Reflex Marine FROG-XT4 User Manual Download

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Rev 3.1

36 | P a g e

Replacement Parts

6.1

Introduction

Replacement parts can be supplied as individual items or as appropriate kits. Prior to

ordering any replacement parts or kits, establish the serial number which is stamped on the

data plate. The serial number is XT4- XXX where XXX represents a three-digit number.

RML holds replacement parts and accessories in stock. We are able to supply most individual

components. A full list of parts is contained in the drawing pack, which is issued with every

unit.

It may be advisable to hold an inventory of frequently replaced parts. This will help to

ensure the continued safe operation of the carrier. Minimum stock quantities will be

influenced by:

Remoteness of location and certifying authority

ii.

Downtime implications

iii.

Criticality of maintaining crew and emergency response (Medevac) access.

iv.

Usage

Customs processing time

vi.

Delivery cost for small parts

RML can recommend stock items and quantities for your operation.

It is recommended that only genuine OEM parts (including lifting assemblies) are
used.

6.2

Kits

The following kits are available for routine and non-routine maintenance. Ordering an

appropriate kit is more economical than replacing individual parts.

Kit Name

Part Number

Contents

Lifting Assembly Kit

RA0116

Wire Rope Lifting Assembly

Lifting Assembly Cover

Associated Fixings

Replacement Parts Kit

RA0117

Critical Parts Minus the Wire Rope Lifting

Assembly

Critical Part Kit

RA0090

Critical Parts

Harness Kit

RA0118

4 X Harnesses

Landing Foot Kit

RA0303

4 X Feet plus

Associated Fixings

Full Service Kit

RA0120

1x Lifting Assembly Kit

1 X Replacement Parts Kit

1 X Harness Kit

1 X Landing Foot Kit

Suspension Kit

RA0132

2 X Springs

2 X Recoil Dampers

Associated Fixings

Summary of Contents for FROG-XT4

Page 1: ...USER MANUAL REV 3 1 DOC 000503 2 Issue date 16 03 2018 Original Instructions ...

Page 2: ...Transfer by Crane video also provides a useful overview of the key risks and considerations in planning crane transfer operations Key references i Offshore Personnel Transfer by Crane Marine Transfer Forum http www marinetransferforum org resources ii 10 Golden Rules Personnel Transfer by Crane Reflex Marine https www youtube com watch v JDljjCqr2Zw Safe and proper use of the FROG XT4 is the respo...

Page 3: ...e 13 3 8 Lifting Assembly Connection 14 3 9 Control of Lifting Assembly 15 4 Inspection Maintenance 16 4 1 Definitions 16 4 2 Care in use Preventative maintenance 16 4 3 Inspection Types 18 4 4 Frequency 18 4 5 Supporting Documentation 19 4 6 FROG XT4 Inspection and Maintenance Schedules 20 Ultra High Usage 21 4 7 Load Test Procedure 22 4 8 Data Plates 23 4 9 Pre Use Check 24 4 10 Visual Inspectio...

Page 4: ... 34 5 9 Feet Deformation during Storage 35 5 10 Replacement Parts 35 6 Replacement Parts 36 6 1 Introduction 36 6 2 Kits 36 6 3 Parts identification 37 6 4 Accessories 37 7 Certificates 39 7 1 EC Attestation of Conformity 39 8 Contact Details 40 Appendix A Stretcher Conversion Instructions Units XT4 001 to XT4 125 41 ...

Page 5: ...Seats 4 x Full Height Seats Harnesses 3 Point Quick Release Buckle Grab Handles 2 Per Passenger Lifting Points SWL Main 1000 kg Backup 1000 kg Handling 1000 kg Wire Rope Lifting Assembly Safe Working Load 1240 kg Wire Rope Anti rotation wire rope Number of Passengers Standard 4 Stretcher Mode 1 Stretcher Luggage Capacity Light Luggage Accessory available on request Large Luggage Tray Accessory ava...

Page 6: ...an body However there are many additional factors that may affect the safety of crane transfer operations These include vessel station keeping crew competence wind and visibility The operator should always refer to general guidelines on crane transfers operations to assess overall risks Technical note The calculation for relative velocity used here is based on the European offshore crane standard ...

Page 7: ...rmally be considered safe subject to due consideration of other risk factors XT4 Performance Limit This envelope is defined by the performance limits of the capsule and the theoretical translation to significant wave height by EN13852 1 2013 However it is assumed that in such elevated sea states other risk factors may become substantial Operations should not normally be performed in this range wit...

Page 8: ...ool that can be used to determine whether the conditions are suitable for transfers to take place Using the Crane Transfer Planning Tool There are four main sections that need to be completed i Risk Assessment ii Pre Transfer Checklist iii Passenger Log iv Post Transfer Review The Crane Transfer Planning Tool can be found on the flash drive contained in your user pack or alternatively you can down...

Page 9: ...est designed to reduce risk of whiplash iv Grab handles and pommel shaped seat cushion for secure seating position Flotation Buoyancy panels ensure the carrier floats with both passengers and stretcher above the water line All XT transfer capsules are performance tested for the most extreme immersion scenarios and self right All Frog XT capsules self rights up to 180 inverted to the vertical posit...

Page 10: ...seat to their left Passengers should ensure they are securely seated and ensure the seat harness is securely fastened Grab handles are provided on the tubular upright members either side of the buoyancy panel and passengers should grip these firmly or the harness straps whenever seated Passengers should never place their hands near the load plate Exit Following landing and when advised to do so by...

Page 11: ...on iii Check that passengers harnesses are secure and correctly fitted iv When the carrier is in the static position on deck for passenger entry and exit the wire rope lifting assembly will be in a static position and may obstruct one or more of the entry exit points Ensure passengers remain clear of the wire rope lifting assembly Deck crew may need to hold the lifting assembly in a safe position ...

Page 12: ...nesses prior to entering the carrier All passengers should be familiar with seating procedure and practice entry prior to operations ENTRY 1 Take your allocated seat 2 Fasten buckle Tightening lower straps then upper straps 3 Give thumbs up when ready 4 Use handholds and keep feet inside Exit 5 Wait for instructions 6 Exit and move to safe area ...

Page 13: ...n the seats behind buoyancy panels A and D 2 Place both thumb screws into place holder 3 Slide stretcher in 4 Insert stretcher into clamp 5 Tighten thumbscrew 6 Attach straps to anchor points The stretcher clamp has been designed to fit the Ferno Model 71 Basket stretcher Please note that not all stretcher types will fit The specific stretcher in use should be test fitted prior to being used ...

Page 14: ...ime passengers spend in the hazardous zone iii Items should be secured prior to passenger boarding and removed after passenger exit iv Small individual hand carry items such as laptop bags may be secured directly underneath a seat in one of two light luggage boxes Items should not exceed 400 mm w x 300 mm l x 120 mm h 16 x 12 x 5 and 5 kg 11 lbs per item v Larger luggage may be secured in under se...

Page 15: ...he top of the carrier The lifting assembly is fitted with two different terminations The main leg is fitted with a bow shackle and the back up leg is fitted with a spelter socket The main leg connects to the centre hole in the load plate and the backup leg connects to either the far right or far left hole A handling line can then be fitted to the other free hole in the load plate ...

Page 16: ...he designated deck crew wearing appropriate PPE i e gloves should manage the position of the slings Table 4 Control of lifting assembly Parameter Recommendation Ideal Sling Length The recommended limits in this section are based on the use of the standard FROG XT wire rope lifting assembly length of 30 ft 9 m Shorter Slings For the use of shorter lifting assemblies an additional risk assessment co...

Page 17: ... to the safety and continued use of the equipment It is recommended that the competent person is sufficiently independent and impartial to allow objective decisions to be made Non Destructive Testing Although not considered necessary some operators choose to carry out non destructive testing prior to any re installation of a critical part If this is done then a dye penetrant test should be used as...

Page 18: ... or kept in a deck area sheltered from sea spray Note for high speed craft wind effects may cause covers to fray Springs are washed down with fresh water at regular intervals i e after each voyage Springs are inspected regularly Specific inspection recommendations for springs can be found in the inspection checklist Protection grease may be used to coat springs to reduce onset of corrosion Seat ha...

Page 19: ...ly All inspections should be i Performed by a competent person ii Carried out as per the frequency indicated in the usage table iii Formally recorded 4 4 Frequency The recommended frequency and type of inspection test and maintenance is shown in Table 7 SEE OVER Please note i If any doubt exists regarding the usage then the maintenance strategy should revert to a more conservative higher usage cat...

Page 20: ...eflexmarine com 4 5 Supporting Documentation Customer drawing pack Every FROG XT comes with a drawing pack that contains all of the relevant drawings to aid in its maintenance This pack contains the following i Assembly drawings ii Replacement parts kit drawings iii Torque settings iv Operational stickers v Bill of materials Certification pack Every FROG XT comes with a certification package which...

Page 21: ...t Post Load Test Visual Inspection Low 100 Prior To Every Use 6 months 12 months 12 months 36 months 4 Years 12 years Medium 100 500 6 months 12 months 12 months 24 months 3 Years 8 years High 500 2000 3 months 12 months 6 months 12 months 2 Years 6 years Very High 2000 5000 3 3 months 6 months 3 months 6 months 1 years 4 years 1 This may be extended subject to a condition service assessment carri...

Page 22: ...ould be visually inspected for cracks and distortion v In addition to the guidance it item 8 the floor grating should be visually inspected for sign of distortion cracking or corrosion The welds should be visually inspected around the mounting plate for cracks Examination i In addition to the guidance it item 3 visually inspect the load plate for cracks and distortion Particular attention should b...

Page 23: ... Load Bearing Assembly iii Seats and Floor Structure Test Proof Load 1500 kg 3307 lb Test Proof Load Distribution At the discretion of the competent person the proof load may be applied to the FROG XT4 either solely on the floor or split between the floor and seats For the latter the recommended distribution is i 500 kg 1102 lb on seats spread equally between them Seats and harnesses should be pro...

Page 24: ...oad test date DD MMM YYYY v Test load kg vi Serial number XT4 XXX where XXX is unit I D No vii Model number XT4 viii Entry into service date DD MMM YYYY Marker Plate i Model number XT4 ii Serial number XT4 XXX where XXX is unit I D No iii Date of manufacture DD MM YYYY iv Tare weight kg v Pay load SWL kg vi Maximum gross load kg vii Maximum number of passengers standard stretcher mode Figure 5 FRO...

Page 25: ...Rev 3 1 24 P a g e 4 9 Pre Use Check ...

Page 26: ... lifting assembly should be replaced at least every 12 months 2 Load Plate Safety Bolts Critical Part Consumable Visually inspect the 4 x M16 load plate safety bolts nuts split pins and tamper proof seals that connect the Load Plate to the central columns for wear or damage 3 Load Plate Critical Part Visually inspect in situ for any signs of wear cracks deformation or other damage 4 Node Plate Saf...

Page 27: ...iding sleeve and the compression stops greater than 10mm then the spring should be replaced Check the spring cap plate for any signs of deformation 8 Frame and Buoyancy Visually inspect for any damage and ensure that all bolts and fasteners are tight and fully secure 9 Landing Feet Examine the feet to ensure that they are in good condition and that they are properly secured to the capsule Do not g...

Page 28: ...ng or damaged The sticker location drawing can be found in the drawing pack 14 Stretcher Fittings Visually inspect the stretcher fittings to ensure that they are all present and in good condition Storage 15 Storage of FROG Check the storage cover is in good condition and not showing any signs of UV or wind degradation Storage off the ground use of spacer chocks whilst not in use 16 Replacement Par...

Page 29: ...2 months 2 Load Plate Safety Bolts Critical Part Consumable Remove and visually inspect the 4 safety bolts for any signs of damage or strain Visually inspect the 4 holes in the 2 central columns for signs of damage or strain Replace appropriate parts according to the usage of the FROG XT or on the recommendation of a Competent Person Inspector 3 Load Plate Critical Part Remove and visually inspect...

Page 30: ...r flaking of wire or if springs have taken a pre compression set then they should be changed out Springs can be susceptible to yield over time This can be verified by measuring the deflection of the seat base in situ The following check is recommended to identify whether the springs are fit for purpose In situ spring check the top of the sliding sleeve should rest against the compression stop If a...

Page 31: ... in each seat and check fastening and unfastening of each harness to ensure correct operation 1 3 2 4 12 Inspection data plate Check the date of the last examination inspection to ensure the unit will remain in compliance with requirements for at least 6 months Update data plate to show visual examination has been done 13 Stickers Check that all of the stickers on the unit are in good condition an...

Page 32: ...wing any signs of UV or wind degradation Storage off the ground use of spacer chocks whilst not in use 18 Replacement Parts Stock Check condition of all associated replacement parts and accessories Lifting assemblies should be stored in an appropriate dry place without high visibility cover fitted Other 19 Clean Has the unit been cleaned Reports Complete Y N 20 Documentation Report including Photo...

Page 33: ...ode plate safety bolts nuts split pins and tamper proof seals that connect the node plates to the central columns for wear or damage 5 Recoil Dampers Visually inspect for any wear or damage and ensure that all bolts clevis and other fasteners are fully secure Ensure that there is no sign of any fluid leaking onto the damper rods 6 Seat Base Assembly Visually inspect for any wear or damage and ensu...

Page 34: ... Stock Inspections You should follow the below table for any carriers or replacement parts that are held in storage Type In Stock Visual Inspection Shelf Life Transfer capsules 1 Year 5 Years Wire Rope Lifting Assembly 6 months 2 Years Other replacement Parts not lifting assemblies None NA Prior to First Use You should follow the below table before using your equipment for the first time Type Tran...

Page 35: ... of the damage 5 6 Preparation for Road Transport Prior to shipping the seat harnesses must be secured by securing the buckle together and then tightening the harness straps This will prevent seat harnesses flapping and damaging the seating area It is recommended that the carrier is covered for shipping either with a FROG XT weatherproof protective cover or other heavy duty tarpaulin material 5 7 ...

Page 36: ...be stored for prolonged periods a set of chocks should be used to lift the feet away from the deck Any chocks used should fit properly underneath the main base frame to ensure that any exposed bolt heads are not impinged The chocks can be pre laid on the deck ready for landing 5 10 Replacement Parts Replacement parts should be stored in dry clean environments and be suitably labelled and tagged ...

Page 37: ... Criticality of maintaining crew and emergency response Medevac access iv Usage v Customs processing time vi Delivery cost for small parts RML can recommend stock items and quantities for your operation It is recommended that only genuine OEM parts including lifting assemblies are used 6 2 Kits The following kits are available for routine and non routine maintenance Ordering an appropriate kit is ...

Page 38: ...ies are available from RML to maximise operational effectiveness They can be supplied with the carrier or ordered separately Strobe Light Provides greater visibility at night and in poor weather conditions High intensity light weight waterproof to 300 m Flash Rate 50 per min and also provides 6 mile visibility C cell battery powered fitted to the overhead protection plate in the FROG XT Note This ...

Page 39: ...tems such as laptop bags to be loaded and transported by the FROG XT4 Large Luggage Tray RML can provide a solution for larger items of luggage that will not fit into the light luggage holder It is attached to the floor grating underneath the passenger seat Please contact RML for further information For a complete list of accessories please contact RML ...

Page 40: ...Rev 3 1 39 P a g e 7 Certificates 7 1 EC Attestation of Conformity ...

Page 41: ...ine Old School House School Hill Shortlanesend Truro TR4 9DU UK Telephone 44 0 1872 321155 Email Addresses General enquiries info reflexmarine com Order enquiries sales replacement parts support reflexmarine com Accounts Department accounts reflexmarine com ...

Page 42: ...r mode 1 Remove fixings and fold down seat 2 Refit fittings 3 Slide stretcher in 4 Rotate clamp anti clockwise 90 degrees 5 Tighten thumbscrew 6 Attach straps to anchor points The stretcher clamp has been designed to fit the Ferno Model 71 Basket stretcher Please note that not all stretcher types will fit The specific stretcher in use should be test fitted prior to being used ...

Page 43: ...Rev 3 1 42 P a g e ...

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