Nov Crane Maintenance Manual 204d2h

Operation and Maintenance Manual AmClyde Unit Model 10000 Crane Serial Number 2710100

RIG/PLANT

REFERENCE

REFERENCE DESCRIPTION

GSP-Upetrom Jackup Drilling Rig “Saturn”

AmClyde Unit Model 10000

Crane

ADDITIONAL CODE

SDRL CODE

TOTAL PGS

REMARKS National Oilwell Varco SO16176 MAIN TAG NUMBER

DISCIPLINE

CLIENT PO NUMBER

This document contains proprietary and confidential information which belongs to National Oilwell Varco, L.L.P.; it is loaned for limited purposes only and remains the property of National Oilwell Varco, L.L.P. Reproduction, in whole or in part; or use of this design or distribution of this information to others is not permitted without the express written consent of National Oilwell Varco, L.L.P. This document is to be returned to National Oilwell Varco, L.L.P. upon request and in any event upon completion of the use for which it was loaned. © National Oilwell Varco, L.L.P.

National Oilwell Varco, L.L.P 73765 Penn Mill Road Covington, Louisiana 70435 USA Phone 985-892-8216 Fax 985-871-8630

CLIENT DOCUMENT NUMBER

DOCUMENT NUMBER

REV

2710100-MAN-001

2710100-MAN-001

01

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2710100-MAN-001 01 ii

REVISION HISTORY

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Date (dd.mm.yyyy)

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First Issue

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TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII WARRANTY 1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.3 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3.1 General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3.2 Operating Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3.3 Maintenance Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.4 Operator Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.5 Inclement Weather Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.6 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Crane Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.3 Crane Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.4 Control Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.5 General Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.5.1 Horn Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.5.2 Boom Angle Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.5.3 Load and Radius Indicator System . . . . . . . . . . . . . . . . . . . . . . 2-6 2.5.4 Window Wiper Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.5.5 Operator’s Cab Air Conditioner/Heater Controls . . . . . . . . . . . . . . . 2-7 2.5.6 Area Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.5.7 Obstruction Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.5.8 LIGHTS Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.5.9 Maintenance Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.5.10 Boom Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.6 Power Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 www.nov.com


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2.6.1 Diesel Engine Throttle Controls. . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.6.2 ENGINE KILL Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.6.3 EMERGENCY ENGINE KILL Control. . . . . . . . . . . . . . . . . . . . . 2-9 2.6.4 Diesel Engine Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2.6.5 Diesel Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2.6.6 AIR STARTER Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2.6.7 Hydraulic Oil Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2.6.8 Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . 2-10 2.6.9 Hydraulic Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2.6.10 AIR PRESSURE Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2.7 Crane Function Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.7.1 Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.7.2 SWING BRAKE OFF/ON Control . . . . . . . . . . . . . . . . . . . . . . 2-11 2.7.3 SWING LOCK OFF/ON Control . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.7.4 BOOM/SWING Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2.7.4.1 Boom Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2.7.4.2 Swing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2.7.5 MAIN and AUXILIARY Hoist Controls . . . . . . . . . . . . . . . . . . . . 2-13 2.7.6 Swing and Hoist Speed Control . . . . . . . . . . . . . . . . . . . . . . . 2-14 2.8 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 2.8.1 Pre-Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 2.8.1.1 Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 2.8.1.2 Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2.8.2 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 2.8.3 Pre-Operating Checks (After Engine Start-Up) . . . . . . . . . . . . . . . 2-18 2.8.3.1 Anti–Two-Block System . . . . . . . . . . . . . . . . . . . . . . 2-18 2.8.3.2 Boom Angle Limit System . . . . . . . . . . . . . . . . . . . . . 2-19 2.8.4 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 2.8.5 Emergency Stop Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 2.8.6 Emergency Load Lowering . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

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3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 Introduction and General Instructions . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2.1 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2.2 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2.2.1 Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2.2.2 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2.2.3 Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.2.2.4 Swing Gear and Pinions. . . . . . . . . . . . . . . . . . . . . . . 3-4 3.2.2.5 Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.2.2.6 Boom Hoist Pawl . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.2.2.7 Hoist Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.2.2.8 Swing Drive Gearboxes . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.3 Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.3.1 As Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.3.2 Before Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.3.3 After Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.3.4 Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.3.5 Every 8 Hours of Operation or Every Day . . . . . . . . . . . . . . . . . . 3-7 3.3.6 Every 40 Hours of Operation or Every Week . . . . . . . . . . . . . . . . . 3-8 3.3.7 First 100 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.3.8 Every 250 Hours of Operation or Every Three Months . . . . . . . . . . . . 3-8 3.3.9 Every 500 Hours of Operation or Every 6 Months . . . . . . . . . . . . . . 3-9 3.3.10 Every 12 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.4.1 Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.5 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.5.1 Air System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.5.2 Releasing Pressure from Air System . . . . . . . . . . . . . . . . . . . . 3-10 3.6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 3.6.1 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-11 www.nov.com


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3.6.1.1 Hydraulic Oil Sampling (National Oilwell Varco Drawing 604289) . 3-12 3.6.1.2 Hydraulic System Contamination Levels (National Oilwell Varco Drawing 604289) . . . . . . . . . . . . . 3-15 3.6.2 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 3.6.3 Hydraulic Piping and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 3.6.4 O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 3.6.4.1 O-Ring Sizes for Bosses and Tube Fittings . . . . . . . . . . . . 3-18 3.6.4.2 Four Bolt O-Ring Flange . . . . . . . . . . . . . . . . . . . . . . 3-19 3.6.5 Releasing Pressure from Hydraulic System . . . . . . . . . . . . . . . . . 3-20 3.6.6 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 3.6.6.1 Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . 3-20 3.6.6.2 Adding Hydraulic Oil to the Reservoir . . . . . . . . . . . . . . . 3-21 3.6.7 Draining and Filling Hydraulic System. . . . . . . . . . . . . . . . . . . . 3-21 3.6.7.1 Draining Hydraulic System . . . . . . . . . . . . . . . . . . . . . 3-22 3.6.7.2 Filling Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 3-23 3.6.8 Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 3.7 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 3.8 Non-Operational Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 3.8.1 Short-Term Storage—7 Days Up to 30 Days . . . . . . . . . . . . . . . . 3-24 3.8.2 Long-Term Storage—30 Days or More . . . . . . . . . . . . . . . . . . . 3-24 3.8.3 Removal from Long-Term Storage . . . . . . . . . . . . . . . . . . . . . 3-25 3.9 Welding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Emergency Load Lowering Procedure . . . . . . . . . . . . . . . . . . . . 603511 Rev. 4 Emergency Hoist Load Lowering Kit . . . . . . . . . . . . . . . . . . . 603457-L01 Rev. 9 4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Crane Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1.1 Hoist and Wire Rope Information . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.1.2 Power Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.1.3 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.1.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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4.2 Tightening Values for SAE Coarse Thread Bolts (National Oilwell Varco Drawing 1525177). . . . . . . . . . . . . . . . . . . . . . 4-4 Load Rating Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1585851 Rev. 0 5 API RECOMMENDED PRACTICE 2D SIXTH EDITION, MAY 2007 (API RP 2D) INSERT FOR API RP 2D SIXTH EDITION (APPENDIX I)

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FOREWORD This technical manual gives information for the recommended operation and maintenance of the equip ment. This technical manual is written for the original design application of the equipment. If the appli cation of the equipment changes, the operation and maintenance information and procedures could change. This technical manual is not a substitute for comprehensive operator and maintenance train ing. Read and completely understand this technical manual, equipment functions, and equipment safety features before operating or doing maintenance to the equipment. If additional technical manuals are needed, they are available for an added cost. The serial number of the equipment must be given with all communication for correct identification of the equipment.

National Oilwell Varco P.O. Box 4720 Covington, Louisiana 70434 73765 Penn Mill Road Covington, Louisiana 70435 Phone: (985) 892-8216 Fax: (985) 871-8630 Accessory Sales For replacement parts, retrofits, upgrades, spares, and accessories. Field Service For service-specific questions and inquiries, including inspections, test-certificates, service work, repair supervision, and operator/maintenance training. Sales For new equipment. This publication is one document of the technical manual for the Unit model 10000 crane, serial number 2710100. The complete technical manual consists of the following documents: • •

Operation and Maintenance Manual, document number 2710100-MAN-001 Parts and Vendor Data Manual, document number 2710100-MAN-002

T2008-09.02

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WARRANTY Products covered hereby are subject to the following warranty and no other: "The Manufacturer warrants each new Product made by the Manufacturer to be free from defects in material and workmanship, its obligation and liability under this Warranty being expressly limited to repairing or, at the Manufacturer's option, replacing free of charge at its factory any part proving defective under normal use and service within - twelve (12) - months or one thousand (1000) hours, whichever comes first, after date the Product is first delivered to a , provided written claim hereunder is received by the Manufacturer within 15 days after expiration of said period. Parts claimed to be defective and for which repair or replacement is desired shall, if requested by the Manufacturer, be returned transportation prepaid to the Manufacturer's factory for inspection. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE, AND THE OBLIGATION AND LIABILITY OF THE MANUFACTURER UNDER THIS WARRANTY SHALL NOT INCLUDE ANY TRANSPORTATION OR OTHER CHARGES OR THE COST OF INSTALLATION OR ANY LIABILITY FOR LOSS OF PRODUCT TIME OR ANY OTHER DIRECT, INDIRECT, OR CONSEQUENTIAL DAMAGES OR DELAY RESULTING FROM THE DEFECT. Any operation beyond rated capacity or the improper use or application of the Product or the substitution upon it of parts not approved by the Manufacturer or any alteration or repair by others in such manner as, in the Manufacturer's judgement, to affect the Product materially and adversely shall void this Warranty. No representative of the Manufacturer is authorized to change this Warranty in any way, and no attempt, effort, or promise to repair Products of the Manufacturer either by the Manufacturer or by any representative of Manufacturer at any time shall change or extend this Warranty in any way.

This Warranty covers only new and unused Products

manufactured by the Manufacturer. Products manufactured by others are covered only by such warranties as are extended to the Manufacturer by its suppliers."

2/2003


1 SAFETY 1.1 Safety Warning It is the responsibility of the owner and of this equipment to know the safety codes; insurance requirements; and national, federal, provincial, state, and local laws and regulations affecting all uses of the equipment. This technical manual does not provide regulatory information, because regulations are subject to change and different from location to location. It is the responsibility of the owner and of the equipment to obtain, read, and understand the current edition of API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP 2D), a document from the American Petroleum Institute (API). The document is published by API Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005. For more information call 202-862-8375 (phone) or 202-962-4776 (fax), or visit the API website (www.api.org/publications/). Not using the equipment according to these regulations can result in damage to the equipment and death or injury to personnel. National Oilwell Varco provides technical manuals for the different types of equipment that it manufactures and sells. The owner and must use these technical manuals to give the correct information and training to the people who will operate, maintain, or supervise the use of the equipment. This equipment is designed to do heavy-duty work and will wear during normal use. Therefore, the owner and must establish a regularly scheduled inspection and maintenance program based on the information in the National Oilwell Varco technical manual. Inspection and maintenance programs help prevent accidents and keep the equipment operating efficiently.

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Correct training, inspection, and maintenance programs are important to avoid personal injury, damage to equipment, high maintenance costs, and lost production. Any performance ratings and specifications for this equipment are valid only when the equipment is used according to the manufacturer’s operating and maintenance procedures. Read and understand the technical manuals provided with this equipment before operating or doing maintenance to the equipment. Assistance is available from the National Oilwell Varco Service Department. The operator must know all the main parts, controls, and safety features of the equipment before operating it. The operator must know the correct operation and inspection procedures of the equipment before operating it. The operator is responsible for the safe operation of the equipment, including the safety of others in the work area.

1.2 Safety Signal Words Throughout this technical manual are steps and procedures that, if not followed, can result in a hazard. The following signal words are used to identify the level of a hazard.

!DANGER •

Danger is used to show a hazard that WILL RESULT in death or serious injury if not avoided.

!WARNING •

Warning is used to show a hazard or unsafe practice that CAN RESULT in death or serious injury if not avoided.


!CAUTION •

Caution is used to show a hazard that WILL or CAN RESULT in minor or moderate injury if not avoided.

CAUTION •

Caution used without the safety alert symbol ! is used to show a hazard that WILL or CAN RESULT in equipment or property damage if not avoided.

NOTICE •

Notice is used to call attention to operation and maintenance information that is important but not hazard-related.

1.3 Safety Rules National Oilwell Varco equipment, as designed, can be used safely; however, no equipment, regardless of design, can prevent injury or damage because of operator error or carelessness. This safety section includes information from many sources. It gives examples of basic safety rules. Additional safety rules can be necessary for safe operation of the equipment. The information in this section is not meant to replace safety codes; insurance requirements; or national, federal, provincial, state, and local laws and regulations.

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1.3.1 General Safety Rules 1. Wear protective clothing and safety equipment as required by job conditions when operating the equipment or working in the area of the equipment. Do not wear loose clothing that could catch on controls or moving equipment parts. 2. Keep the operator’s area and the work area clean and free of debris. 3. Keep the equipment clean and free of dirt and debris, to permit a good inspection of the equipment. 4. Check the rigging before a lift. Rigging that is damaged must be repaired or replaced before it can be used. 5. Do not weld on hooks or shackles. Welding on these items can weaken the material, causing failure. 6. Do not use torches or open flame on or near fuel system, hydraulic, and control equipment. 7. Adequate fire protection equipment must be available and in satisfactory operating condition. Operating and maintenance personnel must be familiar with the use and care of the fire protection equipment.

1.3.2 Operating Safety Rules 1. Do not operate this equipment under any conditions or in any manner other than those for which the equipment has been specified, sold, and described in this technical manual. 2. This equipment must be operated only by personnel who are trained and authorized for its operation.

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3. Do not operate this equipment if you are ill or physically or mentally not fit to operate it correctly and safely.

11. Do not operate the equipment with any personnel near the wire rope or moving equipment.

4. Do not exceed the rated load capacity of the equipment (see Section 4, Load Rating Chart, drawing 1585851). Lifting loads greater than those shown on the load rating chart or operation at positions not shown, or lifting when the boom is solid against the boom stops, can cause structural failure or collapse of the boom or crane and death or injury to personnel.

12. Do not operate the equipment without the safety guards installed.

5. Do not rely on the load monitoring system when common sense judgment indicates an error. Do not use the load monitoring system as a weighing device after lifting the load. 6. Operate the equipment with no load at the start of each workday to make sure all functions work correctly. 7. Test the brakes for correct operation whenever a load at or near the load rating for the boom angle used is to be handled. 8. The operator must watch the load at all times. Do not operate the equipment if the operator’s vision is restricted. Some applications require a signal person. The signal person must be visible to the operator at all times. The operator and the signal person must agree on the signals to be used before operating the equipment. 9. Communication must be maintained between all personnel involved in any operation. The operator must obey a signal to stop from anyone in the area. The signal person must give all other signals. 10. Do not permit personnel to get on or off the equipment while it is operating.

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13. Do not by, disconnect, or ignore safety and warning devices of the equipment. Safely shut down the equipment and investigate the problem. Correct the problem before continuing operation. 14. Do not operate the equipment after an inspection reveals a safety hazard or if any equipment parts require maintenance or replacement. Always look for equipment damage or abnormal functioning during operation. If found, safely shut down the equipment and correct the damage before continuing operation. 15. Before rotating the crane, make sure that the crane tailswing as well as the swing paths of the boom and load are free of obstructions and personnel. Not following this procedure can result in damage to the crane, the load, or other equipment or structures, and death or injury to personnel. 16. Operate the equipment at a slow speed when first learning. 17. Check the load indicating display and all gauges often for normal operating conditions. Shut down the equipment immediately if the display or gauges are out of the normal operating ranges. Investigate and correct the problem before continuing operation. 18. When making a lift, the hook must be directly over the estimated center of gravity of the load before the load is attached to the rigging. Do not attach capacity loads at maximum outreach, because an outward swing of the load, caused by vessel list or trim, or outward drift of the boom, can overload the crane.


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19. Loads must be safely rigged before lifting. Do not overload slings. Slings must be attached to the throat of the hook. Do not permit hook latches to any part of the load. Hook latches keep loose slings from coming off the hooks.

29. The operator must not leave the control station with a load suspended in the air.

20. When making a lift, the boom (hook) must be directly over the load, not the side of the load. Side loading can cause structural failure or collapse of the boom or crane and injury to personnel.

31. Do not permit the wire rope to wind wrong on the hoist drum (see figure 1–1).

30. The hoists must have at least five full wraps of wire rope on the drum at all times during operation.

21. Use extreme caution when rotating the crane with a load suspended. When lifting a heavy or bulky load, it is recommended that taglines (ropes) be attached to each side of the load to prevent the load from rotating or swinging. 22. When using handlines (ropes) to guide or snub a load, do not permit personnel to wrap the rope around any part of their body. 23. Personnel must be clear of the work area before making the lift.

A1929

Figure 1–1. Wire Rope Wound Wrong on Drum

24. Do not quickly accelerate or quickly decelerate a moving load.

1.3.3 Maintenance Safety Rules 25. Loads must be moved at as low a level as possible. If the load slips, it must be lowered with caution immediately. 26. Do not swing or position the load or attachment over personnel. Do not permit personnel to be in a hazardous position between a swinging load and a fixed object. 27. The operator must watch the load at all times. The load must be completely lowered before looking away from the load. 28. The operator must not leave the control station until the equipment has been shut down and is completely stopped.

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1. Shut down the equipment before doing maintenance. Only qualified, trained personnel must do maintenance, adjustment, and inspection procedures, following the procedures outlined in the technical manual. 2. All replacement and repaired parts must meet the manufacturer’s current specifications. 3. After making a repair or adjustment, always check the functioning of the equipment parts before putting the equipment into full operation.


4. The power plant must be stopped and cool before checking fluids. 5. Do not add fuel to the fuel tank while the equipment is operating. When adding fuel, keep the nozzle in with the fuel tank to prevent static electricity sparks. If provided, connect the ground wire before adding fuel. NO SMOKING! Do not permit open flames or sparking devices near the fuel filling area. Remove all spilled fuel before starting the equipment. Add fuel to the fuel tank in a well-ventilated location only. 6. Do not make modifications to the equipment unless approved in writing by National Oilwell Varco.

1.4 Operator Qualification To prevent injury and property damage, the crane operator must be qualified by training and physical capability. The operator must understand the manufacturer’s intended use, and the operation and maintenance procedures. The operator should be familiar with and follow the practice of API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) current edition.

1.5 Inclement Weather Precautions Crane operation should be suspended and the boom lowered during periods of inclement weather, including wind strong enough to affect load control (especially loads with large “sail” areas) or when the operator’s ability to see the signal person or load is hampered by darkness, fog, rain, etc.

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2710100-MAN-001 01 1-5

1.6 Safety Labels Safety labels are located on the equipment in prominent places to advise operating and maintenance personnel of hazards. The labels are reproduced here to improve recognition and thereby increase label effectiveness. Before operating or doing maintenance to the equipment, be sure you understand the meaning of these labels. Drawing 1587840, Decal and Nameplate Installation (see Parts and Vendor Data Manual, Section 2) shows the locations of all the National Oilwell Varco-supplied safety labels. This drawing is a useful reference for the inspection and maintenance of the safety labels (see paragraph 3.3.8). Replace all damaged or missing safety labels.


WARNING Read and fully understand operation, service and parts manuals before operating or servicing equipment. Failure to obey warnings and follow instructions could result in personal injury, death, damage to equipment or property.

2710100-MAN-001 01 1-6

Operating and maintenance personnel must read and understand the manuals provided with the equipment before operating or doing maintenance to the equipment. The equipment must be operated only by personnel who are responsible and authorized for its operation.

p/n 604287

WARNING Swing brake must not be applied while the crane is in motion. Serious damage may occur to the swing gear box components if this procedure is not followed. Refer to operator’s manual for additional swing control information.

Operating and maintenance personnel must read and understand the manuals provided with the equipment before operating or doing maintenance to the equipment. The equipment must be operated only by personnel who are responsible and authorized for its operation.

p/n 603164

WARNING Machinery must be completely stopped before maintenance can be done. Make reference to maintenance manual for correct procedures. p/n 604283

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Shut down the equipment before doing maintenance. Only qualified, trained maintenance personnel must do maintenance, adjustment, and inspection procedures, following the procedures outlined in the maintenance manual.


2710100-MAN-001 01 1-7

WARNING Only trained authorized personnel are to do maintenance or make adjustments to hydraulic, air and electrical systems. See Maintenance Manual for instructions.

Shut down the equipment before doing maintenance. Only qualified, trained maintenance personnel must do maintenance, adjustment, and inspection procedures, following the procedures outlined in the maintenance manual.

p/n 604284

DANGER To prevent injury, do not walk or stand under crane boom, hooks, or load.

Do not access this area while the crane is operating. The equipment can start or stop without warning. Not following this procedure can result in death or serious injury.

p/n 603187

CAUTION OPENING/CLOSING CAB WINDOWS p/n 603762

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Be careful when opening or closing windows of operator’s cab. Keep area clean and free of debris to prevent tripping hazards.


2710100-MAN-001 01 1-8

WARNING Exposed, moving equipment parts can cause serious injury or death. Keep hands, feet, and clothing away from moving equipment parts while the equipment is operating. Do not operate the equipment without the safety guards installed.

p/n 604285

WARNING WATCH YOUR HANDS AND FINGERS

Exposed, moving equipment parts can cause serious injury or death. Keep hands, feet, and clothing away from moving equipment parts while the equipment is operating. Do not operate the equipment without the safety guards installed.

p/n 603698

WARNING Only qualified, trained maintenance personnel must do maintenance, adjustment, and inspection of the electrical equipment. Each maintenance person must install a lockout at each electric power area. Electrical equipment must be maintained and operated according to applicable standards. Not following this procedure can result in death or serious injury.

Electric shock hazard. Authorized personnel only. p/n 604788

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WARNING This enclosure has more than one source of power. Disconnect all sources before doing maintenance.

2710100-MAN-001 01 1-9

Electrical power is supplied to this equipment from multiple sources. All sources of electrical power must be shut off before accessing the indicated equipment. Only qualified, trained maintenance personnel must do maintenance, adjustment, and inspection of the electrical equipment. Not following this procedure can result in death or serious injury.

p/n 604791

Only qualified, trained maintenance personnel must do maintenance, adjustment, and inspection of the electrical equipment. Each maintenance person must install a lockout at each electric power area. Electrical equipment must be maintained and operated according to applicable standards. Not following this procedure can result in death or serious injury. p/n 604796

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2710100-MAN-001 01 1-10


2 OPERATION 2.1 Introduction The following paragraphs describe the operator’s controls and general operating instructions for the crane as outlined by the table of contents.

2.2 Crane Installation The crane pedestal must be properly secured to the foundation, and the installation as well as the foundation itself must be strong enough to withstand the maximum pedestal reactions. Refer to the crane general arrangement drawing for the foundation loading information (see Parts and Vendor Data Manual, Section 2, drawing 1585795, General Arrangement).

!DANGER •

The pedestal installation and the foundation must be strong enough to withstand the maximum pedestal reactions. The pedestal must be properly secured to the foundation before installing the crane.

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2710100-MAN-001 01 2-1


2710100-MAN-001 01 2-2

2.3 Crane Nomenclature

Wind Speed Sensor Obstruction Light (see paragraph 2.5.7) Area Lighting (see paragraph 2.5.6)

Bridle Boom Wire Rope

A-Frame Ladder and Cage Main Wire Rope

Maintenance Crane (see paragraph 2.5.9)

Auxiliary Wire Rope

Auxiliary Hoist Main Hoist

A-Frame

Boom Hoist Diesel Engine

Boom Stop

Air Reservoir

Operator’s Cab

Boom Flood Light (see paragraph 2.5.6) Boom

Boom Angle Indicator (far side) (see paragraph 2.5.2) Turntable

Boom Foot Pin

Diesel Fuel Tank Swing Bearing

Hydraulic Oil Heat Exchanger

Pedestal

A3266

Figure 2–1. Crane

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2710100-MAN-001 01 2-3

Auxiliary Hoist Load Sensor Obstruction Light (see paragraph 2.5.7) Pendant

Wind Speed Sensor

Main Hoist Load Sensor Anti–Two-Block System Weight

Auxiliary Overhaul Ball and Hook

A-Frame Ladder and Cage

Main Hook Block and Hook

Air Conditioning/ Heating Units (see paragraph 2.5.5) A-Frame Operator’s Cab Window Wipers (see paragraph 2.5.4)

Horn (see paragraph 2.5.1)

Front Elevation

Swing Drive

(boom not shown for clarity)

A3266

Figure 2–1. Crane (continued)

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2710100-MAN-001 01 2-4

2.4 Control Nomenclature The controls of the operator’s control station (see figure 2–2) direct the functioning of the crane equipment and show information important to the operation of the crane. Detailed descriptions of the operator’s controls are given in the following paragraphs as outlined by the table of contents. The control descriptions are divided into three groups: general control devices, power control devices, and crane function control devices. This legend refers to figure 2–2 on the following page. ITEM NUMBER

DESCRIPTION

1 2 3 4 5

Diesel engine throttle pedal (see paragraph 2.6.1) BOOM/SWING control (see paragraph 2.7.4) Swing brake pedal (see paragraph 2.7.1) Horn control (see paragraph 2.5.1) MAIN/AUXILIARY hoist control (see paragraph 2.7.5)

6 7 8 9 10

Load and radius indicator system (see paragraph 2.5.3) SWING PRESSURE gauge (see paragraph 2.6.9) MAIN/AUX PRESSURE gauge (see paragraph 2.6.9) BOOM PRESSURE gauge (see paragraph 2.6.9) PILOT PRESSURE gauge (see paragraph 2.6.9)

11 12 13 14 16

AIR PRESSURE gauge (see paragraph 2.6.10) Boom angle indicator (see paragraph 2.5.2) SWING BRAKE OFF/ON control (see paragraph 2.7.2) Diesel ENGINE THROTTLE control (see paragraph 2.6.1) EMERGENCY ENGINE KILL control (see paragraph 2.6.3)

15 17 18 19 20

AIR STARTER control (see paragraph 2.6.6) ENGINE KILL control (see paragraph 2.6.2) SWING LOCK OFF/ON control (see paragraph 2.7.3) ENGINE TACHOMETER/HOUR METER (see paragraph 2.6.4) COOLANT TEMPERATURE gauge (see paragraph 2.6.4)

21 22 23 24 25

OIL PRESSURE gauge (see paragraph 2.6.4) UPPER WIPER control (see paragraph 2.5.4) WINDOW WASHER control (see paragraph 2.5.4) FRONT WIPER control (see paragraph 2.5.4) LIGHTS switch (see paragraph 2.5.8)

26 Seat

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2710100-MAN-001 01 2-5

7 SWING PRESSURE

MAIN/AUX PRESSURE

1

2

3

4

5

6

BOOM PRESSURE

PILOT PRESSURE

8

9 10 11 12

RAISE

O F F

LIGHTS

SWING LEFT BOOM RAISE

FRONT WIPER

25 24

23

17 18 19 20

OIL PRESSURE

UPPER WIPER

26

16

ENGINE TACHOMETER/ COOLANT TEMPERATURE HOUR METER

SWING RIGHT

BOOM LOWER

15

ENGINE KILL

ON

EMERGENCY ENGINE KILL

RAISE

SWING LOCK

LOWER

MAIN

AIR STARTER

ON O F F

ENGINE THROTTLE

SWING BRAKE

LOWER

AUX

14

21

22

A3267

Figure 2–2. Control Station

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10 5

30 25 20 15

35

40

60 55 50

13

45

BOOM ANGLE INDICATOR DEGREES FROM HORIZONTAL

0

80 75 70 65

AIR PRESSURE


2.5 General Control Devices 2.5.1 Horn Control Push the horn control (figure 2–2, item 4) on the floor in front of the operator’s seat to sound the horn located on the operator’s cab (see figure 2–1). The control is a manually engaged spring-released, foot-operated air valve.

2.5.2 Boom Angle Indicator The boom angle indicator (figure 2–2, item 12) is located on the boom (see figure 2–1) and can be viewed from the operator’s cab. The dial shows the angle of the boom in degrees from horizontal.

At loads of 110 percent of rated capacity or more, hoist movement stops and main/auxiliary hoist raising and boom lowering functions are disabled. To restore normal operation, operate the corresponding main/auxiliary hoist in the lowering direction, or raise the boom, until the load on the hoist becomes less than 110 percent. Leave the load and radius indicator system continuously powered during crane operation. See the manufacturer’s information for the operating instructions (see Parts and Vendor Data Manual, Section 11, Aanderaa Data Instruments).

!WARNING •

2.5.3 Load and Radius Indicator System The load and radius indicator system display (figure 2–2, item 6) is located in the operator’s cab and shows the radius, load, rated load capacity (safe working load), and percent of rated load capacity.

!WARNING •

Except at 110 percent of hoist capacity, the load and radius indicator system does not stop crane movement at the capacity and position limits. The operator must respond as necessary to alerts from the load and radius indicator system.

At loads of 85 percent or more of the rated capacity, an audible alarm sounds and the circular analogue scale of the display flashes yellow to warn the crane operator. At loads of 100 percent or more of the rated capacity, an audible alarm sounds and the circular analogue scale of the display flashes red to warn the crane operator.

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2710100-MAN-001 01 2-6

•

Do not exceed the rated load capacity of the crane (see Section 4, Load Rating Chart, drawing 1585851). Lifting loads greater than those shown on the load rating chart or operations at positions not shown, or lifting when the boom is solid against the boom stops, can cause structural failure or collapse of the boom or crane and death or injury to personnel. Do not attach capacity loads at maximum outreach, because an outward swing of the load, caused by vessel list or trim, or outward drift of the boom, can overload the crane.

2.5.4 Window Wiper Controls The FRONT WIPER (figure 2–2, item 24) and UPPER WIPER control (item 22) control the corresponding window wiper of the operator’s cab. Each WIPER control is a two-position switch. In the PARK position, the wiper returns to its parking position and stops.


2710100-MAN-001 01 2-7

In the RUN position, the wiper operates.

2.5.8 LIGHTS Switch

Push the knob of the washer control (item 23) to spray washer fluid on the windows. The reservoir for the washer fluid is located on the exterior rear corner of the operator’s cab.

The LIGHTS switch (figure 2–2, item 25) controls the illumination of the gauges on the gauge control . With the switch in the “on” position, the gauges are illuminated.

2.5.5 Operator’s Cab Air Conditioner/ Heater Controls The controls for the operator’s cab air conditioning/heating units are located on the control of the cab ceiling units (see figure 2–1). See the manufacturer’s information for the operating instructions (see Parts and Vendor Data Manual, Section 11, RVP).

2.5.6 Area Lighting Two 400 W flood lights (see figure 2–1) are located on the boom. The lights are controlled by a switch located inside the operator’s cab. One 400 W flood light (see figure 2–1) is located on the A-frame, illuminating the engine and hoist areas. The light is controlled by a switch inside the operator’s cab. One fluorescent light (two 40 W lamps) is located inside the operator’s cab. The light is controlled by a switch located inside the operator’s cab.

2.5.7 Obstruction Lights Red aircraft obstruction lights (see figure 2–1) are located at the tip of the boom, and on the top of the A-frame. The lights are controlled by circuit breaker CB0242 located in circuit breaker CBP0208, inside the operator’s cab.

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With the switch in the “off” position, the gauges are not illuminated.

2.5.9 Maintenance Crane The maintenance jib (see figure 2–1) is located on the back of the crane A-frame. The maintenance jib has a manually operated chain hoist. The boom of the maintenance jib can be put in a “wind locked” position to prevent the boom from rotating. See the manufacturer’s information for the operating instructions (see Parts and Vendor Data Manual, Section 11, Budgit).

2.5.10 Boom Stops The crane has cushioned boom stops (see figure 2–1) to retard the backward motion of the boom as the boom nears high boom angles. When a load is lifted, the boom suspension system stretches, causing the boom angle to decrease and the load radius to increase. The crane operator should compensate for this by raising the boom a small amount as the load is lifted. When the load is set down, the boom suspension system will contract, causing the boom angle to increase a small amount and the load radius to decrease.


When lifting loads at high boom angles, the operator must take care when setting down the load. The crane operator must also lower the boom a small amount so the boom is not pulled back into the boom stops. The inner section of the boom may be damaged if the boom is pulled back into the boom stops.

CAUTION •

When setting loads down at high boom angles, the boom must be lowered a small amount so the boom is not pulled back into the boom stops causing damage to the inner section of the boom.

CAUTION •

The boom stops are a cushion against minor accidental shocks and an early warning device. They must not be regarded as a failsafe protection against the boom being raised too far or the boom falling over backwards. Do not lift a load when the boom is solid against the boom stops. When landing a load, keep the boom angle a small amount lower as necessary to compensate for the boom rising when the load is put down. Do not exceed the boom operating range on the capacity chart for the load being lifted.

2710100-MAN-001 01 2-8

2.6 Power Control Devices 2.6.1 Diesel Engine Throttle Controls The diesel engine throttle foot pedal (figure 2–2, item 1) is the left pedal located in front of the operator’s seat. The hand-operated diesel ENGINE THROTTLE control (item 14) is located on the control console. Engine speed can be increased by either depressing the foot throttle or pulling up the hand throttle. To decrease engine speed, release the foot throttle and depress the button on top of the hand throttle knob while pushing the knob down. Engine speed can be locked at any speed by depressing the foot throttle to the desired speed and pulling up the hand throttle. The engine speed can be finely adjusted by turning the knob of the hand throttle.

NOTICE •

Higher engine speeds result in faster crane motions due to higher hydraulic pump flows.

2.6.2 ENGINE KILL Control The ENGINE KILL control (figure 2–2, item 17) (with black handle) is used for normal stopping of the diesel engine. Pull the handle of the ENGINE KILL control all the way up to stop the diesel engine (fuel is shut off). The handle must be pushed all the way down to operate the engine.

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2.6.3 EMERGENCY ENGINE KILL Control

2710100-MAN-001 01 2-9

CAUTION •

The EMERGENCY ENGINE KILL control (figure 2–2, item 16) (with red handle) is used for emergency stopping of the diesel engine.

Only use the EMERGENCY ENGINE KILL control for an emergency. Use of the EMERGENCY ENGINE KILL control can cause damage to the diesel engine.

!WARNING •

Explosive vapors in the air intake to the diesel engine can cause the engine to continue operating even after the ENGINE KILL control (see paragraph 2.6.2) is pulled all the way up. In an emergency when such vapors are present, use the EMERGENCY ENGINE KILL control to stop the engine by closing off the air intake. This prevents the vapors from continuing to feed the engine.

2.6.4 Diesel Engine Gauges The gauges listed in table 2–1 are located on the control console and show the operating condition of the diesel engine. See the diesel engine manufacturer’s information for the engine operating instructions (see Parts and Vendor Data Manual, Section 11, Caterpillar).

CAUTION •

Pull the handle of the EMERGENCY ENGINE KILL control all the way up to immediately stop the diesel engine. This closes the engine air inlet shutoff. After the emergency stop, the air inlet shutoff must be reset to the open position and the engine must be checked for damage. The air inlet shutoff is located on the engine air intake housing. See the diesel engine manufacturer’s information for the procedure to reset the air inlet shutoff (see Parts and Vendor Data Manual, Section 11, Caterpillar).

Do not operate the equipment when a gauge is reading outside of its normal operating range (see table 2–1).

2.6.5 Diesel Fuel Level Gauge The gauge on the top of the diesel fuel tank (see figure 2–1) shows the level of diesel fuel remaining in the diesel fuel tank.

Table 2–1. Diesel Engine Gauges NORMAL OPERATING RANGE

FIGURE AND ITEM NUMBERS

See engine manufacturer’s manual

figure 2–2, item 19

COOLANT Coolant water temperature TEMPERATURE



OIL PRESSURE



LABEL

FUNCTION MONITORED

ENGINE TACHOMETER/ HOUR METER

Engine speed, total run time

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Lubrication oil pressure


2.6.6 AIR STARTER Control

CAUTION

The AIR STARTER control (figure 2–2, item 15) controls the air starter motor for the diesel engine. The control is a manually engaged, spring-released air valve.

•

Push and hold the AIR STARTER control to start the diesel engine.

Do not operate the equipment with a hydraulic oil temperature that is too high (more than 180°F [82°C]). Operating with the hydraulic oil temperature too high can reduce the life of hydraulic equipment parts.

2.6.9 Hydraulic Pressure Gauges

2.6.7 Hydraulic Oil Level Gauge The sight gauge on the side of the hydraulic oil reservoir (see figure 2–1) shows the level of the hydraulic oil in the reservoir (see Checking Hydraulic Oil Level, paragraph 3.6.6.1).

The gauges listed in table 2–2 show the operating pressures of the corresponding hydraulic pumping circuits. The pressures are shown in pounds per square inch (psi).

CAUTION

CAUTION •

2710100-MAN-001 01 2-10

Do not operate the equipment with a level of hydraulic oil that is too low or too high.

•

Do not operate the equipment when a gauge is reading outside of its normal operating range as listed in table 2–2.

2.6.8 Hydraulic Oil Temperature Gauge

2.6.10 AIR PRESSURE Gauge

The temperature gauge on the side of the hydraulic oil reservoir (see figure 2–1) shows the temperature of the hydraulic oil in the reservoir. Do not operate the equipment with a hydraulic oil temperature that is too high (more than 180°F [82°C]).

The AIR PRESSURE gauge (figure 2–2, item 11) shows the air pressure at the control console of the crane air system. The pressure is shown in pounds per square inch (psi).

Table 2–2. Hydraulic Pressure Gauges FUNCTION MONITORED

LABEL SWING PRESSURE

BOOM PRESSURE

Swing drive hydraulic pumping circuit Main/auxiliary hoist hydraulic pumping circuit Boom hoist hydraulic pumping circuit

PILOT PRESSURE

Hydraulic system pilot pressure

MAIN/AUX PRESSURE

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NORMAL OPERATING RANGE 100 to 2700 psi (6.8–206.8 bar)

FIGURE AND ITEM NUMBERS figure 2–2, item 7

Raising: up to 2900 psi (200.6 bar) Lowering: 1000–2300 psi (68.9–158.5 bar)


Raising: up to 2950 psi (203.4 bar) Lowering: 1000–2300 psi (68.9–158.5 bar)


475 psi (32.7 bar)



CAUTION •

Do not operate the equipment when the air pressure gauge is reading outside of its normal operating range of 120–125 psi (8.3–8.6 bar).

2.7 Crane Function Control Devices 2.7.1 Swing Brake Pedal The swing brake foot pedal (figure 2–2, item 3) located in front of the operator’s seat controls the brake of the swing drive as a holding brake (variable holding power).

NOTICE •

Normal crane operation does not require use of the swing brake pedal to stop crane rotation. To stop rotation, put the lever of the SWING control (paragraph 2.7.4) in its neutral (center) position. Rotation will slowly come to a stop due to friction in the swing system. The swing brake pedal is provided to temporarily engage the swing brake without using the SWING BRAKE OFF/ON control.

Push the pedal down to engage the brake of the swing drive. As the pedal is pushed down, the brake has more holding power. Release the pedal upward to release the brake. As the pedal is released upward, the brake has less holding power.

2710100-MAN-001 01 2-11

2.7.2 SWING BRAKE OFF/ON Control The SWING BRAKE OFF/ON control (figure 2–2, item 13) controls the brake of the swing drive as a static (parking) brake (fully engaged or fully released). In the ON position, the brake of the swing drive is engaged. The crane cannot rotate (swing). In the OFF position, the brake will release according to the position of the swing brake pedal (see paragraph 2.7.1). The brake can only be released when the diesel engine is operating.

CAUTION •

Do not use the SWING BRAKE OFF/ON control to stop crane rotation. Only put the SWING BRAKE control in the ON position after crane rotation has been completely stopped.

2.7.3 SWING LOCK OFF/ON Control The swing lock consists of a pin that can be lowered into a hole in the top of the pedestal to mechanically prevent the crane from rotating. The pin can be lowered at any of the 8 points 45 degrees apart in the rotation of the crane. The pin is actuated by a hydraulic cylinder. When the crane is in position to permit the pin to be lowered, move the handle of the SWING LOCK OFF/ON control (figure 2–2, item 18) to the ON position to lower the swing lock pin. Move the handle to the OFF position to raise the swing lock pin.

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CAUTION •

2710100-MAN-001 01 2-12

Lower Boom

The crane may need to be rotated a small amount for the pin of the swing lock to align with the hole in the top of the pedestal. This should be done at a slow speed. Fully stop the rotation of the crane using the SWING control before engaging the swing lock. Not following this procedure can cause damage to the equipment.

Swing Left

Swing Right

A1575

Raise Boom

Figure 2–3. Boom/Swing Control

2.7.4 BOOM/SWING Control The BOOM/SWING control (figure 2–2, item 2) on the left armrest of the operator’s chair controls the •

direction and speed of boom movement (boom function) direction and speed of crane rotation (swing function)

•

The boom and swing functions are combined in one dual-axis control, permitting both functions to be controlled at the same time with one control lever (see figure 2–3). The BOOM/ SWING control is a manually operated, proportional hydraulic valve for directional control. The lever of the BOOM/SWING control, when released, returns to its neutral (center) position.

2.7.4.1 Boom Control

CAUTION •

Move the BOOM control lever slowly, to prevent abrupt changes in the speed of the boom.

Pull the lever of the BOOM control back toward the operator to raise the boom. Push the lever forward away from the operator to lower the boom. The speed of the boom increases the

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farther the lever is moved away from its neutral (center) position. To decrease the speed, move the lever toward its neutral position.

NOTICE •

The speed of the boom can also be controlled in combination with engine speed (see paragraph 2.7.6).

To stop and hold the boom, slowly return the lever to its neutral position. The boom stops and the boom hoist friction brake engages if released. The spring-engaged friction brake and one-way (overrunning) clutch on the hoist hold the hoist drum from rotating in the lowering direction. This friction brake remains engaged during boom raising, with the one-way clutch overrunning. The friction brake is automatically released during lowering, engaging again to serve as a parking brake after the hydraulic system counterbalance valve stops the boom. The boom hoist has a ratchet and pawl assembly that provides an automatic lock to prevent the boom from lowering. The pawl automatically disengages when the boom hoist control lever is pushed forward to lower the boom. If the boom will not lower, it may be necessary to first raise the boom a small amount to


remove the load from the pawl, permitting the pawl to release. Then the boom can be lowered.

NOTICE •

!WARNING •

The boom hoist must have at least five full wraps of wire rope on the drum at all times.

The control system protects against raising or lowering the boom beyond its operating limit. See paragraph 2.8.3.2 for a description of the boom angle limit system.

2.7.4.2 Swing Control

NOTICE •

Before rotating the crane, the SWING BRAKE OFF/ON control (see paragraph 2.7.2) must be in the OFF position and the swing brake pedal (see paragraph 2.7.1) must be fully released.

CAUTION •

Move the SWING control lever slowly, to prevent abrupt changes in the speed of crane rotation and minimize the side-loading forces on the boom.

Move the lever of the SWING control to the operator’s left to rotate the crane left (counterclockwise). Move the lever to the operator’s right to rotate the crane right (clockwise). The speed of rotation increases as the lever is moved away from its neutral (center) position. To decrease the speed, move the lever toward its neutral position.

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The speed of rotation can also be controlled in combination with engine speed (see paragraph 2.7.6).

To stop rotation, slowly return the lever to its neutral position. Rotation will slowly come to a stop due to friction in the swing system.

CAUTION

NOTICE •

2710100-MAN-001 01 2-13

•

Do not use the SWING BRAKE OFF/ON control (see paragraph 2.7.2) to stop crane rotation.

2.7.5 MAIN and AUXILIARY Hoist Controls The MAIN and AUXILIARY hoist controls (figure 2–2, item 5) on the right armrest of the operator’s chair control the •

•

rotation direction and speed of the main hoist drum (direction and speed of the main hook block) rotation direction and speed of the auxiliary hoist drum (direction and speed of the auxiliary hook)

The MAIN and AUXILIARY hoist controls are part of a dual-lever, manually operated, proportional hydraulic valve for directional control. The levers of the MAIN and AUXILIARY hoist controls, when released, return to their neutral (center) positions. The left lever controls the auxiliary hoist drum, and the right lever controls the main hoist drum.


!WARNING •

Before lifting a load, always put the SWING BRAKE OFF/ON control (see paragraph 2.7.2) in the OFF position and release the swing brake pedal (see paragraph 2.7.1) to permit the crane boom to center over the load.

!WARNING •

CAUTION Move the MAIN and AUXILIARY hoist control levers slowly, to prevent abrupt changes in the speed of the load.

Pull the lever of the MAIN or AUXILIARY hoist control back toward the operator to raise the load on the corresponding hook. Push the lever forward away from the operator to lower the load on the corresponding hook. The speed of the load increases the farther the lever is moved away from its neutral position. To decrease the speed, move the lever toward its neutral position.

NOTICE •

The speed of the load can also be controlled in combination with engine speed (see paragraph 2.7.6).

The spring-engaged friction brake and one-way (overrunning) clutch on the hoist hold the hoist drum from rotating in the lowering direction. This friction brake remains engaged during load raising, with the one-way clutch overrunning. The friction brake is automatically released during lowering, engaging again to serve as a parking brake after the hydraulic system counterbalance valve stops the load.

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The control system protects against raising the load beyond its upper operating limit, preventing two-blocking. See paragraph 2.8.3.1 for a description of the anti–two-block system.

2.7.6 Swing and Hoist Speed Control The swing and hoist speed can be controlled by displacing the controls and changing the diesel engine speed. Maximum speeds are obtained by displacing the corresponding control the maximum distance and adjusting the engine speed to its highest recommended speed. Minimum speeds are attained by operating the engine at idle speed and displacing the corresponding control until the motion begins.

!WARNING •

To stop and hold the load, slowly return the lever to its neutral position. The load stops and the hoist friction brake engages if released.

The main and auxiliary hoists must have at least five full wraps of wire rope on the drums at all times.

NOTICE •

•

2710100-MAN-001 01 2-14

Under certain loads the diesel engine may stall at low engine speeds when trying to operate crane functions.

The control valves provide precise metering of the hydraulic oil. This precise metering allows for precise speed control of the various crane functions.


2.8 Crane Operation The crane operates by hydraulic power. Slowly move the control levers by applying gradual pressure, even when returning a lever to its neutral (center) position. Not following this procedure will result in over-control of the crane functions and erratic crane response.

CAUTION •

Do not release or jerk a control lever as this will cause sudden movements of the crane and/or load. This sudden movement will cause a hydraulic shock in the hydraulic system which could damage the hydraulic equipment parts and/or crane structural parts.

2710100-MAN-001 01 2-15

API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) (current edition) is a useful guide for owners and operators in developing operating and maintenance practices and procedures. All guidelines in this recommended practice should be followed.

2.8.1 Pre-Starting Procedure Before operating the crane, it is important to make an inspection of the crane and to follow all pre-starting procedures. The following inspections are considered mandatory by National Oilwell Varco. They make sure the equipment is in a safe operating condition. Other inspections can be required by local regulations and must also be made.

NOTICE •

The hydraulic system permits the boom, swing, and hoist functions to operate simultaneously. The boom and swing have priority over the hoist, so hoisting may be slower when rotating the crane or raising the boom.

In the event of diesel engine failure or control malfunction during operation: 1. Return all the control levers to their neutral (center) position. 2. When the crane has stopped rotating (swinging), turn the lever of the SWING BRAKE OFF/ON control (figure 2–2, item 13) to the ON position to engage the static swing brake. 3. If practical, lower the suspended load using the emergency load lowering procedure (see paragraph 2.8.6).

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2.8.1.1 Daily Inspection Do the following at the beginning of each workday, before starting the crane. 1. Check the preventive maintenance records to make sure the scheduled lubrication (see paragraph 3.2.2) and inspections and maintenance (see paragraph 3.3) have been done at the correct intervals. 2. Check the crane and pedestal foundation for possible damage. Check for damaged, distorted, worn, cracked, corroded, loose, or missing parts, fasteners, and welds.

!DANGER •

Do not operate the crane with a damaged boom or if any portion of the boom has been repaired by a company other than National Oilwell Varco.


!WARNING •

If any device or structural member is damaged or in need of repair, such repairs must be made before operating the crane.

!WARNING •

Do not operate the crane in an unsafe or damaged condition.

3. Check the hydraulic equipment for leakage or damage. 4. Check the hydraulic hoses for leaks, abrasion, or advanced weathering that could cause a hose to burst under operating pressure.

2710100-MAN-001 01 2-16

11. Check the crane hook and latch for damaged, distorted, worn, cracked, corroded, loose, or missing parts and fasteners. 12. Check loose gear to be used (such as slings, sling hooks, and shackles) for damaged, distorted, worn, cracked, corroded, loose, or missing parts and fasteners. 13. Make sure that all guards are in place and secured. 14. Check the operation of the obstruction lights. 15. Check the crane load and radius indicator display for correct operation.

5. Check the gearboxes for leaks and damage.

2.8.1.2 Before Start-up

6. Check the boom hoist ratchet and pawl for wear and damage.

Do the following before each start-up of the crane.

7. Check control mechanisms for correct operation. 8. Check the diesel engine start and stop controls.

1. Check that the correct load rating chart for the crane configuration in use is visible to the crane operator at the control station (see Section 4, Load Rating Chart, drawing 1585851).

9. Check all the wire ropes, including pendants, for deterioration or damage.

2. Check that all tools and other items are away from moving equipment parts.

!WARNING •

Do not operate the crane with worn or damaged wire rope.

10. Check that the wire rope is reeved correctly, operating freely, and spooling correctly.

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3. Check that the crane and the operating area of the crane are free of all obstructions and personnel. Not following this procedure can result in damage to the crane or load and injury to personnel. 4. Check that the static swing brake is engaged. The lever of the SWING BRAKE OFF/ON control (figure 2–2, item 13) must be in the ON position.


5. Check that the handle of the ENGINE KILL control (item 17) (with black handle) is pushed all the way down. 6. Check that the handle of the EMERGENCY ENGINE KILL control (item 26) (with red handle) is pushed all the way down. If the handle has been pulled, check that the reason for the emergency stop has been found and corrected, and that the air inlet shutoff of the diesel engine has been reset to the open position (see Emergency Stop Procedure, paragraph 2.8.5).

!CAUTION •

2710100-MAN-001 01 2-17

2.8.2 Startup Procedure 1. Complete the pre-start procedure (paragraph 2.8.1). 2. Check that all the control levers are in their neutral (center) position. 3. Put the diesel engine throttle control (see paragraph 2.6.1) in the “idle” position. 4. Check the temperature of the hydraulic oil. Use the temperature gauge (see paragraph 2.6.8) located on the side of the hydraulic oil reservoir (see figure 2–1).

The control levers must be in the neutral (center) position to prevent sudden movements when the diesel engine is started.

•

•

7. Check that all the control levers are in their neutral (center) position. This will ensure that the load and/or crane will not move when the diesel engine is started. 8. The crane can now be started (see paragraph 2.8.2).

If the hydraulic oil in the reservoir is 0°F (–17°C) or warmer (ISO Grade 46 hydraulic oil minimum start-up temperature, see Hydraulic Oil, paragraph 3.6.2), continue with step 5. If the hydraulic oil is colder, warm the hydraulic oil with the reservoir heater until the temperature is 0°F (–17°C) or warmer. Then continue with step 5.

NOTICE •

The diesel engine has been supplied with an engine block water heater to improve the ability to start the engine in cold weather. See the diesel engine manufacturer’s information for additional information on the diesel engine starting and operating procedures (see Parts and Vendor Data Manual, Section 11, Caterpillar).

5. Push the AIR STARTER control (figure 2–2, item 14) for 1–3 seconds or until the diesel engine starts. If the engine does not start after several attempts, have the engine checked by a qualified service technician. See the diesel engine manufacturer’s information for additional information on the diesel engine starting and operating proce-

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dures (see Parts and Vendor Data Manual, Section 11, Caterpillar). 6. Operate the diesel engine at “idle”. 7. Check the temperature of the hydraulic oil. Use the hydraulic oil temperature gauge located on the side of the hydraulic oil reservoir. •

•

If the hydraulic oil in the reservoir is 55°F (13°C) or warmer (ISO Grade 46 hydraulic oil minimum temperature for full power operation, see Hydraulic Oil, paragraph 3.6.2), continue with step 8. If the hydraulic oil is colder, continue to operate with no load until the temperature is 55°F (13°C) or warmer. Then continue with step 8.

8. Adjust the diesel engine throttle to the desired engine speed (see paragraph 2.6.1).

NOTICE •

•

The diesel engine control system will automatically stop the diesel engine for engine overspeed, low engine oil pressure, and high coolant temperature. The maximum governed diesel engine speed under load is 2100 rpm.

9. Check the cab-mounted instrument gauges for proper engine operation. 10. The crane is now ready for the pre-operating checks (see paragraph 2.8.3).

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2710100-MAN-001 01 2-18

2.8.3 Pre-Operating Checks (After Engine Start-Up) After the diesel engine has been started, the following procedures must be done to make sure that the crane safety systems function correctly.

2.8.3.1 Anti–Two-Block System Anti–two-block systems are provided for the main and auxiliary hoists to prevent accidental of the main hook block and auxiliary overhaul ball with the boom point sheaves.

!WARNING •

Hook block and overhaul ball with the boom point sheaves can cause damage to the wire rope, boom, boom sheaves, and/or hook block and overhaul ball. The wire rope can be damaged and the load can fall.

The anti–two-block safety valves are located near the boom tip, one for the main hook block and one for the auxiliary overhaul ball. The spool of each valve is normally held retracted (hydraulic circuit closed) by the downward force on the lever arm of the suspended anti–two-block weight (see Parts and Vendor Data Manual, Section 4, drawing 750577-L01 [Main] and 750577-L02 [Auxiliary], Anti–Two-Block). If the hook block or overhaul ball makes with the weight, relieving the downward force on the lever arm, the spool of the anti–two-block valve extends (hydraulic circuit opens), venting some hydraulic pilot pressure lines in the hydraulic system. The boom stops if in a lowering motion and the boom hoist friction brake engages. The main and auxiliary hoists stop if in a raising motion and the main and auxiliary hoist friction brakes remain engaged. The hydraulic system prevents further boom lowering and further


main or auxiliary hoist raising. To return to normal operation, lower the hook block or overhaul ball (or raise the boom), until both weights are hanging freely.

NOTICE •

To check the anti–two-block system:

CAUTION •

!WARNING •

•

Use extreme care when engaging the anti–two-block system. Operate the hoist slowly and stop the hoist before the hook block s the boom sheaves.

1. Slowly raise the main hook block into the anti–two-block weight. Use caution to make sure the hoist raising function stops after the weight is raised (approximately 3–4 in [8–10 cm] after ing the weight). Stop the hoist before the hook block s the boom sheaves if it does not stop automatically.

If the main hoist does not stop or the boom can be lowered after the anti–two-block weight has been lifted, shut down the crane and the National Oilwell Varco Service Department for instructions.

2. After the main hoist function stops, check that the boom lowering is inhibited by trying to lower the boom. The boom must not lower. 3. Lower the load until the weight hangs freely. 4. Repeat steps 1 through 3 for the auxiliary hoist. 5. The crane is ready for the boom limit system check (see Boom Angle Limit System, paragraph 2.8.3.2).

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2710100-MAN-001 01 2-19

The exposed surfaces of the valve spools for the anti–two-block safety valves must be lubricated to prevent corrosion (see Safety Valves, paragraph 3.2.2.5). Corrosion may prevent proper operation of the valve. Under certain conditions, lowering the boom onto the boom rest may engage the anti–two-block system. If this happens, the signalperson or a deckhand must maintain a downward load on the anti–two-block system by pulling on the weight cable while the boom is lowered into the stowed position. Use extreme caution to avoid injury from moving equipment parts or the weight cable.

2.8.3.2 Boom Angle Limit System A boom angle limit system is provided to prevent the boom from being raised or lowered outside of the normal operating range. The limits are preset at the factory, but can be adjusted in the field. The boom limit should be set with no load on the boom. The boom upper limit should be set at 78 degrees above horizontal and the boom lower limit should be set at 10 degrees below horizontal.

!WARNING •

Do not activate the boom angle limit system with the boom moving at high speed. The boom will quickly stop, causing the load to swing uncontrollably and the boom to bounce violently.

The boom angle safety valves are located at the boom foot, one for the boom upper limit and one for the boom lower limit. The spool of each


valve is normally extended (hydraulic circuit closed) (see Parts and Vendor Data Manual, Section 4, drawing 750663-L02, Boom Limit Mechanics). If a cam on the boom makes with a valve spool, the spool retracts (hydraulic circuit opens), venting some hydraulic pressure lines in the hydraulic system. If the boom upper limit safety valve is actuated, the boom raising motion stops and the boom hoist friction brake remains engaged. The hydraulic system prevents further boom raising. To return to normal operation, lower the boom. If the boom lower limit safety valve is actuated, the boom stops and the boom hoist friction brake engages. The hydraulic system prevents further boom lowering. To return to normal operation, raise the boom. To check the boom limit system:

2710100-MAN-001 01 2-20

2. After the boom stops, lower the boom away from the boom stops and away from limit cam engagement.

!WARNING •

The boom hoist must have at least five full wraps of wire rope on the drum at all times.

3. Slowly lower the boom into lower limit cam engagement. Use caution to make sure the boom does not strike any object on the platform or deck. Stop the boom before this occurs if it does not stop automatically. 4. After the boom stops, raise the boom away from limit cam engagement. 5. The crane is ready for normal operation.

CAUTION •

Use extreme care when engaging the boom angle limit system. Operate the boom hoist slowly and stop the hoist before the boom s the cushioned boom stops or any obstruction.

1. Slowly raise the boom to the upper limit cam engagement. Use caution to make sure the boom raising function stops before the boom s the cushioned boom stops. Stop the boom before ing the boom stops if it does not stop automatically.

NOTICE •

The exposed surfaces of the valve spools for the boom limit safety valves must be lubricated to prevent corrosion (see Safety Valves, paragraph 3.2.2.5). Corrosion may prevent proper operation of the valve.

2.8.4 Shutdown Procedure 1. Remove the load from the crane. 2. Rotate the crane to its parking position.

!WARNING •

If the boom does not stop when the boom angle limit safety valve s the boom limit cam, shut down the crane and the National Oilwell Varco Service Department for instructions.

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3. Engage the swing lock (see paragraph 2.7.3). 4. Engage the static brake of the swing drive. Turn the lever of the SWING BRAKE OFF/ON control (figure 2–2, item 13) to the ON position.


5. Raise or lower the boom to the desired angle. 6. Raise or lower the main hook block and auxiliary hook to the desired height. 7. Put the diesel engine throttle control (see paragraph 2.6.1) in the “idle” speed position and let the engine operate for 4–5 minutes to cool down. 8. Pull the handle of the ENGINE KILL control (item 17) (with black handle) all the way up to stop the diesel engine. 9. Write down and report any corrective action that must be taken before operation is resumed.

2.8.5 Emergency Stop Procedure 1. Release all control levers to the neutral position. 2. Pull the handle of the EMERGENCY ENGINE KILL control (figure 2–2, item 16) (with red handle) all the way up to immediately stop the diesel engine.

!WARNING •

Only use the EMERGENCY ENGINE KILL control when use of the ENGINE KILL control (see paragraph 2.6.2) fails to stop the diesel engine or there are explosive gases near the engine air intake.

CAUTION •

Only use the EMERGENCY ENGINE KILL control for an emergency. Use of the EMERGENCY ENGINE KILL control can cause damage to the diesel engine.

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2710100-MAN-001 01 2-21

After the reason for the emergency stop has been found and corrected, the air inlet shutoff of the diesel engine must be reset to the open position. The air inlet shutoff is located on the engine air intake housing. The diesel engine must be checked for damage (example: damage to seals from the suction created by blocking the air intake). See the diesel engine manufacturer’s information for the procedure to reset the air intake shutoff (see Parts and Vendor Data Manual, Section 11, Caterpillar).

2.8.6 Emergency Load Lowering The crane is equipped with an emergency load lowering kit that permits the operator to lower a suspended load in the event of a hydraulic or diesel engine failure. A printed procedure is provided in the kit, inside the operator’s cab and in this manual. Table 2–3 lists the emergency load lowering procedures and kit drawing. See Section 3 of this manual for the drawings. Table 2–3. Emergency Load Lowering Procedures and Kit Drawing

HOIST Main Auxiliary

EMERGENCY LOWERING PROCEDURE DRAWING

EMERGENCY LOWERING KIT DRAWING

603511

603457-L01


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2710100-MAN-001 01 2-22


2710100-MAN-001 01 3-1

3 MAINTENANCE

3.2 Lubrication

3.1 Introduction and General Instructions

3.2.1 Lubrication Procedures

This section includes general maintenance schedules and maintenance instructions for the equipment as outlined by the table of contents. At the end of this section are reference drawings. API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) (current edition) is a useful guide for owners and operators in developing operating and maintenance practices and procedures. All guidelines in this recommended practice should be followed. Maintenance must be done at regular intervals. Failure to do the necessary maintenance will result in damage to the equipment parts. The lubrication schedule (see paragraph 3.2.2) and the inspection and maintenance schedule (see paragraph 3.3) are guides for the correct maintenance of the equipment. Permit only qualified service personnel who have received training in the proper maintenance, adjustment, and inspection of the equipment to do these procedures. After making a repair or adjustment, always check the function of the equipment parts before putting the equipment into full operation. Do not make modifications to the equipment unless approved in writing by National Oilwell Varco.

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Do not operate the equipment without proper lubrication. Lubricants that do not meet the requirements of the equipment or lubricants that have deteriorated to a level of unacceptable service must not be used, or must be replaced with acceptable lubricants before operating the equipment.

CAUTION •

Clean the work area and lubrication fittings before and after adding the lubricant. Remove any extra lubricant that has been forced through a bearing. When the equipment is operated, extra lubricant will work its way out of the bearing. This lubricant must be removed.

Do not mix different types and brands of lubricants because of possible incompatibility.

3.2.2 Lubrication Schedule See the Lubrication Schedule (table 3–1) and the Lubricant Legend (table 3–2) for the lubrication schedule, lubrication points, types of lubricant, and fluid capacities.


2710100-MAN-001 01 3-2

Table 3–1. Lubrication Schedule INTERVAL OF LUBRICATION

As required

DESCRIPTION

Wire ropes

See manufacturer’s Diesel engine information Boom foot bushings Sheaves Hook block and overhaul Every 40 hours ball of operation or weekly, which- Swing bearing ever occurs first Swing drives Safety valves

TYPE OF LUBRICANT

WRL

• Boom wire rope • Main wire rope • Auxiliary wire rope • Pendants

ELO

• Diesel engine lubrication oil

AF

Every 40 hours of operation or Hoists every three months, whichever occurs first Swing drives

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• Diesel engine coolant (includes radiator)

CAPACITY

REFERENCE PARAGRAPH

As required

3.2.2.1

26 qt (25 L) 11.0 gal (41.6 L)

3.2.2.2

HPG

• Boom foot

As required

3.2.2.3

HPG

• Boom point sheaves and pendant anchors • A-Frame sheaves • Bridle sheaves

As required

3.2.2.3

HPG

• Sheaves and hooks

As required

3.2.2.3

HPG

• Swing bearing

As required

3.2.2.3

OGL

• Gear teeth

As required

3.2.2.4

OGL

• Pinion gears

As required

3.2.2.4

• Two boom limit safety valves • Two anti–two-block safety valves

As required

3.2.2.5

• Ratchet and pawl

As required

• Pawl cylinder rod and pins

As required

• Boom hoist gearbox— check level of lubricant

As required

3.2.2.7

• Main hoist gearbox— check level of lubricant

As required

3.2.2.7

• Auxiliary hoist gearbox— As required check level of lubricant

3.2.2.7

• Gearbox—check level of lubricant

3.2.2.8

HO HPG

Boom hoist

LUBRICATION LOCATION

HO

HHO

GO

As required

3.2.2.6


2710100-MAN-001 01 3-3

Table 3–1. Lubrication Schedule (continued) INTERVAL OF LUBRICATION

DESCRIPTION

Every 500 hours of opera- Hoists tion or every six months, whichever occurs first Swing drives

Every 12 months of operation

Swing brakes

TYPE OF LUBRICANT

HHO

GO

CAPACITY

REFERENCE PARAGRAPH

• Boom hoist gearbox— drain and refill

70 pt (33.1 L)

3.2.2.7

• Main hoist gearbox— drain and refill

90.0 pt (42.6 L)

3.2.2.7

• Auxiliary hoist gearbox— drain and refill

17.0 pt (8.0 L)

3.2.2.7

• Gearbox—drain and refill

12.75 pt (6.0 L) each

3.2.2.8

As required

3.2.2.9

LUBRICATION LOCATION

See Parts and Vendor Data • Swing brake—check level and condition Manual, Section 11, MICO Table 3–2. Lubricant Legend

SYMBOL

NATIONAL OILWELL VARCO PART NUMBER

AF

903062

Engine anti-freeze

ELO

939084

Engine lubrication oil—SAE 15W-40 (See Parts and Vendor Data Manual, Section 11, Caterpillar)

GO

939049

Gear oil—SAE 90

HHO

939074

Hydraulic hoist gear oil—industrial EP gear oil, specifically Exxon Spartan EP150 as recommended by Braden Hoists

HO

939064

Hydraulic oil ISO-46—such as Shell Tellus 46

HPG

939048

High pressure grease—multi-purpose extreme pressure grease

OGL

939063

Open gear lubricant—black soda lead grease

WRL

939075

Wire rope lubricant—black viscous lubricant such as Texaco Crater A

DESCRIPTION

3.2.2.1 Wire Ropes Wire rope should be lubricated at regular intervals to guard against wire corrosion. When

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corrosion is noticed, the wire rope should be closely inspected for damage. See Section 5, API Recommended Practice 2D, Recommended Practice for Operation and


Maintenance of Offshore Cranes (API RP2D) for the wire rope lubrication procedures.

3.2.2.2 Diesel Engine See the diesel engine manufacturer’s information (see Parts and Vendor Data Manual, Section 11, Caterpillar) for the lubrication instructions, intervals, and lubricant specifications.

3.2.2.3 Grease Fittings

NOTICE •

measured amount of lubricant. Periodic over-lubrication is needed to remove all old lubricant from the bearing. When to over-lubricate a bearing is dependent on the duty cycle of the equipment and its severity of use. Extra lubricant forced out from a bearing must be removed. Check the removed lubricant for water content and particles of metal. Particles of metal in the lubricant indicate bearing wear. If a lubricant fitting will not take lubricant (too much pressure), the problem must be found and corrected before continuing operation.

3.2.2.4 Swing Gear and Pinions

The warranties for the swing bearing and crane will be void if the swing bearing is not lubricated as specified.

NOTICE •

CAUTION •

Clean the work area and lubrication fittings before and after adding the lubricant. Remove any extra lubricant that has been forced through a bearing. When the equipment is operated, extra lubricant will work its way out of the bearing. This lubricant must be removed.

2710100-MAN-001 01 3-4

The warranties for the swing bearing and crane will be void if the swing gear and pinions are not lubricated as specified.

Wipe the swing gear and pinion clean and apply lubricant liberally to all machined surfaces of both the swing gear and pinion.

3.2.2.5 Safety Valves

Use caution regarding the rate and pressure at which lubricant is forced into a bearing, to avoid damaging the seal of the bearing, which can cause damage to the bearing.

Clean the exposed surfaces of the valve spools for the boom limit and anti–two-block safety valves and apply a light oil to prevent corrosion.

When putting new or repaired bearings into service, add lubricant, rotate the bearing, and add more lubricant until a small amount of lubricant begins to show from the bearing. This will make sure that the bearing is completely lubricated.

3.2.2.6 Boom Hoist Pawl

At designated intervals, relubricate the bearings. When relubricating a bearing, add only a

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Check the entire drum ratchet surface and pawl of the boom hoist for a full coverage of lubricant. Apply lubricant as needed. Clean the exposed surfaces of the pawl cylinder rod and apply a light oil to prevent corrosion. Apply a light oil to the pawl cylinder pivot pins.


3.2.2.7 Hoist Gearboxes Check the level of lubricant in the boom, main, and auxiliary hoist drive gearboxes every 40 hours of operation or every three months, whichever occurs first. Add lubricant as necessary. See the hoist manufacturer’s information for the lubrication instructions (see Parts and Vendor Data Manual, Section 11, Braden).

3.3 Inspection and Maintenance Schedule

!WARNING •

Drain and refill the gearboxes with new lubricant after the first 100 hours of operation, then every 500 hours of operation or every six months, whichever occurs first.

Do not operate the equipment if an inspection reveals a possible safety hazard or if any of the equipment parts require replacement or maintenance. Always look for equipment damage during operation. If damage is found, safely shut down the equipment and correct the damage before continuing operation.

3.2.2.8 Swing Drive Gearboxes Check the level of lubricant in both swing drive gearboxes every 40 hours of operation or every three months, whichever occurs first. Add lubricant as necessary. See the gearbox manufacturer’s information for the lubrication instructions (see Parts and Vendor Data Manual, Section 11, Eskridge). Drain and refill the gearboxes with new lubricant after the first 100 hours of operation, then every 500 hours of operation or every six months, whichever occurs first.

2710100-MAN-001 01 3-5

NOTICE •

Other inspections can be required by local regulations and must also be made.

3.3.1 As Necessary Diesel Engine •

See the manufacturer’s information for maintenance instructions, intervals, and procedures (see Parts and Vendor Data Manual, Section 11, Caterpillar).

3.2.2.9 Swing Brakes

Paint

Check the level and condition of cooling oil in the swing brakes every 12 months of operation. Add or change oil as necessary. See the swing brake manufacturer's information for lubrication instructions (see Parts and Vendor Data Manual, Section 11, MICO).

•

Paint any damaged paint surfaces to prevent corrosion.

3.3.2 Before Every Start-Up Crane and Pedestal Foundation •

•

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Check for damaged, distorted, worn, cracked, corroded, loose, or missing parts, fasteners, and welds. If a fastener is found to be defective, replace it and check the remaining fasteners in the group. Check for correct lubrication.


2710100-MAN-001 01 3-6

Hydraulic System

3.3.3 After Every Start-Up

•

Hydraulic Oil Filters

• • •

Check the hydraulic oil reservoir for the correct oil level (see paragraph 3.6.6.1). Check for leaks. Check the hoses and piping for damage. Check the hoses for abrasion or advanced weathering that could cause a hose to burst under operating pressure.

•

With the hydraulic oil at normal operating temperature and the engine operating at 2100 rpm, check the filter indicators (see Hydraulic Oil Filters, paragraph 3.6.8). If the indicator is activated, replace the filter element.

Fuel System Crane • • •

Check the diesel fuel tank for the correct fuel level. Check for leaks. Check the hoses and piping for damage.

Air System • •

• • •

Check for leaks. Check the hoses and piping for damage.

Check control mechanisms for correct operation. Check the diesel engine start, stop, and emergency stop controls. Check the crane load indicator for correct operation (see Parts and Vendor Data Manual, Section 11, Aanderaa Data Instruments).

Electrical System •

•

Check the general condition of the wiring for deterioration, cracked or frayed insulation, and loose connections. Check for damaged, corroded, loose, or missing parts and fasteners.

3.3.4 Before Each Use Wire Ropes •

Gearboxes •

Check for leaks and damage.

Boom Hoist •

Check the boom hoist ratchet and pawl for wear and damage.

Operator Controls •

•

Check that the correct load rating chart for the crane configuration in use is visible to the crane operator at the control station. Check the control labels. Replace all damaged or missing labels.

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•

Inspections must be made by competent, experienced personnel who know the operation of the wire rope. They must have previous experience with wire rope in order to make a correct and safe judgment of the wire rope. See Section 5, API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) for the wire rope inspection procedure. To establish the correct time for replacement of the wire rope, keep dated and detailed records, and review them at each inspection. This will give a comparison of the changes in the wire rope and will be a good aid in determining when to replace the wire rope.


Hooks and Latches •

Check for damaged, distorted, worn, cracked, corroded, loose, or missing parts and fasteners.

Loose Gear •

Check loose gear to be used such as slings, sling hooks, and shackles for damaged, distorted, worn, cracked, corroded, loose, or missing parts and fasteners.

Crane • •

•

Check the boom limit and anti–two-block safety systems for correct operation. Check that the wire rope is reeved correctly, operating freely, and is spooled properly. Check that the correct load rating chart for the crane configuration in use is visible to the crane operator at the control station.

Electrical System •

Check the operation of the crane obstruction warning lights.

3.3.5 Every 8 Hours of Operation or Every Day Do maintenance to or check the following items every 8 hours of operation or every day, whichever occurs first. Fuel Tank • •

Drain the sediment and water condensation from the fuel tank. Fill the fuel tank.

Hydraulic Oil Return Filters •

With the hydraulic oil at normal operating temperature and the engine operating at 2100 rpm, check the filter indicators (see paragraph 3.6.8). If the indicator is activated, replace the filter element.

Hydraulic Oil Heat Exchanger • •

Check for leaks and damage. Clean debris from the hydraulic oil heat exchanger air intake.

Wire Ropes •

•

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2710100-MAN-001 01 3-7

Inspections must be made by competent, experienced personnel who know the operation of the wire rope. They must have previous experience with wire rope in order to make a correct and safe judgment of the wire rope. See Section 5, API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) for the wire rope inspection procedure. To establish the correct time for replacement of the wire rope, keep dated and detailed records, and review them at each inspection. This will give a comparison of the changes in the wire rope and will be a good aid in determining when to replace the wire rope.


3.3.6 Every 40 Hours of Operation or Every Week Do maintenance to or check the following items every 40 hours of operation or every week, whichever occurs first. Swing Drives •

Check the level of lubricant (see paragraph 3.2.2.8).

2710100-MAN-001 01 3-8

Swing Drives •

Drain and refill the lubricant (see paragraph 3.2.2.8).

3.3.8 Every 250 Hours of Operation or Every Three Months Check the following items every 250 hours of operation or every three months, whichever occurs first.

Hoists • •

Check the level of lubricant (see paragraph 3.2.2.7). Check that the wire rope wedges are seated correctly in the drums.

Handrails, Ladders, Walkways, and Safety Guards •

Check for damaged, worn, cracked, corroded, loose, or missing parts, fasteners, and welds.

Sheaves Safety Labels •

Check the sheaves for groove wear, cracks, wire rope path alignment, and bearing condition.

•

Check the safety labels (see paragraph 1.6 for the label locations). Replace all damaged or missing labels. Clean labels for good legibility.

Crane Controls

•

•

Hoists

Check all control linkages and pins for excessive wear and corrosion.

• Crane Structural Equipment Parts •

Visually check for damaged, worn, cracked, corroded, loose, or missing parts, fasteners, and welds.

3.3.7 First 100 Hours of Operation

Do a brake test procedure for the main, auxiliary, and boom hoists per API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) and Braden hoist recommended procedures (see section 3, Brake Test Procedure, drawing 603511; Section 5, API RP2D; and Parts and Vendor Data Manual, Section 11, Braden).

Do maintenance to the following items after the first 100 hours of operation:

Hydraulic Power Plant

Hoists

•

•


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Check for proper performance and compliance with safety requirements.


3.3.9 Every 500 Hours of Operation or Every 6 Months

Hoists

!WARNING

Do maintenance to the following items every 500 hours of operation or every six months, whichever occurs first.

•

Hydraulic Oil •

Analyze for cleanliness, viscosity, proper additives, and water content (see paragraph 3.6.1.1).

•

Hydraulic Oil Return Filters •

Replace the filter elements (see paragraph 3.6.8).

Hoists •


Swing Drives •

An annual inspection is required for safe operation of the equipment. This inspection must be signed by an authorized inspector. Do all the inspections outlined in paragraphs 3.3.1 through 3.3.9, plus the following: Welds •

Check the welds 100 percent visually. Cracked paint with a rust line at the weld is an indication the weld may be cracked. Check any such area by magnetic particle testing after removal of paint. All welds must be free of cracks. All nondestructive testing must conform to the latest edition of AWS D1.1.

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Failure to do the proper hoist maintenance can result in loss of load control and void the hoist and crane warranty. A qualified Braden hoist service technician must disassemble and inspect all components per API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) and Braden hoist recommended procedures. The hoist must be reassembled and tested to Braden recommendations and standards (see Section 5, API RP2D and Parts and Vendor Data Manual, Section 11, Braden).

Swing Bearing •


3.3.10 Every 12 Months

2710100-MAN-001 01 3-9

Check per API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) (see Section 5).

Hydraulic Pressure Gauges •

Check for correct calibration.

Crane Load and Radius Indicator System •

Check for correct calibration (see Parts and Vendor Data Manual, section 11, Aanderaa Data Instruments).


2710100-MAN-001 01 3-10

3.4 Electrical System

3.5.1 Air System Maintenance

Electric power for the crane is supplied from the vessel at 220 VAC. The 220 VAC is also converted by a power supply to 24 VDC for use by control system equipment.

Release pressure from the air system (see paragraph 3.5.2) before doing maintenance to the air system equipment. Residual pressure can remain in the air piping. Use caution when removing any piping or hose. Accidentally releasing air at high pressure can cause injury to you and others, and can damage the equipment.

The electrical schematic shows the relationship of the electrical system equipment. See Parts and Vendor Data Manual, Section 10, Electrical Schematic, drawing 1585636.

3.4.1 Electrical System Maintenance Use caution when doing maintenance on or near the electrical system equipment. Before working on the electrical system, a lockout must be installed by each maintenance person at each electric power source following industry-standard lockout procedures. Electrical equipment must be maintained and operated according to applicable standards. Clean the work area before installing or removing electric wires from the equipment. When removing electric wires, check that the wires are correctly labeled and install caps on all the connectors to prevent corrosion.

3.5 Air System Compressed air for the crane is supplied from the vessel at 120–125 psi (8.3–8.6 bar) to a reservoir located on the crane. The air system controls and operates the diesel engine air starter and the operator’s cab window wipers and horn.

Regular inspection and maintenance of the air system is necessary for reliable performance of the equipment. A good preventive maintenance program will help prevent condensation and air system failures. Cleanliness is very important in the operation and maintenance of the air system. No dirt or abrasive particles can be permitted to enter the system. Some contaminants enter the system when it is opened. Do everything you can to keep the system as clean as possible. Clean the work area and tools before opening any part of the system. Install caps on all open air piping and hoses. Install plugs in all open air ports. Do not leave the air system open to dust and other airborne particles. Do not accept replacement parts that are not in their original protective packages. Wash parts according to the manufacturer’s instructions and permit them to dry before assembly.

3.5.2 Releasing Pressure from Air System 1. Shut down the crane (see paragraph 2.8.4).

The air piping drawings show the relationship of the air system equipment. See Volume 2, Parts and Vendor Data Manual, Section 9.

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2. Release pressure from the air system until the AIR PRESSURE gauge (see paragraph 2.6.10) in the operator’s cab reads 0 psi.


!WARNING •

Residual pressure can remain in the air piping. Use caution when removing any air piping or hose. Release of the air at high pressure by accident can cause personal injury and damage to the equipment.

3.6 Hydraulic System Hydraulic power for the crane is produced by hydraulic pumps driven by the diesel engine. The hydraulic system controls and operates the hoists and swing drive. A small hydraulic pump mounted near the front of the diesel engine powers a hydraulic motor the drives the fan of the hydraulic oil heat exchanger. The fan provides air flow across the heat exchanger to cool the hydraulic oil. The hydraulic schematic shows the relationship of the hydraulic system equipment. See Parts and Vendor Data Manual, section 8, Hydraulic Schematic, drawing 605090.

3.6.1 Hydraulic System Maintenance Release pressure from the hydraulic system and permit the system to cool (see paragraph 3.6.5) before doing maintenance to the hydraulic system equipment. Residual pressure can remain in the hydraulic piping. Use caution when removing any piping or hose. Accidentally releasing hydraulic oil at high pressure can cause injury to you and others, and can damage the equipment. Be careful of the flow of hydraulic oil when the hydraulic system is opened. Some parts of the system will lose hydraulic oil when opened. When personnel are not sure of a port pressure, refer to the hydraulic schematic and make the first pressure check with a test gauge of a large enough scale to prevent gauge failure. See Parts and Vendor Manual, Section 8,

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2710100-MAN-001 01 3-11

Hydraulic Schematic, drawing 605090. Not following this procedure can cause injury to personnel. Regular inspection and maintenance of the hydraulic system is necessary for reliable performance of the equipment. A good preventive maintenance program will help prevent oxidation, condensation, aeration, and hydraulic system failures. Check the hydraulic system equipment parts for overheating. The following are signs of hydraulic system overheating: • • • • •

high hydraulic oil reservoir temperature—more than 180°F (82°C) smell of “burned” oil near the hydraulic oil reservoir breather discolored paint or metal surfaces too much radiant heat reduced crane performance

Cleanliness is very important in the operation and maintenance of the hydraulic system. Small, abrasive particles, invisible to the eye, can decrease the useful life of valves, pumps, and motors. The clearance between hydraulic equipment parts is very small. Particles can squeeze through the clearances and be abrasive to the mating surfaces. The result is early wear, equipment damage, and a loss of power. Some contaminants enter the system when it is opened. Keep the system as clean as possible. Clean the work area and tools before opening any part of the system. Install caps on all open hydraulic hoses and piping. Install plugs in all open hydraulic ports. Do not leave the hydraulic system open to dust and other airborne particles. Do not accept new filter elements or replacement parts that are not in their protective packages. Wash parts in clean solvent and permit them to air-dry before assembly. Flush all new hydraulic piping, hoses, and other equipment parts to meet the requirements of Hydraulic System Contamination Levels, paragraph 3.6.1.2.


!WARNING •

The hydraulic system contains many adjustable equipment parts preset at the factory for optimum performance and safety. Do not adjust these equipment parts. the National Oilwell Varco Service Department for assistance.

G. Open the sampling valve and permit about 1 qt (0.95 L) of hydraulic oil to flow through the valve. H. With the sampling valve still in the “open” position, open the sampling bottle and fill it 50–90 percent full. I.

Remove the sample bottle with the sampling valve still in the “open” position. Put the cover on the sample bottle and close the sampling valve.

J.

Properly dispose of the hydraulic oil collected in the waste container.

3.6.1.1 Hydraulic Oil Sampling (National Oilwell Varco Drawing 604289) Do a hydraulic oil analysis every 500 hours of operation or every six months, whichever occurs first. 1. To take a sample of hydraulic oil: A. Install a hydraulic oil sampling valve (supplied by others) in the hydraulic return circuit at an elbow or in a place where the flow is turbulent during normal operation. The sampling valve must be sized to permit a flow rate through the valve of 30 ft/sec (9.1 m/sec). B. A sampling bottle that has been cleaned to a known cleanliness level and then capped is needed. C. A container to catch up to 1 gal (3.8 L) of waste hydraulic oil is needed. D. The hydraulic system must be at operating temperature and maximum speed, if possible. E. Clean the nozzle of the hydraulic oil sampling valve with a clean, lint-free cloth to remove any visual signs of contamination. F.

Put the waste container under the sampling valve.

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2710100-MAN-001 01 3-12

K. Check the level of hydraulic oil in the reservoir and add hydraulic oil as necessary (see paragraph 3.6.6). L. Record and submit the following information with the sample: • • • • • • • • • • • •

model number serial number hours of operation on the system hours of operation on the hydraulic oil sample date oil temperature sample location name of person taking sample sample appearance: clean, cloudy, milky, visible particles reason for sample additional comments hydraulic oil type

2. Send the hydraulic oil sample and the recorded data to a laboratory for a particle count analysis. The analysis results must be reported by the laboratory on a form similar to figure 3–1. The actual cleanliness level must be plotted on a graph and a curve made by connecting the points.


3. If the analysis results exceed the maximum operating contamination levels permitted (see paragraph 3.6.1.2), correct the problem before continuing operation. Additional sampling, analysis, and testing may be necessary (example: a chemical analysis could assist in determining the cause or source of contamination). The nonconformity can be the result of one of the following: A. A large quantity of new hydraulic oil was added shortly before the sample was taken. If so, operate the hydraulic system (engine) for two hours, but do not operate the hydraulic-driven equipment (crane boom, hoist, and swing functions). Then take and analyze a new hydraulic oil sample. B. One or more return filter elements are bying most of the time. If so, replace the clogged filter element(s) and operate the hydraulic system for two hours, but do not operate the hydraulic-driven equipment. Then take and analyze a new hydraulic oil sample. C. One or more parts in the hydraulic system are in the process of failing. If so, find and replace the failing part(s). After replacement, all the hydraulic oil must be drained and the system filled with new hydraulic oil (see paragraph 3.6.7). D. The hydraulic oil was contaminated during the replacement of a hydraulic equipment part. If so, have the situation reviewed by the National Oilwell Varco Service Department before operating the equipment.

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2710100-MAN-001 01 3-13

Document number Revision Page 10

7

2710100-MAN-001 01 3-14

9

10

30

ISO SOLID CONTAMINANT CODE

29 2.5

28 10

1.3

6

27 6.4

26 3.2

5 4 3 2

CODE: 18/16 5 4 3 2

10

24

7

10

8.0

23

5 4 3

4.0

22 2.0

2

21 10

4

1.0

10

6

20 5.0

19 2.5

18 10

1.3

3

17

6.4

16 3.2

15 1.6 10

14

2

8.0

13 4.0

12

5 4 3

RANGE NUMBER - quote at 5 um & 8 um levels only

NUMBER OF PARTICLES PER MILLILITRE GREATER THAN INDICATED SIZE

1.6 5

2 10

5

5 4 3 2 4

10

5 4 3 2

2.0

11 1.0

10

10

3

10 5.0

5 4 3

9 2.5 1.3

10

7

6.4

6 5

15

5

5

25

27

CURVED 5 / 15 / 25 /100 DATA (USE 5 /15 POINTS)

23

CODE: 27/23

15

25

100

100

2

2

1.6

4

-1

16

5 4 3

3.2

10

18

2

8 1

STRAIGHT LINE DATA

8

10

Reference ANSI/B93.30-1980

25

CODING METHOD

NUMBER OF PARTICLES PER 100 MILLILITRES GREATER THAN INDICATED SIZE

5.0

10

8.0

3

5 4 3

4.0

2 2.0

2

1 1

10

-2

5

10

15

20

25

30

40

50

60

70 80 90 100

Figure 3–1. Particle Count Analysis Form

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A1534


2710100-MAN-001 01 3-15

3.6.1.2 Hydraulic System Contamination Levels (National Oilwell Varco Drawing 604289) Table 3–3 shows the maximum permitted hydraulic system contamination levels. The water content of the hydraulic system must be less than 0.03% by volume. Table 3–3. Hydraulic System Contamination Levels NUMBER OF PARTICLES/mL LARGER THAN INDICATED SIZE PARTICLE SIZE MAXIMUM COMMISSIONING LEVEL(A) MAXIMUM OPERATING LEVEL(B) IN MICRONS (C) ISO 18/15 ISO 17/14(C) 5

2500

1300

15

320

160

25

80

40

50

10

5

100

0.8

0.4

(A) Maximum Commissioning Level: This is the maximum contamination level permitted for accepting new and rebuilt hydraulic systems into service. Do not operate the hydraulic system in excess of this contamination level. The commissioning level is the contamination level at which the equipment can be operated to circulate the system hydraulic oil until the maximum operating contamination levels are reached. This circulation of hydraulic oil must be done at no load and maximum hydraulic oil flow. (B) Maximum Operating Level: This is the maximum operating contamination level permitted. Operate the hydraulic system at low pressure until a contamination level below this is reached using the standard filter system. (C) Table 3–4 compares similar obsolete SAE and NAS Cleanliness Standards to the present ISO Standards: Table 3–4. Hydraulic System Cleanliness Standards LEVEL

ISO CODE

SAE CLASS

NAS CLASS

Maximum commissioning level

18/15

6

9

Maximum operating level

17/14

5

8

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must be filtered. Send the hydraulic oil through a 3-micron filter with no by while adding it to the hydraulic oil reservoir.

3.6.2 Hydraulic Oil

CAUTION •

•

2710100-MAN-001 01 3-16

Use a quality, high viscosity index (V.I.), anti-wear, petroleum-based hydraulic oil compatible with Buna N and Viton A seals for use in high pressure hydraulic systems (3000 psi [207 bar]). Choose an ISO grade that corresponds well to climactic conditions based on the characteristics listed in table 3–5. Original fill of the hydraulic system was Shell Tellus 46 (National Oilwell Varco p/n 939064). If you have a question about a hydraulic oil, the National Oilwell Varco Service Department.

Do not mix different types and brands of hydraulic oil unless they are compatible. Mixing different types and brands can cause a chemical reaction which can cause damage to the hydraulic equipment parts. Hydraulic oil containers that are not stored correctly can collect water in the bottom of the container. Hydraulic oil that is water-contaminated has a cloudy visual appearance and must not be added to the hydraulic system.

Analyze the hydraulic oil (see paragraph 3.6.1.1) for cleanliness, viscosity, proper additives, and water content every 500 hours of operation or every six months, whichever occurs first.

Filter all hydraulic oil to comply with the maximum contamination levels permitted (see paragraph 3.6.1.2) before adding it to the hydraulic reservoir. Even new oil from a new container

Table 3–5. Hydraulic Oil Grade MINIMUM HYDRAULIC OIL MINIMUM HYDRAULIC OIL MAXIMUM HYDRAULIC OIL TEMPERATURE BEFORE TEMPERATURE FOR FULL OPERATING (B) (C) STARTUP POWER OPERATION TEMPERATURE HYDRAULIC (7500 SUS MAXIMUM (750 SUS MAXIMUM (60 SUS MINIMUM OIL GRADE(A) VISCOSITY) VISCOSITY) VISCOSITY) °F

°C

°F

°C

°F

°C

ISO–15

–30

–34

15

–9

125

51

ISO–32

–10

–23

45

8

ISO–46 ISO–68 ISO–100

0 20 30

–17 –6 –1

55 75 90

175

13

(D)

24

(D)

33

(D)

79

180

(D)

82

180

(D)

82

180

(D)

82

(A) The viscosity/temperature curve varies with different hydraulic oil manufacturers. Consult the hydraulic oil manufacturer. Table 3–5 is based on Mobil DTE 10M series hydraulic oil. (B) If the hydraulic oil is below the minimum startup temperature or above the maximum startup viscosity, warm the hydraulic oil with a hydraulic oil reservoir heater until the hydraulic oil reaches the minimum startup temperature (maximum startup viscosity). The temperature of the hydraulic oil can be checked using the temperature gauge on the side of the hydraulic oil reservoir. (C) After startup, operate the hydraulic system at reduced pressure until the hydraulic oil reaches this minimum temperature (maximum operating viscosity). (D) The maximum hydraulic oil operating temperature is limited by the life of oil seals in the hydraulic system.

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3.6.3 Hydraulic Piping and Hoses Replace any piping that is bent or has become flat. This will cause a restriction of the hydraulic oil flow, which will cause heat buildup and slow hydraulic action. Replace hoses that show wear, damage, abrasion, bubbles in the outer covering of the hose, or weather-cracked rubber. Look for areas where two hoses have rubbed together and worn through the outer covering to the wire braid below. Use Loctite brand Hydraulic Sealant or PST Pipe Sealant on all pipe threads. Do not use PFTE or teflon tape—it will contaminate the hydraulic system.

NOTICE •

Use sealants according to the manufacturer’s recommended procedures.

CAUTION •

Flush all new hydraulic piping, hoses, and other equipment parts to meet the requirements of Hydraulic System Contamination Levels, paragraph 3.6.1.2.

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2710100-MAN-001 01 3-17

3.6.4 O-Ring Replacement

CAUTION •

Clean the work area before doing maintenance to the hydraulic system. Keep all the parts clean. Install caps on all open hydraulic piping. Install plugs in all open hydraulic ports. Dirt and contamination will damage the hydraulic system equipment parts if they enter the hydraulic system. (See Hydraulic System Maintenance, paragraph 3.6.1.)

O-ring failure can occur at piping or hose end connections or at equipment part interfaces. The piping or hose end connection can be of the O-ring boss and tube type (see paragraph 3.6.4.1), O-ring face seal, or the SAE four bolt O-ring flange type (see paragraph 3.6.4.2).


2710100-MAN-001 01 3-18

3.6.4.1 O-Ring Sizes for Bosses and Tube Fittings

NOTICE •

O-rings listed in table 3–6 must be 90 durometer Buna N material. Table 3–6. O-Ring Sizes for Bosses and Tube Fittings

The following O-rings are intended for use with internal straight thread bosses and tube fittings, and 10049, 10050, MS33656, MS33657, SAE straight thread O-ring and mating fittings. O-RING ARP 568 UNIFORM DASH NUMBER

AN-6290

TUBE SIZE (in)

–904

4

–905 –906 –908 –910 –912 –914

ACTUAL O-RING SIZE

NOMINAL O-RING SIZE

I.D. (in)

WALL (in)

I.D. (in)

1 4

0.351

0.072

11 32

5

5

5 16

0.414

0.072

13

5

6

3

0.078

25

8

1 2

0.087

41 64

10

5

12

3

14

7

8

8 4 8

0.468 0.644 0.755 0.924 1.047

0.097

3

0.116

59

0.166

3

1

32 32

4 64 64

11 64

WALL (in)

5 3 3 7 7 7

NATIONAL OILWELL VARCO PART NUMBER FOR O-RING

64

946198

64

946210

64

946199

32

946196

32

946211

64

946190

64

946260

64

946200

–916

16

1

1.171

0.116

1

–920

20

1 14

1.475

0.118

115 32

1 8

946201

–924

24

1 2

1.720

0.118

1

23

32

1 8

946213

–932

32

2.337

0.118

21132

1 8

946214

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1

2


2710100-MAN-001 01 3-19

3.6.4.2 Four Bolt O-Ring Flange Piping or Hose

To assemble a four bolt O-ring flange: 1. Clean the surfaces.

Split Flange

Bolt

2. Check the O-ring (see figure 3–2) for damage. Replace the O-ring if it is damaged.

Split Flange

O-Ring

3. Apply clean white petroleum jelly to the O-ring. 4. Install the O-ring in the piping or hose end.

A296

5. Install one-half of the split flange loose.

Figure 3–2. Four Bolt O-Ring Flange Installation

6. Install the piping or hose in the split flange. 7. Install the other half of the split flange loose. 8. Tighten the four bolts of the split flange in sequence (see figure 3–3) evenly, until all the bolts make with the top of the flanges. 9. Tighten the four bolts in sequence (see figure 3–3) one-half turn at a time. Repeat as necessary to the torque value shown in the following tables.

3

2

1

4

A217

Figure 3–3. Flange Tightening Sequence

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2710100-MAN-001 01 3-20

NOTICE •

O-rings listed in table 3–7 must be 90 durometer Buna N material except where noted. Table 3–7. Code 61 Standard Pressure Series Four Bolt O-Ring Flange

NOMINAL BOLT FLANGE THREAD SIZE UNC-2A (in)

TORQUE (in×lb)

O-RING ARP 568 UNIFORM DASH NUMBER

ACTUAL O-RING SIZE I.D. (in)

WALL (in)

WALL (in)

NATIONAL OILWELL VARCO PART NUMBER FOR O-RING

NOMINAL O-RING SIZE I.D. (in)

1 2

5 16

–18

175–225

–210

0.734

0.139

3

4

1 8

944103

3

3

–16

250–350

–214

0.984

0.139

1

1 8

925535

5 16

1 8

925561

4

1

3

8

–16

8

325–425

–219

1.296

0.139

1

425–550

–222

1.484

0.139

1 12

1 8

925333

7

944107

1 14

7 16

1 2

1 2

550–700

–225

1.859

0.139

1

8

1 8

1 2

650–800

–228

2.234

0.139

2 14

1 8

925334

3

925591 944206

1

2 2

1 2

3

–14

–13 –13

1 2

–13

5

–11

8

950–1100 1650–1800

–232

(A)

2.734

0.139

2

4

1 8

–237

(A)

3.359

0.139

33 8

1 8

(A) 70 durometer Buna N material

3.6.5 Releasing Pressure from Hydraulic System

3.6.6 Hydraulic Oil Level

1. Shut down the crane (see paragraph 2.8.4).

3.6.6.1 Checking Hydraulic Oil Level

2. Move all the control levers back and forth, then release the levers to their neutral (center) position. 3. Permit the hydraulic oil to cool (see Hydraulic System Maintenance, paragraph 3.6.1).

!WARNING •

Residual pressure can remain in the hydraulic piping. Read and understand the hydraulic schematic to identify possible areas of residual pressure in the hydraulic system. Use caution when removing any hydraulic piping or hose. Accidentally releasing hydraulic oil at high pressure can cause injury to you and others, and can cause damage to the equipment.

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Check the level of hydraulic oil in the hydraulic oil reservoir using the sight gauge located on the side of the reservoir. The level of hydraulic oil must be above the midpoint of the sight gauge. See paragraph 3.6.6.2 for the procedure to add hydraulic oil.

CAUTION •

Do not operate the equipment with a level of hydraulic oil that is too low or too high.


3.6.6.2 Adding Hydraulic Oil to the Reservoir

CAUTION •

•

Clean the work area and hydraulic oil handling equipment before adding hydraulic oil to the hydraulic oil reservoir. Dirt and contamination will damage the hydraulic system equipment parts if they enter the hydraulic system (see Hydraulic System Maintenance, paragraph 3.6.1). Do not overfill the hydraulic system.

1. Release pressure from the hydraulic system (see paragraph 3.6.5). 2. Use only new, clean, moisture-free hydraulic oil that meets the recommended specifications (see paragraph 3.6.2). 3. All hydraulic oil added to the hydraulic system must be filtered to comply with the maximum operating contamination levels permitted (see paragraph 3.6.1.2). 4. Add hydraulic oil through the fill port located on top of the hydraulic oil reservoir. Add hydraulic oil as necessary to raise the level in the reservoir above the midpoint of the sight gauge. The sight gauge is located on the side of the reservoir.

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2710100-MAN-001 01 3-21

3.6.7 Draining and Filling Hydraulic System When the hydraulic system shows signs of contamination (for example: sludge, water, or chemicals), the hydraulic system must be completely drained, flushed, and refilled (see paragraphs 3.6.7.1 and 3.6.7.2). The hydraulic oil can become contaminated as a result of wear of equipment parts, adding hydraulic oil that was not filtered correctly, or replacing equipment parts in the system with contaminated parts. The hydraulic oil can also become contaminated with chemicals or metallic substances dissolved or suspended in the hydraulic oil, or the additives in the hydraulic oil can become depleted because of the changing of equipment parts. Hydraulic oils will “shear” or thin out with use, requiring replacement of the hydraulic oil. High operating temperatures or age can cause oxidation of the hydraulic oil; this can be seen by a change in color or odor, increased acidity, and formation of sludge, gum, or varnish in the system. Check the condition of the hydraulic oil by periodically taking a sample and having it analyzed for particle or chemical contamination (see paragraph 3.6.1.1). If the contamination is caused by a failed equipment part, make a particle count test to find out if the hydraulic system needs flushing. If possible, take the hydraulic oil sample with the equipment operating. The hydraulic oil cleanliness must comply with the maximum operating contamination levels permitted (see paragraph 3.6.1.2).


3.6.7.1 Draining Hydraulic System 1. If possible, operate the corresponding equipment using all operations until the hydraulic oil is warmed to normal operating temperature.

CAUTION •

Clean the work area before doing maintenance to the hydraulic system. Keep all the parts clean. (See Hydraulic System Maintenance, paragraph 3.6.1.)

2. Release pressure from the hydraulic system (see paragraph 3.6.5). 3. Put tags on all the hydraulic piping and hoses for reassembly purposes.

!WARNING •

The hydraulic oil will be hot if the equipment has been operating. Residual pressure can remain in the hydraulic piping. Use caution when removing any hydraulic piping or hose. Accidentally releasing hydraulic oil at high pressure can cause injury to you and others, and can damage the equipment.

4. Containers must be used to collect the hydraulic oil. Open the drain valve to drain the hydraulic oil reservoir. Remove all the hydraulic piping and hoses from the pumps and other equipment parts. Permit all the hydraulic oil to drain. Properly dispose of the hydraulic oil collected in the waste containers.

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2710100-MAN-001 01 3-22

5. Flush clean all hydraulic piping, hoses, and other equipment parts to meet the requirements of Hydraulic System Contamination Levels, paragraph 3.6.1.2. 6. Disassemble the hydraulic oil filters. Clean the filter housings to remove any visual signs of contamination. Install new filter elements and assemble the filters. 7. Flush the inside of the hydraulic oil reservoir to remove any visual signs of contamination. Clean or replace the strainers. 8. Check all the O-rings, hoses, and wearing parts before assembly. Replace with new parts if any show signs of wear or damage. All the valves, pumps, etc., must not be sticking or binding because of hydraulic oil contamination. If a part does not move easily, it must be disassembled and completely cleaned. Any part in the hydraulic system that is not operating correctly is a possible source of future problems and equipment downtime. 9. Assemble all the parts, hoses, and piping. Close the drain valve of the hydraulic oil reservoir. The hydraulic system is now ready to be filled with new hydraulic oil (see paragraph 3.6.7.2).


3.6.7.2 Filling Hydraulic System

CAUTION •

Clean the work area and hydraulic oil handling equipment before adding hydraulic oil to the hydraulic oil reservoir. Dirt and contamination will damage the hydraulic system equipment parts if they enter the hydraulic system. (See Hydraulic System Maintenance, paragraph 3.6.1.)

2710100-MAN-001 01 3-23

10. Check the hydraulic oil reservoir for the correct oil level. Add filtered hydraulic oil to the hydraulic oil reservoir as necessary (see paragraph 3.6.6). 11. Start the diesel engine. 12. Operate the crane until all the air has been purged from the hydraulic system. Erratic equipment operation can be expected until the air has been purged. 13. Stop the diesel engine.

1. Use only new, clean, moisture-free hydraulic oil that meets the recommended specifications (see paragraph 3.6.2).

14. Check the hydraulic oil reservoir for the correct oil level. Add filtered hydraulic oil to the reservoir as necessary.

2. All hydraulic oil added to the hydraulic system must be filtered to comply with the maximum operating contamination levels permitted (see paragraph 3.6.1.2).

15. Make a particle count test of the hydraulic oil before putting the equipment into operation. The hydraulic oil cleanliness must comply with the maximum operating contamination levels permitted (see paragraph 3.6.1.1).

3. Fill the hydraulic oil reservoir with filtered hydraulic oil (see paragraph 3.6.6.2). 4. Fill all the hoses with filtered hydraulic oil, as possible. 5. Fill the hydraulic pumps and hydraulic motors with filtered hydraulic oil. Bleed the air from each pump and motor housing and permit the oil from the reservoir to fill each housing. 6. Reconnect all hydraulic piping and hoses. 7. Start the diesel engine (see the corresponding steps in paragraph 2.8.2). Check for pressure build-up.

3.6.8 Hydraulic Oil Filters The power plant has four hydraulic oil return filters and two pressure filters. The filters are equipped with an indicator that shows when the element requires replacement. The filter condition must be checked at start-up and after every eight hours of operation. It is normal for the filter to indicate a blocked condition during cold starting conditions because of the increased viscosity of the hydraulic oil. Replace the filter elements every 500 hours of operation or every six months, whichever occurs first.

CAUTION

8. Check for hydraulic system leaks. • 9. Stop the diesel engine (see the corresponding steps in paragraph 2.8.4).

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Clean the work area before doing maintenance to the hydraulic system. Keep all the parts clean. (See paragraph 3.6.1.)


2710100-MAN-001 01 3-24

3.7 Wire Rope

3.8 Non-Operational Storage

Operation, inspection, and maintenance of all wire rope should be done in accordance with API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) (see Section 5). Also, the Parts and Vendor Data Manual contains the following drawings that are beneficial to wire rope maintenance:

Equipment put in storage or removed from service must be protected from deterioration during storage. This will make sure that it can be restored to active service with a minimum of effort.

•

hoist manufacturer’s information (see Section 11, Braden) wire rope reeving diagrams (see Section 3) wire rope dead end installation drawings (see Section 5)

• •

!WARNING •

Do not operate the crane with damaged wire rope.

After new wire rope has been installed properly, the crane should be carefully operated through an operating cycle very slowly. During this trial operation, closely watch all working parts (sheaves, hoists, etc.) to make sure the wire rope moves freely and there are no spooling problems. Operate several more times using a light load at reduced speeds. This will permit the wire rope to work in and prevent any future problems.

3.8.1 Short-Term Storage—7 Days Up to 30 Days When the crane will not to be used for a period of 7 days but less than 30 days, do the following: 1. Lubricate the exposed machined surfaces such as shafts and hydraulic valve spools.

3.8.2 Long-Term Storage—30 Days or More When the crane will not be used for a period of 30 days or more, do the following: 1. Clean the equipment. 2. Apply lubricant to exposed machined surfaces. 3. Lubricate all the equipment (see paragraph 3.2.2). Do all the steps that would occur during the storage period. 4. Shut down the crane (see paragraph 2.8.4). 5. Prepare the diesel engine for storage. See the diesel engine manufacturer’s information (see Parts and Vendor Data Manual, section 11, Caterpillar) for diesel engine storage procedures. 6. Inspect the crane for paint surface damage. Make repairs as necessary to prevent corrosion.

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7. To prevent corrosion, apply Dow Corning brand Metal Protective Coating or an equivalent anti-corrosion coating to the following. The coating must be non-tacky and be able to be removed before operation. • •

Exposed machined surfaces of shaft bores and hydraulic valve spools. All other non-painted surfaces.

8. Completely fill the diesel fuel tank. 9. Check the level of hydraulic oil in the hydraulic oil reservoir. Add filtered hydraulic oil to the reservoir as necessary (see paragraph 3.6.6). 10. Close all cab windows and doors. 11. Cover the engine, valves, and operator’s cab with waterproof coverings to prevent corrosion and deterioration. 12. Once a month the diesel engine must be started and all functions operated for a minimum of one-half hour in each direction at various speeds with no loads.

3.8.3 Removal from Long-Term Storage 1. Remove the anti-corrosion coatings from all surfaces. 2. Clean the equipment. 3. Check the cylinder rod of the boom hoist drum pawl actuator for damage, pits, and scratches that can cause damage to the cylinder seal. Check for cleanliness. 4. Check the level of hydraulic oil in the hydraulic oil reservoir. Add filtered hydraulic oil to the reservoir as necessary (see paragraph 3.6.6).

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2710100-MAN-001 01 3-25

5. Prepare the diesel engine for operation. See the diesel engine manufacturer’s information for the diesel engine removal from storage procedures (see Parts and Vendor Data Manual, section 11, Caterpillar). 6. Start the crane (see paragraph 2.8.2). If possible, operate the crane through all functions until all the air is purged from the hydraulic system. Erratic operation can be expected until the air is purged. Check for correct operation. 7. Check the hydraulic system for leaks. Check hoses and piping for damage. 8. Make a hydraulic oil particle count (see paragraph 3.6.1.1) before continuing. The hydraulic oil particle count must comply with the maximum operating contamination levels permitted (see paragraph 3.6.1.2). 9. Do all necessary lubrication (see paragraph 3.2.2) and inspections and maintenance (see paragraph 3.3). 10. Check the equipment for paint surface damage. Make repairs as necessary. 11. The crane is now ready for operation.


3.9 Welding Instructions Using the wrong weld procedures on any part of the equipment can weaken the material and cause material failure, resulting in equipment damage, injury to personnel, or both. the National Oilwell Varco Service Department before welding any part of the equipment. When welding, attach the electric grounding cable directly to the part or area being welded. Not following this procedure can cause damage to the bearings, bushings, or spacers.

!WARNING •

Do not weld on hooks or shackles. Welding on these items can weaken the material, causing failure.

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2710100-MAN-001 01 3-26

Brake Test and Emergency Lowering Procedures For Hoists Ordered for API 2C Cranes All Braden planetary hoists have a spring-applied, hydraulically-released, multiple-disc brake located inside the drum. This brake acts to hold a suspended load in a stationary position when the directional control valve is in neutral or in the event of loss of hydraulic power. A brake clutch assembly permits the power train and drum to rotate in the direction to lift a load even if the brake is engaged. A load cannot be lowered, however, without first releasing the brake by applying hydraulic pressure to the release port. Hoists ordered for API 2C cranes will have a needle valve located in the brake release line. Those hoists also have a tee located in the brake release line between the needle valve and the brake release port on the hoist. One opening in the tee is plugged. With the valve closed and the plug removed from the tee, the brake is isolated from system pressure and vented to atmosphere. The brake cannot be released under these conditions by actuating the directional control valve. One purpose of the valve/tee combination is to provide a means to test the brake; the other is to provide a means to lower a load in the event of loss of hydraulic power. 1. Brake Test Procedure a.

Remove the lockwire on the valve handle, and close the valve tightly.

b.

Remove the plug in the tee.

c.

With the hydraulic power unit running, move the hoist directional control valve handle to the full-open lowering position.

d.

Increase the engine speed, if necessary, to bring system pressure up to the relief valve setting. The winch drum should remain stationary.

e.

If the drum rotates, the brake should be examined for wear. Also, the brake springs should be measured for correct length in those hoists using helical compression springs.

f.

Replace any parts showing excessive wear, and any spring whose length is shorter than the minimum shown in the Braden service manual.

g.

Reassemble the brake and hoist and repeat the above steps.

h.

When testing is complete, be sure to re-install the plug in the tee, fully open the valve and replace the lockwire.

The above procedure tests the brake's ability to resist about 115% of the rated hoist load. 2. Emergency Lowering Procedure a.

Remove the lockwire on the valve handle, and close the valve tightly.

603511 Rev. 4 (ECN 333421) Page 1 of 2

b.

Remove the plug in the tee.

c.

Remove both main hoses from the motor, and attach a standpipe to the motor port on the opposite side of the motor from the brake valve (counterbalance valve).

d.

Fill the standpipe with hydraulic oil, making certain that oil is not running out of the brake valve (counterbalance valve). If oil is running out of the brake valve (counterbalance valve), remove the spring retainer and tap the spool to the closed position.

e.

Connect a hand pump to the opening in the tee.

f.

Pump the hand pump up to about 1000 psi. A suspended load will slowly come down; releasing the pressure on the hand pump will cause the load to stop. If a chattering noise is heard while the load is coming down, pump the hand pump to a higher pressure until the noise stops. Do not touch the motor or standpipe while using this procedure; these items will become very hot.

CAUTION - The above lowering procedure opens the multiple-disc brake while leaving the brake valve (counterbalance valve) closed. Since hydraulic motors are not zero leak devices, internal motor leakage permits the load to slowly rotate the motor even though its outlet is blocked by the closed brake valve (counterbalance valve). This procedure will not work if there is little or no oil in motor. Attempting to use this procedure with no oil in the motor will cause the load to free fall. This procedure will also cause the load to free fall if the brake valve (counterbalance valve) is stuck in the open position. The purpose of the standpipe is to insure that the motor is full of oil. The standpipe is simply a length of pipe (about 1 foot long) attached to a 90° elbow. The other end of the elbow is attached to a short nipple and fitting suitable for mounting on the motor port or manifold. The standpipe is installed with the 1 foot pipe pointed up and in a vertical position. While lowering, oil must be added to the standpipe as necessary. The pipe size should be at least as big as the motor port size. WARNING- Never allow the standpipe to run out of oil. The load will free fall if there is little or no oil in the stand pipe. NOTE- The hydraulic oil used to fill the stand pipe must be filtered oil to prevent contaminated hydraulic oil from entering the hydraulic motor. Filter the hydraulic oil to meet a cleanliness level of ISO 16/13 or cleaner.

603511 Rev. 4 (ECN 333421) Page 2 of 2


2710100-MAN-001 01 4-1

4 SPECIFICATIONS 4.1 Crane Specifications Crane Model: • 10000 Serial Number: • 2710100 Boom: • Main length—70 ft (21.3 m) • Inner section—30 ft (9.1 m) • Outer section—30 ft (9.1 m) • Center section(s)—1 @ 10 ft (3.0 m) Maximum Hook Travel: • Main hook, 4 parts of line—400 ft (121.9 m) • Main hook, 6 parts of line—270 ft (82.3 m) • Auxiliary hook—300 ft (91.4 m) Maximum Hook Radius: • Main hook—74.7 ft (22.7 m) • Auxiliary hook—79.4 ft (24.2 m) Minimum Hook Radius: • Main hook—14.4 ft (4.3 m) • Auxiliary hook—15 ft (4.5 m) Maximum Available Hook Speed (with the hook positioned at the supply boat elevation and the platform at operational conditions): • Main hook—41.8 fpm (12.7 mpm) (4 parts, 1st layer) • Main hook—62.7 fpm (19.1 mpm) (6 parts, 1st layer) • Auxiliary hook—283 fpm (86.2 mpm) (1 part, 1st layer) Operator’s Station: • Enclosed, left-hand Load and Radius Indicator System: • Aanderaa Data Instruments model Mipeg 2000 Emergency Load Lowering: • Per drawings 603511 and 603457-L01

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4.1.1 Hoist and Wire Rope Information Hoist Make/Model: • Boom—Braden CH210A • Main—Braden CH240A • Auxiliary—Braden CH165A Boom Hoist Wire Rope: • 7/8 in 6x26 EIPS—IWRC • Length—900 ft (274.3 m) • Breaking strength—39.8 tons (36.1 MT) Main Hoist Wire Rope: • 3/4 in Dyform 34LR, grade 2160 • Length—1770 ft (539.5 m) • Breaking strength—40 tons (36.2 MT) Auxiliary Hoist Wire Rope: • 5/8 in Dyform 34LR grade 2160 • Length—420 ft (128.0 m) • Breaking strength—28.2 tons (25.5 MT)

4.1.2 Power Plant Type: • Diesel/hydraulic Diesel Engine: • Caterpillar 3126 • 249 hp @ 2100 rpm Diesel Fuel Tank Capacity: • 150 gal (567.8 L) Diesel Engine Coolant Capacity: • Engine and radiator—11.0 gal (41.6 L) • Radiator only—7.5 gal (28.3 L) Hydraulic Oil Reservoir Capacity: • 250 gal (946.3 L) Hydraulic System Capacity: • 265 gal (1003.1 L) Hydraulic Oil: • Shell Tellus 46, (for hydraulic oil viscosity selection see Hydraulic Oil, paragraph 3.6.2)

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2710100-MAN-001 01 4-2


2710100-MAN-001 01 4-3

4.1.3 Air System Supply (from vessel): • 120–125 psi (8.3–8.6 bar) Air Reservoir Tank: • Capacity—120 gal (454 L)

4.1.4 Electrical System Supply (from vessel): • 220 VAC, 50 Hz, 1 ph, 2 wires plus ground, 60 A • Power Supply PS0228 converts 220 VAC to 24 VDC System Voltage LOAD

SOURCE

VOLTAGE

Circuit Breaker CBP0208

220 VAC, 50 Hz

Control 1585644

24 VDC

Air conditioning units Flood lighting Area lighting Obstruction lights Power receptacle Electrical collector ring anti-condensation heater Diesel engine heater Hydraulic oil reservoir heater Load and radius indicator system Gauge lighting Wind speed indicator system

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2710100-MAN-001 01 4-4

4.2 Tightening Values for SAE Coarse Thread Bolts (National Oilwell Varco Drawing 1525177) Threaded parts must be clean, with no rust or contamination. •

Black or plated Grade 5 and Grade 8 bolts: Torque lubricated. Submerge entire bolt and nut in a container of SAE 30W motor oil just before assembly. Stand-Cote bolts (Teflon coated, blue in color): Torque dry. Do not use lubricant.

•

!WARNING •

Swing bearing bolts require different torque values. See Parts and Vendor Data Manual, Section 2, drawing 721310-L05, Turntable. Table 4–1. Tightening Values for SAE J429 Coarse Thread Bolts GRADE 5

GRADE 8

DIAMETER– THREADS/INCH TIGHTENING TORQUE (ft·lb) (A) 1

TIGHTENING TORQUE (N·m) (A)

TIGHTENING TORQUE (ft·lb) (A)

TIGHTENING TORQUE (N·m) (A)

–20

6

8

9

12

–18

13

18

18

25

–16

23

31

33

44

–14

37

50

52

71

–13

57

77

80

108

–12

81

111

115

156

–11

113

153

159

215

–10

200

271

282

382

–9

322

437

455

617

1–8

483

655

682

924

1- 18–7

595

807

966

1309

1- 4–7

840

1139

1363

1848

1-3 8–6

1102

1494

1787

2423

1462

1983

2371

3215

5

4

16

3 7

8

16

1 9

2

16

5 3

8 4

7

8

1

1

1- 2–6

(A) ft·lb = 0.7375 x torque in N·m, N·m = 1.356 x torque in ft·lb

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Nov Crane Maintenance Manual 204d2h

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More details 6z3438

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