Gruas
Gruas
Gruas
Crane
2703100-MAN-001 2703100-MAN-001 01
www.nov.com
Operation and Maintenance Manual
AmClyde Unit Model 10000XHD Crane
Serial Number 2703100
Operation and Maintenance Manual
AmClyde Unit Model 10000XHD Crane
Serial Number 2703100
Operation and Maintenance Manual
AmClyde Unit Model 10000XHD Crane
Serial Number 2703100
Operation and Maintenance Manual
AmClyde Unit Model 10000XHD Crane
Serial Number 2703100
Document number 2703100-MAN-001
Revision 01
Page ii
REVISION HISTORY
CHANGE DESCRIPTION
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page iii
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
WARRANTY
1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.1 General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.2 Operating Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.3 Maintenance Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Operator Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5 Inclement Weather Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Crane Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Crane Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Control Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 General Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.1 Horn Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.2 Boom Angle Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.3 Load and Radius Indicator System . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.4 Window Wiper Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.5 Operator’s Cab Air Conditioning Controls . . . . . . . . . . . . . . . . . . 2-7
2.5.6 Area Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.7 Obstruction Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.8 PANEL LIGHTS Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.9 Boom Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.6 Power Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6.1 Diesel Engine Throttle Controls. . . . . . . . . . . . . . . . . . . . . . . . 2-8
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page iv
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page v
3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Introduction and General Instructions . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.1 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.2 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.2.1 Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2.2 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2.3 Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.4 Swing Gear and Pinions. . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.5 Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.6 Boom Hoist Pawl . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.7 Hoist Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.8 Swing Drive Gearboxes . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.1 As Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Before Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.3 After Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.4 Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.5 Every 8 Hours of Operation or Every Day . . . . . . . . . . . . . . . . . . 3-7
3.3.6 Every 40 Hours of Operation or Every Week . . . . . . . . . . . . . . . . . 3-8
3.3.7 First 100 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.8 Every 250 Hours of Operation or Every Three Months . . . . . . . . . . . . 3-8
3.3.9 Every 500 Hours of Operation or Every 6 Months . . . . . . . . . . . . . . 3-9
3.3.10 Every 12 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.4.1 Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.1 Air System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.2 Releasing Pressure from Air System . . . . . . . . . . . . . . . . . . . . 3-10
3.6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6.1 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-11
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page vi
3.6.1.1 Hydraulic Oil Sampling (National Oilwell Varco Drawing 604289) . 3-12
3.6.1.2 Hydraulic System Contamination Levels
(National Oilwell Varco Drawing 604289) . . . . . . . . . . . . . 3-15
3.6.2 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.3 Hydraulic Piping and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.4 O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.4.1 O-Ring Sizes for Bosses and Tube Fittings . . . . . . . . . . . . 3-18
3.6.4.2 Four-Bolt O-Ring Flange . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.5 Releasing Pressure from Hydraulic System . . . . . . . . . . . . . . . . . 3-20
3.6.6 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.6.1 Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . 3-20
3.6.6.2 Adding Hydraulic Oil to the Reservoir . . . . . . . . . . . . . . . 3-21
3.6.7 Draining and Filling Hydraulic System. . . . . . . . . . . . . . . . . . . . 3-21
3.6.7.1 Draining Hydraulic System . . . . . . . . . . . . . . . . . . . . . 3-22
3.6.7.2 Filling Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 3-23
3.6.8 Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.7 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.8 Non-Operational Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.8.1 Short-Term Storage—7 Days Up to 30 Days . . . . . . . . . . . . . . . . 3-24
3.8.2 Long-Term Storage—30 Days or More . . . . . . . . . . . . . . . . . . . 3-24
3.8.3 Removal from Long-Term Storage . . . . . . . . . . . . . . . . . . . . . 3-25
3.9 Welding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Emergency Load Lowering Procedure . . . . . . . . . . . . . . . . . . . . 603511 Rev. 3
Emergency Hoist Load Lowering Kit . . . . . . . . . . . . . . . . . . . 603457-L01 Rev. 9
4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Crane Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Hoist and Wire Rope Information . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Power Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.3 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page vii
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page viii
FOREWORD
This technical manual gives information for the recommended operation and maintenance of the equip -
ment. This technical manual is written for the original design application of the equipment. If the appli -
cation of the equipment changes, the operation and maintenance information and procedures could
change. This technical manual is not a substitute for comprehensive operator and maintenance train -
ing. Read and completely understand this technical manual, equipment functions, and equipment
safety features before operating or doing maintenance to the equipment.
If additional technical manuals are needed, they are available for an added cost.
The serial number of the equipment must be given with all communication for correct identifica-
tion of the equipment.
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 10000XHD crane, serial
number 2703100. The complete technical manual consists of the following volumes:
T2008-02.04
www.nov.com
WARRANTY
Products covered hereby are subject to the following warranty and no other: "The Manufacturer
warrants each new Product made by the Manufacturer to be free from defects in material and
workmanship, its obligation and liability under this Warranty being expressly limited to repairing
or, at the Manufacturer's option, replacing free of charge at its factory any part proving defective
under normal use and service within - twelve (12) - months or one thousand (1000) hours,
whichever comes first, after date the Product is first delivered to a user, provided written claim
hereunder is received by the Manufacturer within 15 days after expiration of said period. Parts
claimed to be defective and for which repair or replacement is desired shall, if requested by the
Manufacturer, be returned transportation prepaid to the Manufacturer's factory for inspection.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY
PARTICULAR PURPOSE, AND THE OBLIGATION AND LIABILITY OF THE MANUFACTURER
UNDER THIS WARRANTY SHALL NOT INCLUDE ANY TRANSPORTATION OR OTHER CHARGES
OR THE COST OF INSTALLATION OR ANY LIABILITY FOR LOSS OF PRODUCT TIME OR ANY
OTHER DIRECT, INDIRECT, OR CONSEQUENTIAL DAMAGES OR DELAY RESULTING FROM THE
DEFECT. Any operation beyond rated capacity or the improper use or application of the Product
or the substitution upon it of parts not approved by the Manufacturer or any alteration or repair by
others in such manner as, in the Manufacturer's judgement, to affect the Product materially and
adversely shall void this Warranty. No representative of the Manufacturer is authorized to change
this Warranty in any way, and no attempt, effort, or promise to repair Products of the Manufacturer
either by the Manufacturer or by any representative of Manufacturer at any time shall change or
extend this Warranty in any way. This Warranty covers only new and unused Products
manufactured by the Manufacturer. Products manufactured by others are covered only by such
warranties as are extended to the Manufacturer by its suppliers."
2/2003
Document number 2703100-MAN-001
Revision 01
Page 1-1
It is the responsibility of the owner and user of Any performance ratings and specifications for
this equipment to know the safety codes; insur- this equipment are valid only when the
ance requirements; and national, federal, equipment is used according to the manufac-
provincial, state, and local laws and regulations turer’s operating and maintenance procedures.
affecting all uses of the equipment. This techni- Read and understand the technical manuals
cal manual does not provide regulatory informa- provided with this equipment before operating
tion, because regulations are subject to change or doing maintenance to the equipment. Assis-
and different from location to location. tance is available from the National Oilwell
Varco Service Department.
It is the responsibility of the owner and user of
the equipment to obtain, read, and understand The operator must know all the main parts,
the current edition of API Recommended Prac- controls, and safety features of the equipment
tice 2D, Recommended Practice for Operation before operating it. The operator must know the
and Maintenance of Offshore Cranes (API RP correct operation and inspection procedures of
2D), a document from the American Petroleum the equipment before operating it.
Institute (API). The document is published by
API Publishing Services, 1220 L Street, N.W., The operator is responsible for the safe opera-
Washington, D.C. 20005. For more information tion of the equipment, including the safety of
call 202-862-8375 (phone) or 202-962-4776 others in the work area.
(fax), or visit the API website
(www.api.org/publications/).
1.2 Safety Signal Words
Not using the equipment according to these
regulations can result in damage to the equip- Throughout this technical manual are steps and
ment and death or injury to personnel. procedures that, if not followed, can result in a
National Oilwell Varco provides technical manu- hazard. The following signal words are used to
als for the different types of equipment that it identify the level of a hazard.
manufactures and sells. The owner and user
must use these technical manuals to give the !DANGER
correct information and training to the people
who will operate, maintain, or supervise the use • Danger is used to show a hazard that
of the equipment. WILL RESULT in death or serious
injury if not avoided.
This equipment is designed to do heavy-duty
work and will wear during normal use. There-
fore, the owner and user must establish a regu- !WARNING
larly scheduled inspection and maintenance • Warning is used to show a hazard or
program based on the information in the unsafe practice that CAN RESULT in
National Oilwell Varco technical manual. death or serious injury if not avoided.
Inspection and maintenance programs help
prevent accidents and keep the equipment
operating efficiently.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 1-2
National Oilwell Varco equipment, as designed, 6. Do not use torches or open flame on or
can be used safely; however, no equipment, near fuel system, hydraulic, and control
regardless of design, can prevent injury or equipment.
damage because of operator error or careless-
ness. 7. Adequate fire protection equipment must be
available and in satisfactory operating
This safety section includes information from condition. Operating and maintenance
many sources. It gives examples of basic safety personnel must be familiar with the use and
rules. Additional safety rules can be necessary care of the fire protection equipment.
for safe operation of the equipment. The infor-
mation in this section is not meant to replace
safety codes; insurance requirements; or 1.3.2 Operating Safety Rules
national, federal, provincial, state, and local
laws and regulations. 1. Do not operate this equipment under any
conditions or in any manner other than
those for which the equipment has been
specified, sold, and described in this techni-
cal manual.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 1-3
3. Do not operate this equipment if you are ill 11. Do not operate the equipment with any
or physically or mentally not fit to operate it personnel near the wire rope or moving
correctly and safely. equipment.
4. Do not exceed the rated load capacity of 12. Do not operate the equipment without the
the equipment (see Section 4, Load Rating safety guards installed.
Chart, drawings 831564 and 831563). Lift-
13. Do not bypass, disconnect, or ignore safety
ing loads greater than those shown on the
and warning devices of the equipment.
load rating chart or operation at positions
Safely shut down the equipment and inves-
not shown, or lifting when the boom is solid
tigate the problem. Correct the problem
against the boom stops, can cause struc-
before continuing operation.
tural failure or collapse of the boom or
crane and death or injury to personnel. 14. Do not operate the equipment after an
inspection reveals a safety hazard or if any
5. Do not rely on the load monitoring system equipment parts require maintenance or
when common sense judgment indicates replacement. Always look for equipment
an error. Do not use the load monitoring damage or abnormal functioning during
system as a weighing device after lifting the operation. If found, safely shut down the
load. equipment and correct the damage before
continuing operation.
6. Operate the equipment with no load at the
start of each workday to make sure all func- 15. Before rotating the crane, make sure that
tions work correctly. the crane tailswing as well as the swing
paths of the boom and load are free of
7. Test the brakes for correct operation when- obstructions and personnel. Not following
ever a load at or near the load rating for the this procedure can result in damage to the
boom angle used is to be handled. crane, the load, or other equipment or
structures, and death or injury to personnel.
8. The operator must watch the load at all 16. Operate the equipment at a slow speed
times. Do not operate the equipment if the when first learning.
operator’s vision is restricted. Some appli-
cations require a signal person. The signal 17. Check the load indicating display and all
person must be visible to the operator at all gauges often for normal operating condi-
times. The operator and the signal person tions. Shut down the equipment immedi-
must agree on the signals to be used ately if the display or gauges are out of the
before operating the equipment. normal operating ranges. Investigate and
correct the problem before continuing oper-
9. Communication must be maintained ation.
between all personnel involved in any oper- 18. When making a lift, the hook must be
ation. The operator must obey a signal to directly over the estimated center of gravity
stop from anyone in the area. The signal of the load before the load is attached to
person must give all other signals. the rigging. Do not attach capacity loads at
maximum outreach, because an outward
10. Do not permit personnel to get on or off the swing of the load, caused by vessel list or
equipment while it is operating. trim, or outward drift of the boom, can over-
load the crane.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 1-4
19. Loads must be safely rigged before lifting. 29. The operator must not leave the control
Do not overload slings. Slings must be station with a load suspended in the air.
attached to the throat of the hook. Do not
permit hook latches to support any part of 30. The hoists must have at least five full wraps
the load. Hook latches keep loose slings of wire rope on the drum at all times during
from coming off the hooks. operation.
20. When making a lift, the boom (hook) must 31. Do not permit the wire rope to wind wrong
be directly over the load, not the side of the on the hoist drum (see figure 1–1).
load. Side loading can cause structural fail-
ure or collapse of the boom or crane and
injury to personnel.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 1-5
4. The power plant must be stopped and cool 1.6 Safety Labels
before checking fluids.
Safety labels are located on the equipment in
5. Do not add fuel to the fuel tank while the prominent places to advise operating and main-
equipment is operating. When adding fuel, tenance personnel of hazards. The labels are
keep the nozzle in contact with the fuel tank reproduced here to improve recognition and
to prevent static electricity sparks. If thereby increase label effectiveness. Before
provided, connect the ground wire before operating or doing maintenance to the
adding fuel. NO SMOKING! Do not permit equipment, be sure you understand the mean-
open flames or sparking devices near the ing of these labels. Drawing 604888, Decal and
fuel filling area. Remove all spilled fuel Nameplate Installation (see Parts and Vendor
before starting the equipment. Add fuel to Data Manual, Section 2) shows the locations of
the fuel tank in a well-ventilated location all the National Oilwell Varco-supplied safety
only. labels. This drawing is a useful reference for
the inspection and maintenance of the safety
6. Do not make modifications to the equip- labels (see paragraph 3.3.8). Replace all
ment unless approved in writing by National damaged or missing safety labels.
Oilwell Varco.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 1-6
p/n 604287
p/n 603164
WARNING
Shut down the equipment before doing mainte-
Machinery must nance. Only qualified, trained maintenance
be completely personnel must do maintenance, adjustment, and
stopped before inspection procedures, following the procedures
outlined in the maintenance manual.
maintenance can
be done. Make
reference to
maintenance
manual for correct
procedures.
p/n 604283
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 1-7
WARNING
Shut down the equipment before doing mainte-
Only trained authorized personnel nance. Only qualified, trained maintenance person-
are to do maintenance or make nel must do maintenance, adjustment, and
adjustments to hydraulic, air and inspection procedures, following the procedures
electrical systems. See outlined in the maintenance manual.
Maintenance Manual for
instructions.
p/n 604284
DANGER
Do not access this area while the crane is
To prevent injury, operating. The equipment can start or stop without
warning. Not following this procedure can result in
do not walk or death or serious injury.
stand under crane
boom, hooks, or
load.
p/n 603187
OPENING/CLOSING
CAB WINDOWS
p/n 603762
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 1-8
WARNING
Exposed, moving equipment parts can cause seri-
ous injury or death. Keep hands, feet, and clothing
away from moving equipment parts while the equip-
ment is operating. Do not operate the equipment
without the safety guards installed.
p/n 604285
p/n 603698
WARNING
Only qualified, trained maintenance personnel must
do maintenance, adjustment, and inspection of the
electrical equipment. Each maintenance person
must install a lockout at each electric power area.
Electrical equipment must be maintained and oper-
ated according to applicable standards. Not follow-
ing this procedure can result in death or serious
injury.
Electric shock
hazard. Authorized
personnel only.
p/n 604788
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 1-9
WARNING
Electrical power is supplied to this equipment from
multiple sources. All sources of electrical power
This enclosure must be shut off before accessing the indicated
has more than equipment. Only qualified, trained maintenance
one source of personnel must do maintenance, adjustment, and
power. Disconnect inspection of the electrical equipment. Not following
all sources this procedure can result in death or serious injury.
before doing
maintenance.
p/n 604791
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 1-10
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-1
2 OPERATION
2.1 Introduction
!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
Document number 2703100-MAN-001
Revision 01
Page 2-2
Boom Wire
Rope
Area Lighting
(see paragraph
2.5.6) A-Frame
Platform
A-Frame Ladder
and Cage A-Frame
Main Hoist
Auxiliary Hoist
Boom Hoist (behind cab) Bridle
5
10
75
15
70
20
65
25
60
30
55
35
50
45
40
A3228
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-3
Horn (see
paragraph 2.5.1) Swing Drives
Front Elevation
Pendant (boom not shown for clarity)
Auxiliary Hoist
Load Sensor
Obstruction
Light (see
paragraph
2.5.7)
A3228
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-4
The controls of the operator’s control station (see figure 2–2) direct the functioning of the crane equip-
ment and show information important to the operation of the crane. Detailed descriptions of the opera-
tor’s controls are given in the following paragraphs as outlined by the table of contents. The control
descriptions are divided into three groups: general control devices, power control devices, and crane
function control devices.
ITEM
NUMBER DESCRIPTION
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-5
15
14
SWING PRESSURE
13 MAIN/AUX PRESSURE
12 16 17 18 19 20 21
BOOM PRESSURE
11
PILOT PRESSURE
10
AIR PRESSURE
5
10
75
15
70
20
65
25
60
30
55
35
50
45
40
9
8
ENGINE THROTTLE
SWING BRAKE
AIR STARTER
ON
7
O
F
F
LOWER LOWER
EMERGENCY ENGINE KILL
AUX MAIN
6
SWING LOCK
RAISE RAISE
ENGINE KILL
ON
5
O
F
F
BOOM LOWER
SWING RIGHT
SWING LEFT
COOLANT TEMPERATURE ENGINE TACHOMETER/
4 BOOM RAISE
PANEL LIGHTS
HOUR METER
3
FRONT WIPER
2
AUX HOIST RELEASE
1
OIL PRESSURE
UPPER WIPER
28 27 26 25 24 23 22
A3163
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-6
2.5 General Control Devices Leave the load and radius indicator system
continuously powered during crane operation.
2.5.1 Horn Control The information shown on the load and radius
indicator system display can be shown in metric
Push the horn control (figure 2–2, item 19) on or imperial units. Use the METRIC/IMPERIAL
the floor in front of the operator’s seat to sound switch located on the control panel for the load
the horn located on the operator’s cab (see and radius indicator system to select the
figure 2–1). The control is a manually engaged desired units. The control panel is located on
spring-released, foot-operated air valve. the inside back wall of the operator’s cab. See
the manufacturer’s information for the operating
instructions (see Parts and Vendor Data Man-
2.5.2 Boom Angle Indicator ual, Section 11, Aanderaa Data Instruments).
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-7
The FRONT WIPER (figure 2–2, item 24) and Red aircraft obstruction lights (see figure 2–1)
UPPER WIPER control (item 26) control the are located at the tip of the boom, and on the
corresponding window wiper of the operator’s top of the A-frame. The lights are controlled by
cab. Each WIPER control is a two-position circuit breaker CB0247 located in circuit
switch. breaker panel CBP0207, inside the operator’s
cab.
In the PARK position, the wiper returns to its
parking position and stops.
2.5.8 PANEL LIGHTS Switch
In the RUN position, the wiper operates.
The PANEL LIGHTS switch (figure 2-2, item 23)
Push the knob of the washer control (item 25) controls the illumination of the gauges on the
to spray washer fluid on the windows. The gauge control panel.
reservoir for the washer fluid is located on the
exterior rear corner of the operator’s cab. In the “on” position, the gauges are illuminated.
The controls for the operator’s cab air condi- 2.5.9 Boom Stops
tioning unit are located on the control panel of
the unit on the ceiling of the operator’s cab (see The crane has cushioned boom stops (see
figure 2–1). See the manufacturer’s information figure 2–1) to retard the backward motion of the
for the operating instructions (see Parts and boom as the boom nears high boom angles.
Vendor Data Manual, Section 11, RVP).
When a load is lifted, the boom suspension
system stretches, causing the boom angle to
2.5.6 Area Lighting decrease and the load radius to increase. The
crane operator should compensate for this by
Two 400W flood lights (see figure 2–1) are raising the boom a small amount as the load is
located on the boom. The lights are controlled lifted.
by a switch located inside the operator’s cab.
When the load is set down, the boom suspen-
One 400W light is located over the machinery sion system will contract, causing the boom
area. The light is controlled by a switch located angle to increase a small amount and the load
inside the operator’s cab. radius to decrease.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-8
2.6 Power Control Devices The EMERGENCY ENGINE KILL control (with
red handle) (figure 2–2, item 6) is used for
emergency stopping of the diesel engine.
2.6.1 Diesel Engine Throttle Controls
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-9
Pull the handle of the EMERGENCY ENGINE 2.6.5 Diesel Fuel Level Gauge
KILL control all the way up to immediately stop
the diesel engine. This closes the engine air The gauge on the top of the diesel fuel tank
inlet shutoff. After the emergency stop, the air (see figure 2–1) shows the level of diesel fuel
inlet shutoff must be reset to the open position remaining in the diesel fuel tank.
and the engine must be checked for damage.
The air inlet shutoff is located on the engine air
intake housing. See the diesel engine manufac- 2.6.6 AIR STARTER Control
turer’s information for the procedure to reset the
air inlet shutoff (see Parts and Vendor Data The AIR STARTER control (figure 2–2, item 7)
Manual, Section 11, Caterpillar). controls the air starter motor for the diesel
engine. The control is a manually engaged,
CAUTION spring-released air valve.
• Only use the EMERGENCY ENGINE Push and hold the AIR STARTER control to
KILL control for an emergency. Use of start the diesel engine.
the EMERGENCY ENGINE KILL control
can cause damage to the diesel
engine. 2.6.7 Hydraulic Oil Level Gauge
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-10
• Do not operate the equipment with a The AIR PRESSURE gauge (figure 2–2,
hydraulic oil temperature that is too item 11) shows the air pressure at the control
high (more than 180°F [82°C]). console of the crane air system. The pressure
Operating with the hydraulic oil is shown in pounds per square inch (psi).
temperature too high can reduce the
life of hydraulic equipment parts. CAUTION
• Do not operate the equipment when
the AIR PRESSURE gauge is reading
2.6.9 Hydraulic Pressure Gauges outside of its normal operating range
of 120–125 psi (8.3–8.6 bar).
The gauges listed in table 2–2 show the operat-
ing pressures of the corresponding hydraulic
pumping circuits. The pressures are shown in
pounds per square inch (psi).
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-11
2.7 Crane Function Control Devices only be released when the diesel engine is
operating.
CAUTION
• Normal crane operation does not 2.7.3 SWING LOCK OFF/ON Control
require use of the swing brake pedal to
stop crane rotation. To stop rotation, The swing lock consists of a pin that can be
put the lever of the SWING control lowered into a hole in the top of the pedestal to
(paragraph 2.7.4) in its neutral (center) mechanically prevent the crane from rotating.
position. Rotation will slowly come to
a stop due to friction in the swing The pin can be lowered at any of the 8 points
system. The swing brake pedal is 45 degrees apart in the rotation of the crane.
provided to temporarily engage the The pin is actuated by a hydraulic cylinder.
swing brake without using the SWING
BRAKE OFF/ON control. When the crane is in position to permit the pin
to be lowered, move the handle of the SWING
Push the pedal down to engage the brake of LOCK OFF/ON control (figure 2–2, item 4) to
the swing drive. As the pedal is pushed down, the ON position to lower the swing lock pin.
the brake has more holding power. Release the
pedal upward to release the brake. As the Move the handle to the OFF position to raise
pedal is released upward, the brake has less the swing lock pin.
holding power.
CAUTION
2.7.2 SWING BRAKE OFF/ON Control • The crane may need to be rotated a
small amount for the pin of the swing
The SWING BRAKE OFF/ON control lock to align with the hole in the top of
(figure 2–2, item 9) controls the brake of the the pedestal. This should be done at a
swing drive as a static (parking) brake (fully slow speed. Fully stop the rotation of
engaged or fully released). the crane using the SWING control
before engaging the swing lock. Not
In the ON position, the brake of the swing drive following this procedure can cause
is engaged. The crane cannot rotate (swing). damage to the equipment.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-12
2.7.4 BOOM/SWING Control operator to lower the boom. The speed of the
boom increases as the lever is moved away
The BOOM/SWING control (figure 2–2, item 18) from its neutral (center) position. To decrease
on the left armrest of the operator’s seat the speed, move the lever toward its neutral
controls the position.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-13
NOTICE CAUTION
• The control system protects against • Do not use the SWING BRAKE OFF/ON
raising or lowering the boom beyond control (see paragraph 2.7.2) to stop
its operating limit. See paragraph crane rotation.
2.8.3.2 for a description of the boom
angle limit system.
2.7.5 MAIN and AUXILIARY Hoist
Controls
2.7.4.2 Swing Control
The MAIN and AUXILIARY hoist controls (figure
2–2, item 21) on the right armrest of the opera-
NOTICE tor’s seat control the
• Before rotating the crane, the SWING
BRAKE OFF/ON control (see • rotation direction and speed of the main
paragraph 2.7.2) must be in the OFF hoist drum (direction and speed of the main
position and the dynamic swing brake hook block)
pedal (see paragraph 2.7.1) must be • rotation direction and speed of the auxiliary
fully released. hoist drum (direction and speed of the
auxiliary hook)
CAUTION The MAIN and AUXILIARY hoist controls are a
• Move the SWING control lever slowly, dual-lever, manually operated, proportional
to prevent abrupt changes in the hydraulic valve for directional control. The
speed of crane rotation and minimize levers of the MAIN and AUXILIARY hoist
the side-loading forces on the boom. controls, when released, return to their neutral
(center) position. The left lever controls the
Move the lever of the SWING control (figure auxiliary hoist drum, and the right lever controls
2–2, item 18) to the operator’s left to rotate the the main hoist drum.
crane left (counterclockwise). Move the lever to
the operator’s right to rotate the crane right
!WARNING
(clockwise). The speed of rotation increases as
the lever is moved away from its neutral • Before lifting a load, always put the
(center) position. To decrease the speed, move SWING BRAKE OFF/ON control (see
the lever toward its neutral position. paragraph 2.7.2) in the OFF position
and release the swing brake pedal (see
paragraph 2.7.1) to permit the crane
NOTICE boom to center over the load.
• The speed of rotation can also be
controlled in combination with engine
speed (see paragraph 2.7.6). CAUTION
• Move the MAIN and AUXILIARY hoist
To stop rotation, slowly return the lever to its control levers slowly, to prevent
neutral position. Rotation will slowly come to a abrupt changes in the speed of the
stop due to friction in the swing system. load.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-14
Pull the lever of the MAIN or AUXILIARY hoist 2.7.6 Swing and Hoist Speed Control
control back toward the operator to raise the
load on the corresponding hook. Push the lever The swing and hoist speed can be controlled by
forward away from the operator to lower the displacing the controls and changing the diesel
load on the corresponding hook. The speed of engine speed. Maximum speeds are obtained
the load increases as the lever is moved away by displacing the corresponding control the
from its neutral position. To decrease the maximum distance and adjusting the engine
speed, move the lever toward its neutral posi- speed to its highest recommended speed.
tion.
Minimum speeds are attained by operating the
engine at idle speed and displacing the corre-
NOTICE sponding control until the motion begins.
• The speed of the load can also be
controlled in combination with engine
speed (see paragraph 2.7.6). !WARNING
• Under certain loads the diesel engine
To stop and hold the load, slowly return the may stall at low engine speeds when
lever to its neutral position. The load stops and trying to operate crane functions.
the hoist friction brake engages if released.
The control valves provide precise metering of
The spring-engaged friction brake and one-way the hydraulic oil. This precise metering allows
(overrunning) clutch on the hoist hold the hoist for precise speed control of the various crane
drum from rotating in the lowering direction. functions.
This friction brake remains engaged during load
raising, with the one-way clutch overrunning.
The friction brake is automatically released
during lowering, engaging again to serve as a
parking brake after the hydraulic system 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 anti–two-block
system.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-15
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-16
!DANGER !WARNING
• Do not operate the crane with a • Do not operate the crane with worn or
damaged boom or if any portion of the damaged wire rope.
boom has been repaired by a company
other than National Oilwell Varco. 10. Check that the wire rope is reeved
correctly, operating freely, and spooling
correctly.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-17
11. Check the crane hook and latch for 6. Check that the handle of the EMERGENCY
damaged, distorted, worn, cracked, ENGINE KILL control (with red handle)
corroded, loose, or missing parts and (item 6) is pushed all the way down. If the
fasteners. handle has been pulled, check that the
reason for the emergency stop has been
12. Check loose gear to be used (such as found and corrected, and that the air inlet
slings, sling hooks, and shackles) for shutoff of the diesel engine has been reset
damaged, distorted, worn, cracked, to the open position (see Emergency Stop
corroded, loose, or missing parts and Procedure, paragraph 2.8.5).
fasteners.
13. Make sure that all guards are in place and !CAUTION
secured. • The control levers must be in the
neutral (center) position to prevent
14. Check the operation of the obstruction sudden movements when the diesel
lights. engine is started.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-18
• If the hydraulic oil is colder, warm the 9. Check the cab-mounted instrument gauges
hydraulic oil with a reservoir heater until for proper engine operation.
the temperature is 0°F (–17°C) or
warmer. Then continue with step 5. 10. Check that the configuration of the crane
load and radius indicator system (see para-
5. Push the AIR STARTER control (figure 2–2, graph 2.5.3) corresponds to the crane
item 7) for 1–3 seconds or until the diesel configuration in use. Check the crane load
engine starts. If the engine does not start and radius indicator system for correct
after several attempts, have the engine operation (see Parts and Vendor Data
checked by a qualified service technician. Manual, Section 11, Aanderaa Data Instru-
See the diesel engine manufacturer’s infor- ments).
mation for additional information on the
diesel engine starting and operating proce-
dures (see Parts and Vendor Data Manual, !WARNING
Section 11, Caterpillar). • The main hook of the crane can be
reeved with either 4 parts of line or
6. Operate the diesel engine at “idle”. with 6 parts of line. Before handling a
load, check that the load and radius
7. Check the temperature of the hydraulic oil. indicator system (see paragraph 2.5.3)
Use the temperature gauge located on the is configured to correspond to the
side of the hydraulic oil reservoir. crane configuration in use (correct
number of falls, correct load curve).
• If the hydraulic oil in the reservoir is Not following this procedure can give
55°F (13°C) or warmer (ISO Grade 46 inaccurate load capacity readings and
hydraulic oil minimum temperature for prevent overload warnings from
full power operation, see Hydraulic Oil, operating. This can result in damage to
paragraph 3.6.2), continue with step 8. the crane, the load, or other equipment
• If the hydraulic oil is colder, continue to or structures, and death or injury to
operate with no load until the tempera- personnel.
ture is 55°F (13°C) or warmer. Then
continue with step 8. 11. The crane is now ready for the pre-operat-
ing checks (see paragraph 2.8.3).
8. Adjust the diesel engine throttle to the
desired 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 2200 rpm.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-19
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-20
CAUTION
2.8.3.2 Boom Angle Limit System
• Use extreme care when engaging the
A boom angle limit system is provided to boom angle limit system. Operate the
prevent the boom from being raised or lowered boom hoist slowly and stop the hoist
outside of the normal operating range. before the boom contacts the
cushioned boom stops or any
The limits are preset at the factory, but can be obstruction.
adjusted in the field. The boom limit should be
set with no load on the boom. The boom upper 1. Slowly raise the boom to the upper limit
limit should be set at 78 degrees above hori- cam engagement. Use caution to make
zontal. The boom lower limit should be set at 10 sure the boom raising function stops before
degrees below horizontal. the boom contacts the cushioned boom
stops. Stop the boom before contacting the
boom stops if it does not stop automatically.
!WARNING
• Do not activate the boom angle limit
!WARNING
system with the boom moving at high
speed. The boom will quickly stop, • If the boom does not stop when the
causing the load to swing boom angle limit safety valve contacts
uncontrollably and the boom to the boom limit cam, shut down the
bounce violently. crane and contact the National Oilwell
Varco Service Department for
The boom angle safety valves are located at instructions.
the boom foot, one for the boom upper limit and
one for the boom lower limit. The spool of each
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-21
2. After the boom stops, lower the boom away 2.8.4 Shutdown Procedure
from the boom stops and away from limit
cam engagement. 1. Remove the load from the crane.
4. After the boom stops, raise the boom away 8. Pull the handle of the ENGINE KILL control
from limit cam engagement. (with black handle) (item 5) all the way up
to stop the diesel engine.
5. The crane is ready for normal operation.
9. Write down and report any corrective action
that must be taken before operation is
NOTICE resumed.
• 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.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-22
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-23
EMERGENCY EMERGENCY
LOWERING LOWERING
HOIST
PROCEDURE KIT
DRAWING DRAWING
Main
603511 603457-L01
Auxiliary
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 2-24
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-1
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-2
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-3
Wire rope should be lubricated at regular inter- See the diesel engine manufacturer’s informa-
vals to guard against wire corrosion. When tion (see Parts and Vendor Data Manual,
corrosion is noticed, the wire rope should be Section 11, Caterpillar) for the lubrication
closely inspected for damage. instructions, intervals, and lubricant specifica-
tions.
See Section 5, API Recommended Practice 2D,
Recommended Practice for Operation and
Maintenance of Offshore Cranes (API RP2D)
for the wire rope lubrication procedures.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-4
NOTICE NOTICE
• The warranties for the swing bearing • The warranties for the swing bearing
and crane will be void if the swing and crane will be void if the swing gear
bearing is not lubricated as specified. and pinions are not lubricated as
specified.
CAUTION
Wipe the swing gear and pinion clean and
• Clean the work area and lubrication
apply lubricant liberally to all machined surfaces
fittings before and after adding the
of both the swing gear and pinion.
lubricant. Remove any extra lubricant
that has been forced through a
bearing. When the equipment is
operated, extra lubricant will work its 3.2.2.5 Safety Valves
way out of the bearing. This lubricant
must be removed. Clean the exposed surfaces of the valve spools
for the boom limit and anti–two-block safety
valves and apply a light oil to prevent corrosion.
Use caution regarding the rate and pressure at
which lubricant is forced into a bearing, to avoid
damaging the seal of the bearing, which can
3.2.2.6 Boom Hoist Pawl
cause damage to the bearing.
Check the entire drum ratchet surface and pawl
When putting new or repaired bearings into
of the boom hoist for a full coverage of lubri-
service, add lubricant, rotate the bearing, and
cant. Apply lubricant as needed. Clean the
add more lubricant until a small amount of lubri-
exposed surfaces of the pawl cylinder rod and
cant begins to show from the bearing. This will
apply a light oil to prevent corrosion. Apply a
make sure that the bearing is completely lubri-
light oil to the pawl cylinder pivot pins.
cated.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-5
NOTICE
• Other inspections can be required by
local regulations and must also be
made.
3.3.1 As Necessary
Diesel Engine
Paint
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-6
• Check the hydraulic oil reservoir for the Hydraulic Oil Filters
correct oil level (see paragraph 3.6.6.1).
• Check for leaks. • With the hydraulic oil at normal operating
• Check the hoses and piping for damage. temperature and the engine operating at
• Check the hoses for abrasion or advanced 2200 rpm, check the filter indicators (see
weathering that could cause a hose to burst Hydraulic Oil Filters, paragraph 3.6.8). If the
under operating pressure. indicator is activated, replace the filter
element.
Fuel System
Crane
• Check the diesel fuel tank for the correct
fuel level. • Check control mechanisms for correct
• Check for leaks. operation.
• Check the hoses and piping for damage. • Check the diesel engine start, stop, and
emergency stop controls.
Air System • Check the crane load and radius indicator
system for correct operation (see Parts and
• Check for leaks. Vendor Data Manual, Section 11, Aanderaa
• Check the hoses and piping for damage. Data Instruments).
Electrical System
3.3.4 Before Each Use
• Check the general condition of the wiring
for deterioration, cracked or frayed insula- Wire Ropes
tion, and loose connections.
• Check for damaged, corroded, loose, or • Inspections must be made by competent,
missing parts and fasteners. experienced personnel who know the oper-
ation of the wire rope. They must have
Gearboxes previous experience with wire rope in order
to make a correct and safe judgment of the
• Check for leaks and damage. wire rope. See Section 5, API Recom-
mended Practice 2D, Recommended Prac-
Boom Hoist tice for Operation and Maintenance of
Offshore Cranes (API RP2D) for the wire
• Check the boom hoist ratchet and pawl for rope inspection procedure.
wear and damage. • To establish the correct time for replace-
ment of the wire rope, keep dated and
Operator Controls detailed records, and review them at each
inspection. This will give a comparison of
• Check that the correct load rating chart for the changes in the wire rope and will be a
the crane configuration in use is visible to good aid in determining when to replace
the crane operator at the control station. the wire rope.
• Check the control labels. Replace all
damaged or missing labels.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-7
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-8
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-9
• Analyze for cleanliness, viscosity, proper • A qualified Braden hoist service technician
additives, and water content (see para- must disassemble and inspect all compo-
graph 3.6.1.1). nents per API Recommended Practice 2D,
Recommended Practice for Operation and
Hydraulic Oil Return Filters Maintenance of Offshore Cranes (API
RP2D) and Braden hoist recommended
• Replace the filter elements (see paragraph procedures. The hoist must be reassem-
3.6.8). bled and tested to Braden recommenda-
tions and standards (see Section 5, API
Hoists RP2D and Parts and Vendor Data Manual,
Section 11, Braden).
• Drain and refill the lubricant (see para-
graph 3.2.2.7). Swing Bearing
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-10
Electric power for the crane is supplied from the Release pressure from the air system (see
vessel at 460 VAC. The electric power is paragraph 3.5.2) before doing maintenance to
converted by a transformer to 208–120 VAC for the air system equipment. Residual pressure
use by the electrical system. The 120 VAC can remain in the air piping. Use caution when
electric power is also converted by a power removing any piping or hose. Accidentally
supply to 24 VDC for use by control system releasing air at high pressure can cause injury
equipment. to you and others, and can damage the equip-
ment.
The electrical schematic shows the relationship
of the electrical system equipment. See Parts Regular inspection and maintenance of the air
and Vendor Data Manual, Section 10, Electrical system is necessary for reliable performance of
Schematic, drawing 751753. the equipment. A good preventive maintenance
program will help prevent condensation and air
system failures.
3.4.1 Electrical System Maintenance
Cleanliness is very important in the operation
Use caution when doing maintenance on or and maintenance of the air system. No dirt or
near the electrical system equipment. Before abrasive particles can be permitted to enter the
working on the electrical system, a lockout must system.
be installed by each maintenance person at
each electric power source following indus- Some contaminants enter the system when it is
try-standard lockout procedures. Electrical opened. Do everything you can to keep the
equipment must be maintained and operated system as clean as possible. Clean the work
according to applicable standards. area and tools before opening any part of the
system. Install caps on all open air piping and
Clean the work area before installing or remov- hoses. Install plugs in all open air ports. Do not
ing electric wires from the equipment. When leave the air system open to dust and other
removing electric wires, check that the wires airborne particles. Do not accept replacement
are correctly labeled and install caps on all the parts that are not in their original protective
connectors to prevent corrosion. packages. Wash parts according to the manu-
facturer’s instructions and permit them to dry
before assembly.
3.5 Air System
Compressed air for the crane is supplied from 3.5.2 Releasing Pressure from Air
the vessel at 120–125 psi (8.3–8.6 bar) to a System
reservoir located on the crane. The air system
controls and operates the diesel engine air 1. Shut down the crane (see paragraph 2.8.4).
starter and the operator’s cab window wipers
and horn. 2. Release pressure from the air system until
the AIR PRESSURE gauge (see paragraph
The air piping drawings show the relationship of 2.6.10) in the operator’s cab reads 0 psi.
the air system equipment (see Parts and
Vendor Data Manual, Section 9).
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-11
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-12
3.6.1.1 Hydraulic Oil Sampling (National I. Remove the sample bottle with the
Oilwell Varco Drawing 604289) sampling valve still in the “open” posi-
tion. Put the cover on the sample bottle
Do a hydraulic oil analysis every 500 hours of and close the sampling valve.
operation or every six months, whichever
occurs first. J. Properly dispose of the hydraulic oil
collected in the waste container.
1. To take a sample of hydraulic oil:
K. Check the level of hydraulic oil in the
A. Install a hydraulic oil sampling valve reservoir and add hydraulic oil as
(supplied by others) in the hydraulic necessary (see paragraph 3.6.6).
return circuit at an elbow or in a place
where the flow is turbulent during L. Record and submit the following infor-
normal operation. The sampling valve mation with the sample:
must be sized to permit a flow rate • model number
through the valve of 30 ft/sec • serial number
(9.1 m/sec). • hours of operation on the system
• hours of operation on the hydraulic oil
B. A sampling bottle that has been • sample date
cleaned to a known cleanliness level • oil temperature
and then capped is needed. • sample location
• name of person taking sample
C. A container to catch up to 1 gal (3.8 L) • sample appearance: clean, cloudy,
of waste hydraulic oil is needed. milky, visible particles
• reason for sample
D. The hydraulic system must be at oper- • additional comments
ating temperature and maximum • hydraulic oil type
speed, if possible.
2. Send the hydraulic oil sample and the
E. Clean the nozzle of the hydraulic oil recorded data to a laboratory for a particle
sampling valve with a clean, lint-free count analysis. The analysis results must
cloth to remove any visual signs of be reported by the laboratory on a form
contamination. similar to figure 3–1. The actual cleanliness
level must be plotted on a graph and a
curve made by connecting the points.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-13
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-14
7 9
10 10
30
5.0 5
29 ISO 4
3
CODING METHOD
2.5
28 SOLID 2
STRAIGHT LINE DATA
10
6
1.3
27
CONTAMINANT 10
8
6.4 CODE 5
CODE: 18/16
26 4
3.2 3
Reference 18
25 ANSI/B93.30-1980 2
8.0
23 5
4.0 4
22 3
2.0 2
21
4 6
10 1.0 10
20
5.0 5
RANGE NUMBER - quote at 5 um & 8 um levels only
4
19 3 5 15 25 100
2.5
2 27
18 CURVED
3
1.3 5
5 / 15 / 25 /100
10 10 DATA
17
6.4 (USE 5 /15 POINTS)
5
16 4 23
3.2
CODE: 27/23
3
15 2
1.6
10
2 14 10
4
8.0
13 5
4.0 4
3
12
2.0 2
11
3
10 1.0 10
10
5.0 5 5 15 25 100
4
9 3
2.5
2
8
1.3 A1534
2
1 10
7
6.4
6 5
4
3.2 3
5 2
1.6
10
-1 4 10
8.0
3 5
4.0 4
2 3
2.0 2
1
-2
10
1 5 10 15 20 25 30 40 50 60 70 80 90 100
Figure 3–1. Particle Count Analysis Form
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-15
Table 3–3 shows the maximum permitted hydraulic system contamination levels. The water content of
the hydraulic system must be less than 0.03% by volume.
(A) Maximum Commissioning Level: This is the maximum contamination level permitted for accepting
new and rebuilt hydraulic systems into service. Do not operate the hydraulic system in excess of
this contamination level. The commissioning level is the contamination level at which the equip-
ment can be operated to circulate the system hydraulic oil until the maximum operating contamina-
tion levels are reached. This circulation of hydraulic oil must be done at no load and maximum
hydraulic oil flow.
(B) Maximum Operating Level: This is the maximum operating contamination level permitted. Operate
the hydraulic system at low pressure until a contamination level below this is reached using the
standard filter system.
(C) Table 3–4 compares similar obsolete SAE and NAS Cleanliness Standards to the present ISO
Standards:
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-16
3.6.2 Hydraulic Oil must be filtered. Send the hydraulic oil through
a 3-micron filter with no bypass while adding it
to the hydraulic oil reservoir.
CAUTION
• Do not mix different types and brands Use a premium quality, high viscosity index
of hydraulic oil unless they are (V.I.), anti-wear, petroleum-based hydraulic oil
compatible. Mixing different types and compatible with Buna N and Viton A seals for
brands can cause a chemical reaction use in high pressure hydraulic systems
which can cause damage to the (3000 psi [207 bar]). Choose an ISO grade that
hydraulic equipment parts. corresponds well to climactic conditions based
• Hydraulic oil containers that are not on the characteristics listed in table 3–5. Origi-
stored correctly can collect water in nal fill of the hydraulic system was Shell Tellus
the bottom of the container. Hydraulic 46 (National Oilwell Varco p/n 939064). If you
oil that is water-contaminated has a have a question about a hydraulic oil, contact
cloudy visual appearance and must the National Oilwell Varco Service Department.
not be added to the hydraulic system.
Analyze the hydraulic oil (see para-
Filter all hydraulic oil to comply with the maxi- graph 3.6.1.1) for cleanliness, viscosity, proper
mum contamination levels permitted (see para- additives, and water content every 500 hours of
graph 3.6.1.2) before adding it to the hydraulic operation or every six months, whichever
reservoir. Even new oil from a new container occurs first.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-17
CAUTION
• Flush all new hydraulic piping, hoses,
and other equipment parts to meet the
requirements of Hydraulic System
Contamination Levels (see paragraph
3.6.1.2).
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-18
NOTICE
• O-rings listed in table 3–6 must be 90 durometer Buna N material.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-19
5. Install one-half of the split flange loose. Figure 3–2. Four-Bolt O-Ring Flange
Installation
6. Install the piping or hose in the split flange.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-20
NOTICE
• O-rings listed in table 3–7 must be 90 durometer Buna N material except where noted.
!WARNING CAUTION
• Residual pressure can remain in the • Do not operate the equipment with a
hydraulic piping. Read and understand level of hydraulic oil that is too low or
the hydraulic schematic to identify too high.
possible areas of residual pressure in
the hydraulic system. Use caution
when removing any hydraulic piping or
hose. Accidentally releasing hydraulic
oil at high pressure can cause injury to
you and others, and can cause
damage to the equipment.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-21
3.6.6.2 Adding Hydraulic Oil to the 3.6.7 Draining and Filling Hydraulic
Reservoir System
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-22
3.6.7.1 Draining Hydraulic System 5. Flush clean all hydraulic piping, hoses, and
other equipment parts to meet the require-
1. If possible, operate the corresponding ments of Hydraulic System Contamination
equipment using all operations until the Levels, paragraph 3.6.1.2.
hydraulic oil is warmed to normal operating
temperature. 6. Disassemble the hydraulic oil filters. Clean
the filter housings to remove any visual
signs of contamination. Install new filter
CAUTION elements and assemble the filters.
• Clean the work area before doing
maintenance to the hydraulic system. 7. Flush the inside of the hydraulic oil reser-
Keep all the parts clean (see Hydraulic voir to remove any visual signs of contami-
System Maintenance, paragraph 3.6.1). nation. Clean or replace the strainers.
2. Release pressure from the hydraulic 8. Check all the O-rings, hoses, and wearing
system (see paragraph 3.6.5). parts before assembly. Replace with new
parts if any show signs of wear or damage.
3. Put tags on all the hydraulic piping and All the valves, pumps, etc., must not be
hoses for reassembly purposes. sticking or binding because of hydraulic oil
contamination. If a part does not move
easily, it must be disassembled and
!WARNING completely cleaned. Any part in the hydrau-
• The hydraulic oil will be hot if the lic system that is not operating correctly is a
equipment has been operating. possible source of future problems and
Residual pressure can remain in the equipment downtime.
hydraulic piping. Use caution when
removing any hydraulic piping or hose. 9. Assemble all the parts, hoses, and piping.
Accidentally releasing hydraulic oil at Close the drain valve of the hydraulic oil
high pressure can cause injury to you reservoir. The hydraulic system is now
and others, and can damage the ready to be filled with new hydraulic oil (see
equipment. paragraph 3.6.7.2).
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-23
4. Fill all the hoses with filtered hydraulic oil, The power plant has four hydraulic oil return
as possible. filters and two pressure filters. The filters are
equipped with an indicator that shows when the
5. Fill the hydraulic pumps and hydraulic element requires replacement. The filter condi-
motors with filtered hydraulic oil. Bleed the tion must be checked at start-up and after every
air from each pump and motor housing and eight hours of operation. It is normal for the
permit the oil from the reservoir to fill each filter to indicate a blocked condition during cold
housing. starting conditions because of the increased
viscosity of the hydraulic oil.
6. Reconnect all hydraulic piping and hoses.
Replace the filter elements every 500 hours of
7. Start the diesel engine (see the correspond- operation or every six months, whichever
ing steps in paragraph 2.8.2). Check for occurs first.
pressure build-up.
8. Check for hydraulic system leaks.
CAUTION
9. Stop the diesel engine (see the correspond- • Clean the work area before doing
ing steps in paragraph 2.8.4). maintenance to the hydraulic system.
Keep all the parts clean (see
10. Check the hydraulic oil reservoir for the paragraph 3.6.1).
correct oil level. Add filtered hydraulic oil to
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-24
Operation, inspection, and maintenance of all Equipment put in storage or removed from
wire rope should be done in accordance with service must be protected from deterioration
API Recommended Practice 2D, Recom- during storage. This will make sure that it can
mended Practice for Operation and Mainte- be restored to active service with a minimum of
nance of Offshore Cranes (API RP2D) (see effort.
Section 5). The Parts and Vendor Data Manual
contains the following drawings that are benefi-
cial to wire rope maintenance: 3.8.1 Short-Term Storage—7 Days Up to
30 Days
• hoist manufacturer’s information (see
Section 11, Braden) When the crane will not be used for a period of
• wire rope reeving diagrams (see Section 3) 7 days but less than 30 days, do the following:
• wire rope dead end installation drawings
(see Section 5) 1. Lubricate the exposed machined surfaces
such as shafts and hydraulic valve spools.
!WARNING
• Do not operate the crane with 3.8.2 Long-Term Storage—30 Days or
damaged wire rope. More
After new wire rope has been installed properly, When the crane will not be used for a period of
the crane should be carefully operated through 30 days or more, do the following:
an operating cycle very slowly. During this trial
operation, closely watch all working parts 1. Clean the equipment.
(sheaves, hoists, etc.) to make sure the wire
rope moves freely and there are no spooling 2. Apply lubricant to exposed machined
problems. Operate several more times using a surfaces.
light load at reduced speeds. This will permit
the wire rope to work in and prevent any future 3. Lubricate all the equipment (see para-
problems. graph 3.2.2). Do all the steps that would
occur during the storage period.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-25
7. To prevent corrosion, apply Dow Corning 5. Prepare the diesel engine for operation.
brand Metal Protective Coating or an equiv- See the diesel engine manufacturer’s infor-
alent anti-corrosion coating to the following. mation for the diesel engine removal from
The coating must be non-tacky and be able storage procedures (see Parts and Vendor
to be removed before operation. Data Manual, Section 11, Caterpillar).
• Exposed machined surfaces of shaft 6. Start the crane (see paragraph 2.8.2). If
bores and hydraulic valve spools. possible, operate the crane through all
• All other non-painted surfaces. functions until all the air is purged from the
hydraulic system. Erratic operation can be
8. Completely fill the diesel fuel tank. expected until the air is purged. Check for
correct operation.
9. Check the level of hydraulic oil in the
hydraulic oil reservoir. Add filtered hydraulic 7. Check the hydraulic system for leaks.
oil to the reservoir as necessary (see para- Check hoses and piping for damage.
graph 3.6.6).
8. Make a hydraulic oil particle count (see
10. Close all cab windows and doors. paragraph 3.6.1.1) before continuing. The
hydraulic oil particle count must comply
11. Cover the engine, valves, and operator’s with the maximum operating contamination
cab with waterproof coverings to prevent levels permitted (see paragraph 3.6.1.2).
corrosion and deterioration.
9. Do all necessary lubrication (see para-
12. Once a month the diesel engine must be graph 3.2.2) and inspections and mainte-
started and all functions operated for a nance (see paragraph 3.3).
minimum of one-half hour in each direction
at various speeds with no loads. 10. Check the equipment for paint surface
damage. Make repairs as necessary.
3.8.3 Removal from Long-Term Storage 11. The crane is now ready for operation.
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 3-26
!WARNING
• Do not weld on hooks or shackles.
Welding on these items can weaken
the material, causing failure.
www.nov.com
Brake Test and Emergency Lowering Procedures
For Hoists Ordered for API 2C Cranes
Hoists ordered for API 2C cranes will have a needle valve located in the brake release line. Those
hoists also have a tee located in the brake release line between the needle valve and the brake
release port on the hoist. One opening in the tee is plugged. With the valve closed and the plug
removed from the tee, the brake is isolated from system pressure and vented to atmosphere. The
brake cannot be released under these conditions by actuating the directional control valve.
One purpose of the valve/tee combination is to provide a means to test the brake; the other is to
provide a means to lower a load in the event of loss of hydraulic power.
a. Remove the lockwire on the valve handle, and close the valve tightly.
c. With the hydraulic power unit running, move the hoist directional control valve handle to
the full-open lowering position.
d. Increase the engine speed, if necessary, to bring system pressure up to the relief valve
setting. The winch drum should remain stationary.
e. If the drum rotates, the brake should be examined for wear. Also, the brake springs
should be measured for correct length in those hoists using helical compression springs.
f. Replace any parts showing excessive wear, and any spring whose length is shorter than
the minimum shown in the Braden service manual.
g. Reassemble the brake and hoist and repeat the above steps.
h. When testing is complete, be sure to re-install the plug in the tee, fully open the valve
and replace the lockwire.
The above procedure tests the brake's ability to resist about 115% of the rated hoist load.
603511 Rev. 3
Page 1 of 2
2. Emergency Lowering Procedure
a. Remove the lockwire on the valve handle, and close the valve tightly.
c. Remove both main hoses from the motor, and attach a standpipe to the motor port on
the opposite side of the motor from the brake valve (counterbalance valve).
d. Fill the standpipe with hydraulic oil, making certain that oil is not running out of the brake
valve (counterbalance valve). If oil is running out of the brake valve (counterbalance
valve), remove the spring retainer and tap the spool to the closed position.
f. Pump the hand pump up to about 1000 psi. A suspended load will slowly come down;
releasing the pressure on the hand pump will cause the load to stop. If a chattering
noise is heard while the load is coming down, pump the hand pump to a higher pressure
until the noise stops. Do not touch the motor or standpipe while using this procedure;
these items will become very hot.
CAUTION - The above lowering procedure opens the multiple-disc brake while leaving
the brake valve (counterbalance valve) closed. Since hydraulic motors are not zero leak
devices, internal motor leakage permits the load to slowly rotate the motor even though
its outlet is blocked by the closed brake valve (counterbalance valve). This procedure
will not work if there is little or no oil in motor. Attempting to use this procedure with no
oil in the motor will cause the load to free fall. This procedure will also cause the load to
free fall if the brake valve (counterbalance valve) is stuck in the open position. The
purpose of the standpipe is to insure that the motor is full of oil. The standpipe is simply
a length of pipe (about 1 foot long) attached to a 90° elbow. The other end of the elbow
is attached to a short nipple and fitting suitable for mounting on the motor port or
manifold. The standpipe is installed with the 1 foot pipe pointed up and in a vertical
position. While lowering, oil must be added to the standpipe as necessary. The pipe
size should be at least as big as the motor port size.
WARNING- Never allow the standpipe to run out of oil. The load will free fall if there is
little or no oil in the stand pipe.
NOTE- The hydraulic oil used to fill the stand pipe must be filtered oil to prevent
contaminated hydraulic oil from entering the hydraulic motor. Filter the hydraulic oil to
meet a cleanliness level of ISO 16/13 or cleaner.
603511 Rev. 3
Page 2 of 2
Document number 2703100-MAN-001
Revision 01
Page 4-1
4 SPECIFICATIONS
Crane Model:
• 10000XHD
Serial Number:
• 2703100
Boom:
• Main length—120 ft (36.6 m)
• Inner section—30 ft (9.1 m)
• Inner center section—20 ft (6.0 m)
• Center section—40 ft (12.1 m)
• Outer section—30 ft (9.1 m)
Maximum Available Hook Speed (with the hook positioned at the supply boat elevation and the platform
at operation conditions):
• Main hook, 4 parts of line—44 fpm (13.4 mpm) (4 part 1st layer)
• Main hook, 6 parts of line—31 fpm (9.4 mpm) (6 part 1st layer)
• Auxiliary hook—241 fpm (73.4 mpm) (1 part 1st layer)
Operator’s Station:
• Enclosed, right-hand
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 4-2
Diesel Engine:
• Caterpillar 3126
• 250 hp @ 2200 rpm
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 4-3
Air Reservoir:
• Capacity—200 gal (757 L)
System Voltage
LOAD SOURCE VOLTAGE
Air conditioning unit
Flood lighting
Area lighting Circuit breaker panel
120 VAC, 60 Hz
Obstruction lights CBP0207
Power receptacle
Electrical collector ring anti-condensation heater
Load and radius indicator system
Control panel 751834 24 VDC
Gauge panel lighting
www.nov.com
Document number 2703100-MAN-001
Revision 01
Page 4-4
• Black or plated Grade 5 and Grade 8 bolts: Torque lubricated. Submerge entire bolt and nut in a
container of SAE 30W motor oil just before assembly.
• Stand-Cote bolts (Teflon coated, blue in color): Torque dry. Do not use lubricant.
!WARNING
• Swing bearing bolts require different torque values. See Parts and Vendor Data Manual,
Section 2, drawing 721557, Turntable.
Table 4–1. Tightening Values for SAE J429 Coarse Thread Bolts
GRADE 5 GRADE 8
DIAMETER–
THREADS/INCH
TIGHTENING TIGHTENING TIGHTENING TIGHTENING
TORQUE (ft·lb) (A) TORQUE (N·m) (A) TORQUE (ft·lb) (A) TORQUE (N·m) (A)
1
4 –20 6 8 9 12
5
16 –18 13 18 18 25
3
8 –16 23 31 33 44
7
16 –14 37 50 52 71
1
2 –13 57 77 80 108
9
16 –12 81 111 115 156
5
8 –11 113 153 159 215
3
4 –10 200 271 282 382
7
8–9 322 437 455 617
1–8 483 655 682 924
1- 18–7 595 807 966 1309
1
1- 4–7 840 1139 1363 1848
1-3 8–6 1102 1494 1787 2423
1
1- 2–6 1462 1983 2371 3215
(A) ft·lb = 0.7375 x torque in N·m, N·m = 1.356 x torque in ft·lb
www.nov.com