Excessive motor noise or blow‐by will be noted along with any other abnormal mechanical noise.
Complete Tear Down – The winch is completely disassembled and a full visual inspection of all parts is conducted. All wear parts are subjected to a dimensional inspection comparing to original manufacturing tolerances.
The top hook and or trolley and bottom hooks are removed. Inspections for deformations / damage an measurement of internal surfaces mating to housings for compliance with wear criteria are conducted.
Recommendations for replacement based on results of inspection.
Bottom hook housing / bottom block assembly is dissembled. Internal mating surfaces are checked for wear and compliance with JDN KDS‐0003 criteria. Bearings are removed, cleaned, inspected and re‐packed with grease in all cases.
The Hoist’s gearbox is removed.
The drive shaft from the motor to the first stage is removed. The drive shaft’s gear and bearings are removed and inspected. The gear train is spun by hand checking for unacceptable backlash roughness, binding or stiffness. The gear case is examined for the presence of external contamination such as water. The existing gear‐case grease is evaluated for its condition and appropriate quantity.
The Hoist mid‐section is removed, disassembled and cleaned.
The sheave bearings are degreased, cleaned and re‐ packed with grease in all cases. Bearings are inspected for wear prior to packing with grease; recommendations for replacement are made based on results of inspection.
The chain is removed washed and cleaned. A visual inspection is completed for the entire length. The chain is gauged measuring for elongation of the pitch. If the chain pitch is within tolerance it will be lubricated for installation.
If the original chain is reinstalled the chain‐ends will be switched in the hoist so that the life of the chain will be extended.
Please note:
If the load chain has been in offshore service for a period of five years it should be replaced per JDN recommendations of chain life in offshore service.
Estimate – Based on previous steps the items requiring repair/replacement will be determined.
A remanufacturing / overhaul estimate is compiled. This estimate includes a list of required parts and the labor hours required to make the observed repairs. This list will include all bearings, seals, gaskets, wear parts.
Additional labor will be added for the blast, and application of Ram’s 3‐Part Paint System (Ref: PS‐100001 for a complete paint system description).
Estimate Approval – The estimate is presented to the customer along with an anticipated delivery date based on the delivery time of the required parts and the back‐log at the time the estimate is prepared.