Konecranes Overhead Crane Preventive Maintenance White Paper
NOV Crane Maintenance Manual
description
Transcript of NOV Crane Maintenance Manual
-
REFERENCE
AmClyde Unit Model 10000REFERENCE DESCRIPTION
CraneThis document contains proprietary and confidential informationwhich belongs to National Oilwell Varco, L.L.P.; it is loaned forlimited purposes only and remains the property of National OilwellVarco, L.L.P. Reproduction, in whole or in part; or use of this designor distribution of this information to others is not permitted withoutthe express written consent of National Oilwell Varco, L.L.P. Thisdocument is to be returned to National Oilwell Varco, L.L.P. uponrequest and in any event upon completion of the use for which itwas loaned. National Oilwell Varco, L.L.P.
National Oilwell Varco, L.L.P
73765 Penn Mill RoadCovington, Louisiana 70435USAPhone 985-892-8216Fax 985-871-8630
DOCUMENT NUMBER
2710100-MAN-001
REV
01
Operation and Maintenance Manual
AmClyde Unit Model 10000
Crane
Serial Number 2710100
RIG/PLANTGSP-Upetrom Jackup Drilling Rig Saturn
ADDITIONAL CODE SDRL CODE TOTAL PGS
REMARKSNational Oilwell Varco SO16176
MAIN TAG NUMBER DISCIPLINE
CLIENT PO NUMBER
CLIENT DOCUMENT NUMBER
2710100-MAN-001
www.nov.com
-
Op
era
tion
an
dM
ain
ten
an
ce
Man
ual
AmClyde
UnitModel10000
CraneSerialN
umber2710100
Op
era
tion
an
dM
ain
ten
an
ce
Man
ual
AmClyde
UnitModel10000
CraneSerialN
umber2710100
Op
era
tion
an
dM
ain
ten
an
ce
Man
ual
AmClyde
UnitModel10000
CraneSerialN
umber2710100
Op
era
tion
an
dM
ain
ten
an
ce
Man
ual
AmClyde
UnitModel10000
CraneSerialN
umber2710100
-
www.nov.com
Document number 2710100-MAN-001Revision 01Page ii
REVISION HISTORY
Rev Date (dd.mm.yyyy) Reason for Issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change Description
01 First Issue
-
TABLE OF CONTENTS
1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.3 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.1 General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.3.2 Operating Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.3.3 Maintenance Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Operator Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51.5 Inclement Weather Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51.6 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2 Crane Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.3 Crane Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22.4 Control Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42.5 General Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.1 Horn Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62.5.2 Boom Angle Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62.5.3 Load and Radius Indicator System . . . . . . . . . . . . . . . . . . . . . . 2-62.5.4 Window Wiper Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62.5.5 Operators Cab Air Conditioner/Heater Controls . . . . . . . . . . . . . . . 2-72.5.6 Area Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.5.7 Obstruction Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.5.8 PANEL LIGHTS Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.5.9 Maintenance Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.5.10 Boom Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.6 Power Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
www.nov.com
Document number 2710100-MAN-001Revision 01Page iii
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
WARRANTY
-
2.6.1 Diesel Engine Throttle Controls. . . . . . . . . . . . . . . . . . . . . . . . 2-82.6.2 ENGINE KILL Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82.6.3 EMERGENCY ENGINE KILL Control. . . . . . . . . . . . . . . . . . . . . 2-92.6.4 Diesel Engine Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92.6.5 Diesel Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92.6.6 AIR STARTER Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102.6.7 Hydraulic Oil Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . 2-102.6.8 Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . 2-102.6.9 Hydraulic Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . 2-102.6.10 AIR PRESSURE Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.7 Crane Function Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112.7.1 Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112.7.2 SWING BRAKE OFF/ON Control . . . . . . . . . . . . . . . . . . . . . . 2-112.7.3 SWING LOCK OFF/ON Control . . . . . . . . . . . . . . . . . . . . . . . 2-112.7.4 BOOM/SWING Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.7.4.1 Boom Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122.7.4.2 Swing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.7.5 MAIN and AUXILIARY Hoist Controls . . . . . . . . . . . . . . . . . . . . 2-132.7.6 Swing and Hoist Speed Control . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.8 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152.8.1 Pre-Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.8.1.1 Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152.8.1.2 Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.8.2 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-172.8.3 Pre-Operating Checks (After Engine Start-Up) . . . . . . . . . . . . . . . 2-18
2.8.3.1 AntiTwo-Block System . . . . . . . . . . . . . . . . . . . . . . 2-182.8.3.2 Boom Angle Limit System . . . . . . . . . . . . . . . . . . . . . 2-19
2.8.4 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-202.8.5 Emergency Stop Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 2-212.8.6 Emergency Load Lowering . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Document number 2710100-MAN-001Revision 01Page iv
www.nov.com
-
3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Introduction and General Instructions . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.1 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2.2 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.2.1 Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.2.2 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.2.3 Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.2.2.4 Swing Gear and Pinions. . . . . . . . . . . . . . . . . . . . . . . 3-43.2.2.5 Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.2.2.6 Boom Hoist Pawl . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.2.2.7 Hoist Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.2.2.8 Swing Drive Gearboxes . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 3-53.3.1 As Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53.3.2 Before Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53.3.3 After Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63.3.4 Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63.3.5 Every 8 Hours of Operation or Every Day . . . . . . . . . . . . . . . . . . 3-73.3.6 Every 40 Hours of Operation or Every Week . . . . . . . . . . . . . . . . . 3-83.3.7 First 100 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-83.3.8 Every 250 Hours of Operation or Every Three Months . . . . . . . . . . . . 3-83.3.9 Every 500 Hours of Operation or Every 6 Months . . . . . . . . . . . . . . 3-93.3.10 Every 12 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.4.1 Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.5.1 Air System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.5.2 Releasing Pressure from Air System . . . . . . . . . . . . . . . . . . . . 3-10
3.6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.6.1 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-11
Document number 2710100-MAN-001Revision 01Page v
www.nov.com
-
3.6.1.1 Hydraulic Oil Sampling (National Oilwell Varco Drawing 604289) . 3-123.6.1.2 Hydraulic System Contamination Levels
(National Oilwell Varco Drawing 604289) . . . . . . . . . . . . . 3-153.6.2 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163.6.3 Hydraulic Piping and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3-173.6.4 O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.4.1 O-Ring Sizes for Bosses and Tube Fittings . . . . . . . . . . . . 3-183.6.4.2 Four Bolt O-Ring Flange . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.5 Releasing Pressure from Hydraulic System. . . . . . . . . . . . . . . . . 3-203.6.6 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.6.1 Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . 3-203.6.6.2 Adding Hydraulic Oil to the Reservoir . . . . . . . . . . . . . . . 3-21
3.6.7 Draining and Filling Hydraulic System. . . . . . . . . . . . . . . . . . . . 3-213.6.7.1 Draining Hydraulic System . . . . . . . . . . . . . . . . . . . . . 3-223.6.7.2 Filling Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 3-23
3.6.8 Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-233.7 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-243.8 Non-Operational Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.8.1 Short-Term Storage7 Days Up to 30 Days . . . . . . . . . . . . . . . . 3-243.8.2 Long-Term Storage30 Days or More . . . . . . . . . . . . . . . . . . . 3-243.8.3 Removal from Long-Term Storage . . . . . . . . . . . . . . . . . . . . . 3-25
3.9 Welding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Crane Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.1.1 Hoist and Wire Rope Information . . . . . . . . . . . . . . . . . . . . . . . 4-24.1.2 Power Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.1.3 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34.1.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Document number 2710100-MAN-001Revision 01Page vi
www.nov.com
Emergency Load Lowering Procedure . . . . . . . . . . . . . . . . . . . . 603511 Rev. 4Emergency Hoist Load Lowering Kit . . . . . . . . . . . . . . . . . . . 603457-L01 Rev. 9
-
4.2 Tightening Values for SAE Coarse Thread Bolts(National Oilwell Varco Drawing 1525177). . . . . . . . . . . . . . . . . . . . . . 4-4
Document number 2710100-MAN-001Revision 01Page vii
www.nov.com
Load Rating Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1585851 Rev. 05 API RECOMMENDED PRACTICE 2D SIXTH EDITION, MAY 2007 (API RP 2D)
INSERT FOR API RP 2D SIXTH EDITION (APPENDIX I)
-
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 couldchange. This technical manual is not a substitute for comprehensive operator and maintenance train -ing. Read and completely understand this technical manual, equipment functions, and equipmentsafety 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 identifica-
tion of the equipment.
National Oilwell VarcoP.O. Box 4720 Covington, Louisiana 70434
73765 Penn Mill Road Covington, Louisiana 70435Phone: (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, serialnumber 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
www.nov.com
Document number 2710100-MAN-001Revision 01Page viii
-
WARRANTY
Products covered hereby are subject to the following warranty and no other: "The Manufacturerwarrants each new Product made by the Manufacturer to be free from defects in material andworkmanship, its obligation and liability under this Warranty being expressly limited to repairingor, at the Manufacturer's option, replacing free of charge at its factory any part proving defectiveunder 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 user, provided written claimhereunder is received by the Manufacturer within 15 days after expiration of said period. Partsclaimed to be defective and for which repair or replacement is desired shall, if requested by theManufacturer, be returned transportation prepaid to the Manufacturer's factory for inspection.THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDINGBUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANYPARTICULAR PURPOSE, AND THE OBLIGATION AND LIABILITY OF THE MANUFACTURERUNDER THIS WARRANTY SHALL NOT INCLUDE ANY TRANSPORTATION OR OTHER CHARGESOR THE COST OF INSTALLATION OR ANY LIABILITY FOR LOSS OF PRODUCT TIME OR ANYOTHER DIRECT, INDIRECT, OR CONSEQUENTIAL DAMAGES OR DELAY RESULTING FROM THEDEFECT. Any operation beyond rated capacity or the improper use or application of the Productor the substitution upon it of parts not approved by the Manufacturer or any alteration or repair byothers in such manner as, in the Manufacturer's judgement, to affect the Product materially andadversely shall void this Warranty. No representative of the Manufacturer is authorized to changethis Warranty in any way, and no attempt, effort, or promise to repair Products of the Manufacturereither by the Manufacturer or by any representative of Manufacturer at any time shall change orextend this Warranty in any way. This Warranty covers only new and unused Productsmanufactured by the Manufacturer. Products manufactured by others are covered only by suchwarranties 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 user ofthis equipment to know the safety codes; insur-ance requirements; and national, federal,provincial, state, and local laws and regulationsaffecting all uses of the equipment. This techni-cal manual does not provide regulatory informa-tion, because regulations are subject to changeand different from location to location.
It is the responsibility of the owner and user ofthe equipment to obtain, read, and understandthe current edition of API Recommended Prac-tice 2D, Recommended Practice for Operationand Maintenance of Offshore Cranes (API RP
2D), a document from the American PetroleumInstitute (API). The document is published byAPI Publishing Services, 1220 L Street, N.W.,Washington, D.C. 20005. For more informationcall 202-862-8375 (phone) or 202-962-4776(fax), or visit the API website(www.api.org/publications/).
Not using the equipment according to theseregulations can result in damage to the equip-ment and death or injury to personnel.National Oilwell Varco provides technical manu-als for the different types of equipment that itmanufactures and sells. The owner and usermust use these technical manuals to give thecorrect information and training to the peoplewho will operate, maintain, or supervise the useof the equipment.This equipment is designed to do heavy-dutywork and will wear during normal use. There-fore, the owner and user must establish a regu-larly scheduled inspection and maintenanceprogram based on the information in theNational Oilwell Varco technical manual.Inspection and maintenance programs helpprevent accidents and keep the equipmentoperating efficiently.
Correct training, inspection, and maintenanceprograms are important to avoid personal injury,damage to equipment, high maintenance costs,and lost production.
Any performance ratings and specifications forthis equipment are valid only when theequipment is used according to the manufac-turers operating and maintenance procedures.Read and understand the technical manualsprovided with this equipment before operatingor doing maintenance to the equipment. Assis-tance is available from the National OilwellVarco Service Department.
The operator must know all the main parts,controls, and safety features of the equipmentbefore operating it. The operator must know thecorrect operation and inspection procedures ofthe equipment before operating it.
The operator is responsible for the safe opera-tion of the equipment, including the safety ofothers in the work area.
1.2 Safety Signal Words
Throughout this technical manual are steps andprocedures that, if not followed, can result in ahazard. The following signal words are used toidentify 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.
Document number 2710100-MAN-001Revision 01Page 1-1
www.nov.com
-
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 ordamage because of operator error or careless-ness.
This safety section includes information frommany sources. It gives examples of basic safetyrules. Additional safety rules can be necessaryfor safe operation of the equipment. The infor-mation in this section is not meant to replacesafety codes; insurance requirements; ornational, federal, provincial, state, and locallaws and regulations.
1.3.1 General Safety Rules
1. Wear protective clothing and safety equip-ment as required by job conditions whenoperating the equipment or working in thearea of the equipment. Do not wear looseclothing that could catch on controls ormoving equipment parts.
2. Keep the operators area and the work areaclean and free of debris.
3. Keep the equipment clean and free of dirtand debris, to permit a good inspection ofthe equipment.
4. Check the rigging before a lift. Rigging thatis damaged must be repaired or replacedbefore it can be used.
5. Do not weld on hooks or shackles. Weldingon these items can weaken the material,causing failure.
6. Do not use torches or open flame on ornear fuel system, hydraulic, and controlequipment.
7. Adequate fire protection equipment must beavailable and in satisfactory operatingcondition. Operating and maintenancepersonnel must be familiar with the use andcare of the fire protection equipment.
1.3.2 Operating Safety Rules
1. Do not operate this equipment under anyconditions or in any manner other thanthose for which the equipment has beenspecified, sold, and described in this techni-cal manual.
2. This equipment must be operated only bypersonnel who are trained and authorizedfor its operation.
Document number 2710100-MAN-001Revision 01Page 1-2
www.nov.com
-
3. Do not operate this equipment if you are illor physically or mentally not fit to operate itcorrectly and safely.
4. Do not exceed the rated load capacity ofthe equipment (see Section 4, Load RatingChart, drawing 1585851). Lifting loadsgreater than those shown on the load ratingchart or operation at positions not shown,or lifting when the boom is solid against theboom stops, can cause structural failure orcollapse of the boom or crane and death orinjury to personnel.
5. Do not rely on the load monitoring systemwhen common sense judgment indicatesan error. Do not use the load monitoringsystem as a weighing device after lifting theload.
6. Operate the equipment with no load at thestart of each workday to make sure all func-tions work correctly.
7. Test the brakes for correct operation when-ever a load at or near the load rating for theboom angle used is to be handled.
8. The operator must watch the load at alltimes. Do not operate the equipment if theoperators vision is restricted. Some appli-cations require a signal person. The signalperson must be visible to the operator at alltimes. The operator and the signal personmust agree on the signals to be usedbefore operating the equipment.
9. Communication must be maintainedbetween all personnel involved in any oper-ation. The operator must obey a signal tostop from anyone in the area. The signalperson must give all other signals.
10. Do not permit personnel to get on or off theequipment while it is operating.
11. Do not operate the equipment with anypersonnel near the wire rope or movingequipment.
12. Do not operate the equipment without thesafety guards installed.
13. Do not bypass, disconnect, or ignore safetyand warning devices of the equipment.Safely shut down the equipment and inves-tigate the problem. Correct the problembefore continuing operation.
14. Do not operate the equipment after aninspection reveals a safety hazard or if anyequipment parts require maintenance orreplacement. Always look for equipmentdamage or abnormal functioning duringoperation. If found, safely shut down theequipment and correct the damage beforecontinuing operation.
15. Before rotating the crane, make sure thatthe crane tailswing as well as the swingpaths of the boom and load are free ofobstructions and personnel. Not followingthis procedure can result in damage to thecrane, the load, or other equipment orstructures, and death or injury to personnel.
16. Operate the equipment at a slow speedwhen first learning.
17. Check the load indicating display and allgauges often for normal operating condi-tions. Shut down the equipment immedi-ately if the display or gauges are out of thenormal operating ranges. Investigate andcorrect the problem before continuing oper-ation.
18. When making a lift, the hook must bedirectly over the estimated center of gravityof the load before the load is attached tothe rigging. Do not attach capacity loads atmaximum outreach, because an outwardswing of the load, caused by vessel list ortrim, or outward drift of the boom, can over-load the crane.
Document number 2710100-MAN-001Revision 01Page 1-3
www.nov.com
-
19. Loads must be safely rigged before lifting.Do not overload slings. Slings must beattached to the throat of the hook. Do notpermit hook latches to support any part ofthe load. Hook latches keep loose slingsfrom coming off the hooks.
20. When making a lift, the boom (hook) mustbe directly over the load, not the side of theload. Side loading can cause structural fail-ure or collapse of the boom or crane andinjury to personnel.
21. Use extreme caution when rotating thecrane with a load suspended. When lifting aheavy or bulky load, it is recommended thattaglines (ropes) be attached to each side ofthe load to prevent the load from rotating orswinging.
22. When using handlines (ropes) to guide orsnub a load, do not permit personnel towrap the rope around any part of their body.
23. Personnel must be clear of the work areabefore making the lift.
24. Do not quickly accelerate or quickly decel-erate a moving load.
25. Loads must be moved at as low a level aspossible. If the load slips, it must belowered with caution immediately.
26. Do not swing or position the load or attach-ment over personnel. Do not permit person-nel to be in a hazardous position between aswinging load and a fixed object.
27. The operator must watch the load at alltimes. The load must be completelylowered before looking away from the load.
28. The operator must not leave the controlstation until the equipment has been shutdown and is completely stopped.
29. The operator must not leave the controlstation with a load suspended in the air.
30. The hoists must have at least five full wrapsof wire rope on the drum at all times duringoperation.
31. Do not permit the wire rope to wind wrongon the hoist drum (see figure 11).
1.3.3 Maintenance Safety Rules
1. Shut down the equipment before doingmaintenance. Only qualified, trainedpersonnel must do maintenance, adjust-ment, and inspection procedures, followingthe procedures outlined in the technicalmanual.
2. All replacement and repaired parts mustmeet the manufacturers current specifica-tions.
3. After making a repair or adjustment, alwayscheck the functioning of the equipmentparts before putting the equipment into fulloperation.
Document number 2710100-MAN-001Revision 01Page 1-4
www.nov.com
Figure 11. Wire Rope Wound Wrong on Drum
A1929
-
4. The power plant must be stopped and coolbefore checking fluids.
5. Do not add fuel to the fuel tank while theequipment is operating. When adding fuel,keep the nozzle in contact with the fuel tankto prevent static electricity sparks. Ifprovided, connect the ground wire beforeadding fuel. NO SMOKING! Do not permitopen flames or sparking devices near thefuel filling area. Remove all spilled fuelbefore starting the equipment. Add fuel tothe fuel tank in a well-ventilated locationonly.
6. Do not make modifications to the equip-ment unless approved in writing by NationalOilwell Varco.
1.4 Operator Qualification
To prevent injury and property damage, thecrane operator must be qualified by training andphysical capability. The operator must under-stand the manufacturers intended use, and theoperation and maintenance procedures. Theoperator should be familiar with and follow thepractice 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 theboom lowered during periods of inclementweather, including wind strong enough to affectload control (especially loads with large sailareas) or when the operators ability to see thesignal person or load is hampered by darkness,fog, rain, etc.
1.6 Safety Labels
Safety labels are located on the equipment inprominent places to advise operating and main-tenance personnel of hazards. The labels arereproduced here to improve recognition andthereby increase label effectiveness. Beforeoperating or doing maintenance to theequipment, be sure you understand the mean-ing of these labels. Drawing 1587840, Decaland Nameplate Installation (see Parts andVendor Data Manual, Section 2) shows thelocations of all the National OilwellVarco-supplied safety labels. This drawing is auseful reference for the inspection and mainte-nance of the safety labels (see para-graph 3.3.8). Replace all damaged or missingsafety labels.
Document number 2710100-MAN-001Revision 01Page 1-5
www.nov.com
-
Document number 2710100-MAN-001Revision 01Page 1-6
www.nov.com
WARNINGRead and fully understandoperation, service and partsmanuals before operating orservicing equipment.
Failure to obey warnings and followinstructions could result inpersonal injury, death, damage toequipment or property.
p/n 604287
Operating and maintenance personnel must readand understand the manuals provided with theequipment before operating or doing maintenanceto the equipment. The equipment must be operatedonly by personnel who are responsible and autho-rized for its operation.
WARNINGSwing brake must not be appliedwhile the crane is in motion.Serious damage may occur tothe swing gear box componentsif this procedure is not followed.Refer to operators manual foradditional swing controlinformation.
p/n 603164
Operating and maintenance personnel must readand understand the manuals provided with theequipment before operating or doing maintenanceto the equipment. The equipment must be operatedonly by personnel who are responsible and autho-rized for its operation.
WARNING
Machinery mustbe completelystopped beforemaintenance canbe done. Makereference tomaintenancemanual for correctprocedures.
p/n 604283
Shut down the equipment before doing mainte-nance. Only qualified, trained maintenancepersonnel must do maintenance, adjustment, andinspection procedures, following the proceduresoutlined in the maintenance manual.
-
www.nov.com
Document number 2710100-MAN-001Revision 01Page 1-7
WARNING
Only trained authorized personnelare to do maintenance or makeadjustments to hydraulic, air andelectrical systems. SeeMaintenance Manual forinstructions.
p/n 604284
Shut down the equipment before doing mainte-nance. Only qualified, trained maintenance person-nel must do maintenance, adjustment, andinspection procedures, following the proceduresoutlined in the maintenance manual.
Do not access this area while the crane isoperating. The equipment can start or stop withoutwarning. Not following this procedure can result indeath or serious injury.
DANGER
To prevent injury,do not walk orstand under craneboom, hooks, orload.
p/n 603187
Be careful when opening or closing windows ofoperators cab. Keep area clean and free of debristo prevent tripping hazards.
OPENING/CLOSINGCAB WINDOWS
CAUTION
p/n 603762
-
Document number 2710100-MAN-001Revision 01Page 1-8
www.nov.com
Exposed, moving equipment parts can cause seri-ous injury or death. Keep hands, feet, and clothingaway from moving equipment parts while the equip-ment is operating. Do not operate the equipmentwithout the safety guards installed.
WARNING
p/n 604285
Exposed, moving equipment parts can cause seri-ous injury or death. Keep hands, feet, and clothingaway from moving equipment parts while the equip-ment is operating. Do not operate the equipmentwithout the safety guards installed.
WARNING
WATCH YOURHANDS
ANDFINGERS
p/n 603698
Only qualified, trained maintenance personnel mustdo maintenance, adjustment, and inspection of theelectrical equipment. Each maintenance personmust install a lockout at each electric power area.Electrical equipment must be maintained and oper-ated according to applicable standards. Not follow-ing this procedure can result in death or seriousinjury.
WARNING
Electric shockhazard. Authorizedpersonnel only.
p/n 604788
-
Document number 2710100-MAN-001Revision 01Page 1-9
www.nov.com
This enclosurehas more thanone source ofpower. Disconnectall sourcesbefore doingmaintenance.
WARNING
p/n 604791
Electrical power is supplied to this equipment frommultiple sources. All sources of electrical powermust be shut off before accessing the indicatedequipment. Only qualified, trained maintenancepersonnel must do maintenance, adjustment, andinspection of the electrical equipment. Not followingthis procedure can result in death or serious injury.
Only qualified, trained maintenance personnel mustdo maintenance, adjustment, and inspection of theelectrical equipment. Each maintenance personmust install a lockout at each electric power area.Electrical equipment must be maintained and oper-ated according to applicable standards. Not follow-ing this procedure can result in death or seriousinjury.
p/n 604796
-
This page intentionally left blank.
Document number 2710100-MAN-001Revision 01Page 1-10
www.nov.com
-
2 OPERATION
2.1 Introduction
The following paragraphs describe the opera-tors controls and general operating instructionsfor the crane as outlined by the table ofcontents.
2.2 Crane Installation
The crane pedestal must be properly secured tothe foundation, and the installation as well asthe foundation itself must be strong enough towithstand the maximum pedestal reactions.Refer to the crane general arrangement draw-ing for the foundation loading information (seeParts 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.
Document number 2710100-MAN-001Revision 01Page 2-1
www.nov.com
-
2.3 Crane Nomenclature
Document number 2710100-MAN-001Revision 01Page 2-2
www.nov.com
Figure 21. Crane
Boom Flood Light
(see paragraph 2.5.6)
Boom
Bridle
A-Frame
Boom Stop
Operators
Cab
Boom Angle Indicator (far side)
(see paragraph 2.5.2)
Boom Foot Pin
Hydraulic Oil
Heat Exchanger
Turntable
Diesel Fuel Tank
Wind Speed Sensor
Obstruction Light
(see paragraph 2.5.7)
Area Lighting
(see paragraph 2.5.6)
A-Frame Ladder
and Cage
Maintenance Crane
(see paragraph 2.5.9)
Auxiliary Hoist
Main Hoist
Boom Hoist
Diesel
Engine
Air
Reservoir
Boom Wire Rope
Swing
Bearing
Pedestal
Main Wire Rope
Auxiliary Wire Rope
A3266
-
Document number 2710100-MAN-001Revision 01Page 2-3
www.nov.com
Figure 21. Crane (continued)
Wind Speed Sensor
A-Frame Ladder and
Cage
Air Conditioning/
Heating Units (see
paragraph 2.5.5)
Operators Cab
Window Wipers
(see paragraph
2.5.4)
Horn
(see paragraph 2.5.1)
Swing Drive
A-Frame
Front Elevation(boom not shown for clarity)
Auxiliary Hoist Load Sensor
Obstruction Light
(see paragraph 2.5.7)
Main Hoist
Load Sensor
AntiTwo-Block
System Weight
Pendant
A3266
Auxiliary Overhaul
Ball and Hook
Main Hook Block
and Hook
-
2.4 Control Nomenclature
The controls of the operators control station (see figure 22) direct the functioning of the crane equip-ment and show information important to the operation of the crane. Detailed descriptions of the opera-tors controls are given in the following paragraphs as outlined by the table of contents. The controldescriptions are divided into three groups: general control devices, power control devices, and cranefunction control devices.
This legend refers to figure 22 on the following page.
ITEMNUMBER DESCRIPTION
1 Diesel engine throttle pedal (see paragraph 2.6.1)2 BOOM/SWING control (see paragraph 2.7.4)3 Swing brake pedal (see paragraph 2.7.1)4 Horn control (see paragraph 2.5.1)5 MAIN/AUXILIARY hoist control (see paragraph 2.7.5)
6 Load and radius indicator system (see paragraph 2.5.3)7 SWING PRESSURE gauge (see paragraph 2.6.9)8 MAIN/AUX PRESSURE gauge (see paragraph 2.6.9)9 BOOM PRESSURE gauge (see paragraph 2.6.9)10 PILOT PRESSURE gauge (see paragraph 2.6.9)
11 AIR PRESSURE gauge (see paragraph 2.6.10)12 Boom angle indicator (see paragraph 2.5.2)13 SWING BRAKE OFF/ON control (see paragraph 2.7.2)14 Diesel ENGINE THROTTLE control (see paragraph 2.6.1)16 EMERGENCY ENGINE KILL control (see paragraph 2.6.3)
15 AIR STARTER control (see paragraph 2.6.6)17 ENGINE KILL control (see paragraph 2.6.2)18 SWING LOCK OFF/ON control (see paragraph 2.7.3)19 ENGINE TACHOMETER/HOUR METER (see paragraph 2.6.4)20 COOLANT TEMPERATURE gauge (see paragraph 2.6.4)
21 OIL PRESSURE gauge (see paragraph 2.6.4)22 UPPER WIPER control (see paragraph 2.5.4)23 WINDOW WASHER control (see paragraph 2.5.4)24 FRONT WIPER control (see paragraph 2.5.4)25 PANEL LIGHTS switch (see paragraph 2.5.8)
26 Seat
Document number 2710100-MAN-001Revision 01Page 2-4
www.nov.com
-
Document number 2710100-MAN-001Revision 01Page 2-5
www.nov.com
SWING PRESSURE
MAIN/AUX PRESSURE
BOOM PRESSURE
PILOT PRESSURE
EN
GIN
ET
HR
OT
TLE
EM
ER
GE
NC
YE
NG
INE
KILL
AIR
STA
RT
ER
EN
GIN
EK
ILL
FR
ON
TW
IPE
RU
PP
ER
WIP
ER
HO
UR
ME
TE
RE
NG
INE
TAC
HO
ME
TE
R/
OIL
PR
ES
SU
RE
CO
OLA
NT
TE
MP
ER
AT
UR
E
PA
NE
LLIG
HT
S
SW
ING
LOC
K
ON
ON
SW
ING
BR
AK
E
10
60
80
75
70
65
50 25
30 20
45
35
40
15
55
5
0
BOOM ANGLE INDICATOR
DEGREES FROM HORIZONTAL
F OFF OF
AIR PRESSURE
BOOM LOWER
BOOM RAISE
SWING
LEFT
SWING
RIGHT
LOWER
RAISE
MAIN
RAISE
LOWER
AUX
Figure 22. Control Station
A3267
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
1 2 3 4 5 6
26 25 24 23 22
-
2.5 General Control Devices
2.5.1 Horn Control
Push the horn control (figure 22, item 4) onthe floor in front of the operators seat to soundthe horn located on the operators cab (seefigure 21). The control is a manually engagedspring-released, foot-operated air valve.
2.5.2 Boom Angle Indicator
The boom angle indicator (figure 22, item 12)is located on the boom (see figure 21) and canbe viewed from the operators cab. The dialshows the angle of the boom in degrees fromhorizontal.
2.5.3 Load and Radius Indicator System
The load and radius indicator system display(figure 22, item 6) is located in the operatorscab and shows the radius, load, rated loadcapacity (safe working load), and percent ofrated 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 ratedcapacity, an audible alarm sounds and thecircular analogue scale of the display flashesyellow to warn the crane operator.
At loads of 100 percent or more of the ratedcapacity, an audible alarm sounds and thecircular analogue scale of the display flashesred to warn the crane operator.
At loads of 110 percent of rated capacity ormore, hoist movement stops and main/auxiliaryhoist raising and boom lowering functions aredisabled. To restore normal operation, operatethe corresponding main/auxiliary hoist in thelowering direction, or raise the boom, until theload on the hoist becomes less than 110percent.
Leave the load and radius indicator systemcontinuously powered during crane operation.
See the manufacturers information for theoperating instructions (see Parts and VendorData Manual, Section 11, Aanderaa DataInstruments).
WARNING
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 22, item 24) andUPPER WIPER control (item 22) control thecorresponding window wiper of the operatorscab. Each WIPER control is a two-positionswitch.
In the PARK position, the wiper returns to itsparking position and stops.
Document number 2710100-MAN-001Revision 01Page 2-6
www.nov.com
-
In the RUN position, the wiper operates.
Push the knob of the washer control (item 23)to spray washer fluid on the windows. Thereservoir for the washer fluid is located on theexterior rear corner of the operators cab.
2.5.5 Operators Cab Air Conditioner/
Heater Controls
The controls for the operators cab air condi-tioning/heating units are located on the controlpanel of the cab ceiling units (see figure 21).See the manufacturers information for theoperating instructions (see Parts and VendorData Manual, Section 11, RVP).
2.5.6 Area Lighting
Two 400 W flood lights (see figure 21) arelocated on the boom. The lights are controlledby a switch located inside the operators cab.
One 400 W flood light (see figure 21) islocated on the A-frame, illuminating the engineand hoist areas. The light is controlled by aswitch inside the operators cab.
One fluorescent light (two 40 W lamps) islocated inside the operators cab. The light iscontrolled by a switch located inside the opera-tors cab.
2.5.7 Obstruction Lights
Red aircraft obstruction lights (see figure 21)are located at the tip of the boom, and on thetop of the A-frame. The lights are controlled bycircuit breaker CB0242 located in circuitbreaker panel CBP0208, inside the operatorscab.
2.5.8 PANEL LIGHTS Switch
The PANEL LIGHTS switch (figure 22,item 25) controls the illumination of the gaugeson the gauge control panel.
With the switch in the on position, the gaugesare illuminated.
With the switch in the off position, the gaugesare not illuminated.
2.5.9 Maintenance Crane
The maintenance jib (see figure 21) is locatedon the back of the crane A-frame. The mainte-nance jib has a manually operated chain hoist.The boom of the maintenance jib can be put ina wind locked position to prevent the boomfrom rotating.
See the manufacturers information for theoperating instructions (see Parts and VendorData Manual, Section 11, Budgit).
2.5.10 Boom Stops
The crane has cushioned boom stops (seefigure 21) to retard the backward motion of theboom as the boom nears high boom angles.
When a load is lifted, the boom suspensionsystem stretches, causing the boom angle todecrease and the load radius to increase. Thecrane operator should compensate for this byraising the boom a small amount as the load islifted.
When the load is set down, the boom suspen-sion system will contract, causing the boomangle to increase a small amount and the loadradius to decrease.
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-7
-
When lifting loads at high boom angles, theoperator must take care when setting down theload. The crane operator must also lower theboom a small amount so the boom is not pulledback into the boom stops. The inner section ofthe boom may be damaged if the boom ispulled 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.
2.6 Power Control Devices
2.6.1 Diesel Engine Throttle Controls
The diesel engine throttle foot pedal(figure 22, item 1) is the left pedal located infront of the operators seat. The hand-operateddiesel ENGINE THROTTLE control (item 14) islocated on the control console.
Engine speed can be increased by eitherdepressing the foot throttle or pulling up thehand throttle. To decrease engine speed,release the foot throttle and depress the buttonon top of the hand throttle knob while pushingthe knob down.
Engine speed can be locked at any speed bydepressing the foot throttle to the desired speedand pulling up the hand throttle. The enginespeed can be finely adjusted by turning theknob 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 22, item 17)(with black handle) is used for normal stoppingof the diesel engine.
Pull the handle of the ENGINE KILL control allthe way up to stop the diesel engine (fuel isshut off). The handle must be pushed all theway down to operate the engine.
Document number 2710100-MAN-001Revision 01Page 2-8
www.nov.com
-
2.6.3 EMERGENCY ENGINE KILL
Control
The EMERGENCY ENGINE KILL control(figure 22, item 16) (with red handle) is usedfor emergency stopping of 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.
Pull the handle of the EMERGENCY ENGINEKILL control all the way up to immediately stopthe diesel engine. This closes the engine airinlet shutoff. After the emergency stop, the airinlet shutoff must be reset to the open positionand the engine must be checked for damage.The air inlet shutoff is located on the engine airintake housing. See the diesel engine manufac-turers information for the procedure to reset theair inlet shutoff (see Parts and Vendor DataManual, Section 11, Caterpillar).
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.
2.6.4 Diesel Engine Gauges
The gauges listed in table 21 are located onthe control console and show the operatingcondition of the diesel engine. See the dieselengine manufacturers information for theengine operating instructions (see Parts andVendor Data Manual, Section 11, Caterpillar).
CAUTION
Do not operate the equipment when a
gauge is reading outside of its normal
operating range (see table 21).
2.6.5 Diesel Fuel Level Gauge
The gauge on the top of the diesel fuel tank(see figure 21) shows the level of diesel fuelremaining in the diesel fuel tank.
Document number 2710100-MAN-001Revision 01Page 2-9
www.nov.com
LABEL FUNCTION MONITORED NORMAL OPERATINGRANGEFIGURE AND ITEM
NUMBERSENGINETACHOMETER/HOUR METER
Engine speed, total run time See engine manufacturersmanual figure 22, item 19
COOLANTTEMPERATURE Coolant water temperature
See engine manufacturersmanual figure 22, item 20
OIL PRESSURE Lubrication oil pressure See engine manufacturersmanual figure 22, item 21
Table 21. Diesel Engine Gauges
-
2.6.6 AIR STARTER Control
The AIR STARTER control (figure 22, item 15)controls the air starter motor for the dieselengine. The control is a manually engaged,spring-released air valve.
Push and hold the AIR STARTER control tostart the diesel engine.
2.6.7 Hydraulic Oil Level Gauge
The sight gauge on the side of the hydraulic oilreservoir (see figure 21) shows the level of thehydraulic oil in the reservoir (see CheckingHydraulic Oil Level, paragraph 3.6.6.1).
CAUTION
Do not operate the equipment with a
level of hydraulic oil that is too low or
too high.
2.6.8 Hydraulic Oil Temperature Gauge
The temperature gauge on the side of thehydraulic oil reservoir (see figure 21) showsthe temperature of the hydraulic oil in the reser-voir. Do not operate the equipment with ahydraulic oil temperature that is too high (morethan 180F [82C]).
CAUTION
Do not operate the equipment with a
hydraulic oil temperature that is too
high (more than 180F [82C]).
Operating with the hydraulic oil
temperature too high can reduce the
life of hydraulic equipment parts.
2.6.9 Hydraulic Pressure Gauges
The gauges listed in table 22 show the operat-ing pressures of the corresponding hydraulicpumping circuits. The pressures are shown inpounds per square inch (psi).
CAUTION
Do not operate the equipment when a
gauge is reading outside of its normal
operating range as listed in table 22.
2.6.10 AIR PRESSURE Gauge
The AIR PRESSURE gauge (figure 22,item 11) shows the air pressure at the controlconsole of the crane air system. The pressureis shown in pounds per square inch (psi).
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-10
LABEL FUNCTIONMONITORED NORMAL OPERATING RANGEFIGURE AND
ITEM NUMBERSSWINGPRESSURE
Swing drive hydrau-lic pumping circuit 100 to 2700 psi (6.8206.8 bar) figure 22, item 7
MAIN/AUXPRESSURE
Main/auxiliary hoisthydraulic pumpingcircuit
Raising: up to 2900 psi (200.6 bar)figure 22, item 8
Lowering: 10002300 psi (68.9158.5 bar)BOOMPRESSURE
Boom hoist hydraulicpumping circuit
Raising: up to 2950 psi (203.4 bar) figure 22, item 9Lowering: 10002300 psi (68.9158.5 bar)
PILOTPRESSURE
Hydraulic systempilot pressure 475 psi (32.7 bar) figure 22, item 10
Table 22. Hydraulic Pressure Gauges
-
CAUTION
Do not operate the equipment when
the air pressure gauge is reading
outside of its normal operating range
of 120125 psi (8.38.6 bar).
2.7 Crane Function Control Devices
2.7.1 Swing Brake Pedal
The swing brake foot pedal (figure 22, item 3)located in front of the operators seat controlsthe 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 ofthe swing drive. As the pedal is pushed down,the brake has more holding power. Release thepedal upward to release the brake. As thepedal is released upward, the brake has lessholding power.
2.7.2 SWING BRAKE OFF/ON Control
The SWING BRAKE OFF/ON control(figure 22, item 13) controls the brake of theswing drive as a static (parking) brake (fullyengaged or fully released).
In the ON position, the brake of the swing driveis engaged. The crane cannot rotate (swing).
In the OFF position, the brake will releaseaccording to the position of the swing brakepedal (see paragraph 2.7.1). The brake canonly be released when the diesel engine isoperating.
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 belowered into a hole in the top of the pedestal tomechanically prevent the crane from rotating.The pin can be lowered at any of the 8 points45 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 pinto be lowered, move the handle of the SWINGLOCK OFF/ON control (figure 22, item 18) tothe ON position to lower the swing lock pin.
Move the handle to the OFF position to raisethe swing lock pin.
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-11
-
CAUTION
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.
2.7.4 BOOM/SWING Control
The BOOM/SWING control (figure 22, item 2)on the left armrest of the operators chaircontrols the
direction and speed of boom movement(boom function)
direction and speed of crane rotation (swingfunction)
The boom and swing functions are combined inone dual-axis control, permitting both functionsto be controlled at the same time with onecontrol lever (see figure 23). The BOOM/SWING control is a manually operated, propor-tional hydraulic valve for directional control. Thelever of the BOOM/SWING control, whenreleased, 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 towardthe operator to raise the boom. Push the leverforward away from the operator to lower theboom. The speed of the boom increases the
farther the lever is moved away from its neutral(center) position. To decrease the speed, movethe 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 thelever to its neutral position. The boom stopsand the boom hoist friction brake engages ifreleased.
The spring-engaged friction brake and one-way(overrunning) clutch on the hoist hold the hoistdrum from rotating in the lowering direction.This friction brake remains engaged duringboom raising, with the one-way clutch overrun-ning. The friction brake is automaticallyreleased during lowering, engaging again toserve as a parking brake after the hydraulicsystem counterbalance valve stops the boom.
The boom hoist has a ratchet and pawl assem-bly that provides an automatic lock to preventthe boom from lowering. The pawl automaticallydisengages when the boom hoist control leveris pushed forward to lower the boom.
If the boom will not lower, it may be necessaryto first raise the boom a small amount to
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-12
Figure 23. Boom/Swing Control
Swing
Left
Swing
Right
Lower
Boom
Raise
Boom
A1575
-
remove the load from the pawl, permitting thepawl to release. Then the boom can belowered.
WARNING
The boom hoist must have at least five
full wraps of wire rope on the drum at
all times.
NOTICE
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 theoperators left to rotate the crane left (counter-clockwise). Move the lever to the operatorsright to rotate the crane right (clockwise). Thespeed of rotation increases as the lever ismoved away from its neutral (center) position.To decrease the speed, move the lever towardits neutral position.
NOTICE
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 itsneutral position. Rotation will slowly come to astop due to friction in the swing system.
CAUTION
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 (figure22, item 5) on the right armrest of the opera-tors chair control the
rotation direction and speed of the mainhoist drum (direction and speed of the mainhook block)
rotation direction and speed of the auxiliaryhoist drum (direction and speed of theauxiliary hook)
The MAIN and AUXILIARY hoist controls arepart of a dual-lever, manually operated, propor-tional hydraulic valve for directional control. Thelevers of the MAIN and AUXILIARY hoistcontrols, when released, return to their neutral(center) positions. The left lever controls theauxiliary hoist drum, and the right lever controlsthe main hoist drum.
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-13
-
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.
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 hoistcontrol back toward the operator to raise theload on the corresponding hook. Push the leverforward away from the operator to lower theload on the corresponding hook. The speed ofthe load increases the farther the lever ismoved away from its neutral position. Todecrease the speed, move the lever toward itsneutral position.
NOTICE
The speed of the load can also be
controlled in combination with engine
speed (see paragraph 2.7.6).
To stop and hold the load, slowly return thelever to its neutral position. The load stops andthe hoist friction brake engages if released.
The spring-engaged friction brake and one-way(overrunning) clutch on the hoist hold the hoistdrum from rotating in the lowering direction.This friction brake remains engaged during loadraising, with the one-way clutch overrunning.The friction brake is automatically releasedduring lowering, engaging again to serve as aparking brake after the hydraulic system coun-terbalance valve stops the load.
WARNING
The main and auxiliary hoists must
have at least five full wraps of wire
rope on the drums at all times.
NOTICE
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 antitwo-block
system.
2.7.6 Swing and Hoist Speed Control
The swing and hoist speed can be controlled bydisplacing the controls and changing the dieselengine speed. Maximum speeds are obtainedby displacing the corresponding control themaximum distance and adjusting the enginespeed to its highest recommended speed.
Minimum speeds are attained by operating theengine at idle speed and displacing the corre-sponding control until the motion begins.
WARNING
Under certain loads the diesel engine
may stall at low engine speeds when
trying to operate crane functions.
The control valves provide precise metering ofthe hydraulic oil. This precise metering allowsfor precise speed control of the various cranefunctions.
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-14
-
2.8 Crane Operation
The crane operates by hydraulic power. Slowlymove the control levers by applying gradualpressure, even when returning a lever to itsneutral (center) position. Not following thisprocedure will result in over-control of the cranefunctions 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.
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 controlmalfunction 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 SWINGBRAKE OFF/ON control (figure 22,item 13) to the ON position to engage thestatic swing brake.
3. If practical, lower the suspended load usingthe emergency load lowering procedure(see paragraph 2.8.6).
API Recommended Practice 2D, Recom-mended Practice for Operation and Mainte-
nance of Offshore Cranes (API RP2D) (currentedition) is a useful guide for owners and opera-tors in developing operating and maintenancepractices and procedures. All guidelines in thisrecommended practice should be followed.
2.8.1 Pre-Starting Procedure
Before operating the crane, it is important tomake an inspection of the crane and to followall pre-starting procedures. The followinginspections are considered mandatory byNational Oilwell Varco. They make sure theequipment is in a safe operating condition.Other inspections can be required by localregulations and must also be made.
2.8.1.1 Daily Inspection
Do the following at the beginning of each work-day, before starting the crane.
1. Check the preventive maintenance recordsto make sure the scheduled lubrication (seeparagraph 3.2.2) and inspections and main-tenance (see paragraph 3.3) have beendone at the correct intervals.
2. Check the crane and pedestal foundationfor 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.
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-15
-
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 leakageor damage.
4. Check the hydraulic hoses for leaks, abra-sion, or advanced weathering that couldcause a hose to burst under operating pres-sure.
5. Check the gearboxes for leaks anddamage.
6. Check the boom hoist ratchet and pawl forwear and damage.
7. Check control mechanisms for correct oper-ation.
8. Check the diesel engine start and stopcontrols.
9. Check all the wire ropes, includingpendants, for deterioration or damage.
WARNING
Do not operate the crane with worn or
damaged wire rope.
10. Check that the wire rope is reevedcorrectly, operating freely, and spoolingcorrectly.
11. Check the crane hook and latch fordamaged, distorted, worn, cracked,corroded, loose, or missing parts andfasteners.
12. Check loose gear to be used (such asslings, sling hooks, and shackles) fordamaged, distorted, worn, cracked,corroded, loose, or missing parts andfasteners.
13. Make sure that all guards are in place andsecured.
14. Check the operation of the obstructionlights.
15. Check the crane load and radius indicatordisplay for correct operation.
2.8.1.2 Before Start-up
Do the following before each start-up of thecrane.
1. Check that the correct load rating chart forthe crane configuration in use is visible tothe crane operator at the control station(see Section 4, Load Rating Chart, drawing1585851).
2. Check that all tools and other items areaway from moving equipment parts.
3. Check that the crane and the operatingarea of the crane are free of all obstructionsand personnel. Not following this procedurecan result in damage to the crane or loadand injury to personnel.
4. Check that the static swing brake isengaged. The lever of the SWING BRAKEOFF/ON control (figure 22, item 13) mustbe in the ON position.
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-16
-
5. Check that the handle of the ENGINE KILLcontrol (item 17) (with black handle) ispushed all the way down.
6. Check that the handle of the EMERGENCYENGINE KILL control (item 26) (with redhandle) is pushed all the way down. If thehandle has been pulled, check that thereason for the emergency stop has beenfound and corrected, and that the air inletshutoff of the diesel engine has been resetto the open position (see Emergency StopProcedure, paragraph 2.8.5).
CAUTION
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 theirneutral (center) position. This will ensurethat the load and/or crane will not movewhen the diesel engine is started.
8. The crane can now be started (see para-graph 2.8.2).
2.8.2 Startup Procedure
1. Complete the pre-start procedure (para-graph 2.8.1).
2. Check that all the control levers are in theirneutral (center) position.
3. Put the diesel engine throttle control (seeparagraph 2.6.1) in the idle position.
4. Check the temperature of the hydraulic oil.Use the temperature gauge (see paragraph2.6.8) located on the side of the hydraulicoil reservoir (see figure 21).
If the hydraulic oil in the reservoir is 0F(17C) or warmer (ISO Grade 46hydraulic oil minimum start-up tempera-ture, see Hydraulic Oil, para-graph 3.6.2), continue with step 5.
If the hydraulic oil is colder, warm thehydraulic oil with the reservoir heateruntil the temperature is 0F (17C) orwarmer. 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
manufacturers 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 22,item 14) for 13 seconds or until the dieselengine starts. If the engine does not startafter several attempts, have the enginechecked by a qualified service technician.See the diesel engine manufacturers infor-mation for additional information on thediesel engine starting and operating proce-
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-17
-
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 gaugelocated on the side of the hydraulic oilreservoir.
If the hydraulic oil in the reservoir is55F (13C) or warmer (ISO Grade 46hydraulic oil minimum temperature forfull power operation, see Hydraulic Oil,paragraph 3.6.2), continue with step 8.
If the hydraulic oil is colder, continue tooperate with no load until the tempera-ture is 55F (13C) or warmer. Thencontinue with step 8.
8. Adjust the diesel engine throttle to thedesired engine speed (see para-graph 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 gaugesfor proper engine operation.
10. The crane is now ready for the pre-operat-ing checks (see paragraph 2.8.3).
2.8.3 Pre-Operating Checks (After
Engine Start-Up)
After the diesel engine has been started, thefollowing procedures must be done to makesure that the crane safety systems functioncorrectly.
2.8.3.1 AntiTwo-Block System
Antitwo-block systems are provided for themain and auxiliary hoists to prevent accidentalcontact of the main hook block and auxiliaryoverhaul ball with the boom point sheaves.
WARNING
Hook block and overhaul ball contact
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 antitwo-block safety valves are locatednear the boom tip, one for the main hook blockand one for the auxiliary overhaul ball. Thespool of each valve is normally held retracted(hydraulic circuit closed) by the downward forceon the lever arm of the suspendedantitwo-block weight (see Parts and VendorData Manual, Section 4, drawing 750577-L01[Main] and 750577-L02 [Auxiliary],AntiTwo-Block). If the hook block or overhaulball makes contact with the weight, relieving thedownward force on the lever arm, the spool ofthe antitwo-block valve extends (hydrauliccircuit opens), venting some hydraulic pilotpressure lines in the hydraulic system. Theboom stops if in a lowering motion and theboom hoist friction brake engages. The mainand auxiliary hoists stop if in a raising motionand the main and auxiliary hoist friction brakesremain engaged. The hydraulic systemprevents further boom lowering and further
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-18
-
main or auxiliary hoist raising. To return tonormal operation, lower the hook block or over-haul ball (or raise the boom), until both weightsare hanging freely.
To check the antitwo-block system:
CAUTION
Use extreme care when engaging the
antitwo-block system. Operate the
hoist slowly and stop the hoist before
the hook block contacts the boom
sheaves.
1. Slowly raise the main hook block into theantitwo-block weight. Use caution to makesure the hoist raising function stops afterthe weight is raised (approximately 34 in[810 cm] after contacting the weight). Stopthe hoist before the hook block contacts theboom sheaves if it does not stop automati-cally.
WARNING
If the main hoist does not stop or the
boom can be lowered after the
antitwo-block weight has been lifted,
shut down the crane and contact the
National Oilwell Varco Service
Department for instructions.
2. After the main hoist function stops, checkthat the boom lowering is inhibited by tryingto lower the boom. The boom must notlower.
3. Lower the load until the weight hangsfreely.
4. Repeat steps 1 through 3 for the auxiliaryhoist.
5. The crane is ready for the boom limitsystem check (see Boom Angle LimitSystem, paragraph 2.8.3.2).
NOTICE
The exposed surfaces of the valve
spools for the antitwo-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 antitwo-block system. If this
happens, the signalperson or a
deckhand must maintain a downward
load on the antitwo-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 toprevent the boom from being raised or loweredoutside of the normal operating range.
The limits are preset at the factory, but can beadjusted in the field. The boom limit should beset with no load on the boom. The boom upperlimit should be set at 78 degrees above hori-zontal and the boom lower limit should be set at10 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 atthe boom foot, one for the boom upper limit andone for the boom lower limit. The spool of each
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-19
-
valve is normally extended (hydraulic circuitclosed) (see Parts and Vendor Data Manual,Section 4, drawing 750663-L02, Boom LimitMechanics). If a cam on the boom makescontact with a valve spool, the spool retracts(hydraulic circuit opens), venting some hydrau-lic pressure lines in the hydraulic system. If theboom upper limit safety valve is actuated, theboom raising motion stops and the boom hoistfriction brake remains engaged. The hydraulicsystem prevents further boom raising. To returnto normal operation, lower the boom. If theboom lower limit safety valve is actuated, theboom stops and the boom hoist friction brakeengages. The hydraulic system prevents furtherboom lowering. To return to normal operation,raise the boom.
To check the boom limit system:
CAUTION
Use extreme care when engaging the
boom angle limit system. Operate the
boom hoist slowly and stop the hoist
before the boom contacts the
cushioned boom stops or any
obstruction.
1. Slowly raise the boom to the upper limitcam engagement. Use caution to makesure the boom raising function stops beforethe boom contacts the cushioned boomstops. Stop the boom before contacting theboom stops if it does not stop automatically.
WARNING
If the boom does not stop when the
boom angle limit safety valve contacts
the boom limit cam, shut down the
crane and contact the National Oilwell
Varco Service Department for
instructions.
2. After the boom stops, lower the boom awayfrom the boom stops and away from limitcam 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 camengagement. Use caution to make sure theboom does not strike any object on the plat-form or deck. Stop the boom before thisoccurs if it does not stop automatically.
4. After the boom stops, raise the boom awayfrom limit cam engagement.
5. The crane is ready for normal operation.
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.
3. Engage the swing lock (see para-graph 2.7.3).
4. Engage the static brake of the swing drive.Turn the lever of the SWING BRAKEOFF/ON control (figure 22, item 13) to theON position.
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-20
-
5. Raise or lower the boom to the desiredangle.
6. Raise or lower the main hook block andauxiliary hook to the desired height.
7. Put the diesel engine throttle control (seeparagraph 2.6.1) in the idle speed positionand let the engine operate for 45 minutesto cool down.
8. Pull the handle of the ENGINE KILL control(item 17) (with black handle) all the way upto stop the diesel engine.
9. Write down and report any corrective actionthat must be taken before operation isresumed.
2.8.5 Emergency Stop Procedure
1. Release all control levers to the neutralposition.
2. Pull the handle of the EMERGENCYENGINE KILL control (figure 22, item 16)(with red handle) all the way up to immedi-ately 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.
After the reason for the emergency stop hasbeen found and corrected, the air inlet shutoffof the diesel engine must be reset to the openposition. The air inlet shutoff is located on theengine air intake housing. The diesel enginemust be checked for damage (example:damage to seals from the suction created byblocking the air intake). See the diesel enginemanufacturers information for the procedure toreset the air intake shutoff (see Parts andVendor Data Manual, Section 11, Caterpillar).
2.8.6 Emergency Load Lowering
The crane is equipped with an emergency loadlowering kit that permits the operator to lower asuspended load in the event of a hydraulic ordiesel engine failure. A printed procedure isprovided in the kit, inside the operators caband in this manual.
Table 23 lists the emergency load loweringprocedures and kit drawing. See Section 3 ofthis manual for the drawings.
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-21
HOISTEMERGENCYLOWERING
PROCEDUREDRAWING
EMERGENCYLOWERING
KITDRAWING
Main603511 603457-L01
Auxiliary
Table 23. Emergency Load Lowering
Procedures and Kit Drawing
-
This page intentionally left blank.
www.nov.com
Document number 2710100-MAN-001Revision 01Page 2-22
-
3 MAINTENANCE
3.1 Introduction and General
Instructions
This section includes general maintenanceschedules and maintenance instructions for theequipment as outlined by the table of contents.At the end of this section are reference draw-ings.
API Recommended Practice 2D, Recom-mended Practice for Operation and Mainte-
nance of Offshore Cranes (API RP2D) (currentedition) is a useful guide for owners and opera-tors in developing operating and maintenancepractices and procedures. All guidelines in thisrecommended practice should be followed.
Maintenance must be done at regular intervals.Failure to do the necessary maintenance willresult in damage to the equipment parts. Thelubrication schedule (see paragraph 3.2.2) andthe inspection and maintenance schedule (seeparagraph 3.3) are guides for the correct main-tenance of the equipment.
Permit only qualified service personnel whohave received training in the proper mainte-nance, adjustment, and inspection of the equip-ment to do these procedures.
After making a repair or adjustment, alwayscheck the function of the equipment partsbefore putting the equipment into full operation.
Do not make modifications to the equipmentunless approved in writing by National OilwellVarco.
3.2 Lubrication
3.2.1 Lubrication Procedures
Do not operate the equipment without properlubrication. Lubricants that do not meet therequirements of the equipment or lubricants thathave deteriorated to a level of unacceptableservice must not be used, or must be replacedwith acceptable lubricants before operating theequipment.
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 lubri-cants because of possible incompatibility.
3.2.2 Lubrication Schedule
See the Lubrication Schedule (table 31) andthe Lubricant Legend (table 32) for the lubrica-tion schedule, lubrication points, types of lubri-cant, and fluid capacities.
Document number 2710100-MAN-001Revision 01Page 3-1
www.nov.com
-
Document number 2710100-MAN-001Revision 01Page 3-2
www.nov.com
INTERVAL OFLUBRICATION DESCRIPTION
TYPE OFLUBRICANT LUBRICATION LOCATION CAPACITY
REFERENCEPARAGRAPH
As required Wire ropes WRL Boom wire rope Main wire rope Auxiliary wire rope Pendants
As required 3.2.2.1
Seemanufacturersinformation
Diesel engineELO Diesel engine lubrication
oil26 qt(25 L)
3.2.2.2AF Diesel engine coolant(includes radiator)
11.0 gal(41.6 L)
Every 40 hoursof operation orweekly, which-ever occursfirst
Boom footbushings HPG Boom foot As required 3.2.2.3
Sheaves HPG Boom point sheaves andpendant anchors
A-Frame sheaves Bridle sheaves
As required 3.2.2.3
Hook blockand overhaulball
HPG Sheaves and hooks As required 3.2.2.3
Swing bearingHPG Swing bearing As required 3.2.2.3OGL Gear teeth As required 3.2.2.4
Swing drives OGL Pinion gears As required 3.2.2.4
Safety valves HO Two boom limit safetyvalves
Two antitwo-blocksafety valves
As required 3.2.2.5
Boom hoistHPG Ratchet and pawl As required
3.2.2.6HO Pawl cylinder rod andpins As required
Every 40 hoursof operation orevery threemonths, which-ever occursfirst
Hoists HHO
Boom hoist gearboxcheck level of lubricant As required 3.2.2.7
Main hoist gearboxcheck level of lubricant As required 3.2.2.7
Auxiliary hoist gearboxcheck level of lubricant As required 3.2.2.7
Swing drives GO Gearboxcheck level oflubricant As required 3.2.2.8
Table 31. Lubrication Schedule
-
3.2.2.1 Wire Ropes
Wire rope should be lubricated at regular inter-vals to guard against wire corrosion. When
corrosion is noticed, the wire rope should beclosely inspected for damage.
See Section 5, API Recommended Practice 2D,Recommended Practice for Operation and
Document number 2710100-MAN-001Revision 01Page 3-3
www.nov.com
INTERVAL OFLUBRICATION DESCRIPTION
TYPE OFLUBRICANT LUBRICATION LOCATION CAPACITY
REFERENCEPARAGRAPH
Every 500hours of opera-tion or everysix months,whicheveroccurs first
Hoists HHO
Boom hoist gearboxdrain and refill
70 pt(33.1 L) 3.2.2.7
Main hoist gearboxdrain and refill
90.0 pt(42.6 L) 3.2.2.7
Auxiliary hoist gearboxdrain and refill
17.0 pt(8.0 L) 3.2.2.7
Swing drives GO Gearboxdrain andrefill
12.75 pt(6.0 L)each
3.2.2.8
Every 12months ofoperation
Swing brakes
See Partsand Vendor
DataManual,
Section 11,MICO
Swing brakechecklevel and condition As required 3.2.2.9
Table 31. Lubrication Schedule (continued)
SYMBOL
NATIONALOILWELLVARCOPART
NUMBER
DESCRIPTION
AF 903062 Engine anti-freeze
ELO 939084 Engine lubrication oilSAE 15W-40 (See Parts and Vendor Data Manual,Section 11, Caterpillar)GO 939049 Gear oilSAE 90
HHO 939074 Hydraulic hoist gear oilindustrial EP gear oil, specifically Exxon SpartanEP150 as recommended by Braden HoistsHO 939064 Hydraulic oil ISO-46such as Shell Tellus 46
HPG 939048 High pressure greasemulti-purpose extreme pressure greaseOGL 939063 Open gear lubricantblack soda lead greaseWRL 939075 Wire rope lubricantblack viscous lubricant such as Texaco Crater A
Table 32. Lubricant Legend
-
Maintenance of Offshore Cranes (API RP2D)for the wire rope lubrication procedures.
3.2.2.2 Diesel Engine
See the diesel engine manufacturers informa-tion (see Parts and Vendor Data Manual,Section 11, Caterpillar) for the lubricationinstructions, intervals, and lubricant specifica-tions.
3.2.2.3 Grease Fittings
NOTICE
The warranties for the swing bearing
and crane will be void if the swing
bearing is not lubricated as specified.
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.
Use caution regarding the rate and pressure atwhich lubricant is forced into a bearing, to avoiddamaging the seal of the bearing, which cancause damage to the bearing.
When putting new or repaired bearings intoservice, add lubricant, rotate the bearing, andadd more lubricant until a small amount of lubri-cant begins to show from the bearing. This willmake sure that the bearing is completely lubri-cated.
At designated intervals, relubricate the bear-ings. When relubricating a bearing, add only a
measured amount of lubricant. Periodicover-lubrication is needed to r