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.


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.


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.


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.


www.nov.com


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


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


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


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.


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.


www.nov.com

2.3 Crane Nomenclature


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)


Boom Foot Pin

Hydraulic Oil

Heat Exchanger

Turntable

Diesel Fuel Tank

Wind Speed Sensor

Obstruction Light


Area Lighting


A-Frame Ladder

and Cage

Maintenance Crane


Auxiliary Hoist

Main Hoist

Boom Hoist

Diesel

Engine

Air

Reservoir

Boom Wire Rope

Swing

Bearing

Pedestal

Main Wire Rope

Auxiliary Wire Rope

A3266


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


Swing Drive

A-Frame

Front Elevation(boom not shown for clarity)

Auxiliary Hoist Load Sensor

Obstruction Light


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


www.nov.com


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.


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


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.


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.


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


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


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


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



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


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



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


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


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


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


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


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


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


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


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


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


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


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.


www.nov.com


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


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

Documents

NOV Crane Maintenance Manual