WINEL Musketeer Instruction manual

Installation, Operation & Maintenance Manual
Musketeer Door
Watertight
Version: 1.0
Date: May 2020

Contact information
WINEL BV
Dr. A. F. Philipsweg 55, 9403 AD Assen
P.O. box 70, 9400 AB Assen
The Netherlands
Tel. [phone]
Fax. [phone]
E-mail: [email protected]
www.winel.nl
2

Contents
1 About this manual.................................................................................... 4
1.1 Contents of this manual............................................................................................................... 4
1.2 Intended audience....................................................................................................................... 4
1.3 Copyright and disclaimer............................................................................................................. 4
1.4 Symbols used in this manual....................................................................................................... 4
2 Safety and warranty................................................................................. 5
2.1 General safety instructions.......................................................................................................... 5
2.2 Specific safety instructions...........................................................................................................5
2.3 Use of spare parts........................................................................................................................5
3 Introduction to the product....................................................................... 6
3.1 Intended use................................................................................................................................ 6
3.2 Product description...................................................................................................................... 6
3.2.1 Overview of the product.................................................................................................... 6
3.2.2 Working principle...............................................................................................................7
4 Installation................................................................................................8
4.1 Delivery, insurance and acceptance............................................................................................8
4.1.1 Delivery............................................................................................................................. 8
4.1.2 Insurance.......................................................................................................................... 8
4.1.3 Acceptance....................................................................................................................... 8
4.2 Recommendations for handling and unpacking...........................................................................8
4.3 Storage........................................................................................................................................ 9
4.3.1 Warehouse storage...........................................................................................................9
4.3.2 On-board storage..............................................................................................................9
4.4 Welding........................................................................................................................................9
4.4.1 General welding recommendations...................................................................................9
4.4.2 Welding instruction............................................................................................................9
5 Operation............................................................................................... 12
5.1 Open the door............................................................................................................................12
5.2 Close the door............................................................................................................................12
6 Maintenance.......................................................................................... 13
6.1 Maintenance schedule...............................................................................................................13
6.2 Maintenance tasks.....................................................................................................................13
6.2.1 Replace the rubber gasket..............................................................................................13
6.2.2 Adjust the hinges.............................................................................................................14
6.2.3 Adjust the cleats..............................................................................................................14
6.2.4 Replace the hinge bushes...............................................................................................14
6.2.5 Replace the cleat bearing............................................................................................... 15
6.2.6 Replace the handle bearing............................................................................................ 16
7 Trouble shooting.................................................................................... 17
Contents
- - 3

1 About this manual
1.1 Contents of this manual
This manual contains information about the installation, operation and maintenance of the
Winel Musketeer door. This manual often refers to the Musketeer door as "the product".
1.2 Intended audience
This manual is intended for:
• Personnel that installs the product.
• Personnel that operates the product.
• Personnel that does maintenance and repairs on the product.
1.3 Copyright and disclaimer
© WINEL BV. All rights reserved.
No part of this document may be reproduced, distributed or transmitted in any form or by
any means, electronically or mechanically, including photocopying and recording for any
purpose, without the express written authorisation by WINEL BV.
WINEL BV continuously improves its products, therefore the designs and specifications in
this manual are subject to change without prior notice.
1.4 Symbols used in this manual
Symbol Type Description
Danger This indicates a situation with a high level of risk which, if
not avoided, can cause death or serious injury.
Warning This indicates a situation with a medium level of risk
which, if not avoided, can cause serious injury or serious
damage to the product.
Caution This indicates a situation with a low level of risk which, if
not avoided, can cause minor to moderate injury or dam-
age or the product.
Note This provides useful background information that is not
hazard related.
About this manual
419 - 001 - 29.05.2020

2 Safety and warranty
2.1 General safety instructions
• Always read the instructions of this product before you operate the product.
• Do not endanger people and the environment. Obey the safety instructions.
• The door(s) must be operated by qualified personnel.
• Follow the maintenance instructions given by WINEL BV. This is in the interest of
safety and reliability of the vessel and of its crew and passengers.
• No welding or modification to the product is allowed without prior written approval and
permission of WINEL BV and the certifying authorities.
• Disconnect all electrical wiring before welding activities near the product. The welding
current can cause damage to the electrics and electronics of the product.
• If the system is not functioning properly, do not try to force the system. Never overrule
or ignore safety features.
• Performing proper maintenance and service to the system will prevent most of the
malfunctioning.
• Small malfunctions must be solved immediately, if not this might lead to severe
damage to the system or injury to operating personnel.
2.2 Specific safety instructions
• Do not use grease on the bearings of these parts:
• Hinges
• Handle
• Cleats
2.3 Use of spare parts
• Only use original WINEL BV spare parts or spare parts that are recommended by
WINEL BV.
The use of other parts can result in unsafe operations and servere damage to the
equipment, to personnel and to the environment.
• All damage resulting from the use of non-original spare parts is beyond the
responsibility of WINEL BV.
• WINEL BV only accepts warranty claims if the maintenance instructions are carefully
followed and if original WINEL BV spare parts have been used.
In case of neglected maintenance procedures and mounting non-WINEL BV parts,
WINEL BV will not accept any responsibility.
Safety and warranty
19 - 001 - 29.05.2020 5

3 Introduction to the product
3.1 Intended use
All doors produced by Winel BV are manufactured according to special customer
requirements as well as to SOLAS and IMO regulations.
The doors are designed to allow the passage of people and goods through a watertight
bulkhead when opened. When closed, the doors maintain the watertight integrity of the
bulkhead in which the door is fitted.
Every door is factory tested and adjusted as far as possible. On site installation is
therefore limited to welding of the frame into ship construction and adjustment of cleats/
hinges.
3.2 Product description
3.2.1 Overview of the product
H
I
J
A
C
B
D
E
F
G
K
A Sensor (option)
B Frame
C Doorblade
D Wedge
E Cleat
F Latching device
G Corner piece
H Rubber gasket
I Handle
J End cleat
K Hinge, with maintenance-free self-
greasing bushes
For specific details about the door installed on the vessel, refer to the general
arrangement drawings and the documentation enclosed.
Introduction to the product
619 - 001 - 29.05.2020

3.2.2 Working principle
The user can open and close the door with the handle or hand wheel on the door from
both sides. The handle or hand wheel operates the latching device.
When the door is closed and latched correctly, the compression of the gasket makes the
door watertight.
Introduction to the product
19 - 001 - 29.05.2020 7

4 Installation
4.1 Delivery, insurance and acceptance
4.1.1 Delivery
The door frame including the door is placed on a pallet and strapped with bands.
Depending on the scope of supply, the components are premounted on the door frame or
are delivered separately.
4.1.2 Insurance
The responsibilities of transport and insurance are stated in the sales order confirmation
and in the general conditions of sale of WINEL BV.
4.1.3 Acceptance
During acceptance of the delivery, WINEL BV recommends to proceed as follows:
Procedure
1. WINEL BV recommends to have an authorized official of the transportation company
present during this procedure.
2. Check if the packing and all the pallets and/or boxes are undamaged and if all parts
are present.
a) Compare the labels with the WINEL BV packing list and the order confirmation.
b) If there is damage or if parts are missing, immediately report this to the sales
department of WINEL BV.
4.2 Recommendations for handling and unpacking
General
• Use a fork lift or a hoist to transport the pallets or the boxes as closely to the
installation site as possible.
• Do not use hooks or other tools that may penetrate the packing and cause damage to
the packed items.
• Only use lifting equipment with adequate capacity for the load.
For the weights and dimensions of the delivery, refer to the General Arrangement
drawings enclosed.
• Only unpack the parts in the cardboard boxes just before you install them. This
prevents parts from being lost.
• Use a sharp knife to open the cardboard boxes but take care not to cause damage to
the parts inside the boxes.
Door assembly (door frame with door and components)
Danger:
• The door assembly is heavy.
• Use correct and certified lifting materials.
• Only authorized personnel are allowed to operate the lifting equipment.
• Follow the appropriate safety procedures.
Installation
819 - 001 - 29.05.2020

• Remove the bands that hold the door assembly to the pallet.
• Make sure that the door itself is secured in the closed position. This prevents that the
door moves during the lifting operation.
• Use at least two steadying lines to guide the door assembly during the lifting
operation.
4.3 Storage
4.3.1 Warehouse storage
• Store the parts in a safe, dry and dust free environment.
This prevents unnecessary damage and wear of the parts.
• If the parts were unpacked from their transport packing, repack the parts using
appropriate packing materials.
• Use the original WINEL BV pallet to store the door assembly.
• Do NOT stack pallets with the products on top of each other.
4.3.2 On-board storage
• Store the parts as close as possible to the future position.
• Make sure to place the door assembly at the correct side of the bulkhead.
• Make sure to protect the parts from damage caused by work in the vicinity of the parts.
• Re-pack or cover the door assembly and the other parts in order to prevent damage
by grinding or welding nearby.
4.4 Welding
4.4.1 General welding recommendations
Danger:
• Welding the door frame into or against the bulkhead must be done by a
certified and qualified welder and according to the requirements of the
shipyard and the applicable class society.
• WINEL BV cannot be held responsible if the welding recommendation and
the advised welding procedures were not followed.
WINEL BV can only make welding recommendations with respect to the product, not with
respect to the construction of the vessel to which the product is installed.
4.4.2 Welding instruction
Caution:
If you do not obey these instructions, you may cause damage to the product
and the watertightness of the product is not guaranteed.
Installation
19 - 001 - 29.05.2020 9

Caution:
Keep both door and frame straight. Do not force it towards the bulkhead. Do
not force the doorframe, for example with clamp tools.
• Close and latch the door on the frame. Keep the door closed during the entire welding
procedure.
• Welding must be done carefully to prevent thermal stresses in the door.
• Make sure that the heat-dissipation into the door is as little as possible.
• Refer also to the instruction on the door.
• Weld also the backside of the doorframe by interrupted welding.
• Refer to the illustration, start at position 1, interrupted welding (length ± 100mm).
Follow to position 2 – 3 – 4 etc.
• Complete the welding: Fill the open spaces between doorframe and wall.
Caution:
Max frame deflection after welding to ship construction: 1mm / mtr
Installation
10 19 - 001 - 29.05.2020

1 5 3
4 6 2
9
12 10
15
19
13
24
7
22
18 16
20
14
23
8
21
17
11
A=4,5
37,5
75
A=4,5
Cut in Plate
Clear
Opening
Clear Opening
Cut in Plate
A=4,5
A=4,5
D(10)
D/2 (5)
Installation
19 - 001 - 29.05.2020 11

5 Operation
5.1 Open the door
Procedure
1. Set the handle in the vertical position.
2. Open the door.
5.2 Close the door
Procedure
1. Close the door. Make sure that
nothing gets trapped between the
door and the frame.
2. Set the handle in the horizontal
position.
3. Make sure that the door latches
correctly.
Operation
12 19 - 001 - 29.05.2020

6 Maintenance
Do the maintenance to keep the door safe and reliable. Refer to the maintenance
schedule.
Caution:
Only use WINEL genuine spare parts or parts advised by WINEL
Note:
• All bushes used in hinges and/or cleats are maintenance-free bushes that
do NOT require lubrication.
• WINEL BV can offer you a service contract. For example, the doors can be
examined and, when necessary, serviced every 3 – 5 years by a service
engineer of WINEL BV.
6.1 Maintenance schedule
Monthly (depending on the frequency of use):
Examine the parts that follow. If any bearing bush is worn, replace it.
• Hinges
• Handle
• Cleats
Examine the rubber gasket. If you see cracks or other visual damage, replace the rubber
gasket.
6.2 Maintenance tasks
6.2.1 Replace the rubber gasket
Procedure
1. Remove the old rubber gasket.
2. Remove the remainder of the glue.
3. Apply glue to the gutter (A) and the
new gasket (B). Refer to the
instructions of the glue manufacturer.
4. Install the new rubber gasket.
Closing requirements
1. Make sure that the hinges and cleats
are adjusted correctly to make sure
that the door is watertight:
a. Adjust the hinges. Refer to
section Adjust the hinges on
page 14.
b. Adjust the cleats. Refer to
section Adjust the cleats on page 14.
A B
Maintenance
19 - 001 - 29.05.2020 13

6.2.2 Adjust the hinges
Note:
If the door has two cleats on the hinge side, do not adjust the hinges.
Procedure
1. On all hinges, remove the plastic
caps (B).
2. On all hinges, turn the socket screws
(A) a ¼ turn.
a) Clockwise to increase the hinge
force.
b) Counterclockwise to decrease
the hinge force.
3. Repeat the previous step as many
times as necessary.
4. Install the plastic caps on all hinges.
6.2.3 Adjust the cleats
Note: The rubber gasket must be compressed 3-4 mm to make the door
watertight.
Procedure
1. On all cleats, turn the hexagonal nut
(A) a quarter of a turn.
a) Clockwise to increase the
compression of the rubber
gasket.
b) Counterclockwise to decrease
the compression of the rubber
gasket.
2. Repeat the previous step until the
compression of the rubber gasket s
correct for all cleats.
6.2.4 Replace the hinge bushes
Warning:
RISK OF INJURY - HEAVY OBJECT
• Use correct and certified lifting materials.
• Do this task with two persons
A
B
--
+
A
Maintenance
14 19 - 001 - 29.05.2020

Procedure
1. Close the door. Make sure that the
door is latched.
2. Attach hoisting slings to the door.
3. Use the hoist to slowly lift the door
until the weight of the door is taken
off the hinges.
4. Remove the parts that follow:
a) Plastic caps (A)
b) Socket screws (B)
c) Retainer ring (F). Use special
pliers.
d) Hinge axle (E). Use a hammer
with a nylon head.
5. Release the latches and lift the door
out of the door frame.
6. Remove the bush (C and D).
7. Clean the bracket and the hinge
plate.
8. Install the new bush (C) into the
hinge part at the frame.
9. Place the new bushes (D) into the
hinge part of the door.
10. Carefully place the door in the correct
position to assemble the door and
frame parts of the hinges.
11. Install the hinge axle, the retainer
ring and the socket screws.
12. Adjust the hinge. Refer to section
Adjust the hinges on page 14.
13. Install the plastic caps.
6.2.5 Replace the cleat bearing
Procedure
1. Secure the door in the open position.
2. If the door has insulation, remove the
cover plate and the insulation.
3. Remove these parts:
a) Hexagon nut (A)
b) Ring (B)
c) Cleat (C)
d) Bearing bush (D)
4. Install these parts:
a) New bearing bush
b) Cleat
c) Ring
d) Hexagon nut
E
A
B
F
C
D
E
A
B
F
C
D
B
A
C
D
Maintenance
19 - 001 - 29.05.2020 15

5. If applicable, install the insulation and the cover plate.
6. Adjust the cleats. Refer to section Adjust the cleats on page 14.
6.2.6 Replace the handle bearing
Procedure
1. Secure the door in the open position.
2. If the door has insulation, remove the
cover plate and the insulation.
3. Remove these parts:
a) Pillar bolt (A)
b) Socket bolt (B)
c) Handle (C)
4. Remove the internal mechanism.
5. Replace the bearing bush (A) and the
seal (B).
6. Install the internal mechanism.
7. Install these parts:
a) Handle (C)
b) Socket bolt (B)
c) Pillar bolt (A)
8. If applicable, install the insulation and
the cover plate.
9. Close the door.
B C
A
B
A
B C
A
Maintenance
16 19 - 001 - 29.05.2020

7 Trouble shooting
Warning:
Always read the safety instructions §2 of the manual before trouble shooting.
Do not endanger people and the environment. Obey the safety instructions.
Fault Possible cause Check Remedy
Door cannot be
opened or closed with
handle
Bolts in cleating sys-
tem come loose
Cleating system Place new bolts/nuts
(apply locking fluid)
Safety bolt of handle is
broken
Safety bolt operating
handle
Place new bolt
(apply locking fluid)
Door does not close
well
Damage on frame,
door, rubber gasket,
musketeer system,
door frame is bent
Complete system,
door, rubber gasket
and frame
Repair and/or replace
damaged pieces
and/or parts. Then ad-
just cleating system
and hinges
Door is leaking Rubber gasket is com-
pressed too little
Rubber gasket, cleat-
ing and hinges
Replace rubber gasket
and/or adjust cleating
system and hinges
Damage on frame,
door, rubber gasket,
musketeer system,
door frame is bent
Complete system,
door, rubber gasket
and frame
Repair and/or replace
damaged pieces
and/or parts. Then ad-
just cleating system
and hinges
Door not operating cor-
rect and/or to heavy
Rubber gasket is com-
pressed too much
compression of the
rubber gasket when
door is closed and
latched
Adjust cleating system
and hinges
No grease on wedges Wedges Apply grease to wedg-
es
Sticking of handle in
bush
Handle Disassemble handle
and clean or replace
handle and/or bushes
Cleating rod is bended Cleating system Repair or replace dam-
aged parts
Damage on frame,
door, rubber gasket,
musketeer system,
door frame is bent
Complete system,
door, rubber gasket
and frame
Repair and/or replace
damaged pieces
and/or parts. Then ad-
just cleating system
and hinges
Paint on system parts Parts that should not
been painted for paint
Remove the paint
If the problems cannot be solved using the instructions in the manual, contact WINEL
After-sales department.
Trouble shooting
19 - 001 - 29.05.2020 17

Page 1 of 6
Winel BV
PO Box 70, 9400 AB
Assen, The Netherlands
[email protected]
www.winel.nl
SPARE PARTS SPECIFICATION SHEET
Rev 0
Splash/Weather and Watertight
Musketeer Doors
General information
Please use below list for ordering original Winel spare parts. You can fill in the needed quantity; your company details and
return to Winel [email protected] for quote and delivery time.
Company/billing address:
Delivery address (if different as above):
Quote reference/ship:
Spare parts
Article code
Description
Picture
Minimum order
Length
Quantity
(multiple
of
minimum
order
length
9552.1010.4220.1
Door-seal 42.5x20.4 mm,
shore 30, EPDM, including
100ml Bison Tix® glue and
instructions
6 Meter
9552.1010.4220
Door-seal 42.5x20.4 mm,
shore 30, EPDM, with
instructions, without glue
(for air transport)
12,5 Meter roll
Article code
Description
Picture
Reference drawing
Quantity
9552.00010
Wedge brass (standard),
incl. 2 Screws DIN 966A
M5x12. For steel frame,
splash & weather tight
door
421.000.03.5000
9552.00059
Wedge brass (heavy), incl.
2 Screws DIN 966A M5x12.
For steel frame, heavy
watertight door
426.000.03.0018/1

Page 2 of 6
Winel BV
PO Box 70, 9400 AB
Assen, The Netherlands
[email protected]
www.winel.nl
SPARE PARTS SPECIFICATION SHEET
Rev 0
Splash/Weather and Watertight
Musketeer Doors
9552.00060
Wedge POM (standard),
incl. 2 Screws DIN 966A
M5x12. For aluminium
frame, splash & weather
tight door
421.000.03.5100
9552.1510.3011
Assembly cleat. For splash
& weather tight, LH door,
8mm (except GRP)
421.100.03.1000
9552.1510.6011
Assembly end cleat. For
splash & weather tight, LH
door, 8mm (except GRP)
421.100.03.2000
9552.1530.9010.10
Assembly end corner piece.
For splash & weather tight,
LH door (except GRP)
421.100.03.6000
9552.1510.3015
Assembly cleat. For splash
& weather tight, RH door,
8mm (except GRP)
421.200.03.1000
9552.1510.6015
Assembly end cleat. For
splash & weather tight, RH
door, 8mm (except GRP)
421.200.03.2000
9552.1530.9010.20
Assembly end corner piece
For splash & weather tight,
RH door (except GRP)
421.200.03.6000
9552.1530.5010
Assembly corner piece
splash & weather & water
tight, (except GRP)
421.100.03.3000

Page 3 of 6
Winel BV
PO Box 70, 9400 AB
Assen, The Netherlands
[email protected]
www.winel.nl
SPARE PARTS SPECIFICATION SHEET
Rev 0
Splash/Weather and Watertight
Musketeer Doors
9552.1510.3051
Assembly cleat. For splash
& weather tight, LH GRP
door, 8mm
425.100.03.1500
9552.1510.6051
Assembly end cleat. For
splash & weather tight, LH
GRP door, 8mm
425.200.03.2000
9552.1530.9020.10
Assembly end corner piece.
For splash & weather tight,
LH GRP door
425.100.03.3500
9552.1510.3055
Assembly cleat. For splash
& weather tight, RH GRP
door, 8mm
426.200.03.1000
9552.1510.6055
Assembly end cleat. For
splash & weather tight, RH
GRP door, 8mm
425.200.03.2000
9552.1530.9020.20
Assembly end corner piece.
For splash & weather tight,
RH GRP door
425.200.03.3000
9552.1530.5020
Assembly corner piece. For
splash & weather tight,
GRP door
425.000.03.4000
9552.1510.3091.55
Assembly cleat. For LH,
water tight, heavy door,
20mm steel
426.100.03.1000