WINEL Musketeer Hatch Instruction manual

Installation, Operation & Maintenance Manual
Musketeer Hatch
with counterweight
Version: 1.0
Date: January 2021

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.................................................................................... 5
1.1 Contents of this manual............................................................................................................... 5
1.2 Intended audience....................................................................................................................... 5
1.3 Copyright and disclaimer............................................................................................................. 5
1.4 Symbols used in this manual....................................................................................................... 5
2 Safety and warranty................................................................................. 6
2.1 General safety instructions.......................................................................................................... 6
2.2 Specific safety instructions...........................................................................................................6
2.3 Use of spare parts........................................................................................................................6
3 Introduction to the product....................................................................... 8
3.1 Intended use................................................................................................................................ 8
3.2 Overview of the product...............................................................................................................8
3.3 Working principle......................................................................................................................... 9
4 Installation..............................................................................................10
4.1 Delivery, insurance and acceptance..........................................................................................10
4.1.1 Delivery........................................................................................................................... 10
4.1.2 Insurance........................................................................................................................ 10
4.1.3 Acceptance..................................................................................................................... 10
4.2 Recommendations for handling and unpacking.........................................................................10
4.3 Storage...................................................................................................................................... 11
4.3.1 Warehouse storage.........................................................................................................11
4.3.2 On-board storage............................................................................................................11
4.4 Welding......................................................................................................................................11
4.4.1 General welding recommendations.................................................................................11
4.4.2 Welding instruction..........................................................................................................11
5 Operation............................................................................................... 14
5.1 Open the hatch.......................................................................................................................... 14
5.2 Close the hatch..........................................................................................................................15
6 Maintenance.......................................................................................... 16
6.1 Maintenance schedule...............................................................................................................16
6.2 Maintenance tasks.....................................................................................................................16
6.2.1 Replace the rubber gasket..............................................................................................16
6.2.2 Adjust the cleats..............................................................................................................17
6.2.3 Adjust the hinges.............................................................................................................17
6.2.4 Replace the cleat bearing............................................................................................... 18
6.2.5 Replace the handle bearing............................................................................................ 18
6.2.6 Replace the hinge bushes...............................................................................................19
6.2.7 Remove the hatch...........................................................................................................20
6.2.8 Install the hatch...............................................................................................................20
Contents
3
7 Troubleshooting..................................................................................... 22

Contents
4

1 About this manual
1.1 Contents of this manual
This manual contains information about the installation, operation and maintenance of the
Winel Musketeer hatches with counterweight. This manual refers to the Musketeer hatch
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
22 - 001 - 15.01.2021 5

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 product 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 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
• Keep away form the turning circle of the hatch and the counterweight.
• Make sure that the turning circle of the counterweight is free.
• 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.
Safety and warranty
622 - 001 - 15.01.2021

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
22 - 001 - 15.01.2021 7

3 Introduction to the product
3.1 Intended use
All hatches produced by Winel BV are manufactured according to special customer
requirements as well as to SOLAS and IMO regulations.
The hatches are designed to allow the passage of people and goods through a watertight
or weathertight deck when opened. When closed, the hatches maintain the watertight or
weathertight integrity of the deck in which the hatch is fitted.
Every hatch 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 Overview of the product
E
F
G
A
BCD
J
I
H
K L
M
N
A Rubber gasket
B Handle
C Latching device
D Cleat
E Hatch
F Corner piece
G End cleat
H Frame
I Counterweight
J End cleat
K Sensor (option)
L Wedge
M Open holder (option)
N Key (option, a handle on the
upperside is standard)
For specific details about the hatch that is installed on the vessel, refer to the general
arrangement drawings and the documentation enclosed.
Introduction to the product
822 - 001 - 15.01.2021

3.3 Working principle
The user can open and close the hatch with the handle or hand wheel on the hatch from
both sides. The handle or hand wheel operates the latching device.
When the hatch is closed and latched correctly, the compression of the gasket makes the
hatch weathertight/watertight.
Introduction to the product
22 - 001 - 15.01.2021 9

4 Installation
4.1 Delivery, insurance and acceptance
4.1.1 Delivery
The product including the frame is placed on a pallet and strapped with bands. All
components are premounted if possible. If necessary, depending on the scope of supply,
components 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.
Hatch assembly (frame with hatch and components)
Danger:
• The product is heavy.
• Use correct and certified lifting materials.
• Only authorized personnel are allowed to operate the lifting equipment.
• Follow the appropriate safety procedures.
Installation
10 22 - 001 - 15.01.2021

• Remove the bands that hold the product to the pallet.
• Make sure that the hatch is secured in the closed position. This prevents that the
hatch moves during the lifting operation.
• Use at least two steadying lines to guide the product 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 product.
• 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 hatch assembly on the correct deck.
• Make sure to protect the parts from damage caused by work in the vicinity of the parts.
• Re-pack or cover the hatch 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 frame into or against the structure 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.
Caution:
Keep both hatch and frame straight. Do not force it towards the deck. Do not
force the frame, for example with clamp tools.
Max frame deflection: 1mm / mtr
Installation
22 - 001 - 15.01.2021 11

• Close and latch the hatch on the frame. Keep the hatch closed during the entire
welding procedure.
• Welding must be done carefully to prevent thermal stresses in the product.
• Make sure that the heat-dissipation into the hatch is as little as possible.
• Refer also to the instruction on the hatch.
• Weld also the backside of the frame 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 frame and deck.
Installation
12 22 - 001 - 15.01.2021

1 5 3
4 6 2
9
12 10
13
15
7 14
16
8
11
a4
a4
Clear opening
Note: Do a check on the weld sizes in relation to the thickness of the plates.
Installation
22 - 001 - 15.01.2021 13

5 Operation
5.1 Open the hatch
Caution:
Keep away form the turning circle of the hatch and the counterweight. The
hatch can partly open/close itself.
Procedure
1. If applicable, use the key.
2. Set the handle or key in the open (O)
position.
3. Open the hatch upwards.
Operation
14 22 - 001 - 15.01.2021

5.2 Close the hatch
Procedure
1. Close the hatch, push/pull it
downwards. Make sure that nothing
gets trapped between the hatch and
the frame.
2. Set the handle or key in the closed
(C) position. If applicable, use the
key.
3. Make sure that the hatch latches
correctly.
Operation
22 - 001 - 15.01.2021 15

6 Maintenance
Do the maintenance to keep the product 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 products 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
• Wedges
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 compression of
the rubber gasket is correct to make
sure that the hatch is watertight:
Adjust the cleats. Refer to section
Adjust the cleats on page 17.
A B
Maintenance
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6.2.2 Adjust the cleats
Note: The rubber gasket must be compressed 3-4 mm to make the door or
hatch 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 is
correct for all cleats.
6.2.3 Adjust the hinges
Procedure
1. Close the hatch. Make sure that the
hatch is latched.
2. On all hinges, loosen the nuts (A).
3. Make sure that the hinge height is
correct and tighten the nuts.
--
+
A
A
Maintenance
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6.2.4 Replace the cleat bearing
Procedure
1. Secure the door or hatch in the open
position.
2. If the door or hatch has insulation,
remove the cover plate and the
insulation.
3. Remove the pillar bold (E).
4. Remove these parts:
a) Hexagon nut (A)
b) Ring (B)
c) Cleat (C)
d) Bearing bush (D)
5. Install these parts:
a) New bearing bush
b) Cleat
c) Ring
d) Hexagon nut
6. Install the pillar bold (E).
7. If applicable, install the insulation and the cover plate.
8. Adjust the cleats. Refer to section
Adjust the cleats on page 17.
6.2.5 Replace the handle bearing
Procedure
1. Secure the hatch in the open
position.
2. If the hatch has insulation, remove
the cover plate and the insulation.
3. Remove these parts:
a) Pillar bolt (A)
b) Socket bolt (C)
c) Handle (B)
B
A
C
D
E
A
CB
Maintenance
18 22 - 001 - 15.01.2021

4. Remove the internal mechanism.
5. Replace the bearing rings (E) and
the seals (C).
6. Install the internal mechanism.
7. Install these parts:
a) Handle (B)
b) Socket bolt (C)
c) Pillar bolt (A)
8. If applicable, install the insulation
and the cover plate.
9. Close the hatch.
6.2.6 Replace the hinge bushes
Warning:
RISK OF INJURY - HEAVY OBJECT
• Use correct and certified lifting materials.
• Do this task with two persons
A
B
C
C
D
E
E
A
CB
Maintenance
22 - 001 - 15.01.2021 19

Procedure
1. Remove the hatch. Refer to section
Remove the hatch on page 20.
2. Remove the bushes (A and B).
3. Clean the bracket and the hinge
plate.
4. Install the new bushes (B) into the
bracket at the frame.
5. Install the new bushes (A) into the
hinge plate on the hatch.
6. Install the hatch. Refer to section
Install the hatch on page 20.
7. Adjust the hinges. Refer to section
Adjust the hinges on page 17.
6.2.7 Remove the hatch
Warning:
RISK OF INJURY - HEAVY OBJECT
• Use correct and certified lifting materials.
• Do this task with two persons
Procedure
1. If applicable, release the open
holder.
2. Close the hatch. Make sure that the
hatch is latched.
3. Remove the parts that follow:
a) Retainer rings (A). Use special
pliers.
b) Hinge axles (B). Use a hammer
with a nylon head.
4. Release the latches.
5. Lift the hatch.
6.2.8 Install the hatch
Warning:
RISK OF INJURY - HEAVY OBJECT
• Use correct and certified lifting materials.
• Do this task with two persons
A
C
B
D
A B
Maintenance
20 22 - 001 - 15.01.2021