Amclyde Crane Operation Maintenance Manua

Operation and Maintenance Manual
AmClyde Model 52
Crane
Serial Number BP5376
REFERENCE REFERENCE DESCRIPTION

AmClyde Model 52 Crane
This document contains proprietary and confidential information Hydralift AmClyde, Inc.
which belongs to Hydralift AmClyde, Inc.; it is loaned for limited
purposes only and remains the property of Hydralift AmClyde, Inc..
240 East Plato Boulevard
Reproduction, in whole or in part; or use of this design or St. Paul, Minnesota 55107
distribution of this information to others is not permitted without the USA
express written consent of Hydralift AmClyde, Inc.. This document
is to be returned to Hydralift AmClyde, Inc. upon request and in any
Phone 651-293-4646
event upon completion of the use for which it was loaned. Fax 651-293-4648
© Hydralift AmClyde, Inc.
DOCUMENT NUMBER REV
BP5376-MAN-002 01
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Document number BP5376-MAN-002
Revision 01
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REVISION HISTORY
Rev Date (dd.mm.yyyy) Reason for Issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change Description

01 First Issue
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TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI
Software License Agreement . . . . . . . . . . . . . . . . . . . . . . . 1525409 (Rev. 3)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3.3 Maintenance Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4 Planning Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.5 Crane Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.6 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2 DESCRIPTION OF CRANE AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.1 Lighting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.2.1.1 Area Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.2.1.2 Floodlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.2.1.3 Obstruction Lights . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.2.1.4 Emergency Lighting . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.2.2 Operator’s Cab Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3 Control Console Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4 General Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.4.1 Solenoid Valve Override Plungers. . . . . . . . . . . . . . . . . . . . . . 2-21
2.4.2 EMERGENCY STOP Switches . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.4.3 EMERGENCY POWER OFF Switch . . . . . . . . . . . . . . . . . . . . 2-23
2.4.4 LAMP/ALARM TEST Push Button. . . . . . . . . . . . . . . . . . . . . . 2-24
2.4.5 Load Monitoring System (LMS) Display . . . . . . . . . . . . . . . . . . . 2-24
2.4.5.1 START Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
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2.4.5.2 HOIST Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2.4.5.3 MAIN HOIST CHART SELECTION Screen . . . . . . . . . . . . 2-34
2.4.5.4 ALL HOOKS Screen . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.4.5.5 CRANE STATUS Screens . . . . . . . . . . . . . . . . . . . . . 2-42
2.4.5.6 CALIBRATION Screens . . . . . . . . . . . . . . . . . . . . . . 2-50
2.4.5.7 FAULT Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
2.4.5.8 CLOCK & DATE ADJUST Screen . . . . . . . . . . . . . . . . . 2-51
2.4.5.9 ADJUST BRIGHTNESS Screen . . . . . . . . . . . . . . . . . . 2-52
2.4.5.10 Data Entry Keypad . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
2.4.6 Visitor’s Cab Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
2.4.7 MONITORS Controls and Closed Circuit Television (CCTV) System . . . . 2-53
2.4.8 HORN Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.4.9 Boom Angle Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.4.10 Swing Warning Light and Alarm . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.4.11 Sound-Powered Telephones . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.4.12 WIPERS Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.4.13 HEATER OFF/ON Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.4.14 DEFROSTER OFF/ON Switch and DEFROSTER
LOW/MED/HIGH Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
2.4.15 Operator’s Cab and Visitor’s Cab Air Conditioning Controls . . . . . . . . 2-55
2.4.16 Electrical House Air Conditioning and Heating Thermostats . . . . . . . . 2-55
2.4.17 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
2.4.18 Electrical Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
2.5 Power Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
2.5.1 System Air Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . 2-56
2.5.2 CONTROL POWER Push Buttons . . . . . . . . . . . . . . . . . . . . . 2-56
2.5.3 DRIVE RESET Push Button and DRIVE READY Indicator Lights. . . . . . 2-56
2.6 Crane Function Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
2.6.1 Hoist Drum Brakes—Boom, Main, Auxiliary, Whip Drums. . . . . . . . . . 2-57
2.6.2 BOOM Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
2.6.3 MAIN/AUXILIARY Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . 2-58
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2.6.4 WHIP Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

2.6.5 BOOM/SWING Control and Thumb Button . . . . . . . . . . . . . . . . . 2-59
2.6.6 BOOM/BOTH/SWING Switch . . . . . . . . . . . . . . . . . . . . . . . . 2-60
2.6.7 HOIST Control and Thumb Button . . . . . . . . . . . . . . . . . . . . . 2-60
2.6.8 Drum SELECT Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . 2-60
2.6.9 MAN RIDER MODE OFF/ON Key Switch . . . . . . . . . . . . . . . . . . 2-61
2.6.10 PAWL Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
1
2.6.11 SPEED 4 / FULL switches . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
2.6.12 SWING LOCK IN and OUT Push Buttons . . . . . . . . . . . . . . . . . . 2-63
2.6.13 E-RELEASE ENABLE OFF/ON Switch and Push Buttons . . . . . . . . . 2-64
2.6.14 WHIP EMERGENCY BRAKE RELEASE VALVE . . . . . . . . . . . . . . 2-64
2.6.15 LIMIT BYPASS Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . 2-65
3 CRANE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Personnel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Pre-Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3.1 Each Workday . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3.2 Before Each Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.5 Emergency Stop Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5.1 Emergency Power Off Procedure. . . . . . . . . . . . . . . . . . . . . . . 3-7
3.6 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.7 Operating in the Wind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.7.1 High Wind Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.8 Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.9 Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.9.1 Lowering (Engaging) the Swing Lock . . . . . . . . . . . . . . . . . . . . 3-12
3.9.2 Raising (Disengaging) the Swing Lock . . . . . . . . . . . . . . . . . . . 3-13
3.10 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.10.1 Boom Hoist Pawl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
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3.10.1.1 Engaging the Boom Hoist Pawl . . . . . . . . . . . . . . . . . . 3-15

3.10.1.2 Disengaging the Boom Hoist Pawl . . . . . . . . . . . . . . . . . 3-15
3.11 Main, Auxiliary, and Whip Fall . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.11.1 Main, Auxiliary, and Whip Drum Pawl . . . . . . . . . . . . . . . . . . . . 3-17
3.11.1.1 Engaging the Main, Auxiliary, or Whip Drum Pawl . . . . . . . . . 3-18
3.11.1.2 Disengaging the Main, Auxiliary, or Whip Drum Pawl . . . . . . . 3-18
3.12 Emergency Release—Empty Block . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.13 Whip Emergency Load Lowering Procedure . . . . . . . . . . . . . . . . . . . . 3-19
3.14 Block Pocket—Main and Auxiliary Fall . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.14.1 Putting the Block in the Block Pocket . . . . . . . . . . . . . . . . . . . . 3-20
3.14.2 Lowering the Block Out of the Block Pocket. . . . . . . . . . . . . . . . . 3-21
3.15 Backing Out of Limit Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.15.1 Boom Upper Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.15.2 Boom Lower Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.15.3 Main, Auxiliary, or Whip Fall Two-Block Limit . . . . . . . . . . . . . . . . 3-22
3.15.4 Main, Auxiliary, or Whip Fall Lower Limit . . . . . . . . . . . . . . . . . . 3-23
3.15.5 Block Pocket Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.15.6 Boom and Main, Auxiliary, or Whip Fall Overspeed Fault . . . . . . . . . . 3-23
3.15.7 NO CAPACITY Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.15.8 90% CAPACITY Warning . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.15.9 Overload Automatic Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
4 TUGGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Tugger Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Control Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.1 Tugger Controls—Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.2 Tugger Pendant Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 Tugger Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.1 Tugger EMERGENCY STOP Switch . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.2 TUGGER CONTROL OPCAB/LOCAL Switch and TUGGER CONTROL
Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
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4.4.3 START and STOP Push Buttons . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.4.4 TUGGER Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.5 PAYOUT/NEUTRAL/INHAUL Switch . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.6 SPEED Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.7 TENSION Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.8 RESET Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.5 Tugger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5.1 Pre-Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5.1.1 Each Workday . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5.1.2 Before Each Start-Up . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5.2 Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5.3 Tugger EMERGENCY STOP Procedure . . . . . . . . . . . . . . . . . . . 4-8
4.5.4 Operation Procedure—Operator’s Cab Control. . . . . . . . . . . . . . . . 4-9
4.5.5 Operation Procedure—Pendant Control. . . . . . . . . . . . . . . . . . . 4-11
4.6 Tugger Motor Overload Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Introduction and General Instructions . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.1 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.2 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3.1 Introduction and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3.2 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3.3 Inspection Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3.4 Inspection Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.5 Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.6 Adjustments and Repairs—General Precautions . . . . . . . . . . . . . . . 5-4
5.3.7 As Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.8 Frequent Inspections (Daily to Monthly Depending on Severity of Use) . . . 5-6
5.3.9 Periodic Inspections (Monthly to Annually Depending on Severity of Use) . . 5-8
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5.3.10 Cranes Not in Regular Use . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.3.11 Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5 Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5.1 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5.1.1 How to Calibrate the Load Monitoring System (LMS) . . . . . . . 5-13
5.5.1.2 CALIBRATION DATA Screen . . . . . . . . . . . . . . . . . . . 5-15
5.5.1.3 Boom Angle Calibration . . . . . . . . . . . . . . . . . . . . . . 5-16
5.5.1.4 Main, Auxiliary, and Whip Hoist Calibration . . . . . . . . . . . . 5-17
5.5.1.5 Hook Height Calibration . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.1.6 Load Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.5.1.7 Load Span Calibration . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.5.1.8 Load Shunt Calibration. . . . . . . . . . . . . . . . . . . . . . . 5-19
5.5.1.9 Cross and Heel Angle Calibration . . . . . . . . . . . . . . . . . 5-20
5.5.1.10 Cross Angle Calibration . . . . . . . . . . . . . . . . . . . . . . 5-20
5.5.1.11 Heel Angle Calibration . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.6 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.6.1 Air System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.6.2 Releasing Pressure from Air System . . . . . . . . . . . . . . . . . . . . 5-23
5.7 Hoist Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.7.1 Check and Adjustment of Hoist Drum Brake . . . . . . . . . . . . . . . . 5-23
5.7.2 Hoist Drum Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.7.2.1 Inspection of Hoist Drum Brake Lining . . . . . . . . . . . . . . . 5-27
5.7.2.2 Replacement of Hoist Drum Brake Lining
(National Oilwell Varco Standards 1525333, 1525334) . . . . . . 5-27
5.7.2.3 Sanding Hoist Drum Brake Lining
5.7.2.4 Burnishing Hoist Drum Brake Lining
(National Oilwell Varco Standard 1525336) . . . . . . . . . . . . 5-35
5.8 Hoist Drum Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
5.8.1 Check and Adjustment of Hoist Drum Clutch . . . . . . . . . . . . . . . . 5-37
5.8.2 Hoist Drum Clutch Lining . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
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5.8.2.1 Inspection of Hoist Drum Clutch Lining . . . . . . . . . . . . . . 5-39

5.8.2.2 Replacement of Drum Clutch Lining
5.8.2.3 Sanding Hoist Drum Clutch Lining
5.8.2.4 Burnishing Hoist Drum Clutch Lining
5.9 Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.10 Welding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Calibration Data Table
Lubrication Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1595432
Lubricant, Wire Rope, Temperate . . . . . . . . . . . . . . . . . . . . . . 310305 (Rev. 1)
Lubricant, Bearings, Temperate . . . . . . . . . . . . . . . . . . . . . . . 310306 (Rev. 1)
Lubricant, Chain, Temperate . . . . . . . . . . . . . . . . . . . . . . . . 310307 (Rev. 1)
Lubricant, Open Gears, Temperate . . . . . . . . . . . . . . . . . . . . . 310310 (Rev. 5)
Lubricant, Wire Rope, Arctic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310311
Lubricant, Bearings, Arctic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310312
Lubricant, Chain, Arctic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310313
Lubricant, Open Gears, Arctic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310318
Lubricant, SAE 30 Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . 829800 (Rev. 1)
Lubricant, Enclosed Gears . . . . . . . . . . . . . . . . . . . . . . . . . 841147 (Rev. 1)
Application of Asphaltic Base Open Gear Lubricant . . . . . . . . . . . . . . . . 1525532
Wire Rope User’s Manual
6 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wire Rope and Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4 Swing Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.5 Tuggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.6 Power Generation and Distribution . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.6.1 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
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6.6.2 Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.7 Inch to Millimeter Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.8 Millimeter to Inch Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.9 U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.10 Tightening Procedures for ASTM, SAE, and ISO Bolts . . . . . . . . . . . . . . . 6-8
6.10.1 Tightening Procedure for ASTM A325 and ASTM A490
High-Strength Structural Coarse Thread Bolts and Hex Nuts
(National Oilwell Varco Standard 1525179). . . . . . . . . . . . . . . . . . 6-8
6.10.2 Tightening Values for SAE Grade 2 Coarse Thread Bolts
(National Oilwell Varco Standard 1525177) . . . . . . . . . . . . . . . . . 6-10
(National Oilwell Varco Standards 1525177 and 1525515) . . . . . . . . . 6-12
6.10.5 Tightening Values for Metric ISO Class 8.8 Bolts
(National Oilwell Varco Standards 1525314 and 1525516) . . . . . . . . . 6-14
6.10.8 Tightening Values for 316 Stainless Steel Coarse Thread Bolts
6.10.9 Tightening Values for Metric ISO Type A4 316 Stainless Steel Bolts
Capacity Chart, Main Fall, Full Water Tank . . . . . . . . . . . . . . . . . . . . . 1594855
Capacity Chart, Main Fall, Empty Water Tank. . . . . . . . . . . . . . . . . . . . 1594856
Capacity Chart, Auxiliary Fall, Full Water Tank . . . . . . . . . . . . . . . . . . . 1594857
Capacity Chart, Whip Fall, Full Water Tank . . . . . . . . . . . . . . . . . . . . . 1594858
Capacity Chart, Whip Fall, Man Rider Mode . . . . . . . . . . . . . . . . . . . . 1596451
Capacity Lift Height Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1598177
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FOREWORD
This technical manual gives information for the recommended operation and maintenance of the equip-
ment. This technical manual is written for the original design application of the equipment. If the appli-
cation of the equipment changes, the operation and maintenance information and procedures could
change. This technical manual is not a substitute for comprehensive operator and maintenance train-
ing. Read and completely understand this technical manual, equipment functions, and equipment
safety features before operating or doing maintenance to the equipment.
If additional technical manuals are needed, they are available for an added cost.
The serial number of the equipment must be given with all communication for correct identifica-
tion of the equipment.
National Oilwell Varco

240 East Plato Boulevard
St. Paul, Minnesota 55107-1631
Phone: 651-293-4646
Fax: 651-293-4648
Accessory Sales For replacement parts, retrofits, upgrades,

spares, and accessories: 651-293-4600
Field Service For service-specific questions and inquiries, including
inspections, test-certificates, service work, repair supervision, and
operator/maintenance training: 651-293-4745
Sales For new equipment: 651-293-4646
This publication is one document of the technical manual for the AmClyde model 52 crane, serial
number BP5376. The complete technical manual consists of the following documents:
• Erection Manual, document number BP5376–MAN-001

• Operation and Maintenance Manual, document number BP5376–MAN-002
• Parts Manual, document number BP5376–MAN-003
• Vendor Data Manual, document number BP5376–MAN-004
• Vendor Data—Rockwell, document number BP5376–MAN-005
T2010-05.02
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1 SAFETY damage to equipment, high maintenance costs,

and lost production.
1.1 Safety: Warning Any performance ratings and specifications for

this equipment are valid only when the equip-
It is the responsibility of the owner and user of ment is used according to the manufacturer’s
this equipment to know the safety codes; insur- operating and maintenance procedures. Read
ance requirements; and national, federal, and understand the technical manuals provided
provincial, state, and local laws and regulations with this equipment before operating or doing
affecting all uses of the equipment. This techni- maintenance to the equipment. Assistance is
cal manual does not provide regulatory informa- available from the National Oilwell Varco
tion, because regulations are subject to change Service Department.
and are different from location to location.
The operator must know all the main parts,
It is the responsibility of the owner and user of controls, and safety features of the equipment
the equipment to obtain, read, and understand before operating it. The operator must know the
the current publication of American National correct operation and inspection procedures of
Standard for Floating Cranes and Floating the equipment before operating it.
Derricks, ANSI/ASME B30.8. Published by the
American Society of Mechanical Engineers, The operator is responsible for the safe opera-
Three Park Avenue, New York, NY 10016-5990, tion of the equipment, including the safety of
USA. others in the work area.
Not using the equipment according to these

regulations can result in damage to the equip- 1.2 Safety Signal Words
ment and death or injury to personnel.
Throughout this technical manual are steps and
National Oilwell Varco provides technical manu- procedures that, if not followed, can result in a
als for the different types of equipment it manu- hazard. The following signal words are used to
factures and sells. The owner and user must identify the level of a hazard.
use these technical manuals to give the correct
information and training to the people who will
operate, maintain, or supervise the use of the
!DANGER
equipment. • Danger is used to show a hazard that
WILL RESULT in death or serious
This equipment is designed to do heavy-duty injury if not avoided.
work and will wear during normal use. There-
fore, the owner and user must establish a regu-
larly scheduled inspection and maintenance !WARNING
program based on the information in the • Warning is used to show a hazard or
National Oilwell Varco technical manual. unsafe practice that CAN RESULT in
Inspection and maintenance programs help death or serious injury if not avoided.
prevent accidents and keep the equipment
operating efficiently.
Correct training, inspection, and maintenance

programs are important to avoid personal injury,
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1.3.1 General Safety Rules

!CAUTION
• Caution is used to show a hazard that 1. DO NOT USE ANY PART OF THIS
WILL or CAN RESULT in minor or EQUIPMENT BESIDES THE WHIP HOIST
moderate injury if not avoided. TO LIFT OR LOWER PERSONNEL. WITH
THE EXCEPTION OF THE WHIP HOIST,
THIS EQUIPMENT IS MADE FOR
CAUTION MATERIAL HANDLING ONLY. USING THE
• Caution used without the safety alert WHIP HOIST TO LIFT OR LOWER
symbol ! is used to show a hazard PERSONNEL REQUIRES FOLLOWING
that WILL or CAN RESULT in SPECIAL PERSONNEL-HANDLING
equipment or property damage if not SAFETY PRECAUTIONS. REFER TO
avoided. “PERSONNEL LIFTING” IN THE LATEST
REVISION OF ANSI/ASME STANDARD
B30.8 AND ANSI/ASME B30.23 (SEE
NOTICE PARAGRAPH 3.2).
• Notice is used to call attention to
operation and maintenance 2. Wear protective clothing and safety equip-
information that is important but not ment as required by job conditions when
hazard-related. operating the equipment or working in the
area of the equipment. Do not wear loose
clothing that can catch on controls or
1.3 Safety Rules moving equipment parts.
National Oilwell Varco equipment, as designed, 3. Keep the operator’s area and the work area
can be used safely; however, no equipment, clean and free of debris.
regardless of design, can prevent injury or
damage because of operator error or careless- 4. Keep all platforms, steps, and walking
ness. surfaces clean, dry, and free of debris.
Keep them painted with non-skid paint.
This safety section includes information from
many sources. It gives examples of basic safety 5. Keep the equipment clean and free of dirt
rules. Additional safety rules can be necessary and debris, to permit a good inspection of
for safe operation of the equipment. The infor- the equipment.
mation in this section is not meant to replace
safety codes; insurance requirements; or 6. Check the rigging daily and before any
national, federal, provincial, state, and local heavy lifts. Rigging that is damaged must
laws and regulations. be repaired or replaced before it can be
used.
7. Before making a heavy lift, make a test lift

of a known load or a calibration check of
the load monitoring system (LMS). Do this
to check that the LMS is operating correctly
and displaying accurate information.
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8. Do not use a chain or sling having a knot or Do not permit a tugger to resist a
kink or is spliced using bolts. Do not use load—doing so can cause the rated linepull
knots, bolts, or hook wraps to shorten capacity to be exceeded.
slings.
5. Do not rely on the load monitoring system
9. Do not weld on hooks, sockets, or shack- (LMS) when common sense judgment
les. Welding on these items can weaken suggests an error. Do not use the LMS as a
the material, causing failure. weighing device after lifting the load.
10. Do not use torches or open flame on or 6. Operate the equipment with no load at the
near control equipment parts. start of each workday to make sure all func-
tions work correctly.
11. Adequate fire protection equipment must be
available and in satisfactory operating 7. The operator must watch the load at all
condition. Operating and maintenance times. Do not operate the equipment if the
personnel must be familiar with the use and operator’s vision is restricted. Some appli-
care of the fire protection equipment. cations require a signal person. The signal
person must be visible to the operator at all
times. The operator and the signal person
1.3.2 Operating Safety Rules must agree on the signals to be used
before operating the equipment (see para-
1. Do not operate this equipment under any graph 1.5).
conditions or in any manner other than
those for which the equipment has been 8. An audible signal must be sounded to warn
specified, sold, and described in this techni- personnel in the area before a load or
cal manual. empty lifting equipment is raised, lowered,
or swung.
2. This equipment must be operated only by
personnel who are trained and authorized 9. Communication must be maintained
for its operation. between all personnel involved in any oper-
ation. The operator must obey a signal to
3. Do not operate this equipment if you are ill stop from anyone in the area. The signal
or physically or mentally not fit to operate it person must give all other signals.
correctly and safely.
10. Do not permit personnel to get on or off the
4. Do not exceed the rated load capacity of equipment while it is operating.
the equipment (see Section 6, Capacity
Charts, drawings 1594855, 1594856, 11. Do not operate the equipment with any
1594857, 1594858, 1596451, and personnel near the wire rope or moving
1598177). Lifting loads greater than those equipment.
shown on the capacity chart or operation at
positions not shown, or lifting when the 12. Do not operate the equipment without the
boom is solid against the boom stops, can safety guards installed.
cause structural failure or collapse of the
boom or crane and death or injury to 13. Do not bypass, disconnect, or ignore safety
personnel. Do not exceed the rated linepull and warning devices of the equipment.
capacity of the tuggers (see paragraph 6.5). Safely shut down the equipment and inves-
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tigate the problem. Correct the problem 20. When making a lift the boom (hook) must
before continuing operation. be directly over the load, not the side of the
load. Side loading can cause structural fail-
14. Do not operate the equipment after an ure or collapse of the boom or crane and
inspection reveals a safety hazard or if any injury to personnel.
equipment parts require maintenance or
replacement. Always look for equipment 21. When making a lift the hook must be
damage or abnormal functioning during directly over the estimated center of gravity
operation. If found, safely shut down the of the load before the load is attached to
equipment and correct the problem before the rigging. Do not attach capacity loads at
continuing operation. maximum outreach, because an outward
swing of the load, caused by vessel list or
15. Before rotating the crane, make sure that trim, or outward drift of the boom, can over-
the crane tailswing as well as the swing load the crane.
paths of the boom and load are free of
obstructions and personnel. Not following 22. Loads must be safely rigged before lifting.
this procedure can result in damage to the Do not overload slings. Slings must be
crane, the load, and other equipment and attached to the throat of the hook. Do not
structures, and death or injury to personnel. permit hook latches to support any part of
the load. Hook latches keep loose slings
16. Operate the equipment at a slow speed from coming off the hooks.
when first learning.
23. Use extreme caution when rotating the
17. Check the load monitoring system (LMS) crane with a load suspended. When lifting a
display and all closed circuit television heavy or bulky load, it is recommended that
(CCTV) monitors, gauges, and indicator the load control tugger wire ropes be
lights often for normal operating conditions. attached to each side of the load to prevent
Shut down the equipment immediately if the the load from rotating or swinging.
displays, monitors, gauges, and indicator
lights show that the equipment is outside of 24. When using handlines (ropes) to guide or
its normal operating conditions. Investigate snub a load, do not permit personnel to
and correct the problem before continuing wrap the rope around any part of their body.
operation.
25. Personnel must be clear of the work area
18. Carefully plan your lifts to prevent accidents before making the lift.
(see paragraph 1.4). If you have questions
about the safety of the lift, ask your supervi- 26. Do not quickly accelerate or quickly decel-
sor. If there is a problem during a lift, stop erate a moving load.
the lift and safely lower the load.
27. Loads must be moved at as low a level as
19. Maximum crane stability is achieved when possible. If the load slips, it must be
the boom is at its highest working angle lowered with caution immediately.
(minimum outreach). Consequently, all lifts
should be made with the shortest possible 28. Do not swing or position the load or attach-
working radius (outreach). ment over personnel. Do not permit person-
nel to be in a hazardous position between a
swinging load and a fixed object.
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29. The operator must watch the load at all 1.3.3 Maintenance Safety Rules
times. The load must be completely
lowered before looking away from the load. 1. Shut down the equipment before doing
maintenance. Only qualified, trained main-
30. The operator must not leave the control tenance personnel must do maintenance,
station until the equipment has been shut adjustment, and inspection procedures,
down and is completely stopped. following the procedures outlined in the
technical manual.
31. The operator must not leave the control
station with a load suspended in the air. 2. All replacement and repaired parts must
meet the manufacturer’s current specifica-
32. The hoist drum pawls (dogs) must be tions.
engaged when the drums are to be kept
from rotating for a period of time. 3. After making a repair or adjustment, always
check the functioning of the equipment
33. The boom hoist must have at least one-half parts before putting the equipment into full
layer of wire rope on the drum at all times operation.
during operation. Other hoist drums must
have at least three wraps of wire rope on 4. The brakes and clutches of the hoists,
the drums at all times during operation. swing drives, and tuggers must always be
dry, correctly adjusted, and free from lubri-
34. Do not permit the wire rope to wind wrong cant contamination. Injury to personnel or
on the hoist drum (see figure 1–1). damage to the equipment can result if the
brake and clutch adjustments are not
correct.
5. Do not make modifications to the equip-

ment unless approved in writing by National
Oilwell Varco.
A1929
Figure 1–1. Wire Rope Wound Wrong on Drum
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1.4 Planning Lifts
The signal person must be visible to the opera-

tor at all times. The operator and the signal
person must agree on the signals to be used
before operating the equipment (see para-
graph 1.5).
Carefully plan your lifts to prevent accidents. If

you have questions about the safety of the lift,
ask your supervisor. If there is a problem during
the lift, stop the lift and safely lower the load.
!WARNING
• Do not operate the equipment if you
are ill or physically or mentally not fit
to operate it correctly and safely.
The operator must check the following before

making the lift:
1. The shape of the object to be lifted.
2. The rated load capacity of the equipment.
3. The weight and center of gravity of the

load, including the slings.
4. The limits of the slings.
5. The crane tailswing and swing path of the

boom and load for obstructions and person-
nel.
6. The position the load will take when it is

lifted.
7. How high the load will have to be lifted.
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1.5 Crane Signals
Standard Hand Signals for Controlling Floating Cranes and Floating Derricks. Extracted from the American
National Standard for Floating Cranes and Floating Derricks, ASME B30.8-2004, with the permission of the
publisher. Publisher: The American Society of Mechanical Engineers, Three Park Avenue, New York, NY 10016.
Stand in clear view of the operator. Stay a safe distance from the hook, block, and boom.
Hoist. With forearm vertical, Lower. With arm extended Use Main Hoist. Tap Use Whipline. Tap
forefinger pointing up, move downward, forefinger pointing fist on head, then use regular elbow with one hand, then use
hand in small horizontal circle. down, move hand in small signals. regular signals.
horizontal circle.
Move Slowly. Use one Raise the Boom and

Raise Boom. Arm Lower Boom. Arm hand to give any motion signal
extended, fingers closed, thumb extended, fingers closed, thumb and place other hand motionless Lower the Load. With
pointing upward. pointing downward. in front of hand giving the motion arm extended, thumb pointing up,
signal. (Hoist slowly shown as flex fingers in and out as long as
example). load movement is desired.
Lower the Boom and Swing. Arm extended, point Stop. Arm extended, palm Emergency Stop. Both
Raise the Load. With with finger in direction of swing of down, move arm back and forth arms extended, palms down,
boom. horizontally. move arms back and forth
arm extended, thumb pointing
horizontally.
down, flex fingers in and out as
long as load movement is desired.
A2170
Dog Everything. Clasp

hands in front of body.
Figure 1–2. Crane Signals
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1.6 Safety Labels
Safety labels are located on the equipment in prominent places to advise operating and maintenance
personnel of hazards. The labels are reproduced here to improve recognition and increase label effec-
tiveness. Before operating or doing maintenance to the equipment, be sure you understand the mean-
ing of these labels. Warning Label Installation, drawing 1595206 (see the Parts Manual, Section 2)
shows the locations of all the National Oilwell Varco-supplied safety labels. This drawing is a useful
reference for the inspection and maintenance of the safety labels (see paragraph 5.3.9). Replace all
damaged or missing safety labels.
WARNING
Only use the whip hoist to lift or lower personnel.
ONLY whip hoist Do not use the other hoists. They are made for
can be used for material handling only.
personnel handling.
Before lifting or
lowering personnel,
see Operation and
Maintenance
Manual for special
lifting instructions
and requirements
of ANSI/ASME B30.8.
1813035
p/n 1813035
WARNING Install the equipment using National Oilwell Varco

Follow National recommended procedures only. Contact the
Oilwell Varco National Oilwell Varco Service Department for
recommended answers to questions regarding equipment installa-
tion.
mounting
procedure to fasten
this equipment to
the foundation.
1561567
p/n 1561567
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WARNING
Read and fully understand Operation Operating and maintenance personnel must read
and Maintenance Manuals before and understand the manuals provided with the
operating or doing maintenance to equipment before operating or doing maintenance
the equipment. Failure to obey to the equipment. The equipment must be operated
warnings and follow instructions
could result in personal injury, death, only by personnel who are responsible and autho-
and damage to equipment or rized for its operation.
property.
416J10
p/n 416J10
WARNING
The operator must not leave the control console
Engage pawls until all the drum pawls (dogs) and parking brakes
have been engaged, the equipment has been shut
(dogs) before down, and the equipment is completely stopped.
leaving Not following this procedure can result in death,
serious injury, or equipment damage.
operator’s cab.
1546149
p/n 1546149
WARNING
Shut down the equipment before doing mainte-
Stop machinery nance. Only qualified, trained maintenance
personnel must do maintenance, adjustment, and
before doing inspection procedures, following the procedures
maintenance. See outlined in the maintenance manual.
the Maintenance
Manual for correct
procedures.
416J8
p/n 416J8
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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 Maintenance outlined in the maintenance manual.
Manual for instructions.
1540331
p/n 1540331
WARNING
Do not access or enter this area while the crane is
STOP, Do not access operating. The equipment can start or stop without
while crane is operating! warning. Not following this procedure can result in
Failure to obey warnings death or serious injury.
can cause injury or
death.
1536916
p/n 1536916
WARNING Do not enter this area unless authorized to do so.

The equipment can start or stop without warning.
Do not enter. Not following this procedure can result in death or
serious injury.
Authorized
personnel only.
1561358
p/n 1561358
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DANGER
Do not enter this area unless authorized to do so.
Confined space. Confined space. Not following this procedure can
result in death or serious injury.
Authorized
personnel only. 1588999
p/n 1588999
WARNING
Do not access Access the boom walkway only when the boom is
boom walkway horizontal and the equipment is shut down. Not
following this procedure can result in death or seri-
unless crane ous injury from falling.
is shut down
and boom is
horizontal.
1543637
p/n 1543637
WARNING
Do not access this area while the crane is operat-
Stay clear of crane ing. Crane rotation can start or stop without warn-
swing area. Death ing. Not following this procedure can result in death
or serious injury or serious injury.
may result.
1536351
p/n 1536351
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WARNING
Do not access the ladder while the crane is operat-
Ladder to ing. Crane rotation can start or stop without warn-
machinery ing. Not following this procedure can result in death
deck rotates or serious injury.
with crane
upper-
structure.
1538692
p/n 1538692
WARNING
Keep the access hole cover closed when not in
use. Not following this procedure can result in
Keep access death or serious injury from falling.
cover closed
at all times.
1541682
1541682
WARNING
Equipment can start and stop without warning.
Moving equipment parts can cause death or serious
Stay clear of rope. injury.
Rope movement may
start without warning.
1541686
p/n 1541686
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WARNING
Exposed, moving equipment parts can cause seri-
ous injury or death. Keep hands, feet, and clothing
Do not away from moving equipment parts while the equip-
operate ment is operating. Do not operate the equipment
without the safety guards installed.
without
guards in
place.
1545955
p/n 1545955
CAUTION
Keep away from this surface; it can be hot.
Hot
1540334
p/n 1540334
WARNING To protect your hearing, wear ear protection when

entering this area because of high noise levels.
High noise level.
Wear ear
protection in this
area.
416J1
p/n 416J1
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Only qualified, trained maintenance personnel must

do maintenance, adjustment, and inspection of the
electrical equipment. Each maintenance person
must use a lockout/tag out procedure at each elec-
tric power area. Electrical equipment must be main-
tained and operated according to applicable
1560794
standards. Not following this procedure can result
in death or serious injury.
p/n 1560793
WARNING Only qualified, trained maintenance personnel must

do maintenance, adjustment, and inspection of the
Arc flash and shock electrical equipment. Each maintenance person
hazard. Appropriate must use a lockout/tag out procedure at each elec-
tric power area. Appropriate personal protection
personal protection equipment is required. Electrical equipment must
equipment required. be maintained and operated according to applica-
1574174 ble standards. Not following this procedure can
result in death or serious injury.
p/n 1574174
DANGER High voltage will remain in the 600 VAC conductors

Electrocution hazard. even after power has been shut off. Before inspec-
Shut off 600 VAC
power. Then ground tion or maintenance of the high voltage panels,
600 VAC conductors cables, cable reels, or other high voltage equip-
before inspection or ment, power must first be shut off. Then the
maintenance. Failure 600 VAC conductors must be grounded by qualified
to do so will result in
injury or death. 1582474 service personnel. Not following this procedure
WILL result in death or serious injury.
p/n 1582474
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WARNING
Electrical power is supplied to this equipment from
This enclosure multiple sources. All sources of electrical power
has more than must be shut off before accessing the indicated
one source of equipment. Only qualified, trained maintenance
personnel must do maintenance, adjustment, and
power. Disconnect inspection of the electrical equipment. Not following
all sources before this procedure can result in death or serious injury.
doing
maintenance.
1540325
p/n 1540325
WARNING
Do not weld on hooks or shackles. Welding can
weaken the material, causing failure.
Never do any
welding on hook
or shackle.
416J2
p/n 416J2
FIRE
Shows the location of the fire extinguisher.
E
X
T
I
N
G
U
I
S
H
E
R
p/n 1537827
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Revision 01
Page 1-16
FIRE Indicates that a fire extinguisher is located inside

this area.
EXTINGUISHER
INSIDE
1536915
p/n 1536915
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Revision 01
Page 2-1
2 DESCRIPTION OF CRANE AND 2.2 Equipment Description

CONTROLS
The AmClyde model 52 crane (see figure 2–1),
serial number BP5376, is a vessel-mounted
2.1 Introduction crane used for hook operation. See Section 6,
Capacity Charts, drawings 1594855, 1594856,
This section includes a general description of 1594857, 1594858, 1596451, and 1598177 for
the crane and detailed descriptions of the crane the crane load capacity ratings. See figures 2–1
operator’s controls as outlined by the table of through 2–14 for the names and locations of
contents. See Section 3, Crane Operation, for the main equipment parts and control devices.
the general operating instructions for the crane. The rotating upperstructure of the crane rotates
See Section 4, Tuggers, for the tugger instruc- about the center pin. The roller carriage carries
tions. the rotating crane and the load on rails that
encircle the center pin. Three swing drives,
located inside the machinery house, rotate the
crane.
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Boom Wire Rope
Obstruction Light (see

paragraph 2.2.1.3)
Main Wire Rope

Auxiliary Wire Rope Boom
Whip Wire Rope
A-Frame Boom Walkway
Backleg Boom Stop
Water Tank
Machinery
House (see
figure 2–2) Block Control Tugger (see Section 4)
Operator’s Cab (see figures 2–7 and 2–8)

Light Switch (see paragraph 2.2.1.1)
Load Control Tugger (see Section 4)
Swing Warning Light and Alarm (see paragraph 2.4.10)
Machinery Light Switch (see paragraph 2.2.1.1)
House Access
Stairway Tub
A3688
Figure 2–1. Crane
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Revision 01
Page 2-3
Auxiliary Fall Jib Obstruction Light

Block Pocket (see paragraph 2.2.1.3)
Main Fall
Block Pocket
Whip Fall
Lower Block
Auxiliary Fall
Lower Block
Main Fall
Lower Block
Figure 2–1. Crane (continued)
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Revision 01
Page 2-4
Electrical House Air Conditioning and

EMERGENCY STOP Switch Heating Thermostat
(see paragraph 2.4.2) (see paragraph 2.4.16)
Air Conditioning and
Heating Thermostat
(see paragraph 2.4.16) CP10 DP1 LP1 XS226
CP3 T461
T457
Main Hoist (see Figure 2–3) S S

SWING SWING SWING BCU HOIST BOOM BCU BLOCK LOAD LOAD CP1
#3 #2 #1 TUGGER TUGGER TUGGER
#2 #1
F
S
Boom Hoist (see Figure 2–4)
Water Tank
F
S
Louver Ventilation Fan

Motor Starter
Symbol Legend Louver

Access to Tub
F Fire Extinguisher (see paragraph 2.4.17) E-STOP Switch
Emergency Light (see paragraph 2.2.1.4) (see paragraph 2.4.2) Lubricator Compressor
Telephone (see paragraph 2.4.11)
Refrigerated Air Dryer Anti-Freezer
Camera (see paragraph 2.4.7)
S Light Switch (see paragraph 2.2.1.1) Air Filter
230 VAC Receptacle (see paragraph 2.4.18)
Figure 2–2. Machinery Plan
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Revision 01
Page 2-5
Load Control Tugger #2

XS226
(see Section 4)
Swing Drive #3
Swing Drive #2
S
CP1
Block Control Tugger

(see Section 4)
A3687
Swing Drive #1
Load Control Tugger #1

(see Section 4)
Operator’s Cab
(see figures 2–7 and 2–8)
Figure 2–2. Machinery Plan (continued)
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Revision 01
Page 2-6
Encoder Intermediate Shaft

Drum Brake
Actuator
Auxiliary Drum
Drum Brake
Pawl
Pawl Actuator
Main Drum Whip Drum
Drum Brake
Drum Gear
Drum Brake
Actuator
Gear Reducer
Motor Brake
Electric Motor
Motor Blower
Plan View
Main Drum Auxiliary Drum

Inhaul
Inhaul Inhaul
Whip Drum
Drum Brake
Actuator
Pawl
Bed
A3689
Intermediate Shaft
Elevation View
Figure 2–3. Main Hoist
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Revision 01
Page 2-7
Encoder Pawl Actuator

Brake Actuator
Drum Brake
Pawl
Drum
Intermediate Shaft
Drum Brake
Drum Gear
Brake Actuator
Gear Reducer
Motor Brake
Electric Motor
Motor Blower
Plan View Inhaul
Intermediate Shaft
Brake Actuator
Drum
Pawl
A3690 Bed
Elevation View
Figure 2–4. Boom Hoist
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Revision 01
Page 2-8
Encoder
Brake
Electric Motor
Gearbox
Pinion
Rotating Frame
Bullgear A3685
Figure 2–5. Swing Drive
Air Cylinder Pin (Raised Position)
Limit Switch Limit Switch
Pin (Lowered Position)
Rotating Frame
A3686
Hole in Tub
Figure 2–6. Swing Lock
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Revision 01
Page 2-9
2.2.1 Lighting System
2.2.1.1 Area Lighting
Table 2–1. Area Lighting

QUANTITY
OF LIGHT WATTAGE
LABEL SWITCH LOCATION AREA ILLUMINATED FIXTURES/ OF EACH
BULBS PER LAMP BULB
FIXTURE
Bottom of machinery house
access stairway (see figure 2–1) Exterior platforms and
22/1 100 W
Operator’s cab platform (see walkways
figure 2–1)
Inside machinery house, near Interior of machinery 32 W
20/2
each door (see figure 2–2) house (florescent)
Inside electrical house, near Interior of electrical 32 W
8/2
each door (see figure 2–2) house (florescent)
Machinery house roof,
Bottom of roof access ladders
electrical house roof, 16/1 100 W
(see figure 2–1)
and top of water tank
Bottom of A-frame stairway (see A-frame platforms and
9/1 100 W
figure 2–1) stairways
Bottom of crane tub access
Interior of crane tub 4/1 100 W
ladder
Beginning of boom walkway (see
Boom walkway 20/1 100 W
figure 2–1)
OP CAB Operator’s cab control console
LIGHT (figure 2–14, item 6)
Operator’s cab interior 1/2 40 W
Operator’s cab control console
DIMMER
(figure 2–14, item 7)
Operator’s cab control console
VISITOR (figure 2–14, item 1) Visitor’s cab interior 1/2 40 W
CAB LIGHT
Visitor’s cab (see figure 2–8)
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Revision 01
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2.2.1.2 Floodlighting 2.2.1.4 Emergency Lighting
Floodlighting is controlled by the push buttons Emergency lighting units are located inside the
located on the lighting control panel listed in machinery house above the exits and inside the
table 2–2. The push buttons are main- electrical house, above the exits (see figure
tained-contact illuminated push buttons that illu- 2–2). The lighting units provide battery-powered
minate green when the floodlight is on. light in case of electric power loss, for a mini-
mum of 90 minutes. Each emergency lighting
unit has two 9-watt incandescent lights. The
2.2.1.3 Obstruction Lights charge of the battery is maintained by the elec-
trical system when electric power is available to
A flashing red aircraft obstruction light is located the normal lighting circuit.
on the tip of the boom (see figure 2–1). Also a
pair of steady illuminated red aircraft obstruc-
tion lights are located on the boom and another
pair on the A-frame. The lights are controlled by
a light-sensing controller that turn the lights on
at dusk and off at dawn.
Table 2–2. Floodlighting

WATTAGE OF
FIGURE AND ITEM AREA QUANTITY OF
LABEL EACH
NUMBERS ILLUMINATED FLOODLIGHTS
FLOODLIGHT
MACHINE Work area in front
figure 2–14, item 9 4 1000 W
HOUSE FLOODS of machinery house
LOWER BOOM
figure 2–14, item 10 2 1000 W
FLOODS
MIDDLE BOOM Work area below
figure 2–14, item 11 2 1000 W
FLOODS boom
UPPER BOOM
figure 2–14, item 12 2 1000 W
FLOODS
Determined by
SPOT LIGHT figure 2–14, item 2 1 1000 W
operator
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Revision 01
Page 2-11
2.2.2 Operator’s Cab Nomenclature
Communication Radio Antenna

Anemometer
Electronic Compass
Lights (see paragraph 2.2.1.1)
Operator’s Cab Air Conditioning Unit
Visitor’s Cab Air Conditioning
(see paragraph 2.4.15)
Unit (see paragraph 2.4.15)
Searchlight
Visitor’s Cab Display
(see paragraph 2.2.1.2)
Sound-Powered
Telephone (see
paragraph 2.4.11)
DP3
Load Monitoring System

(LMS) Display (see
paragraph 2.4.5)
Closed Circuit Television

(CCTV) Monitor (qty 3)
Brake Pedal
A3683
Electrical Receptacle Distribution Control Console Load Monitoring System
(see paragraph 2.4.18) Panelboard DP3 (LMS) Horn (see
Visitor’s Cab paragraph 3.15.8 and
3.15.9)
Windshield Washer Reservoir
Figure 2–7. Operator’s Cab and Visitor’s Cab (Elevation View)
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Revision 01
Page 2-12
MAIN/AUXILIARY Horn (see paragraph 2.4.8) Closed Circuit Television

Brake Pedal (see (CCTV) Monitor (qty 3)
paragraph 2.6.3) (see paragraph 2.4.7)
Load Monitoring System

(LMS) Horn (see WHIP Brake Pedal
paragraph 3.15.8 and (see paragraph 2.6.4)
3.15.9)
Load Monitoring Defroster (see
System (LMS) Display paragraph 2.4.14)
Heater (see
BOOM Brake Pedal MAIN/AUX
WHIP
paragraph 2.4.13)
BO
OM
Right Control Console

Left Control Console (see figure 2–12)
(see figure 2–9)
Right Control Panel

Left Control Panel (see figure 2–13)
(see figure 2–10)
Sound-Powered
Telephone (see
Left Rear Control paragraph 2.4.11)
Panel (see figure 2–11)
Lighting Control Panel
Communication Radio (see figure 2–14)
VISITOR CAB LIGHT

Light (see push button (see
paragraph 2.2.1.1) paragraph 2.2.1.1)
Distribution Electrical Receptacle
Panelboard DP3 (see paragraph 2.4.18)
Windshield Washer Heater (see
Reservoir (see paragraph 2.4.13)
paragraph 2.4.12)
Visitor’s Cab
Visitor’s Cab Display
(see paragraph 2.4.6) Door
A3684
Figure 2–8. Operator’s Cab and Visitor’s Cab (Plan View)
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Revision 01
Page 2-13
2.3 Control Console Nomenclature
The controls of the operator’s cab control consoles (see figures 2–9 through 2–14) direct the
functioning of the crane equipment and show information important to the operation of the crane.
Detailed descriptions of the operator’s controls are given in the following paragraphs as outlined by the
table of contents. The control descriptions are divided into three groups: general control devices, power
control devices, and crane function control devices.
This legend refers to figure 2–9 on the following page.
ITEM
NUMBER DESCRIPTION
1 WHIP EMERGENCY BRAKE RELEASE (see paragraph 2.6.14)

2 System air pressure gauge (see paragraph 2.5.1)
3 HORN push button (see paragraph 2.4.8)
4 Swing drive brake release thumb button (see paragraph 2.6.5)
5 BOOM/SWING control (see paragraph 2.6.5)
6 BOOM/BOTH/SWING switch (see paragraph 2.6.6)

7 WIPERS UPPER control (see paragraph 2.4.12)
8 WIPERS LOWER control (see paragraph 2.4.12)
9 WIPERS TOP control (see paragraph 2.4.12)
10 MONITORS UPPER control (see paragraph 2.4.7)
11 MONITORS MIDDLE control (see paragraph 2.4.7)

12 MONITORS LOWER control (see paragraph 2.4.7)
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1
WHIP EMERGENCY
BRAKE RELEASE
2
BO B
OM OT
H
SW
IN
MONITORS G
WIPERS
UPPER 1 2 3 4
HO
RN
TOP UPPER L
E
MIDDLE 1 2 3 4 F T BO
T OU
T
P HU OM
BR US MB /S
AK H F BU WIN
E OR TT G
Page
RE S ON
IN LEAWIN R
SE G I
G
H
T
Revision
LOWER 1 2 3 4
LOWER
Figure 2–9. Left Control Console

5
4
3
Document number
A3681
01
9
8
7
11
12
10
2-14
BP5376-MAN-002
Revision 01
Page 2-15
4 5 6
BOOM SWING BOOM DRIVE SWING DRIVE HOIST DRIVE

PAWL OUT LOCK OUT READY READY READY
7
G G G G G
3
BOOM SWING BOOM SWING HOIST
PAWL IN LOCK IN SPEED SPEED SPEED
8
FU
FU
FU
4
4
1/
1/
1/
LL
LL
LL
R R
2 BOOM
LIMIT BYPASS
9
1 R
10
11
A3677
Figure 2–10. Left Control Panel
ITEM
NUMBER DESCRIPTION
1 SWING LOCK IN red illuminated push button (see paragraph 2.6.12)

2 BOOM PAWL IN red illuminated push button (see paragraph 2.6.10)
3 BOOM PAWL OUT green illuminated push button (see paragraph 2.6.10)
4 SWING LOCK OUT green illuminated push button (see paragraph 2.6.12)
5 BOOM DRIVE READY green indicator light (see paragraph 2.5.3)
6 SWING DRIVE READY green indicator light (see paragraph 2.5.3)

7 HOIST DRIVE READY green indicator light (see paragraph 2.5.3)
8 HOIST SPEED 14 / FULL switch (see paragraph 2.6.11)
9 SWING SPEED 14 / FULL switch (see paragraph 2.6.11)
10 BOOM SPEED 14 / FULL switch (see paragraph 2.6.11)
11 BOOM LIMIT BYPASS red illuminated push button (see paragraph 2.6.15)
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Revision 01
Page 2-16
E-RELEASE MAN RIDER CONTROL POWER CONTROL POWER

ENABLE MODE ON OFF
2 3
F
F
ON
ON
OF
OF
G
TUGGER LAMP/ALARM
4
1 CONTROL DRIVE RESET TEST
5
LO
CA
CA
OP
L
Tugger Control Device
(see Section 4)
A3678
Figure 2–11. Left Rear Control Panel
ITEM
NUMBER DESCRIPTION
1 MAN RIDER MODE OFF/ON key switch (see paragraph 2.6.9)

2 E-RELEASE ENABLE OFF/ON switch (see paragraph 2.6.13)
3 CONTROL POWER OFF push button (see paragraph 2.5.2)
4 CONTROL POWER ON green illuminated push button (see paragraph 2.5.2)
5 LAMP/ALARM TEST push button (see paragraph 2.4.4)
6 DRIVE RESET push button (see paragraph 2.5.3)
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Revision 01
Page 2-17
ITEM
NUMBER DESCRIPTION
1 WHIP SELECT green illuminated push button (see paragraph 2.6.8)

2 AUXILIARY SELECT green illuminated push button (see paragraph 2.6.8)
3 MAIN SELECT green illuminated push button (see paragraph 2.6.8)
4 HOIST control (see paragraph 2.6.7)
5 Load float thumb button (see paragraph 2.6.7)
6 EMERGENCY STOP push-pull switch (see paragraph 2.4.2)

7 EMERGENCY POWER OFF push-pull switch (see paragraph 2.4.3)
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Revision 01
Page 2-18
6 7
5
4
EM
ER
G
ST ENC
LO
WE OP Y
TH HO R EM
UM
BB T
IS ER
LO
AD
UT
TO G PO GEN
FL N W C
OF ER Y
RA OA
ISE T
M F
SE AIN
LE
CT
3 A
SE UX
LE
CT
2 G
W
SE HIP
1 LE
CT
LOAD CONTROL
TUGGER #2
Tugger Control Devices

BLOCK CONTROL
(see Section 4)
TUGGER
LOAD CONTROL
TUGGER #1
A3676
Figure 2–12. Right Control Console
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Revision 01
Page 2-19
Tugger Control Device Tugger Control Devices

(see Section 4) 5 6 7 8 (see Section 4)
TUGGER MAIN AUX WHIP

CONTROL PAWL IN PAWL IN PAWL IN STOP START STOP START STOP START
Y R R R G G G
MAIN AUX WHIP

PAWL OUT PAWL OUT PAWL OUT TENSION TENSION TENSION
4
G G G
3 MAIN LIMIT
BYPASS
AUX LIMIT
BYPASS
WHIP LIMIT
BYPASS TUGGER #2 TUGGER TUGGER #1
LOAD CONTROL BLOCK CONTROL LOAD CONTROL
R R R
2
MAIN AUX WHIP
E-RELEASE E-RELEASE E-RELEASE
A3680
12 11 10 9
Figure 2–13. Right Control Panel

ITEM
NUMBER DESCRIPTION
1 MAIN E-RELEASE push button (see paragraph 2.6.13)

2 MAIN LIMIT BYPASS red illuminated push button (see paragraph 2.6.15)
3 MAIN PAWL OUT green illuminated push button (see paragraph 2.6.10)
4 MAIN PAWL IN red illuminated push button (see paragraph 2.6.10)
5 AUXILIARY PAWL OUT green illuminated push button (see paragraph 2.6.10)
6 AUXILIARY PAWL IN red illuminated push button (see paragraph 2.6.10)

7 WHIP PAWL OUT green illuminated push button (see paragraph 2.6.10)
8 WHIP PAWL IN red illuminated push button (see paragraph 2.6.10)
9 WHIP LIMIT BYPASS red illuminated push button (see paragraph 2.6.15)
10 WHIP E-RELEASE push button (see paragraph 2.6.13)
11 AUXILIARY LIMIT BYPASS red illuminated push button (see paragraph 2.6.15)
12 AUXILIARY E-RELEASE push button (see paragraph 2.6.13)
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Revision 01
Page 2-20
1 2 3 4 5 6 7 8
VISITOR
CAB SPOT DEFROSTER
LIGHT LIGHT HEATER DEFROSTER MED
HI
W
F
ON
ON
OF
OF
G
LO
H
G G
G
UPPER MIDDLE LOWER MACHINE
BOOM BOOM BOOM HOUSE
FLOODS FLOODS FLOODS FLOODS OP CAB LIGHT DIMMER
G G G G 230 VAC 230 VAC
A3679
9 10 11 12
Figure 2–14. Lighting Control Panel

ITEM
NUMBER DESCRIPTION
1 VISITOR CAB LIGHT green illuminated push button (see paragraph 2.2.1.1)
2 SPOT LIGHT green illuminated push button (see paragraph 2.2.1.2)
3 HEATER OFF/ON switch (see paragraph 2.4.13)
4 DEFROSTER OFF/ON switch (see paragraph 2.4.14)
5 DEFROSTER LOW/MED/HIGH switch (see paragraph 2.4.14)
6 OPERATOR CAB LIGHT green illuminated push button (see paragraph 2.2.1.1)
7 DIMMER control (see paragraph 2.2.1.1)
8 230 VAC electrical receptacle (see paragraph 2.4.18)
9 MACHINE HOUSE FLOODS green illuminated push button (see paragraph 2.2.1.2)
10 LOWER BOOM FLOODS green illuminated push button (see paragraph 2.2.1.2)
11 MIDDLE BOOM FLOODS green illuminated push button (see paragraph 2.2.1.2)
12 UPPER BOOM FLOODS green illuminated push button (see paragraph 2.2.1.2)
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Revision 01
Page 2-21
2.4 General Control Devices
2.4.1 Solenoid Valve Override Plungers
!WARNING Override plunger
• The override plungers of all the

solenoid valves must be in the “out”
position during operation. Otherwise,
the emergency stop switches,
automatic shutdowns, and crane
controls will not function correctly.
• Do not actuate the override plunger of
a solenoid valve during normal Single solenoid valve
operation, even if the load or boom is
not moving. Unexpected equipment
movement including free fall of the
load or boom can result, causing
death, serious injury, and equipment
damage. For example, activating the
override plunger of a parking brake
solenoid valve causes the release of
the corresponding hoist drum parking
brake.
Solenoid valves (see figure 2–15) in the air

system have override plungers that must all be Double solenoid valve S896
in the “out” position during operation. The over- S897
ride plunger is located on the solenoid housing Figure 2–15. Typical Solenoid Valves
of the valve, inside a protective hexagonal
sleeve. The double-solenoid valves have two
solenoid housings, each with its own plunger.
See table 2–3 for the locations of these sole-
noid valves.
For further identification of the solenoid valves,

see the air system drawings in the Parts
Manual, Section 12.
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Revision 01
Page 2-22
Table 2–3. Air System Solenoid Valves

EQUIPMENT
LOCATION NUMBER OF VALVES VALVE TYPE
OPERATED
Hoist enable 1 Single solenoid valve
Boom hoist bed Drum parking brake 1 Single solenoid valve
Drum pawl 1 Double solenoid valve
Boom hoist motor bed Hoist motor brake 1 Single solenoid valve
Hoist enable 1 Single solenoid valve
1 per drum
Drum parking brake Single solenoid valve
(main, auxiliary, whip)
Main hoist bed 1 per drum
Drum pawl Double solenoid valve
1 per drum
Drum clutch Double solenoid valve
Main hoist motor bed Hoist motor brake 1 Single solenoid valve
Front of boom hoist bed Swing lock pin 1 Double solenoid valve
Machinery house wall (near Swing drive motor
3 Single solenoid valve
swing drive) brake
Tugger bed Tugger motor brake 3 Single solenoid valve
Operator’s left control console Air horn 1 Single solenoid valve
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Revision 01
Page 2-23
2.4.2 EMERGENCY STOP Switches Table 2–4. EMERGENCY STOP Switches

FIGURE
!WARNING LABEL LOCATION AND ITEM
• Pushing an EMERGENCY STOP switch NUMBERS
will engage the brakes of the tuggers. Operator’s cab,
EMERGENCY figure 2–12,
Engaging the brake of a tugger when right control
STOP item 6
the wire rope of the tugger is console
connected to a load can overload the Near machinery
tugger, foundation, and reeving system E-STOP house entrance figure 2–2
if the radius of the load increases due door
to vessel list or trim or outward drift of
the boom. Electrical
EMERGENCY
house, CP1 figure 2–2
STOP
panel
Push the knob of an EMERGENCY STOP
switch (see table 2–4) all the way down to Electrical
immediately stop all crane motions. The drive EMERGENCY house, Brake
figure 2–2
motors for the following crane functions stop STOP Chopper 1
and all corresponding brakes engage: panel
Electrical
• boom hoist EMERGENCY house, Brake
• main hoist - main drum, auxiliary drum, figure 2–2
STOP Chopper 2
whip drum panel
• swing drives
• tuggers
The swing lock pin, main hoist drum clutches, 2.4.3 EMERGENCY POWER OFF Switch
and the main hoist and boom hoist drum pawls
remain in the same position they were before
!WARNING
the emergency stop.
• Pushing the EMERGENCY POWER
The EMERGENCY STOP switches are main- OFF switch will engage the brakes of
tained position push-pull switches. Before the the tuggers. Engaging the brake of a
crane can be operated, the knobs of all the tugger when the wire rope of the
EMERGENCY STOP switches must be pulled tugger is connected to a load can
all the way out. To pull out the knob of the overload the tugger, foundation, and
E-STOP switch in the machinery house twist reeving system if the radius of the load
the knob to release its latch, and then pull the increases due to vessel list or trim or
knob all the way out. See Emergency Stop outward drift of the boom.
Procedure, paragraph 3.5.
Push the knob of the EMERGENCY POWER
OFF switch (figure 2–12, item 7), located on the
right control console, all the way down to
• activate the emergency stop trip coil of

disconnect switch DS1 (supplied by others)
in the tub
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Revision 01
Page 2-24
• immediately remove all incoming 440/690 V 2.4.5 Load Monitoring System (LMS)
electric power from transformer T205 Display
(supplied by others)
• remove all electrical power from the crane, The load monitoring system (LMS) display (see
immediately stopping all crane motions and figure 2–8), located in the operator’s cab, is for
engaging the corresponding brakes equipment monitoring, diagnostics, and instru-
ment calibration purposes.
The swing lock pin, main hoist drum clutches,
and the main hoist and boom hoist drum pawls The principal screens of the LMS display are
remain in the same position they were before listed below and shown in figure 2–16. The
the emergency power off. screens are described in more detail by the
following paragraphs:
The EMERGENCY POWER OFF switch is a • START screen (see paragraph 2.4.5.1)
maintained push-pull switch. Before the crane • HOIST screens (see paragraph 2.4.5.2)
can be operated, the knob of the switch must • ALL HOOKS screen (see paragraph
be pulled all the way out and disconnect switch 2.4.5.4)
DS1 must be closed. See Emergency Power • CRANE STATUS screens (see paragraph
Off Procedure, paragraph 3.5.1. 2.4.5.5)
• CALIBRATION screen (see paragraph
2.4.5.6)
2.4.4 LAMP/ALARM TEST Push Button • FAULT screen (see paragraph 2.4.5.7)
• CLOCK & DATE ADJUST screen (see
The LAMP/ALARM TEST push button (figure paragraph 2.4.5.8)
2–11, item 5), located on the left rear control
panel Operation of the LMS display is controlled by
an OFF/ON switch located on the back of the
• tests the indicator lights on the operator’s display.
cab control consoles
• changes the indicators and command NOTICE
button on the load monitoring system (LMS)
display (see paragraph 2.4.5) to a fault not • The CONTROL POWER ON push
active condition button (see paragraph 2.5.2) must be
illuminated for the LMS display to
When the LAMP/ALARM TEST push button is function.
pushed and held down, the lights on the control
consoles illuminate. The lights return to their The LMS measures the actual load on the
pre-test condition (either illuminated or extin- main, auxiliary, and whip falls and shows the
guished) when the push button is released. load on the screens. The LMS compares this
measured load to the values of a corresponding
The LAMP/ALARM TEST push button can be capacity chart to determine whether the crane
pushed at any time without affecting the opera- is capable of lifting the load at the current radius
tion of the controls. as calculated by the boom angle sensor. If the
LMS determines that an overload condition
exists, a warning indicator is shown on the
!WARNING screen and an audible alarm sounds. For the
• Do not operate the equipment with a main fall only, the operator must select which
failed indicator light. capacity chart the LMS is using to compare with
the measured load.
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Revision 01
Page 2-25
START
START
Screen
MAIN HOIST
Screen
MAIN HOIST
ALL HOOKS AUX HOIST WHIP HOIST MAIN HOIST FAULT
CHART
Screen Screen Screen STATUS Screen
SELECTION
Screen
Screen
AUX HOIST
Screen
ALL HOOKS MAIN HOIST WHIP HOIST AUX HOIST FAULT

Screen
WHIP HOIST
Screen
ALL HOOKS MAIN HOIST AUX HOIST WHIP HOIST FAULT

Screen
ALL HOOKS
Screen
MAIN HOIST AUX HOIST WHIP HOIST FAULT

Screen Screen Screen Screen
05
CRANE STATUS
Screen
BLOCK LOAD CONTROL LOAD CONTROL BUS STATUS

CONTROL TUGGER 1 TUGGER 2 BRAKE CHOPPER
TUGGER STATUS STATUS STATUS STATUS
PROFIBUS AUX HOIST

NETWORK RAW DATA SWING STATUS
Screen Screen STATUS
Screen Screen
CALIBRATION
Screen
(See Calibration
Procedures,
paragraph 4.62)
BOOM HOIST CRANE DRIVE MAIN HOIST WHIP HOIST
STATUS STATUS STATUS STATUS
FAULT
Screen
CLOCK & DATE ADJUST

ADJUST BRIGHTNESS
Screen Screen A3699
Figure 2–16. LMS Display Screen Organization
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2.4.5.1 START Screen • WHIP HOIST screen (see paragraph

2.4.5.2)
When the load monitoring system (LMS) display • ALL HOOKS screen (see paragraph
starts up, the START screen (see figure 2–17) 2.4.5.4)
shows. The START screen shows the date and • CRANE STATUS screens (see paragraph
time, equipment model number, the LMS soft- 2.4.5.5)
ware part number and revision level, and the • CALIBRATION screen (see paragraph
following warning: 2.4.5.6)
• FAULT screen (see paragraph 2.4.5.7)
!WARNING
• It is not the intent of the load monitor The background color on the screens of the
system to relieve the crane operator of LMS display that do not require a password can
the responsibility of determining safe be in black or white. Touch the DAY MODE or
crane working conditions. The LMS is NIGHT MODE command button to change the
only intended to be an aid to the background color selection. (The same
operator; giving information regarding command button is labeled DAY MODE or
the condition of the load and crane. NIGHT MODE to be the opposite of the current
background color selection).
From the START screen, the operator can go to
any of the following screens by touching the To adjust the system time and date, touch the
corresponding command button on the screen: date or time at the top of the screen to bring up
the CLOCK & DATE ADJUST screen (see para-
• MAIN HOIST screen (see paragraph graph 2.4.5.8).
2.4.5.2)
• AUX HOIST screen (see paragraph 2.4.5.2)
Figure 2–17. START Screen
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2.4.5.2 HOIST Screens
The MAIN HOIST screen (see figure 2–18),

AUX HOIST screen, and the WHIP HOIST
screen show information for the selected fall.
Select a screen by touching the corresponding
MAIN HOIST, AUX HOIST, or WHIP HOIST
command button on the START screen (see
paragraph 2.4.5.1), another HOIST screen, or
the ALL HOOKS screen (see paragraph
2.4.5.4).
See table 2–5 for a description of the indicators

and command buttons on the HOIST screens.
Figure 2–18. MAIN HOIST Screen
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Table 2–5. HOIST Screens

ITEM TYPE DESCRIPTION
• The presently selected main fall capacity chart (see paragraph
2.4.5.3). This only shows on the MAIN HOIST screen.
• MAN RIDER MODE shows as the selected capacity chart for the
Selected Capacity
Text whip fall when the MAN RIDER ENABLE OFF/ON key switch
Chart
(see paragraph 2.6.9) is in the ON position, otherwise
STANDARD MODE shows as the selected chart. This only
shows on the WHIP HOIST screen.
• The load on the corresponding main, auxiliary, or whip fall. The
LOAD (MT) Number
value is shown in metric tons (MT).
• The radius of the corresponding main, auxiliary, or whip fall. The
RADIUS (M) Number
value is shown in meters (M).
• The actual load on the corresponding main, auxiliary, or whip fall
shown as a percentage of load capacity.
• Shown numerically and as a bar graph with a range of 0–110
Number and percent.
% CAP
bar graph • Bar graph changes from normal green color to yellow near or at
overload conditions as explained in the 90% CAPACITY and
OVERLOAD warning indicators described elsewhere in this
table.
• The rated load capacity of the corresponding main, auxiliary, or
CAP (MT) Number whip fall for the present hook radius. The value is shown in
metric tons (MT).
DRUM SPEED • Speed of the corresponding main, auxiliary, or whip hoist drum.
Number
(RPM) The speed is shown in revolutions per minute (rpm).
SWING SPEED • Speed of crane rotation. The speed is shown in revolutions per
Number
(RPM) minute (rpm).
• The absolute height of the corresponding main, auxiliary, or whip
hook above the vessel deck. The value is shown in meters (M).
HOOK HT (M) Number
• The value is determined by an absolute encoder driven by the
corresponding hoist drum.
• The height of the corresponding main, auxiliary, or whip hook
relative to an arbitrary zero point that is set by the operator. To
REL HK HT (M) Number make the present hook height be the zero point, touch and hold
the REL HK HT command button for three seconds. The value is
shown in meters (M).
• Boom angle in degrees.
BOOM ANG. Number • Boom angle is determined by the boom angle sensor mounted
on the boom.
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Table 2–5. HOIST Screens (continued)

• Crane machine list angle (cross angle) in degrees. The machine
list angle is positive when the left side of the crane is lower than
MACHINE LIST the right side.
Number
ANG. • Machine list angle is determined by a dual-axis inclinometer
located inside the left-hand control console sub panel in the
operator’s cab.
• Crane machine trim angle (heel angle) in degrees. The machine
trim angle is positive when the front (boom side) of the crane is
MACHINE TRIM lower than the rear.
Number
ANG. • Machine trim angle is determined by a dual-axis inclinometer
located inside the left-hand control console sub panel in the
operator’s cab.
WIND • Wind direction as determined by the electronic compass (see
Number
DIRECTION figure 2–7) located on the roof of the operator’s cab.
• Wind speed as measured by the anemometer (see figure 2–7)
WIND SPEED
Number located on the roof of the operator’s cab. The value is shown in
(KPH)
kilometers per hour (KPH).
• Visible when the rated load capacity of the corresponding main,
auxiliary, or whip fall reaches one of the following limits. Not visi-
[fall] NO Red
ble otherwise. Only one of the following indicators is shown at a
CAPACITY indicator
time.
• Red [fall] NO CAPACITY indicator shows for the corresponding
main, auxiliary, or whip fall when the fall is outside the operating
range specified on the capacity chart (see paragraph 3.15.7). Do
[fall] 90% Yellow not lift a load when this warning indicator is showing.
CAPACITY indicator • Yellow [fall] 90% CAPACITY indicator shows for the correspond-
ing main, auxiliary, or whip fall when the fall is at 90 percent or
more of its rated load capacity for the present hook radius (see
paragraph 3.15.8). In addition, the % CAP bar graph changes to
[fall] 110% Red yellow.
OVERLOAD indicator • Red [fall] OVERLOAD indicator flashes for the corresponding
main, auxiliary, or whip fall when the fall is at 110 percent or
paragraph 3.15.9). In addition, the % CAP bar graph changes to
yellow.
MULTI-HOOK Yellow
• Yellow [fall] MULTI-HOOK WARNING indicator shows when
WARNING indicator
more than 20 percent of the rated load capacity is detected on
any two falls at the same time.
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• Visible when one of the following lower operating limits is acti-
[fall] ROPE vated for the corresponding main, auxiliary, or whip fall. Not visi-
Yellow
LOWER LIMIT ble otherwise. Only one of the following indicators is shown at a
indicator
WARNING time.
• Yellow [fall] ROPE LOWER LIMIT WARNING indicator shows
when the corresponding main, auxiliary, or whip fall is near its
lower operating limit (see paragraph 3.15.4).
[fall] ROPE Red
• Red [fall] ROPE LOWER LIMIT indicator shows when the corre-
LOWER LIMIT indicator
sponding main, auxiliary, or whip fall has reached its lower oper-
ating limit (see paragraph 3.15.4).
• Visible when one of the following anti–two-block limits is acti-
[fall] ANTI-TWO- vated for the corresponding main, auxiliary, or whip fall. Not visi-
Yellow
BLOCK ble otherwise. Only one of the following indicators is shown at a
indicator
WARNING time.
• Yellow [fall] ANTI-TWO-BLOCK WARNING indicator shows
when the corresponding main, auxiliary, or whip fall is near the
anti–two-block limit (see paragraph 3.15.3).
[fall] ANTI-TWO- Red
• Red [fall] ANTI-TWO-BLOCK LIMIT indicator shows when the
BLOCK LIMIT indicator
corresponding main, auxiliary, or whip fall reaches the
anti–two-block limit (see paragraph 3.15.3).
• Shows the position of the corresponding main or auxiliary fall
[fall] HOOK NOT Green
block in relation to the block pocket. Only one of the following
IN POCKET indicator
indicators is shown at a time.
• Green [fall] HOOK NOT IN POCKET indicator shows when the
[fall] HOOK corresponding main or auxiliary fall block is not in the block
Yellow
ENTERING pocket.
indicator
POCKET • Yellow [fall] HOOK ENTERING POCKET indicator shows when
the corresponding main or auxiliary fall block is entering the
block pocket.
[fall] HOOK IN Red
• Red [fall] HOOK IN POCKET indicator shows when the corre-
POCKET indicator
sponding main or auxiliary fall block is positioned in the block
pocket.
AUX HOOK • Red AUX HOOK DEEP IN POCKET indicator flashes when the
Red
DEEP IN auxiliary fall block is raised too far in the block pocket (see para-
indicator
POCKET graph 3.14.5).
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• Visible when one of the following reduced speed modes is
50% SPEED active. Not visible otherwise. Only one of the following yellow
MODE indicators is shown at a time.
• 50% SPEED MODE indicator shows when the MAN RIDER
ENABLE OFF/ON key switch (see paragraph 2.6.9) is in the ON
QUARTER Yellow
position.
SPEED MODE indicator
• QUARTER SPEED MODE indicator shows when a slowdown
limit is active, or when a SPEED 14 / FULL switch (see para-
5% SPEED graph 2.6.11) is in the 14 position.
MODE • 5% SPEED MODE indicator shows when the PAWL IN push
button (see paragraph 2.6.10) is flashing.
• Visible when one of the following boom travel limits is activated.
BOOM TRAVEL Yellow Not visible otherwise. Only one of the following indicators is
SLOW DOWN indicator shown at a time.
• Yellow BOOM TRAVEL SLOW DOWN indicator shows when the
BOOM UPPER Red boom slowdown limit is activated to reduce the speed of the
TRAVEL LIMIT indicator boom to 25 percent of the normal speed.
• Red BOOM UPPER TRAVEL LIMIT indicator shows when the
boom upper limit is reached (see paragraph 3.15.1).
BOOM LOWER Red
• Red BOOM LOWER TRAVEL LIMIT indicator shows when the
TRAVEL LIMIT indicator
boom lower limit is reached (see paragraph 3.15.2).
• Visible when one of the following machine list angle (cross
MACHINE LIST angle) or machine trim angle (heel angle) limits is activated. Not
ANGLE LIMIT visible otherwise. Only one of the following red indicators is
shown at a time.
• MACHINE LIST ANGLE LIMIT indicator shows when the
MACHINE TRIM machine list angle is outside the permitted operating range for
ANGLE LIMIT Red
the selected capacity chart.
indicator
• MACHINE TRIM ANGLE LIMIT indicator shows when the
machine trim angle is outside the permitted operating range for
MACHINE LIST the selected capacity chart.
AND TRIM • MACHINE LIST AND TRIM LIMITS indicator shows when both
LIMITS the machine list and machine trim angle are outside the permit-
ted operating range for the selected capacity chart.
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• Visible when one of the following power management system
(PMS) modes of operation is activated. Not visible otherwise.
Yellow The PMS monitors the status of the drive rectifiers and braking
PMS 1 MODE chopper equipment. The PMS sends a signal on equipment
indicator
availability to the programmable logic controller (PLC). The
crane then reduces power as necessary by reducing function
speed to match the mode. Only one of the following indicators is
shown at a time.
• Yellow PMS 1 MODE indicator shows when two of the three
Yellow drive rectifiers are operating normally. Operation of the boom,
PMS 2 MODE
indicator main, auxiliary, or whip function that is first operated is limited to
75 percent of the normal maximum speed. The boom, main,
auxiliary, or whip function that is operating must be completely
stopped before another boom, main, auxiliary, or whip function
can be operated. All other functions operate at normal speed.
• Yellow PMS 2 MODE indicator shows when one of the three
Red drive rectifiers are operating normally. Operation of the boom,
PMS 3 MODE
• Red PMS 3 MODE indicator flashes when none of the drive
Yellow rectifiers are operating normally. All functions are disabled.
PMS 4 MODE
indicator • Yellow PMS 4 MODE indicator shows when one of the two brak-
ing choppers is operating normally. Operation of the boom,
main, auxiliary, or whip function that is first operated is limited to
Red can be operated. All other functions operate at normal speed.
PMS 5 MODE
indicator • Red PMS 5 MODE indicator flashes when none of the braking
choppers are operating normally. All functions operate at 10
percent of the normal maximum speed.
Command
ALL HOOKS • Selects the ALL HOOKS screen (see paragraph 2.4.5.4).
button
Command
MAIN HOIST • Selects the MAIN HOIST screen.
button
Command
AUX HOIST • Selects the AUX HOIST screen.
button
Command
WHIP HOIST • Selects the WHIP HOIST screen.
button
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Command
START SCREEN • Selects the START screen (see paragraph 2.4.5.1).
button
• Selects the MAIN HOIST CHART SELECTION screen (see
Command
MAIN CHARTS paragraph 2.4.5.3). This command button is only on the MAIN
button
HOIST screen.
Command • Selects the MAIN HOIST STATUS Screen (see paragraph
MAIN STATUS
button 2.4.5.5).
Command • Selects the AUX HOIST STATUS Screen (see paragraph
AUX STATUS
button 2.4.5.5).
Command • Selects the WHIP HOIST STATUS Screen (see paragraph
WHIP STATUS
button 2.4.5.5).
• Selects the FAULT screen (see paragraph 2.4.5.7). Command
Command
FAULT SCREEN button changes to alternately flash yellow and red when a fault
button
condition shown on the FAULT screen is active.
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2.4.5.3 MAIN HOIST CHART

!WARNING
SELECTION Screen
• Select the correct capacity chart that
The MAIN HOIST CHART SELECTION screen corresponds to the operating
(see figure 2–19) permits selection of the main condition for the crane. Not following
hoist capacity chart that is used by the load this procedure can give inaccurate
monitoring system (LMS) to compare with the load capacity readings and prevent the
measured load. Select the screen by touching safety warning messages and overload
the MAIN CHARTS command button on the automatic stop from operating,
MAIN HOIST screen (see paragraph 2.4.5.2). resulting in damage to the crane and
death or injury to personnel.
The command button is orange for the selected
chart. To change the capacity chart used by the To exit the MAIN HOIST CHART SELECTION
LMS, touch the desired capacity chart screen and return to the previous screen, touch
command button. the EXIT command button at the bottom of the
screen.
Figure 2–19. MAIN HOIST CHART SELECTION Screen
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2.4.5.4 ALL HOOKS Screen
The ALL HOOKS screen (see figure 2–20)

shows information for the main fall, auxiliary
fall, and the whip fall. Select the screen by
touching the ALL HOOKS command button on
the START screen (see paragraph 2.4.5.1) or
on any of the HOIST screens (see paragraph
2.4.5.2).
See table 2–6 for a description of the indicators

and command buttons on the ALL HOOKS
screen.
Figure 2–20. ALL HOOKS Screen
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Table 2–6. ALL HOOKS Screen

• The presently selected main fall capacity chart (see paragraph
2.4.5.3).
Selected Capacity • MAN RIDER MODE shows as the selected capacity chart for the
Text
Chart whip fall when the MAN RIDER ENABLE OFF/ON key switch
(see paragraph 2.6.9) is in the ON position, otherwise
STANDARD MODE shows as the selected chart.
• The load on the main, auxiliary, and whip fall. The value is
LOAD (MT) Number
shown in metric tons (MT).
• The radius of the main, auxiliary, and whip fall. The value is
RADIUS (M) Number
DRUM SPEED • Speed of the main, auxiliary, and whip hoist drum. The speed is
Number
(RPM) shown in revolutions per minute (rpm).
• The actual load on the main, auxiliary, and whip fall shown as a
% CAP Number
percentage of load capacity.
• The rated load capacity of the main, auxiliary, and whip fall for
CAP (MT) Number
the present hook radius. The value is shown in metric tons (MT).
• The absolute height of the main, auxiliary, and whip hook above
the vessel deck. The value is shown in meters (M).
HOOK HT (M) Number
• The value is determined by an absolute encoder driven by the
corresponding hoist drum.
• The height of the main, auxiliary, and whip hook relative to an
REL HK HT (M) Number arbitrary zero point that is set by the operator. The value is
• Boom angle in degrees.
BOOM ANG. Number • Boom angle is determined by the boom angle sensor mounted
on the boom.
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Table 2–6. ALL HOOKS Screen (continued)

• Crane list angle (cross angle) in degrees. The list angle is posi-
tive when the left side of the crane is lower than the right side.
LIST ANG. Number • List angle is determined by a dual-axis inclinometer located
inside the left-hand control console sub panel in the operator’s
cab.
• Crane trim angle (heel angle) in degrees. The trim angle is posi-
tive when the front (boom side) of the crane is lower than the
rear.
TRIM ANG. Number
• Trim angle is determined by a dual-axis inclinometer located
inside the left-hand control console sub panel in the operator’s
cab.
WIND • Wind direction as determined by the electronic compass (see
Number
DIRECTION figure 2–7) located on the roof of the operator’s cab.
• Wind speed as measured by the anemometer (see figure 2–7)
WIND SPEED
Number located on the roof of the operator’s cab. The value is shown in
(KPH)
kilometers per hour (KPH).
SWING SPEED • Speed of crane rotation. The speed is shown in revolutions per
Number
(RPM) minute (rpm).
• Visible when the rated load capacity of the corresponding main,
[fall] NO Red auxiliary, or whip fall reaches one of the following limits. Not visi-
CAPACITY indicator ble otherwise. Only one of the following indicators is shown at a
time.
• Red [fall] NO CAPACITY indicator shows for the corresponding
main, auxiliary, or whip fall when the fall is outside the operating
[fall] 90% Yellow range specified on the capacity chart (see paragraph 3.15.7). Do
CAPACITY indicator not lift a load when this warning indicator is showing.
• Yellow [fall] 90% CAPACITY indicator shows for the correspond-
ing main, auxiliary, or whip fall when the fall is at 90 percent or
[fall] 110% Red paragraph 3.15.8).
OVERLOAD indicator • Red [fall] OVERLOAD indicator flashes for the corresponding
main, auxiliary, or whip fall when the fall is at 110 percent or
paragraph 3.15.9).
MULTI-HOOK Yellow • Yellow [fall] MULTI-HOOK WARNING indicator shows when
WARNING indicator more than 20 percent of the rated load capacity is detected on
any two falls at the same time.
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• Shows the position of the corresponding main or auxiliary fall
[fall] NOT IN Green indi-
block in relation to the block pocket. Only one of the following
POCKET cator
indicators is shown at a time.
• Green [fall] NOT IN POCKET indicator shows when the corre-
[fall] ENTERING Yellow sponding main or auxiliary fall block is not in the block pocket.
POCKET indicator • Yellow [fall] ENTERING POCKET indicator shows when the
corresponding main or auxiliary fall block is entering the block
Red pocket.
[fall] IN POCKET
indicator • Red [fall] IN POCKET indicator shows when the corresponding
main or auxiliary fall block is positioned in the block pocket.
AUX DEEP IN Red • Red AUX DEEP IN POCKET indicator flashes when the auxiliary
POCKET indicator fall block is raised too far in the block pocket (see paragraph
3.14.5).
• Visible when one of the following operating limits is activated for
[fall] LOWER Yellow the corresponding main, auxiliary, or whip fall. Not visible other-
WARNING indicator wise. Only one of the following indicators is shown at a time.
• Yellow [fall] LOWER WARNING indicator shows when the corre-
sponding main, auxiliary, or whip fall is near its lower operating
[fall] LOWER Red limit (see paragraph 3.15.4).
LIMIT indicator • Red [fall] LOWER LIMIT indicator shows when the correspond-
ing main, auxiliary, or whip fall has reached its lower operating
limit (see paragraph 3.15.4).
[fall] A2B Yellow • Yellow [fall] A2B WARNING indicator shows when the corre-
WARNING indicator sponding main, auxiliary, or whip fall is near the anti–two-block
limit (see paragraph 3.15.3).
• Red [fall] A2B LIMIT indicator shows when the corresponding
Red
[fall] A2B LIMIT main, auxiliary, or whip fall reaches the anti–two-block limit (see
indicator
paragraph 3.15.3).
• Visible when one of the following boom travel limits is activated.
BOOM SLOW Yellow Not visible otherwise. Only one of the following indicators is
DOWN indicator shown at a time.
• Yellow BOOM SLOW DOWN indicator shows when the boom
BOOM UPPER Red slowdown limit is activated to reduce the speed of the boom to
LIMIT indicator 25 percent of the normal speed.
• Red BOOM UPPER LIMIT indicator shows when the boom
upper limit is reached (see paragraph 3.15.1).
BOOM LOWER Red
• Red BOOM LOWER LIMIT indicator shows when the boom
LIMIT indicator
lower limit is reached (see paragraph 3.15.2).
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• Visible when one of the following list angle (cross angle) or trim
LIST ANGLE angle (heel angle) limits is activated. Not visible otherwise. Only
LIMIT one of the following red indicators is shown at a time.
• LIST ANGLE LIMIT indicator shows when the list angle is
outside the permitted operating range for the selected capacity
TRIM ANGLE Red chart.
LIMIT indicator • TRIM ANGLE LIMIT indicator shows when the trim angle is
outside the permitted operating range for the selected capacity
chart.
LIST & TRIM • LIST & TRIM LIMITS indicator shows when both the list and trim
LIMITS angle are outside the permitted operating range for the selected
capacity chart.
• Visible when one of the following reduced speed modes is
50% SPEED active. Not visible otherwise. Only one of the following yellow
MODE indicators is shown at a time.
• 50% SPEED MODE indicator shows when the MAN RIDER
ENABLE OFF/ON key switch (see paragraph 2.6.9) is in the ON
QUARTER Yellow
position.
SPEED MODE indicator
• QUARTER SPEED MODE indicator shows when a slowdown
limit is active, or when a SPEED 14 / FULL switch (see para-
5% SPEED graph 2.6.11) is in the 14 position.
MODE • 5% SPEED MODE indicator shows when the PAWL IN push
button (see paragraph 2.6.10) is flashing.
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• Visible when one of the following power management system
(PMS) modes of operation is activated. Not visible otherwise.
Yellow The PMS monitors the status of the drive rectifiers and braking
PMS 1 MODE chopper equipment. The PMS sends a signal on equipment
indicator
availability to the programmable logic controller (PLC). The
crane then reduces power as necessary by reducing function
speed to match the mode. Only one of the following indicators is
shown at a time.
• Yellow PMS 1 MODE indicator shows when two of the three
Yellow drive rectifiers are operating normally. Operation of the boom,
PMS 2 MODE
• Yellow PMS 2 MODE indicator shows when one of the three
Red drive rectifiers are operating normally. Operation of the boom,
PMS 3 MODE
• Red PMS 3 MODE indicator flashes when none of the drive
Yellow rectifiers are operating normally. All functions are disabled.
PMS 4 MODE
indicator • Yellow PMS 4 MODE indicator shows when one of the two brak-
ing choppers is operating normally. Operation of the boom,
main, auxiliary, or whip function that is first operated is limited to
Red can be operated. All other functions operate at normal speed.
PMS 5 MODE
indicator • Red PMS 5 MODE indicator flashes when none of the braking
choppers are operating normally. All functions operate at 10
percent of the normal maximum speed.
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Command
MAIN HOIST • Selects the MAIN HOIST screen (see paragraph 2.4.5.2).
button
Command
AUX HOIST • Selects the AUX HOIST screen (see paragraph 2.4.5.2).
button
Command
WHIP HOIST • Selects the WHIP HOIST screen (see paragraph 2.4.5.2).
button
Command
START SCREEN • Selects the START screen (see paragraph 2.4.5.1).
button
• Selects the FAULT screen (see paragraph 2.4.5.7). Command
Command
FAULT SCREEN button changes to alternately flash yellow and red when a fault
button
condition shown on the FAULT screen is active.
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2.4.5.5 CRANE STATUS Screens ments are met if the circular indicator for the
row illuminates green. If there is more than one
To monitor the status of the control system permissive in a column, the indicators for the
permissives and the equipment parts, select the permissives that are not met are shown as text.
CRANE STATUS screen (see figure 2–21).
Select the CRANE STATUS screen by touching The status of the equipment parts is shown by
the CRANE STATUS command button on the an indicator. If an equipment part is in the state
START screen (see paragraph 2.4.5.1). shown, the indicator illuminates green. If an
equipment part is not in the state shown, the
From the CRANE STATUS screen, the operator indicator is shown as text.
can go to any of the following screens by touch-
ing the corresponding command button on the Some of the indicators can activate a fault
CRANE STATUS screen: condition. The indicators that activate a fault
condition are normally shown as text. If a fault
• BLOCK CONTROL TUGGER STATUS condition is active, the corresponding indicator
screen (see figure 2–22) illuminates yellow or red as shown on the
• LOAD CONTROL TUGGER STATUS STATUS screen. The corresponding fault is
screen (see figure 2–23) listed on the FAULT screen (see paragraph
• BUS STATUS and BRAKE CHOPPER 2.4.5.7) and the FAULT SCREEN command
STATUS screen (see figure 2–24) button on the START screen (see paragraph
• PROFIBUS NETWORK screen (see figure 2.4.5.1), the HOIST screens (see paragraph
2–31) 2.4.5.2), and the ALL HOOKS screen (see
• RAW DATA Screen (see figure 2–32) paragraph 2.4.5.4) alternately flashes yellow
• SWING STATUS screen (see figure 2–25) and red.
• AUX HOIST STATUS screen (see figure
2–26)
• BOOM HOIST STATUS screen (see figure
2–27)
• CRANE DRIVE STATUS screen (see figure
2–28)
• MAIN HOIST STATUS screen (see figure
2–29)
• WHIP HOIST STATUS screen (see figure
2–30)
The status screens (see figures 2–22 through

2–30) can show:
• control system permissives status

• control system run permissive interlock
(RPI) status
• equipment part status
• motor information
Each permissive is shown by an indicator. For

the corresponding equipment to function, all the
required permissives must be met. All require-
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Table 2–7. CRANE STATUS Screens

MOTOR RPM • Speed of the corresponding motor. The speed is shown in revo-
Number
MOTOR SPEED lutions per minute (rpm).
• Speed of the hoist drum. The speed is shown in revolutions per
DRUM RPM Number
minute (rpm).
MOTOR AMPS
• The electric current draw of the corresponding motor. The
MOTOR Number
current is shown in amperes (A).
CURRENT
• The temperature of the corresponding motor. The temperature is
MOTOR TEMP Number
shown in degrees Celsius (C).
• Speed of crane rotation. The speed is shown in revolutions per
SWING SPEED Number
minute (rpm).
Figure 2–21. CRANE STATUS Screen
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Figure 2–22. BLOCK CONTROL TUGGER STATUS Screen
Figure 2–23. LOAD CONTROL TUGGER STATUS Screen—Typical
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Figure 2–24. BUS STATUS and BRAKE CHOPPER STATUS Screen
Figure 2–25. SWING STATUS Screen
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Figure 2–26. AUX HOIST STATUS Screen
Figure 2–27. BOOM HOIST STATUS Screen
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Figure 2–28. CRANE DRIVE STATUS Screen
Figure 2–29. MAIN HOIST STATUS Screen
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Figure 2–30. WHIP HOIST STATUS Screen
To monitor the status of the profibus network

connections, select the PROFIBUS NETWORK
screen (see figure 2–31). The connection indi-
cators are normally green (fault condition not
active). If a fault condition is active, the corre-
sponding indicator illuminates red.
To view the raw data that the information shown

on the operating screens is based on, select
the RAW DATA screen (see figure 2–32). Raw
data is shown for the hoist encoder counts,
hoist motor temperatures, load pins, load links,
cross, boom and heel angle sensors, and oper-
ator control speed and tension references. The
information shown on the RAW DATA screen
can be useful for maintenance or inspection
purposes.
To exit a screen and return to the previous

screen, touch the EXIT command button at the
bottom of the screen.
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Figure 2–31. PROFIBUS NETWORK Screen
Figure 2–32. RAW DATA Screen
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2.4.5.6 CALIBRATION Screens If a fault condition is active:
The calibration screens are used to calibrate • a description of the fault condition is listed
the: with the date and time that the fault
became active
• Boom angle (see paragraph 5.5.1.3) • the FAULT SCREEN command button on
• Hook height, load zero point, load span the START screen (see paragraph 2.4.5.1),
point, and load shunt for the main, auxiliary, the HOIST screen (see paragraph 2.4.5.2),
and whip hoist (see paragraph 5.5.1.4) and the ALL HOOKS screen (see para-
• Cross and heel angle (see paragraph graph 2.4.5.4) alternately flashes yellow
5.5.1.9) and red
Select the CALIBRATION screen by touching
the CALIBRATE command button on the If there are more faults listed than can be
START screen (see paragraph 2.4.5.1). displayed on screen, use the scroll bar to scroll
through the list of faults.
2.4.5.7 FAULT Screen The fault remains listed, and the FAULT
SCREEN command button alternately flashes
To determine what fault conditions are active, yellow and red until the fault is no longer active
select the FAULT screen (see figure 2–33). and the LAMP/ALARM TEST push button (see
Select the FAULT screen by touching the paragraph 2.4.4) has been pressed.
FAULT SCREEN command button on the
START screen (see paragraph 2.4.5.1), the To exit the FAULT screen and return to the
HOIST screen (see paragraph 2.4.5.2), or the previous screen, touch the EXIT command
ALL HOOKS screen (see paragraph 2.4.5.4). button at the bottom of the screen.
Figure 2–33. FAULT Screen
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2.4.5.8 CLOCK & DATE ADJUST Screen To adjust the brightness of the load monitoring
system (LMS) display screens, touch the
To adjust the system time and date, select the BRIGHTNESS command button at the bottom
CLOCK & DATE ADJUST screen (see figure of the screen to view the ADJUST
2–34). Select the CLOCK & DATE ADJUST BRIGHTNESS screen (see paragraph 2.4.5.9).
screen by touching the date or time on the
START screen (see paragraph 2.4.5.1). To exit the CLOCK & DATE ADJUST screen
and return to the previous screen, touch the
1. Touch any of the following command EXIT command button at the bottom of the
buttons to adjust the corresponding value: screen.
• SET HOUR
• SET MINUTE
• AM/PM
• SET MONTH
• SET DAY
• SET YEAR
2. Enter the new value using the data entry

keypad (see paragraph 2.4.5.10).
3. Touch the SET DATE AND TIME command

button.
Figure 2–34. CLOCK & DATE ADJUST Screen
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2.4.5.9 ADJUST BRIGHTNESS Screen Touch the BRIGHTNESS (1-100) command

button to bring up the data entry keypad (see
To adjust the brightness of the load monitoring paragraph 2.4.5.10). Enter the desired value
system (LMS) display screens, select the using the data entry keypad. A higher value
ADJUST BRIGHTNESS screen (see figure increases the brightness of the screen display.
2–35). Select the ADJUST BRIGHTNESS A lower value decreases the brightness of the
screen by touching the BRIGHTNESS screen display.
command button on the CLOCK & DATE
ADJUST screen (see paragraph 2.4.5.8). To exit the ADJUST BRIGHTNESS screen and
return to the previous screen, touch the EXIT
Touch the UP command button to increase the command button at the bottom of the screen.
brightness of the screen display.
Touch the DOWN command button to decrease

the brightness of the screen display.
Figure 2–35. ADJUST BRIGHTNESS Screen
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2.4.5.10 Data Entry Keypad 2.4.6 Visitor’s Cab Display
When an input button on the load monitoring The visitor’s cab display (see figure 2–8),
system (LMS) display is touched, the on-screen located in the visitor’s cab, shows the same
data entry keypad (see figure 2–36) shows on equipment monitoring and diagnostic screens
the display. as the load monitoring system (LMS) display
(see paragraph 2.4.5). The calibration screens
The current value is shown in the entry field. are not available on the visitor’s cab display.
The minimum (low) and maximum (high) entry NOTICE

values are shown.
• The CONTROL POWER ON push
button (see paragraph 2.5.2) must be
Use the Backspace button to backspace and
illuminated for the visitor’s cab display
delete characters.
to function.
Use the Clear button to clear the entry.
Operation of the visitor’s cab display is
1. Touch the numeric buttons and the OK controlled by an OFF/ON switch on the back of
button to enter a new value. If the value is the display.
out of range or otherwise incorrect, the
display will beep and a warning message
flashes. 2.4.7 MONITORS Controls and Closed
Circuit Television (CCTV) System
2. If the data is valid when the OK button is
touched, the value is sent to the program- Four video cameras (see figure 2–2) are
mable logic controller (PLC) and the normal located in the machinery house above the
screen will show. hoists. Each camera is aimed to view a different
hoist drum. The view of the cameras can be
seen on the three monitors (see figure 2–8)
located in the operator’s cab. Use the push
buttons of a MONITORS control (see table
2–8), located on the left control console, to
select any of the four possible cameras for
viewing on the corresponding monitor. See the
Manufacturer's information for the operation
instructions. See the Vendor Data Manual,
Pelco.
Table 2–8. MONITORS Controls

FIGURE AND ITEM
LABEL
NUMBERS
Figure 2–36. Data Entry Keypad UPPER figure 2–9, item 10
MIDDLE figure 2–9, item 11
LOWER figure 2–9, item 12
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2.4.8 HORN Push Button Turn the knob of the WIPERS control clockwise
to start and operate the wiper. The more the
The HORN push button, (figure 2–9, item 3), control is rotated clockwise, the faster the wiper
located on the left control console, sounds the will operate.
horn (see figure 2–8) located below the front of
the operator’s cab. The push button is a Turn the knob all the way counterclockwise to
momentary-contact push button. Push and hold return the wiper to its parking position and stop
down the HORN push button to sound the horn. the wiper.
Push the knob of the WIPERS control to spray

2.4.9 Boom Angle Indicator washer fluid on the corresponding window. The
reservoirs for the washer fluid are located on
The boom angle indicator (see figure 2–1) is the floor in the visitor's cab, on the left wall (see
located on the boom and can be viewed from figure 2–8).
the operator’s cab. The mechanical pointer
points to the dial marking that represents the Table 2–9. WIPERS Controls
current boom angle in degrees from horizontal.
FIGURE AND ITEM
LABEL
NUMBERS
2.4.10 Swing Warning Light and Alarm TOP figure 2–9, item 9
UPPER figure 2–9, item 7
The swing warning light and alarm (see figure
LOWER figure 2–9, item 8
2–1), located on the machinery deck access
stairway, flashes yellow and sounds when the
crane is rotating.
2.4.13 HEATER OFF/ON Switch
2.4.11 Sound-Powered Telephones The HEATER OFF/ON switch (figure 2–14,

item 3) located on the lighting control panel,
The crane is equipped with three eight station controls the space heaters (see figure 2–8)
sound-powered telephones that permit commu- located in the operator’s cab and the visitor’s
nication with vessel personnel. One cab. The switch is a two-position selector
sound-powered telephone is located in the switch.
operator’s cab (see figure 2–7). Two sound-
powered telephones are located in the machin- In the ON position, the heaters are controlled
ery house, one in the machinery room and one by thermostats, operating only as needed.
in the electrical house (see figure 2–2). For the
operating instructions, see the telephone manu- In the OFF position, the heaters do not operate.
facturer’s information.
2.4.12 WIPERS Controls
The WIPERS controls (see table 2–9), located

on the left control console, control the corre-
sponding window wiper of the operator’s cab.
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2.4.14 DEFROSTER OFF/ON Switch and 2.4.17 Fire Extinguishers

DEFROSTER LOW/MED/HIGH
Switch Three fire extinguishers are located in the
machinery house (see figure 2–2) and one is
The DEFROSTER OFF/ON switch (figure 2–14, located in the visitor’s cab (location determined
item 4), located on the lighting control panel, by others).
controls the window defroster (see figure 2–8)
located at the bottom of the front window of the
operator’s cab. The switch is a two-position 2.4.18 Electrical Receptacles
selector switch.
Electrical receptacles are located as listed in
In the ON position, the window defroster is table 2–10.
controlled by a thermostat, and operates only
as needed. Table 2–10. Electrical Receptacles
LOCATION QUANTITY VOLTAGE
In the OFF position, the window defroster does
not operate. Operator’s
cab control 3 (duplex)
The temperature range of the window defroster console
output air is controlled by the DEFROSTER Visitor’s cab 1
LOW/MED/HIGH switch (item 5).
Machinery
4 230 VAC,
house
1 ph, 50 Hz
2.4.15 Operator’s Cab and Visitor’s Cab Electrical
2
Air Conditioning Controls house
Mast 2
The controls for the air conditioning units for the Boom
operator’s cab (see figure 2–7) and the visitor’s 2
walkway
cab are located on the control panels of the
units, on the cab ceiling. See the manufac-
turer’s information for the operating instructions,
see the Vendor Data Manual, RVP.
2.4.16 Electrical House Air Conditioning

and Heating Thermostats
The thermostats for regulating the two air condi-

tioning and heating units for the electrical house
are located on the walls in the electrical house,
one near each door (see figure 2–2). Each ther-
mostat controls a separate air conditioning and
heating system. See the manufacturer’s infor-
mation for the operating instructions, see the
Vendor Data Manual, Lemoine Marine.
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2.5 Power Control Devices 2.5.3 DRIVE RESET Push Button and
DRIVE READY Indicator Lights
2.5.1 System Air Pressure Gauge Push the DRIVE RESET push button (figure
2–11, item 6), located on the left rear control
The air pressure gauge (figure 2–9, item 2), panel, to reset the drive control panels for the
located on the left control console, shows the
operating pressure of the air system at the • main hoist
control console. The pressure is shown in • boom hoist
pounds per square inch (psi). • swing drives
The following green DRIVE READY indicator

CAUTION lights on the left control panel illuminate when
• During normal operation, the system the corresponding drive control panel is ready
air pressure gauge must read for operation.
7.23–8.61 bar (105–125 psi). Do not
operate the equipment when the air • BOOM DRIVE READY (figure 2–10, item 5)
pressure is not within this range of • SWING DRIVE READY (item 6)
pressure. Operating the equipment • HOIST DRIVE READY (item 7)
when the system air pressure is not
within this range can cause equipment
failure or damage. NOTICE
• There are also DRIVE RESET push
buttons and READY indicator lights on
2.5.2 CONTROL POWER Push Buttons each drive control panel, located in the
electrical house. Pushing a RESET
Push the CONTROL POWER ON push button push button on a drive control panel
(figure 2–11, item 4) located on the left rear resets that panel only. The READY
control panel to indicator light on the panel functions
the same as the corresponding DRIVE
• supply electric power to the crane control READY indicator light on the
system operator’s control console.
• enable the main drive, boom drive, swing
drive and tugger drive control panels
The push button illuminates green when electric

power is supplied and the operator's controls
are enabled.
Push the CONTROL POWER OFF push button

(item 3) to remove electric power from the
crane control system. The operator's controls
are disabled.
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2.6 Crane Function Control Devices 2.6.2 BOOM Brake Pedal
2.6.1 Hoist Drum Brakes—Boom, Main,

NOTICE
Auxiliary, Whip Drums • Normal crane operation does not
require use of the BOOM brake pedal
The hoist drum brakes for the boom, main, to stop boom movement. The control
auxiliary, and whip drums each consist of two system automatically sequences the
external contracting bands (see figures 2–3 and parking brake function of the boom
2–4). Each band acts on a flange of the drum. hoist drum brake.
The two brake bands operate at the same time.
The BOOM brake pedal (see figure 2–8)
A drum brake can be operated as follows: located in front of the operator’s chair controls
the service brake function of the boom hoist
• As a parking brake by the control system. drum brake. The brake pedal is a foot-operated,
Air is sent to the parking brake air cylinders graduated-delivery air valve.
to release the parking brake engage
springs of the brake actuators, causing the Push the toe of the BOOM brake pedal down to
drum brake to release. engage the drum brake of the boom hoist. The
• As a service brake by the crane operator brake has more holding power as the pedal is
using the corresponding BOOM brake pushed down.
pedal (see paragraph 2.6.2),
MAIN/AUXILIARY brake pedal (see para- Release the pedal upward to release the brake.
graph 2.6.3), or WHIP brake pedal (see The brake has less holding power as the pedal
paragraph 2.6.4). Air is sent to the service is released upward.
brake air cylinders of the corresponding
brake actuators in an amount proportional A plunger-operated limit switch under the toe of
to the downward travel of the brake pedal, the brake pedal is actuated when the brake
causing the service brake air cylinders to pedal is pushed down all the way. This causes
engage the drum brake. the control system to release air from the park-
ing brake air cylinders, resulting in additional
braking power from the parking brake engage
NOTICE springs.
• The electric motors for the boom hoist
and main hoist (main, auxiliary, and
whip drums) have motor brakes that
!WARNING
are controlled automatically by the • Excessive use of the BOOM brake
drive control system. pedal will cause too much brake wear
and can cause the brake to overheat
and “fade” (have reduced brake
holding capacity).
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2.6.3 MAIN/AUXILIARY Brake Pedal 2.6.4 WHIP Brake Pedal
NOTICE NOTICE
• Normal crane operation does not • Normal crane operation does not
require use of the MAIN/AUXILIARY require use of the WHIP brake pedal to
brake pedal to stop movement of the stop movement of the whip fall. The
main and auxiliary falls. The control control system automatically
system automatically sequences the sequences the parking brake function
parking brake function of the main and of the whip drum brake.
auxiliary drum brakes.
The WHIP brake pedal (see figure 2–8) located
The MAIN/AUXILIARY brake pedal (see figure in front of the operator’s chair can be used to
2–8) located in front of the operator’s chair can control the service brake function of the whip
be used to control the service brake function of drum brake of the main hoist. The brake pedal
the main and auxiliary drum brakes of the main is a foot-operated, graduated-delivery air valve.
hoist. The drum brakes for both hoist drums are
controlled at the same time. The brake pedal is Push the toe of the WHIP brake pedal down to
a foot-operated, graduated-delivery air valve. engage the drum brake of the whip hoist. The
brake has more holding power as the pedal is
Push the toe of the brake pedal down to pushed down.
engage the drum brakes for both hoists. The
brakes have more holding power as the pedal Release the pedal upward to release the brake.
is pushed down. The brake has less holding power as the pedal
is released upward.
Release the pedal upward to release the
brakes. The brakes have less holding power as A plunger-operated limit switch located under
the pedal is released upward. the toe of the brake pedal is actuated when the
brake pedal is pushed down all the way. The
A plunger-operated limit switch located under control system uses the limit switch to monitor
the toe of the brake pedal is actuated when the the full engagement of the brake pedal, to
brake pedal is pushed down all the way. The permit the functioning of the WHIP E-RELEASE
control system uses the limit switch to monitor push button (see paragraph 2.6.13).
the full engagement of the brake pedal, to
permit the functioning of the corresponding
E-RELEASE push buttons (see paragraph !WARNING
2.6.13). • Excessive use of the WHIP brake pedal
will cause too much brake wear and
can cause the brake to overheat and
!WARNING “fade” (have reduced brake holding
• Excessive use of the MAIN/AUXILIARY capacity).
brake pedal will cause too much brake
wear and can cause the brake to
overheat and “fade” (have reduced
brake holding capacity).
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2.6.5 BOOM/SWING Control and Thumb To decrease the speed more quickly and stop,
Button move the lever past its neutral position to a
position for rotating in the opposite direction. As
The BOOM/SWING control (figure 2–9, item 5), the crane stops, put the lever in its neutral posi-
located on the left control console, controls the tion.
• direction and speed of boom movement NOTICE

(boom function)
• direction and speed of crane rotation (swing • When the crane is rotating, the swing
function) warning light and alarm (see paragraph
2.4.10), located on the machinery deck
The boom and swing functions are combined in access stairway, flashes yellow and
one dual-axis control, permitting both functions sounds.
to be controlled at the same time with one
control lever (see figure 2–37). The Push and hold depressed the thumb button
BOOM/SWING control is a stepless, dual-axis (item 4) located on the handle of the
master switch whose lever, when released, BOOM/SWING control while rotating the crane
returns to its neutral (center) position. to prevent the swing drive motor brakes from
engaging when the lever of the SWING control
Pull the lever of the BOOM control back toward is returned to its neutral position. This can be
the operator to move the boom in (decrease the useful when operating near zero speed by
radius of the fall). Push the lever forward away preventing unnecessary cycling of the brakes
from the operator to move the boom out when the control lever is momentarily returned
(increase the radius of the fall). The speed of to its neutral position. The swing drive motors
the boom increases as the lever is moved away continue to operate (the “run” command to the
from its neutral position. To decrease the drive is not removed), but the speed reference
speed, move the lever toward its neutral posi- is zero because the control lever is in its neutral
tion. To stop the boom, return the lever to its position. The thumb button is a momen-
neutral position. The control system slows the tary-contact push button. Releasing the thumb
motor of the boom hoist to a stop and engages button when the control lever is in is neutral
the boom hoist motor brake, and then engages position causes the swing drive motor brakes to
the boom hoist drum brake. engage.
Move the lever of the SWING control to the Boom Out

operator’s left to rotate the crane left (counter-
clockwise). Move the lever to the operator’s
right to rotate the crane right (clockwise). The Swing Swing
speed of rotation increases as the lever is Left Right
moved away from its neutral position. To
decrease the speed, move the lever toward its
neutral position. To stop rotation, return the Boom In
A1575
lever to its neutral position. The control system
slows the motors of the swing drives to a stop Figure 2–37. BOOM/SWING Control
and then engages the swing drive motor
brakes.
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2.6.6 BOOM/BOTH/SWING Switch Pull the lever of the HOIST control back toward
the operator to raise the selected fall. Push the
The BOOM/BOTH/SWING switch (figure 2–9, lever forward away from the operator to lower
item 6), located on the left control console, the selected fall. The speed of the fall increases
controls the mode of operation of the as the lever is moved away from its neutral
BOOM/SWING control (see paragraph 2.6.5). position. To decrease the speed, move the
lever toward its neutral position. To stop the fall,
Changing the position of the BOOM/BOTH/ return the lever to its neutral position. The
SWING switch has no effect unless the lever of control system slows the motor of the main
the BOOM/SWING control is in its neutral hoist to a stop and engages the main hoist
(center) position and the boom hoist motor motor brake, and then engages the correspond-
brake and swing drive motor brakes are ing drum brake.
engaged. The switch is a three-position selector
switch. Push and hold depressed the thumb button
(item 5) located on the handle of the HOIST
In the BOOM position, only the boom function control while raising or lowering the fall to
can be controlled by the BOOM/SWING control. prevent the main hoist motor brake and corre-
The swing function is disabled. sponding drum brake from engaging when the
lever of the HOIST control is returned to its
In the BOTH position, both the boom function neutral position (“load float”). This can be useful
and the swing function can be controlled. when operating near zero speed by preventing
unnecessary cycling of the brakes when the
In the SWING position, only the swing function control lever is momentarily returned to its
can be controlled. The boom function is neutral position. The hoist motor continues to
disabled. operate (the “run” command to the drive is not
removed), but the speed reference is zero
because the control lever is in its neutral posi-
2.6.7 HOIST Control and Thumb Button tion. The thumb button is a momentary-contact
push button. Releasing the thumb button when
The HOIST control (figure 2–12, item 4), the control lever is in its neutral position causes
located on the right control console, controls the main hoist motor brake and the correspond-
the ing drum brake to engage.
• direction and speed of the main fall (main

drum function of the main hoist) or the 2.6.8 Drum SELECT Push Buttons
• direction and speed of the auxiliary fall
(auxiliary drum function of the main hoist) The drum SELECT push buttons (see
or the table 2–11), located on the right control
• direction and speed of the whip fall (whip console, select which drum of the main hoist is
drum function of the main hoist) controlled by the HOIST control (see paragraph
2.6.7). The HOIST control will then control the
Only one fall can be selected to operate at a corresponding fall (main, auxiliary, or whip).
time, using the drum SELECT push buttons
(see paragraph 2.6.8). The HOIST control is a Pushing a drum SELECT push button has no
stepless single-axis master switch whose lever, effect unless
when released, returns to its neutral (center)
position.
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• the lever of the HOIST control is in its In the ON position, the whip drum can be oper-
neutral (center) position and ated for personnel-handling. Zero to full travel
• the main, auxiliary, and whip drums of the of the HOIST control lever produces 0-50
main hoist are stopped and their parking percent of the normal speed.
brakes are engaged.
In the OFF position, the whip drum cannot be
The drum SELECT push buttons are momen- operated for personnel-handling.
tary-contact illuminated push buttons.
Push a drum SELECT push button to select the 2.6.10 PAWL Push Buttons
corresponding drum for operation. The push
button illuminates green. Selecting a new drum
for operation cancels the previous selection, !WARNING
causing the push button for the previously • When the load or boom must be
selected drum to extinguish. suspended in the air, engage the pawls
for the boom hoist drum and the
Table 2–11. Drum SELECT Push Buttons corresponding main, auxiliary, or whip
drum of the main hoist. The operator
FIGURE AND ITEM must not leave the control console
LABEL
NUMBERS with a load suspended in the air.
MAIN SELECT figure 2–12, item 3
AUXILIARY SELECT figure 2–12, item 2 The PAWL push buttons (see table 2–12)
control the engagement and disengagement of
WHIP SELECT figure 2–12, item 1
the corresponding drum pawl. The drum pawl
can be engaged into a ratchet pocket of the
boom hoist drum or the main, auxiliary, or whip
drum of the main hoist to mechanically prevent
2.6.9 MAN RIDER MODE OFF/ON Key the drum from rotating in the lowering (payout)
Switch direction.
Pushing a PAWL IN push button has no effect

!WARNING
unless the lever of the corresponding BOOM
• Only use the whip drum of the main control or HOIST control is in its neutral (center)
hoist to lift or lower personnel. Do not position and the corresponding hoist motor
use the main or auxiliary drums. The brake is engaged. For the procedure on how to
main and auxiliary drums are made for engage or disengage the boom drum pawl, see
material handling only. Using the whip Boom Hoist Pawl, paragraph 3.10.1. For the
drum to lift or lower personnel requires procedure on how to engage or disengage the
following special personnel handling main, auxiliary, or whip drum pawl, see Main,
safety precautions (see paragraph 3.2). Auxiliary, and Whip Drum Pawl, paragraph
3.11.1.
The MAN RIDER MODE OFF/ON key switch
(figure 2–11, item 1), located on the left rear
control panel, controls the mode of operation
for the whip drum of the main hoist. The switch
is a two-position, key-operated selector switch.
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The PAWL IN and PAWL OUT push buttons are Table 2–12. PAWL Push Buttons
momentary-contact illuminated push buttons.
FIGURE
Push a PAWL IN push button to move the LABEL LOCATION AND ITEM
corresponding pawl in (engage). When the pawl NUMBERS
is engaged all the way in the drum ratchet figure 2–10,
BOOM PAWL IN
pocket (see figure 2–38) and the drum is Left control item 2
prevented from rotating, the push button illumi- BOOM PAWL panel figure 2–10,
nates red. OUT item 3
Push a PAWL OUT push button to move the figure 2–13,
MAIN PAWL IN
corresponding pawl out (disengage). When the item 4
pawl is all the way out of the drum ratchet MAIN PAWL figure 2–13,
pocket (see figure 2–39) and the drum can be OUT item 3
rotated, the push button illuminates green.
AUXILIARY figure 2–13,
PAWL IN Right control item 6
When the pawl is all the way in or out the corre-
sponding push button illuminates steady. If the AUXILIARY panel figure 2–13,
push button flashes, the pawl is not completely PAWL OUT item 5
in or out. Push and hold the push button figure 2–13,
depressed while rotating the drum until the pawl WHIP PAWL IN
item 8
is all the way in or out and the selected push
WHIP PAWL figure 2–13,
button illuminates steady.
OUT item 7
NOTICE
• The control system prevents operation
of the hoist drum when the
corresponding PAWL push button is
flashing, unless the Pocket
• PAWL IN push button is pushed
and held depressed. Then the Drum
corresponding drum can be
Pawl
rotated in the lowering (payout)
direction only, at up to 5 percent of
the normal full speed.
A1263
• PAWL OUT push button is pushed
and held depressed. Then the Figure 2–38. Pawl Engaged in Drum Ratchet
corresponding drum can be Pocket
rotated in the raising (inhaul)
direction only, at up to 25 percent
of the normal full speed.
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2.6.12 SWING LOCK IN and OUT Push

Buttons
Pocket The SWING LOCK IN push button (figure 2–10,

item 1) and the SWING LOCK OUT push button
Drum (item 4), located on the left control panel,
control the engagement and disengagement of
Pawl
the swing lock pin (see figure 2–6). The swing
lock pin, located in the rotating frame, can be
lowered into a hole in the tub to mechanically
A1266 prevent the crane from rotating. The swing lock
Figure 2–39. Pawl Released All the Way pin can be lowered at a single position in the
rotation of the crane. The SWING LOCK IN and
SWING LOCK OUT push buttons are momen-
2.6.11 SPEED 1
4 / FULL switches tary-contact illuminated push buttons.
The SPEED 14 / FULL switches (see table When the crane is in position to permit the
2–13), located on the left control panel, control swing lock pin to be lowered (engaged), push
the reduced speed mode of operation for the and hold depressed the SWING LOCK IN push
corresponding crane function. Use the reduced button to lower the swing lock pin. When the
speed mode when more precise control of the swing lock pin is lowered all the way into the
crane function is desired. The switches are hole in the tub, the push button illuminates red.
two-position selector switches.
Push and hold depressed the SWING LOCK
1
In the 4 position, zero to full travel of the corre- OUT push button to raise (disengage) the swing
sponding control lever produces 0–25 percent lock pin. When the swing lock pin is raised all
of the normal full speed. the way out of the hole in the tub and the crane
can be rotated, the push button illuminates
In the FULL position, the corresponding control green.
lever operates normally.
When the swing lock is all the way in or out the
1
corresponding push button illuminates steady. If
Table 2–13. SPEED 4 / FULL switches the push button flashes, the swing lock is not
FIGURE AND ITEM completely in or out. Push and hold the push
LABEL button depressed while rotating the crane until
NUMBERS
1 the swing lock is all the way in or out and the
HOIST SPEED 4 /FULL figure 2–10, item 8
selected push button illuminates steady.
1 figure 2–10, item
BOOM SPEED 4 /FULL
10
1
SWING SPEED 4 /FULL figure 2–10, item 9
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system releases the corresponding drum clutch

NOTICE and at the same time actuates the parking
• The control system prevents rotation brake release function of the corresponding
of the crane when the SWING LOCK drum brake. The corresponding brake pedal
push button is flashing, unless a must then be used to begin motion of the block
SWING LOCK push button is pushed and to slow and stop the block. Each
and held depressed. This can be E-RELEASE push button is a momen-
necessary for proper alignment when tary-contact push button. Releasing the push
lowering or raising the swing lock pin button will cause the corresponding drum park-
(see paragraph 3.9). When a SWING ing brake to engage and stop the block.
LOCK push button is pushed, the
crane can be rotated at up to 25 Table 2–14. E-RELEASE Push Buttons
percent of the normal full speed.
FIGURE AND ITEM
LABEL
NUMBERS
2.6.13 E-RELEASE ENABLE OFF/ON MAIN E-RELEASE figure 2–13, item 1
Switch and Push Buttons AUXILIARY
figure 2–13, item 12
E-RELEASE
The E-RELEASE ENABLE OFF/ON switch
WHIP E-RELEASE figure 2–13, item 10
(figure 2–11, item 2), located on the left rear
control panel, controls the functioning of the
E-RELEASE push buttons. The switch is a
two-position selector switch. 2.6.14 WHIP EMERGENCY BRAKE
RELEASE VALVE
In the ON position, the E-RELEASE push
buttons are enabled. The WHIP EMERGENCY BRAKE RELEASE
VALVE (figure 2–9, item 1), located on the left
In the OFF position, the E-RELEASE push control console, permits the whip hoist to be
buttons are disabled. lowered in the event of a loss of electrical
power.
!WARNING
With the WHIP brake pedal (see paragraph
• Do not use the E-RELEASE push 2.6.4) held all the way down, pull the WHIP
buttons to lower a load. To lower an EMERGENCY BRAKE RELEASE VALVE all
empty block, use the procedure in the way out to release the drum parking brake.
paragraph 3.12. The control system releases the corresponding
drum clutch and at the same time actuates the
The E-RELEASE push buttons (see table parking brake release function of the drum
2–14), located on the right control panel, permit brake. The brake pedal must then be used to
the corresponding empty main, auxiliary, or begin motion of the load and to slow and stop
whip block to be lowered without hoist motor the load.
power. With the corresponding brake pedal
(see paragraphs 2.6.3 and 2.6.4) held all the Push the valve all the way down to engage the
way down, push and hold depressed an drum parking brake.
E-RELEASE push button to initiate the emer-
gency release mode of operation. The control
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2.6.15 LIMIT BYPASS Push Buttons

!WARNING
The following limit conditions (see para- • Use the LIMIT BYPASS push buttons
graph 3.15) occur at a predetermined position for reeving, inspection, maintenance,
in the operation of the corresponding crane or putting the main or auxiliary block
function: in the block pocket only. Do not use
the push buttons during normal
• main fall two-block limit operation.
• main fall lower limit • When a LIMIT BYPASS push button for
• auxiliary fall two-block limit a fall is pushed there is no protection
• auxiliary fall lower limit against raising the corresponding
• whip fall two-block limit block into the boom (two-blocking) or
• whip fall lower limit from paying out the wire rope to its
• boom upper limit dead end on the drum.
• boom lower limit • When the BOOM LIMIT BYPASS push
button is pushed, there is no
When the crane function reaches a limit condi- protection against raising the boom
tion listed above, the corresponding LIMIT into the boom stop or from paying out
BYPASS push button (see table 2–15) flashes the wire rope to its dead end on the
red. The control system automatically stops the boom hoist drum.
corresponding crane function and does not
permit further operation of that crane function in Slowdown limits occur at a predetermined point
the direction that caused the limit condition. In near the corresponding crane function limit.
the case of the main, auxiliary, and whip fall When the slowdown limit is reached, the control
two-block limit, the boom is also stopped if system automatically reduces the speed of the
moving out (lowering), and further moving of the corresponding crane function, recalibrating the
boom out is not permitted. The LIMIT BYPASS corresponding control lever to have a lower full
push button continues to flash until the affected speed setpoint.
crane function is no longer in the limit condition.
To bypass the limit (for example: for reeving, Table 2–15. LIMIT BYPASS Push Buttons
inspection, maintenance, or putting the block in FIGURE AND
the block pocket), push and hold depressed the LABEL LOCATION ITEM
corresponding LIMIT BYPASS push button and NUMBERS
operate the corresponding crane function.
Operating speed is limited to 25 percent of the MAIN LIMIT figure 2–13,
normal full speed. Each LIMIT BYPASS push BYPASS item 2
button is a momentary-contact push button. AUXILIARY
Right control figure 2–13,
Releasing the push button while operating the LIMIT
console item 11
crane function will stop the function. BYPASS
WHIP LIMIT figure 2–13,
BYPASS item 9
BOOM LIMIT Left control figure 2–10,
BYPASS panel item 11
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3 CRANE OPERATION 3.3 Pre-Start Procedure
The following inspections are considered

3.1 Introduction mandatory by National Oilwell Varco. They
make sure the equipment is in a safe operating
The following paragraphs describe the general condition. Other inspections can be required by
operating instructions for the crane as outlined local regulations and must also be made.
by the table of contents.
3.3.1 Each Workday

3.2 Personnel Handling
Do the following at the beginning of each work
day.
!WARNING
• Only use the whip hoist to lift or lower 1. Check the preventive maintenance records
personnel. With the exception of the to make sure that the scheduled lubrication
whip hoist, this equipment is made for (see paragraph 5.2.2) and inspections and
material handling only. Using the whip maintenance (see paragraph 5.3) have
hoist to lift or lower personnel requires been done at the correct intervals.
following special personnel-handling
safety precautions. 2. Check that 400 V electric power from the
vessel is available to the crane.
It is the responsibility of the owner and user of
the equipment to obtain, read and understand 3. Check that disconnect switch DS1
“Personnel Lifting” in the corresponding current (supplied by others) located in the tub is
publication section of closed.
• American National Standard for Floating

Cranes and Floating Derricks, ANSI/ASME 3.3.2 Before Each Start-Up
B30.8-2004, 8-3.2.8
• American National Standard for Personnel 1. Remove any tie-downs or restraints from
Lifting Systems, ANSI/ASME B30.23-2005 the boom and crane. Check that the main,
auxiliary, and whip fall lower blocks and
Published by the American Society of boom are free of any restraints.
Mechanical Engineers, Three Park Avenue,
New York, NY 10016-5990, USA. 2. Check that the crane operating area,
including the tailswing and boom swing
A crane that is used for personnel handling paths, are free of all obstructions and
must be given an inspection daily per personnel. Not following this procedure can
ANSI/ASME publication sections B30.8-2004, result in damage to the crane, the load, and
8-2.1.2 (a) and 8-2.4.1. See also Inspection and other equipment and structures, and death
Maintenance schedule paragraph 5.3. or injury to personnel.
3. The crane can now be started (see para-

graph 3.4).
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3.4 Start Procedure 5. Check that the knob of the E-STOP switch
(see figure 2–2) is pulled all the way out.
The E-STOP switch is located inside the
!WARNING machinery house, near the main door
• Do not operate the crane when wind below the sound-powered telephone.
speeds (including momentary gusts)
are more than 20 m/sec. When wind 6. If desired, start the machinery house venti-
speeds of more than 20 m/sec are lation fan. Push the START push button on
expected, see Operating in the Wind, the ventilation fan motor starter panel
paragraph 3.7. located near the main door by the fire extin-
guisher.
NOTICE 7. If the ventilation fan was started, adjust the

• This procedure assumes that wall-mounted louvers if necessary.
400/230 V electric power was supplied
by the vessel to electric power transfer 8. Start the air compressors. The START
switch XS226 during shutdown and the switch is located on the air compressor.
crane was shut down using the See the manufacturer’s information for the
procedure in paragraph 3.6. operating instructions (see the Vendor Data
Manual, Ingersoll-Rand).
1. Complete the pre-start procedure (see
paragraph 3.3). 9. Start the air dryer. The ON/OFF switch is
located on the air dryer. See the manufac-
2. If desired, turn on the lighting for the turer’s information for the operating instruc-
machinery house exterior platforms and tions (see the Vendor Data Manual,
walkways and the operator’s cab platform. Ingersoll-Rand).
The light switch is located at the bottom of
the machinery house access stairway (see 10. If desired, turn on the lighting for the interior
figure 2–1). of the crane tub using the light switch
located at the bottom of the crane tub
3. If desired, turn on the lighting for the access ladder.
machinery and electrical house roof and the
top of the water tank. The light switch is NOTICE
located at the bottom of the machinery
house roof access ladder (see figure 2–1). • Do steps 11 through 14 in the electrical
house.
NOTICE 11. Turn on the lighting for the interior of the

• Do steps 4 through 10 in the electrical house. Light switches (see
machinery house. figure 2–2) are located inside the electrical
house near each door.
4. Turn on the lighting for the interior of the
machinery house. The light switch (see 12. Check that the knobs of the EMERGENCY
figure 2–2) is located inside the machinery STOP switches located on the boom, main,
house, below the sound-powered tele- swing, and tugger drive control panels are
phone. pulled all the way out.
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13. Adjust the two wall-mounted thermostats facturer’s information for the operating
for the electrical house air conditioning and instructions (see the Vendor Data Manual,
heating units as necessary to maintain a RVP).
temperature not to exceed 30°C (85°F).
The thermostats are located near each 19. As necessary, turn on and adjust the follow-
door. See the manufacturer’s information ing controls:
for the operating instructions (see the
Vendor Data Manual, Lemoine Marine). • window defroster (figure 2–9, items 4
and 5)
• heater (item 3)
NOTICE
• A momentary interruption will occur to 20. Adjust the operator’s seat as necessary.
the lighting and other electrical circuits
during the transfer of electric power.
CAUTION
14. Switch electric power transfer switch XS226 • During normal operation the system air
from the auxiliary feed to the vessel supply pressure gauge must read
position. 7.23–8.61 bar (105–125 psi). Do not
operate the equipment when the air
15. If desired, turn on the lighting for the boom pressure is not within this range of
walkway using the light switch located at pressure.
the beginning of the boom walkway (see
figure 2–1). 21. Check that the system air pressure gauge
(figure 2–9, item 2) reads 105–125 psi.
16. If desired, turn on the lighting for the
A-frame platforms and stairways using the 22. Check that the controls listed in table 3–1
light switch located at the beginning of the are in the position indicated.
A-frame stairway (see figure 2–1).
23. Push the CONTROL POWER ON push
button (figure 2–11, item 4). The push
NOTICE button must illuminate.
• Do steps 17 through 35 in the
operator’s cab. 24. Push the LAMP/ALARM TEST push button
(item 5) to test the indicator lights on the
17. If desired, turn on the lighting for the interior operator’s cab control consoles. The indica-
of the operator’s cab and visitor’s cab. tor lights that are extinguished must
Push the OPERATOR CAB LIGHT push
button (figure 2–14, item 6) and the • illuminate when the push button is held
VISITOR CAB LIGHT (item 1). Adjust the down and
lighting as necessary using the DIMMER • extinguish when the push button is
control (item 7). released
18. If desired, turn on and adjust the controls

as necessary for the operator’s cab and
!WARNING
visitor’s cab air conditioning units. The • Do not operate the equipment with a
controls are located on the control panels of failed indicator light.
the units, on the cab ceiling. See the manu-
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25. Push the DRIVE RESET push button 28. If desired, push the ON/OFF switch on the
(item 6). back of the diagnostic display located in the
visitor’s cab to the ON position. Check that
26. Check that the indicator lights listed in the display is functioning and showing data.
table 3–2 are illuminated. All other indicator
lights must not be illuminated. 29. If necessary, turn on and adjust the controls
for the following:
27. Push the OFF/ON switch (see figure 2–8)
on the back of the load monitoring system • operator’s cab window wipers
(LMS) display to the ON position. Check (figure 2–9, items 7, 8, and 9)
that the LMS display is correctly positioned, • closed circuit television (CCTV) moni-
functioning and showing data. tors (see paragraph 2.4.7)
• communication radio
Table 3–1. Control Positions Before Start-Up

FIGURE AND ITEM
CONTROL POSITION LOCATION
NUMBERS
Left control
BOOM/SWING control Neutral (center) figure 2–9, item 5
console
Right control
HOIST control Neutral (center) figure 2–12, item 4
console
Right control
TUGGER control Neutral (center) figure 4–1, item 2
console
WHIP EMERGENCY BRAKE Knob pushed all the Left control
RELEASE valve way down console
Knob pulled all the Right control
EMERGENCY STOP switch figure 2–12, item 6
way out console
EMERGENCY POWER OFF Knob pulled all the Right control
switch way out console
1
HOIST SPEED 4 / FULL switch FULL Left control panel figure 2–10, item 8
1
BOOM SPEED 4 / FULL switch FULL Left control panel figure 2–10, item 10
1
SWING SPEED 4 / FULL switch FULL Left control panel figure 2–10, item 9
E-RELEASE ENABLE OFF/ON Left rear control
OFF figure 2–11, item 2
switch panel
MAN RIDER MODE OFF/ON Left rear control
key switch panel
Knob turned all the
TENSION control Right control panel figure 4–1, item 6
way counterclockwise
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30. If desired, turn on the floodlights. Push the 32. If the boom is in a boom rest or resting on
following push buttons. The push buttons any other surface, raise the boom (see
must illuminate. paragraph 3.10) so that it is suspended by
the boom hoist wire rope. Then stop the
• MACHINE HOUSE FLOODS boom and engage the boom hoist pawl
(figure 2–14, item 12) (see paragraph 3.10.1.1).
• UPPER BOOM FLOODS (item 9)
• MIDDLE BOOM FLOODS (item 10) 33. Raise (disengage) the swing lock (see
• LOWER BOOM FLOODS (item 11) paragraph 3.9.2).
• SPOT LIGHT (item 2)
34. Position the main, auxiliary, and whip fall
31. Check that the horn functions by pushing lower blocks as necessary.
the HORN push button (figure 2–9, item 3).
35. To start a tugger(s), see paragraph 4.5.2.
36. The crane is now ready for normal opera-

tion.
Table 3–2. Indicator Light Conditions After Turning on Control Power

FIGURE AND ITEM
INDICATOR LIGHT CONDITION LOCATION
NUMBERS
CONTROL POWER ON indicator Left rear control
Illuminated figure 2–11, item 4
light panel
HOIST DRIVE READY indicator
Illuminated Left control panel figure 2–10, item 7
light
BOOM DRIVE READY indicator
light
SWING DRIVE READY indicator
light
SWING LOCK IN push button Illuminated Left control panel figure 2–10, item 1
BOOM PAWL IN push button Illuminated Left control panel figure 2–10, item 2
MAIN PAWL IN push button Illuminated Right control panel figure 2–13, item 4
AUXILIARY PAWL IN push button Illuminated Right control panel figure 2–13, item 6
WHIP PAWL IN push button Illuminated Right control panel figure 2–13, item 8
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3.5 Emergency Stop Procedure

NOTICE
• There are also EMERGENCY STOP
!WARNING switches on the drive control panels
• Pushing an EMERGENCY STOP switch for the individual crane functions
will engage the brakes of the tuggers. (boom hoist drive, main hoist drive,
Engaging the brake of a tugger when and swing drives). Pushing the knob of
the wire rope of the tugger is an EMERGENCY STOP switch located
connected to a load can overload the on a drive control panel only stops the
tugger, foundation, and reeving system equipment for the corresponding
if the radius of the load increases due crane function. Before that function
to vessel list or trim or outward drift of can be operated, the knob of the
the boom. EMERGENCY STOP switch must be
pulled all the way out and the drive
1. To immediately stop all crane motions, push control panel must be reset (see
the knob of an EMERGENCY STOP switch paragraph 2.5.3).
listed in table 3–3 all the way down. See
EMERGENCY STOP Switches, paragraph Table 3–3. EMERGENCY STOP Switches
2.4.2, for a description of the response of
FIGURE
the control system to the emergency stop.
LABEL LOCATION AND ITEM
NUMBERS
2. To resume operation after pushing an
EMERGENCY STOP switch listed in table Operator’s cab,
EMERGENCY figure 2–12,
3–3 and after the reason for the emergency right control
STOP item 6
stop has been corrected: console
Near machinery
A. Put the controls in their shutdown posi- E-STOP house entrance figure 2–2
tion (see table 3–4 and paragraphs door
4.5.4 and 4.5.5).
Electrical
EMERGENCY
house, CP1 figure 2–2
B. Check the brakes of all equipment that STOP
panel
was operating when the emergency
stop occurred for wear, damage, and Electrical
correct adjustment. EMERGENCY house, Brake
figure 2–2
STOP Chopper 1
C. Pull the knob of the EMERGENCY panel
STOP switch that was pushed in step 1 Electrical
all the way out. To pull out the knob of EMERGENCY house, Brake
the E-STOP switch in the machinery figure 2–2
STOP Chopper 2
house twist the knob to release its panel
latch, and then pull the knob all the way
out.
3. The crane can now be started (see para-

graph 3.4).
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3.5.1 Emergency Power Off Procedure 3.6 Shutdown Procedure
!WARNING !WARNING
• Pushing the EMERGENCY POWER • If high wind conditions (including
OFF switch will engage the brakes of momentary gusts) of more than
the tuggers. Engaging the brake of a 20 m/sec are expected, see Operating
tugger when the wire rope of the in the Wind, paragraph 3.7.
tugger is connected to a load can
overload the tugger, foundation, and
reeving system if the radius of the load NOTICE
increases due to vessel list or trim or • This procedure assumes that
outward drift of the boom. 400/230 V electric power will be
supplied by the vessel to electric
1. To immediately remove all electric power power transfer switch XS226 during
from the crane, push the knob of the shutdown.
EMERGENCY POWER OFF switch (figure • Anti-condensation heaters for various
2–12, item 7) all the way down. See equipment including electric motors,
EMERGENCY POWER OFF Switch, para- transformers, and electrical panels
graph 2.4.3, for a description of the remain on during shutdown to prevent
response of the control system to the emer- equipment damage.
gency power off.
1. Remove the load from the crane.
2. To resume operation after pushing the
EMERGENCY POWER OFF switch and 2. If the tuggers are operating, shut down the
after the reason for the emergency power tuggers (see paragraphs 4.5.4 and 4.5.5).
off has been corrected:
3. Rotate the crane to align the swing lock pin
A. Put the controls in their shutdown posi- to the locking hole in the tub.
tion (see table 3–4 and paragraphs
4.5.4 and 4.5.5). 4. Lower (engage) the swing lock (see para-
graph 3.9.1).
B. Close disconnect switch DS1 in the tub.
5. Put the boom in its parking position.
C. Check the brakes of all equipment that
was operating when the emergency
stop occurred for wear, damage, and !WARNING
correct adjustment. • Engage the hoist drum pawls before
leaving the control console.
D. Pull the knob of the EMERGENCY
POWER OFF switch all the way out. 6. Check that the BOOM PAWL IN push
button (figure 2–10, item 2) is illuminated
3. The equipment can now be started (see steady. If the push button is not illuminated
paragraph 3.4). or is flashing, engage the pawl for the boom
hoist (see paragraph 3.10.1.1).
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7. Raise the main, auxiliary, and whip lower 13. As necessary, push the ON/OFF switch on
falls to their highest operating position. the back of the diagnostic display located in
the visitor’s cab to the OFF position.
8. Check that the following push buttons are
illuminated steady: 14. Push the CONTROL POWER OFF push
button (figure 2–11, item 3).
• MAIN PAWL IN push button (figure
2–13, item 4) 15. Turn off the operator’s cab and visitor’s cab
• AUXILIARY PAWL IN push button air conditioning units. The controls are
(item 6), and located on the control panels of the units,
• WHIP PAWL IN push button (item 8) on the cab ceiling. See the manufacturer’s
information for the operating instructions
If a push button is not illuminated or is (see the Vendor Data Manual, RVP).
flashing, engage the corresponding drum
pawl (see paragraph 3.11.1.1). 16. Turn off the lighting for the interior of the
operator’s cab and visitor’s cab as neces-
9. Check that each control listed in table 3–4 sary. The controls are located on the light-
is in the position indicated. ing control panel (see figure 2–14).
10. As necessary, turn off the floodlights. Push 17. Exit the operator’s cab.
the following push buttons:
18. If necessary, turn on the lighting for the
• MACHINE HOUSE FLOODS machinery house exterior platforms and
(figure 2–14, item 12) ladders. The light switch is located on the
• UPPER BOOM FLOODS (item 9) operator’s cab platform (see figure 2–1).
• MIDDLE BOOM FLOODS (item 10)
• LOWER BOOM FLOODS (item 11) 19. Turn off the boom walkway lighting as
• SPOT LIGHT (item 2) necessary. The light switch is located at the
beginning of the boom walkway.
11. As necessary, turn off the following:
20. Turn off the A-frame platform and stairway
• window defroster (item 4) lighting as necessary. The light switch is
• heater (item 3) located at the bottom of the A-frame stair-
• operator’s cab window wipers (figure way.
2–9, items 7, 8, and 9)
• closed circuit television (CCTV) moni-
tors (see paragraph 2.4.7)
NOTICE
• communication radio • Do steps 21 through 24 in the electrical
house.
12. Push the OFF/ON switch (see figure 2–8)
located on the back of the load monitoring 21. If necessary, turn on the lighting for the
system (LMS) display to the OFF position. interior of the electrical house. Light
switches (see figure 2–2) are located inside
the electrical house near each door.
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22. Turn off the two electrical room air condi-

tioners using the wall-mounted thermostats.
NOTICE
The thermostats are located near each • Do steps 26 through 31 in the
door. See the manufacturer’s information machinery house.
for the operating instructions (see the
Vendor Data Manual, Lemoine Marine). 26. If necessary, turn on the lighting for the
interior of the machinery house. The light
switch (see figure 2–2) is located inside the
NOTICE
machinery house near the door.
• A momentary interruption will occur to
the lighting and other electrical circuits 27. Stop the air compressors. The STOP switch
during the transfer of power. is located on the air compressor. See the
manufacturer’s information for the operat-
23. Switch electric power transfer switch XS226 ing instructions (see the Vendor Data
from the vessel supply position to the auxil- Manual, Ingersoll-Rand).
iary feed position.
28. Stop the air dryer. The ON/OFF switch is
24. Turn off the lighting for the interior of the located on the air dryer. See the manufac-
electrical house as necessary. turer’s information for the operating instruc-
tions (see the Vendor Data Manual,
25. Exit the electrical house. Ingersoll-Rand).
Table 3–4. Control Positions for Shutdown

FIGURE AND ITEM
CONTROL POSITION LOCATION
NUMBERS
Left control
BOOM/SWING control Neutral (center) figure 2–9, item 5
console
Right control
HOIST control Neutral (center) figure 2–12, item 4
console
Right control
TUGGER control Neutral (center) figure 4–1, item 2
console
1
HOIST SPEED 4 / FULL switch FULL Left control panel figure 2–10, item 8
1
BOOM SPEED 4 / FULL switch FULL Left control panel figure 2–10, item 10
1
SWING SPEED 4 / FULL switch FULL Left control panel figure 2–10, item 9
E-RELEASE ENABLE OFF/ON Left rear control
switch panel
MAN RIDER MODE OFF/ON Left rear control
key switch panel
Knob turned all the
TENSION control Right control panel figure 4–1, item 6
way counterclockwise
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29. If desired, stop the machinery house venti- 3.7 Operating in the Wind
lation fan. Push the STOP push button
located on the ventilation fan motor starter
panel located near the main door by the fire !WARNING
extinguisher. • It is not safe to operate the crane when
wind speeds exceed the guidelines for
30. If necessary, adjust the wall-mounted safe operation in table 3–5.
louvers.
31. Turn off the lighting for the interior of the !WARNING
machinery house as necessary. • Table 3–5 does not take into account
wind force on the load, which must be
32. Exit the machinery house. considered by the operator. When the
load has a large surface area, the
33. Turn off the machinery and electrical house effect of the wind on it can be
roof and water tank lighting as necessary. substantial.
The light switch is located at the bottom of • Use taglines (ropes) to control the load
the machinery house roof access ladder when operating in windy conditions, to
(see figure 2–1). avoid side loading of the boom.
• Not following these warnings can
34. Use the machinery house access ladder result in damage to the crane, the load,
(see figure 2–1) and exit the crane. and other equipment and structures,
and death or injury to personnel.
35. Turn off the lighting for the machinery
house exterior platforms and ladders as
The wind speeds in table 3–5 refer to maximum
necessary. The light switch is located at the
wind speed, whether the wind is steady or only
bottom of the machinery house access
reaches maximum speed in brief gusts. All
ladder.
measurements must be taken at the highest
elevation of the boom. Weather bureau reports
36. Write down and report any corrective action
of wind speed at ground level might not accu-
that must be taken before operation is
rately reflect the highest speed of gusts at the
resumed.
highest elevation of the boom.
3.7.1 High Wind Shutdown
Shut down the crane. Do all the steps of Shut-

down Procedure, paragraph 3.6, but for step 7,
lower and secure the main, auxiliary and whip
lower blocks to the vessel deck.
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Table 3–5. Wind Speed Guideline Chart

Normal operation of the crane permitted, within the limits of the
0–20 m/sec capacity chart (see Section 6, Capacity Charts, drawings 1594855,
1594856, 1594857, 1594858, 1596451, and 1598177)
NO OPERATION. OBSERVE SAFETY PRECAUTIONS:
1. Remove the load from the crane.
Wind speeds over 20 m/sec— 2. Lower (engage) the swing lock (see paragraph 3.9.1).
standby condition 3. Position the boom at a 21 degree angle.
4. Lower and secure the main, auxiliary, and whip lower blocks to
the vessel deck.
Wind speeds over 20 m/sec— NO OPERATION. OBSERVE SAFETY PRECAUTIONS:
shutdown condition See High Wind Shutdown, paragraph 3.7.1.
3.8 Swing • SWING SPEED 14 / FULL switch

(figure 2–10, item 9) is in the desired
position
!WARNING
• Before rotating the crane, make sure 2. If the SWING LOCK OUT push button
that there are no obstructions or (item 4) is illuminated steady, continue with
personnel in the crane tailswing and step 3. If the push button is not illuminated
boom swing areas, including the swing or is flashing, raise the swing lock pin (see
paths of the main, auxiliary, and whip paragraph 3.9.2).
falls and the load. Not following this
procedure can result in damage to the
crane, the load, and other equipment
CAUTION
and structures, and death or serious • Move the lever of the SWING control
injury to personnel. slowly, to prevent abrupt changes in
• Use extreme caution when rotating the the speed of rotation of the crane.
crane with a load suspended. When
lifting a heavy or bulky load, it is
recommended that the load control
NOTICE
tugger wire ropes be attached to each • When the crane is rotating, the swing
side of the load to prevent the load warning light and alarm (see paragraph
from rotating or swinging. 2.4.10), located on the machinery deck
access stairway, flashes yellow and
1. Check that the sounds.
• SWING DRIVE READY indicator light 3. Slowly move the lever of the SWING
(figure 2–10, item 6) is illuminated control (figure 2–9, item 5)
• BOOM/BOTH/SWING switch
(figure 2–9, item 6) is in a position for • to the operator’s left to rotate the crane
swing operation (BOTH or SWING) left (counterclockwise)
• to the operator’s right to rotate the
crane right (clockwise)
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The speed of rotation increases as the 3.9.1 Lowering (Engaging) the Swing
lever is moved away from its neutral Lock
(center) position. To decrease the speed,
move the lever toward its neutral position. 1. Rotate the crane to align the swing lock pin
To stop rotation, return the lever to its to the locking hole in the tub.
neutral position.
2. With the crane completely stopped, push
To decrease the speed more quickly and the SWING LOCK IN push button
stop, move the lever past its neutral posi- (figure 2–10, item 1). The push button must
tion to a position for rotating in the opposite illuminate steady. If the push button flashes,
direction. As the crane stops, put the lever continue with step 3.
in its neutral position.
NOTICE
NOTICE
• Friction or misalignment of the swing
• To prevent the swing drive motor lock pin to the hole in the tub may
brakes from engaging when the lever prevent the swing lock pin from
of the SWING control is returned to its lowering all the way.
neutral (center) position, push and
hold depressed the thumb button 3. If the SWING LOCK IN push button flashes,
(item 4) located on the handle of the the swing lock pin has not lowered all the
SWING control while rotating the way into the hole in the tub. To lower the
crane. Releasing the thumb button swing lock pin all the way into the hole in
when the control lever is in its neutral the tub
position causes the swing drive motor
brakes to engage. A. Push and hold depressed the SWING
LOCK IN push button.
3.9 Swing Lock B. Slowly move the lever of the SWING

control (figure 2–9, item 5) a small
A swing lock pin (see figure 2–6), located in the amount to the left and right to align the
rotating frame, can be lowered into a hole in the swing lock pin and permit the pin to
tub to mechanically prevent the crane from lower. The SWING LOCK IN push
rotating. The swing lock pin can be lowered at a button must illuminate steady.
single position in the rotation of the crane.
C. Release the SWING LOCK IN push
button.
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3.9.2 Raising (Disengaging) the Swing 3.10 Boom

Lock
1. Push the SWING LOCK OUT push button

!WARNING
(figure 2–10, item 4). The push button illu- • Do not exceed the rated load capacity
minate steady. If the push button flashes, of the crane (see Section 6, Capacity
continue with step 2. Charts, drawings 1594855, 1594856,
1594857, 1594858, 1596451, and
1598177). Lifting loads greater than
NOTICE those shown on the capacity chart or
• Side pressure on the swing lock pin by operating at positions or conditions
the hole in the tub may prevent the pin not shown, or lifting when the boom is
from raising out of the hole. solid against the boom stops, can
cause structural failure or collapse of
2. If the SWING LOCK OUT push button the boom or crane and can result in
flashes, the swing lock pin has not raised death or serious personal injury as
all the way out of the hole in the tub. To well as damage to equipment or
raise the swing lock pin all the way out of structures in the area.
the hole in the tub • Before handling a load, check that the
load monitoring system (LMS) display
A. Push and hold depressed the SWING (see paragraph 2.4.5) is configured to
LOCK OUT push button. show information about the load on
the fall being used, showing the
B. Slowly move the lever of the SWING correct screen for the operation being
control (figure 2–9, item 5) a small performed. Also the correct capacity
amount to the left and right to relieve chart must be selected, and the LMS
the side pressure on the swing lock pin must be correctly calibrated. Not
and permit the pin to raise. The SWING following this procedure can give
LOCK OUT push button must illuminate inaccurate load capacity readings and
steady. prevent the safety warning messages
and overload automatic stop from
C. Release the SWING LOCK OUT push operating, resulting in damage to the
button. equipment and death or serious injury
to personnel.
• The operator must move the boom in,
reducing the outreach of the boom, to
compensate for any increase in radius
caused by vessel motions.
• Before operating the boom, make sure
that there are no obstructions in the
path of the boom. Not following this
procedure can result in damage to the
crane, the load, and other equipment
and structures, and death or serious
injury to personnel.
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3. Slowly move the lever of the BOOM control

NOTICE (figure 2–9, item 5)
• The control system protects against
moving the boom in (decreasing the • back toward the operator to move the
radius of the fall) beyond 81.5 degrees boom in (decrease the radius of the
boom angle. See paragraph 3.15.1 for a fall)
description of the limit stop and the • forward away from the operator to
procedure to back out of the condition. move the boom out (increase the
• The control system protects against radius of the fall)
moving the boom out (increasing the
radius of the fall) beyond horizontal. The speed of the boom increases as the
See paragraph 3.15.2 for a description lever is moved away from its neutral
of the limit stop and the procedure to (center) position. To decrease the speed,
back out of the condition. move the lever toward its neutral position.
To stop the boom, return the lever to its
1. Check that the neutral position.
• BOOM READY indicator light NOTICE

(figure 2–10, item 5) is illuminated
• load monitoring system (LMS) display • The BOOM brake pedal (see paragraph
(see paragraph 2.4.5) is configured to 2.6.2) is not needed for normal
show information about the load on the operation of the crane.
fall being used, showing the correct
screen for the operation being
performed
!WARNING
• BOOM/BOTH/SWING switch • Slowing the boom by “dragging” with
(figure 2–9, item 6) is a position for the BOOM brake pedal will cause too
boom operation (BOOM or BOTH) much brake wear and can cause the
• BOOM SPEED 14 / FULL switch brake to overheat and “fade” (have
(figure 2–10, item 10) is in the desired reduced brake holding capacity).
position
• BOOM brake pedal (see figure 2–8) is 4. To engage the pawl for the boom hoist, use
released the procedure in paragraph 3.10.1.1.
2. If the BOOM PAWL OUT push button

(figure 2–10, item 3) is illuminated steady,
continue with step 3. If the push button is
not illuminated or is flashing, disengage the
pawl for the boom hoist (see paragraph
3.10.1.2).
CAUTION
• Move the lever of the BOOM control
slowly, to prevent abrupt changes in
the speed of the boom.
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3.10.1 Boom Hoist Pawl C. When the drum rotation stops, return
the lever of the BOOM control to its
neutral position.
!WARNING
• When the load or boom must be D. Release the BOOM PAWL IN push
suspended in the air, engage the pawls button.
corresponding main, auxiliary, or whip
drum of the main hoist. The operator 3.10.1.2 Disengaging the Boom Hoist
must not leave the control console Pawl
with a load suspended in the air.
1. Put the lever of the BOOM control (figure
The boom hoist has a pawl that can be 2–9, item 5) in its neutral (center) position.
engaged into a ratchet pocket of the boom hoist
drum to mechanically prevent the drum from 2. Push the BOOM PAWL OUT push button
rotating in the lowering (payout) direction. (figure 2–10, item 3). The push button must
illuminate steady. If the push button flashes,
continue with step 3.
3.10.1.1 Engaging the Boom Hoist Pawl
3. If the BOOM PAWL OUT push button
1. Put the lever of the BOOM control (figure flashes, the pawl is not all the way out of
2–9, item 5) in its neutral (center) position. the drum ratchet pocket. Do the following to
completely disengage the pawl:
2. With the boom completely stopped, push
the BOOM PAWL IN push button (figure A. Push and hold depressed the BOOM
2–10, item 2). The push button must illumi- PAWL OUT push button.
nate steady. If the push button flashes,
continue with step 3. B. Slowly pull the lever of the BOOM
control back toward the operator to
3. If the BOOM PAWL IN push button flashes, rotate the boom hoist drum in the boom
the pawl has not engaged all the way into in (inhaul) direction a small amount
the drum ratchet pocket. To engage the until the BOOM PAWL OUT push
pawl all the way in the drum ratchet pocket button illuminates steady.
A. Push and hold depressed the BOOM C. Return the lever of the BOOM control
PAWL IN push button. to its neutral position to stop the boom.
B. Slowly push the lever of the BOOM D. Release the BOOM PAWL OUT push
control forward away from the operator button.
a small amount until drum rotation
(boom out movement) stops. The
BOOM PAWL IN push button must illu-
minate steady.
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3.11 Main, Auxiliary, and Whip Fall

NOTICE
• The control system protects against
!WARNING raising the main, auxiliary, or whip fall
• Do not exceed the rated load capacity beyond their upper operating limit,
of the crane (see Section 6, Capacity preventing two-blocking. See
Charts, drawings 1594855, 1594856, paragraph 3.15.3 for a description of
1594857, 1594858, 1596451, and the limit stop and the procedure to
1598177). Lifting loads greater than back out of the condition.
those shown on the capacity chart or • The control system protects against
operating at positions or conditions lowering the main, auxiliary, or whip
not shown, or lifting when the boom is fall beyond their lower operating limit.
solid against the boom stops, can See paragraph 3.15.4 for a description
cause structural failure or collapse of of the limit stop and the procedure to
the boom or crane and can result in back out of the condition.
death or serious personal injury as
well as damage to equipment or 1. Check that the
structures in the area.
• Before handling a load, check that the • HOIST DRIVE READY indicator light
load monitoring system (LMS) display (figure 2–10, item 7) is illuminated
(see paragraph 2.4.5) is configured to • load monitoring system (LMS) display
show information about the load on (see paragraph 2.4.5) is configured to
the fall being used, showing the show information about the load on the
correct screen for the operation being fall being used, showing the correct
performed. Also the correct capacity screen for the operation being
chart must be selected, and the LMS performed
must be correctly calibrated. Not • HOIST SPEED 14 / FULL switch (item
following this procedure can give 8) is in the desired position
inaccurate load capacity readings and • corresponding brake pedal (see figure
prevent the safety warning messages 2–8) is released
and overload automatic stop from
operating, resulting in damage to the 2. If operating the whip fall
equipment and death or serious injury
to personnel. for material handling, turn the MAN RIDER
• Only use the whip drum of the main MODE OFF/ON key switch (figure 2–11,
hoist to lift or lower personnel. Do not item 1) to the OFF position.
use the main or auxiliary drums. The
main and auxiliary drums are made for to lift or lower personnel, turn the MAN
material handling only. Using the whip RIDER MODE OFF/ON key switch to the
drum to lift or lower personnel requires ON position.
following special personnel handling
safety precautions (see paragraph 3.2). 3. Push the desired drum SELECT push
button (figure 2–12, item 1, 2, or 3) to select
the hoist drum to be operated by the HOIST
control (item 4).
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4. If the corresponding PAWL OUT push

button (figure 2–13, item 3, 5, or 7) is illumi-
NOTICE
nated steady, continue with step 5. If the • The MAIN/AUXILIARY brake pedal and
push button is not illuminated or is flashing, the WHIP brake pedal (see paragraphs
disengage the pawl for the corresponding 2.6.3 and 2.6.4) are not needed for
hoist drum (see paragraph 3.11.1.2). normal operation of the crane.
CAUTION !WARNING
• Move the lever of the HOIST control • Slowing the load by “dragging” with
slowly, to prevent abrupt changes in the brake pedal will cause too much
the speed of the corresponding fall. brake wear and can cause the brake to
overheat and “fade” (have reduced
5. Slowly move the lever of the HOIST control brake holding capacity).
• back toward the operator to raise the 6. To engage the pawl for the main, auxiliary,
selected fall or whip drum, use the procedure in para-
• forward away from the operator to graph 3.11.1.1.
lower the selected fall
The speed of the fall increases as the lever 3.11.1 Main, Auxiliary, and Whip Drum
is moved away from its neutral (center) Pawl
position. To decrease the speed, move the
lever toward its neutral position. To stop the
fall, return the lever to its neutral position. !WARNING
• When the load or boom must be
NOTICE suspended in the air, engage the pawls
• To prevent the main hoist motor brake corresponding main, auxiliary, or whip
and the corresponding drum brake drum of the main hoist. The operator
from engaging when the lever of the must not leave the control console
HOIST control is returned to its neutral with a load suspended in the air.
(center) position (“load float”), push
and hold depressed the thumb button
The main, auxiliary, and whip drums of the main
(figure 2–12, item 5) on the handle of
hoist each have a pawl that can be engaged
the HOIST control while raising or
into a ratchet pocket of the drum to mechani-
lowering the fall. Releasing the thumb
cally prevent the drum from rotating in the
button when the control lever is in its
lowering (payout) direction.
neutral position causes the main hoist
motor brake and the corresponding
drum brake to engage.
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3.11.1.1 Engaging the Main, Auxiliary, or 3. If the PAWL OUT push button flashes, the
Whip Drum Pawl pawl is not all the way out of the drum
ratchet pocket. Do the following to
1. Put the lever of the HOIST control (figure completely disengage the pawl:
2–12, item 4) in its neutral (center) position.
A. Push and hold depressed the corre-
2. With the selected fall completely stopped, sponding PAWL OUT push button.
push the corresponding PAWL IN push
button (figure 2–13, item 4, 6, or 8). The B. Slowly pull the lever of the HOIST
push button must illuminate steady. If the control back toward the operator to
push button flashes, continue with step 3. rotate the selected hoist drum in the
raise (inhaul) direction a small amount
3. If the corresponding PAWL IN push button until the PAWL OUT push button illumi-
flashes, the pawl has not engaged all the nates steady.
way in the drum ratchet pocket. To engage
the pawl all the way in the drum ratchet C. Return the lever of the HOIST control
pocket to its neutral position to stop the fall.
A. Push and hold depressed the PAWL IN D. Release the PAWL OUT push button.
push button.
B. Slowly push the lever of the HOIST 3.12 Emergency Release—Empty Block
control forward away from the operator
a small amount until drum rotation
(lowering movement) stops. The PAWL
!WARNING
IN push button must illuminate steady. • Do not lower a load using the
emergency release procedure. Only
C. When the drum rotation stops, return use the emergency release procedure
the lever of the HOIST control to its to lower an empty block.
neutral position.
The emergency release procedure permits an
D. Release the PAWL IN push button. empty main, auxiliary, or whip block to be
lowered without hoist motor power. Lowering
speed is controlled by using the corresponding
3.11.1.2 Disengaging the Main, Auxiliary, brake pedal only.
or Whip Drum Pawl
1. Turn the E-RELEASE ENABLE OFF/ON
1. Put the lever of the HOIST control (figure switch (figure 2–11, item 2) to the ON posi-
2–12, item 4) in its neutral (center) position. tion.
2. Push the corresponding PAWL OUT push 2. Push and hold the brake pedal (see figure
button (figure 2–13, item 3, 5, or 7). The 2–8) corresponding to the block to be
push button must illuminate steady. If the lowered all the way down.
push button flashes, continue with step 3.
3. With the brake pedal held down, push and
hold depressed the E-RELEASE push
button (figure 2–13, item 1, 10, or 12) corre-
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sponding to the block to be lowered. The 3.13 Whip Emergency Load Lowering
control system Procedure
• releases the corresponding drum clutch If a loss of electrical power occurs, the control
• actuates the parking brake release system engages the drum brakes automatically.
function for the corresponding drum If this happens when there is a load on the whip
brake fall, use the following procedure to lower the
load. This procedure requires the operator to
The drum brake is now controlled only by control the load using the WHIP brake pedal in
the brake pedal. the operator’s cab and at least one other
person in the machinery house to release the
!WARNING drum clutch. This procedure requires that the
whip drum pawl is released.
• In step 4, use the corresponding brake
pedal to control the speed of lowering. 1. Check the whip drum brakes. The brakes
Not doing so will result in uncontrolled must be engaged all the way (brake band
lowering of the block, which can result tight against the drum flange). Check that
in damage to the equipment and death the drum pawl is released.
or serious injury to personnel.
• If an emergency stop is necessary,
release the E-RELEASE push button, NOTICE
causing the drum brake to engage. • If the air compressor is not operating,
a separate air supply of 7.23–8.61 bar
4. With the E-RELEASE push button (105-125 psi) will be needed.
depressed, slowly release the correspond-
ing brake pedal upward to begin lowering. 2. Check that the system air pressure gauge
The speed of lowering increases as the (figure 2–9, item 2) reads 105—125 psi.
brake pedal is released upward. To
decrease the speed, push down more on 3. Push and hold the WHIP brake pedal all the
the brake pedal. To stop the block, push way down.
and hold the brake pedal all the way down.
When the block has stopped, release the
E-RELEASE push button. NOTICE
• Reference the Parts Manual, Section
5. Release the brake pedal. 12, drawing 150496, Air Piping
Schematic and drawing 1590499 Main
6. Turn the E-RELEASE ENABLE OFF/ON Hoist Air Piping.
switch to the OFF position.
4. Communicate with personnel in the
machinery house to release the whip drum
clutch.
5. Pull the WHIP EMERGENCY BRAKE

RELEASE VALVE (item 1) all the way out to
release the drum parking brake.
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6. Slowly release the brake pedal upward to the position of travel of the block in the
begin lowering. The speed of lowering block pocket.
increases as the brake pedal is released
upward. To decrease the speed, push down
more on the brake pedal.
NOTICE
• As the block is raised, the upper end
7. To stop the load, push and hold the brake of the guides on the block must catch
pedal all the way down. on the sloped rails of the block pocket.
The sloped rails will then guide the
8. With the brake pedal held all the way down, block into the pocket.
push the WHIP EMERGENCY BRAKE
RELEASE VALVE all the way down to 5. Push and hold depressed the MAIN LIMIT
engage the drum parking brake. BYPASS push button (figure 2–12, item 2)
or the AUXILIARY LIMIT BYPASS push
9. Release the brake pedal. button (item 11).
6. With the LIMIT BYPASS push button

3.14 Block Pocket—Main and Auxiliary depressed, raise the block very slowly into
Fall the guide rails of the block pocket. When
the block begins to enter the pocket the
Block pockets are provided in the boom (see corresponding HOOK ENTERING POCKET
figure 2–1) for storing the main and auxiliary shows on the screen of the LMS display.
falls during operation to keep the block from Continue raising the block until the corre-
swaying during operation of other falls. sponding HOOK IN POCKET shows on the
screen. The control system automatically
stops the block.
3.14.1 Putting the Block in the Block
Pocket 7. With the block stopped, release the LIMIT
BYPASS push button.
1. Remove the load and all attachments from
the block that will be put in the pocket. NOTICE
2. Raise the block to be put in the pocket so • If the block is raised too far into the
that it will be a short distance below the block pocket the control system slows
corresponding main or auxiliary block the motor of the main hoist to a stop
pocket when the boom is at the angle for and engages the main hoist motor
putting the block in the pocket. brake, and then engages the
corresponding drum brakes. The
3. Position the boom at 80.4 degrees boom HOIST control (see paragraph 2.6.7)
angle. will not function in the raise direction.
To back out of this condition, see
4. Go to the corresponding HOIST screen or paragraph 3.15.5.
the ALL HOOKS screen of the load moni-
toring system (LMS) display (see figure
2–8). This screen will be used to monitor
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3.14.2 Lowering the Block Out of the 3.15.1 Boom Upper Limit
Block Pocket
The control system protects against moving the
boom in (decreasing the radius of the fall)
CAUTION beyond 81.5 degrees boom angle. When the
• Do step 1 to prevent the block from boom is moved in to its upper operating limit,
swinging as it leaves the block pocket. the
1. Position the boom at 80.4 degrees boom • control system slows the boom to a stop
angle. and engages the boom hoist motor brake
and drum brake. The BOOM control (figure
2. Lower the main or auxiliary fall block until it 2–9, item 5) will not function in the in (rais-
is out of the block pocket. ing) direction.
• BOOM LIMIT BYPASS push button (figure
2–10, item 11) flashes red
3.15 Backing Out of Limit Conditions • BOOM UPPER LIMIT indicator shows on
the HOIST screen (see paragraph 2.4.5.2)
The control system stops certain crane func- and the ALL HOOKS screen (see para-
tions when the limit conditions listed in table graph 2.4.5.4)
3–6 are reached. See the paragraphs listed in
the table for a description of the limit condition To back out of the limit stop, move the boom
and the procedure to back out of the condition. out (increase the radius of the fall).
Before the boom upper limit occurs, a slow-

Table 3–6. Limit Conditions
down limit is activated to reduce the speed of
LIMIT CONDITION PARAGRAPH the boom to 25 percent of the normal speed.
Boom upper limit 3.15.1 When the slowdown limit occurs, the BOOM
SLOW DOWN indicator shows on the HOIST
Boom lower limit 3.15.2 screen and the ALL HOOKS screen.
Main, auxiliary, or whip
3.15.3
fall two-block limit
Main, auxiliary, or whip
3.15.4
fall lower limit
Boom and Main, Auxiliary,
or Whip Fall Overspeed 3.15.6
Fault
Block pocket limit 3.15.5
No capacity warning 3.15.7
90% capacity warning 3.15.8
Overload automatic stop 3.15.9
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3.15.2 Boom Lower Limit 3.15.3 Main, Auxiliary, or Whip Fall

Two-Block Limit
The control system protects against moving the
boom out (increasing the radius of the fall) The control system protects against raising the
beyond horizontal. When the boom is lowered main, auxiliary, or whip fall beyond their upper
to its lower operating limit, the operating limit, to prevent the sheaves of the
lower block from contacting the sheaves in the
• control system slows the boom to a stop boom (“two-blocking”). The two-block limit can
and engages the boom hoist motor brake occur from raising the fall, or from lowering the
and drum brake. The BOOM control (figure boom when the fall is near its two-block limit.
2–9, item 5) will not function in the out When the two-block limit is activated, the
(lowering) direction.
• BOOM LIMIT BYPASS push button (figure • control system slows the fall to a stop if in a
2–10, item 11) flashes red raising motion and engages the main hoist
• BOOM LOWER LIMIT indicator shows on motor brake and the corresponding drum
the HOIST screen (see paragraph 2.4.5.2) brake. The HOIST control (figure 2–12,
and the ALL HOOKS screen (see para- item 4) will not function in the raise direc-
graph 2.4.5.4) tion.
• control system slows the boom hoist motor
To back out of the limit stop, move the boom in to a stop if in a lowering motion, and
(decrease the radius of the fall). engages the boom hoist motor brake and
drum brake. The BOOM control (figure 2–9,
Before the boom lower limit occurs, a slowdown item 5) will not function in the out (lowering)
limit is activated to reduce the speed of the direction.
boom to 25 percent of the normal speed. When • corresponding MAIN, AUXILIARY, or WHIP
the slowdown limit occurs, the BOOM SLOW LIMIT BYPASS push button (figure 2–13,
DOWN indicator shows on the HOIST screen item 2, 11, or 9) flashes red
and the ALL HOOKS screen. • MAIN, AUX, or WHIP ANTI-TWO-BLOCK
LIMIT indicator shows on the corresponding
HOIST screen (see paragraph 2.4.5.2) and
the MAIN, AUX, or WHIP A2B LIMIT indica-
tor shows on the ALL HOOKS screen (see
paragraph 2.4.5.4)
To back out of the limit stop, lower the corre-

sponding main, auxiliary, or whip fall or move
the boom in (decrease the radius of the fall).
Before the two-block limit occurs, a slowdown

limit is activated to reduce the speed of the fall
to 25 percent of the normal speed. When the
slowdown limit occurs MAIN, AUX, or WHIP
ANTI-TWO-BLOCK WARNING indicator shows
on the HOIST screen and the MAIN, AUX, or
WHIP A2B WARNING shows on the ALL
HOOKS screen.
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3.15.4 Main, Auxiliary, or Whip Fall 3.15.6 Boom and Main, Auxiliary, or Whip
Lower Limit Fall Overspeed Fault
The control system protects against lowering The control system protects against overspeed
the main, auxiliary, or whip fall too far. When the in the lowering direction of the boom hoist drum
lower limit is activated, the and the main, auxiliary, and whip drums of the
main hoist. When an overspeed condition
• control system slows the fall to a stop and occurs, the
engages the main hoist motor brake and
the corresponding drum brake. The HOIST • control system slows the motor of the corre-
control (figure 2–12, item 4) will not function sponding hoist to a stop and engages the
in the lower direction. corresponding hoist motor brake and the
• corresponding MAIN, AUXILIARY, or WHIP corresponding drum brake
LIMIT BYPASS push button (figure 2–13, • corresponding BOOM control (figure 2–9,
item 2, 11, or 9) flashes red item 4) or HOIST control (figure 2–12, item
• MAIN, AUX, or WHIP LOWER LIMIT indica- 4) will not function
tor shows on the corresponding HOIST • corresponding overspeed alarm condition
screen (see paragraph 2.4.5.2) and the ALL shows on the FAULT screen and the FAULT
HOOKS screen (see paragraph 2.4.5.4) SCREEN command button on the START
screen (see paragraph 2.4.5.1), the HOIST
To back out of the limit stop, raise the corre- screen (see paragraph 2.4.5.2), and the
sponding fall. ALL HOOKS screen (see paragraph
2.4.5.4) alternately flashes yellow and red.
Before the lower limit occurs, a slowdown limit
is activated to reduce the speed of the fall to 25 To reset the control system after a drum
percent of the normal speed. When the slow- overspeed condition has occurred, return the
down limit occurs, the LOWER LIMIT lever of the corresponding BOOM control or
WARNING indicator shows on the HOIST HOIST control to its neutral (center) position.
screen and the ALL HOOKS screen.
3.15.5 Block Pocket Limit
The control system protects against raising the

main and auxiliary blocks too far into their block
pockets. If the block is raised too far into the
pocket, the control system slows the motors of
the corresponding hoist to a stop and engages
the hoist motor brake(s) and corresponding
drum brake. The HOIST control (figure 2–12,
item 7) will not function in the raise direction.
To back out of the limit stop, lower the corre-

sponding block.
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3.15.7 NO CAPACITY Warning 3.15.8 90% CAPACITY Warning
!WARNING !WARNING
• The load monitoring system (LMS) • The load monitoring system (LMS)
display must be correctly configured, display must be correctly configured,
in order for the safety warning in order for the safety warning
messages and overload automatic messages and overload automatic
stop to function. stop to function.
• The control system responds to the 90
percent load warning condition only
NOTICE when the boom is within the operating
• See Section 6, Capacity Charts, range on the selected capacity chart
drawings 1594855, 1594856, 1594857, (the NO CAPACITY warning condition
1594858, 1596451, and 1598177 for the is not active).
crane load capacity ratings.
The MAIN, AUX, or WHIP NO CAPACITY

NOTICE
indicator is visible on the HOIST screen (see • See Section 6, Capacity Charts,
paragraph 2.4.5.2) and the ALL HOOKS screen drawings 1594855, 1594856, 1594857,
(see paragraph 2.4.5.4) when the fall that corre- 1594858, 1596451, and 1598177 for the
sponds to the screen shown has no rated load crane load capacity ratings.
capacity at the present boom angle. When NO
CAPACITY shows, it indicates that the boom is The 90% CAPACITY indicator is visible on the
outside the operating range for the correspond- HOIST screen (see paragraph 2.4.5.2) and the
ing fall and therefore no load must be lifted. Not ALL HOOKS screen (see paragraph 2.4.5.4)
following this warning can result in damage to when the fall is at 90 percent or more of its
the equipment and death or serious injury to rated load capacity for the present boom angle.
personnel. In addition, the horn located below the left front
corner of the operator’s cab and the audible
alarm of the LMS display sounds intermittently
for 6 seconds and then remains off for 30
seconds, and then repeats this cycle until the
alarm condition is no longer active.
To back out of this warning condition, lower the

load all the way, or depending on the boom
angle, move the boom in (decrease the radius
of the fall) until the condition is no longer active.
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3.15.9 Overload Automatic Stop To back out of the overload automatic stop,
lower the load all the way, or, depending on the
boom angle, move the boom in (decrease the
!WARNING radius of the fall) until the condition is no longer
• The load monitoring system (LMS) active.
display must be correctly configured,
in order for the safety warning
messages and overload automatic
stop to function.
• The control system responds to the
overload condition only when the
boom is within the operating range on
the selected capacity chart (the NO
CAPACITY warning condition is not
active).
NOTICE
• See Section 6, Capacity Charts,
drawings 1594855, 1594856, 1594857,
1594858, 1596451, and 1598177 for the
crane load capacity ratings.
The OVERLOAD indicator is visible on the

HOIST screen (see paragraph 2.4.5.2) and the
ALL HOOKS screen (see paragraph 2.4.5.4)
when the corresponding fall is at 110 percent or
more of its rated load capacity for the present
boom angle. When an overload condition
occurs, the
• control system slows the fall to a stop and

engages the main hoist motor brake and
corresponding drum brake. The HOIST
control (figure 2–12, item 4) will not function
in the raise direction.
• control system slows the boom to a stop if
the boom is in a lowering motion and
engages the boom hoist motor brake and
drum brake. The BOOM control (figure 2–9,
item 5) will not function in the out (lowering)
direction.
• horn located below the left front corner of
the operator’s cab and the audible alarm of
the LMS display sounds continuously until
the alarm condition is no longer active
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4 TUGGERS
4.1 Introduction
This section contains:
• a general description of the tugger equip-

ment (see paragraph 4.2)
• control nomenclature and description of the
operator's controls (see paragraphs 4.3 and
4.4)
• general operating instructions for the
tuggers (see paragraph 4.5)
4.2 Tugger Equipment Description
Three tuggers (see figures 2–1 and 2–2) are

located on the crane. Two tuggers (the load
control tuggers), located on the machinery plat-
form, can be used to horizontally position a load
or horizontally hold a load with constant
tension. One tugger (the block control tugger),
located on the boom, can be used to horizon-
tally position the block of the main fall or hori-
zontally hold the block with constant tension.
The load control tuggers can be controlled from

the right control console and left rear control
panel (see figure 4–1) in the operator’s cab or
from a hand-held tugger pendant control (see
figure 4–2) located by the tugger. The block
control tugger is controlled from the right control
console.
!WARNING
• Do not use a tugger for load lifting.
Lifting a load can overload the tugger,
foundation, and reeving system,
resulting in damage to the crane, the
load, and death or serious injury to
personnel.
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4.3 Control Nomenclature
4.3.1 Tugger Controls—Operator’s Cab
The controls of the operator’s right control console, right control panel, and the left rear control panel
(see figure 4–1) direct the functioning of the tugger equipment. The right control panel has three groups
of controls, one group for each tugger. Detailed descriptions of the operator’s controls are given in the
following paragraphs as outlined by the table of contents.
ITEM
NUMBER DESCRIPTION
1 TUGGER CONTROL OPCAB/LOCAL switch (see paragraph 4.4.2)

2 TUGGER control (see paragraph 4.4.4)
3 TUGGER CONTROL yellow indicator light (see paragraph 4.4.2)
4 STOP push button (see paragraph 4.4.3)
5 START green illuminated push button (see paragraph 4.4.3)
6 TENSION control (see paragraph 4.4.7)
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E-RELEASE MAN RIDER CONTROL POWER CONTROL POWER EM

ER
G
ENABLE MODE ON OFF ST ENC
LO
WE OP Y
EM
F R
F
HO
ON
ON
TH
OF
ER
OF
UM IS
BB T
G
LO
AD
UT
TO G PO GEN
FL N W C
OF ER Y
RA OA
ISE T
M F
SE AIN
LE
CT
TUGGER LAMP/ALARM
CONTROL DRIVE RESET TEST
G
B
LO
CA
CA
A
SE UX
OP
LE
CT
1 G
W
SE HIP
LE
CT
LOAD CONTROL
TUGGER #2
BLOCK CONTROL
Left Rear Control Panel
TUGGER
LOAD CONTROL
TUGGER #1
3 4 5 6 Right Control
Console
TUGGER MAIN AUX WHIP

CONTROL PAWL IN PAWL IN PAWL IN STOP START STOP START STOP START
Y R R R G G G
MAIN AUX WHIP

PAWL OUT PAWL OUT PAWL OUT TENSION TENSION TENSION
G G G
MAIN LIMIT AUX LIMIT WHIP LIMIT

BYPASS BYPASS BYPASS TUGGER #2 TUGGER TUGGER #1
LOAD CONTROL BLOCK CONTROL LOAD CONTROL
R R R
MAIN AUX WHIP

E-RELEASE E-RELEASE E-RELEASE
A3678
A3676
A3680
Right Control Panel
Figure 4–1. Tugger Controls—Operator’s Cab
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4.3.2 Tugger Pendant Control

The hand-held pendant control permits the load control tugger to be controlled by the operator from a
more visible location than the operator’s cab control consoles. The pendant control for the tugger is
located by each tugger.
NEUTRAL
INH
OU
AU
PAY
L
7 SPEED
TENSION
6
5 RESET
4 START
3
STOP
2
EMERGENCY
STOP
1
A3682
Figure 4–2. Tugger Pendant Control

ITEM
NUMBER DESCRIPTION
1 EMERGENCY STOP push-pull switch (see paragraph 4.4.1)

2 STOP push button (see paragraph 4.4.3)
3 START green illuminated push button (see paragraph 4.4.3)
4 RESET push button (see paragraph 4.4.8)
5 TENSION control (see paragraph 4.4.7)
6 SPEED control (see paragraph 4.4.6)

7 PAYOUT/NEUTRAL/INHAUL switch (see paragraph 4.4.5)
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4.4 Tugger Control Devices 4.4.2 TUGGER CONTROL

OPCAB/LOCAL Switch and
TUGGER CONTROL Indicator
4.4.1 Tugger EMERGENCY STOP Switch Light
!WARNING The TUGGER CONTROL OPCAB/LOCAL

switch (see figure 4–1, item 1), located on the
• Pushing the tugger EMERGENCY left rear control panel in the operator’s cab,
STOP switch will engage the brake of permits the load control tuggers to be controlled
the tugger. Engaging the brake of a by the use of the control pendant (see para-
tugger when the wire rope of the graph 4.3.2) located by the tugger. The switch
tugger is connected to a load can is a two-position selector switch.
reeving system if the radius of the load In the OPCAB position,
increases due to vessel list or trim or
outward drift of the boom. After an • control of the load control tuggers is from
emergency stop, check the foundation the control console in the operator’s cab
bolts of the tuggers. • the controls located on the control
pendants do not function
Push the knob of a tugger EMERGENCY STOP • the TUGGER CONTROL indicator light
switch (figure 4–2, item 1), located on the (item 3) located on the right control panel in
control pendant, all the way down to immedi- the operator’s cab is not illuminated
ately stop all motions of the corresponding
tugger. When a tugger EMERGENCY STOP In the LOCAL position,
switch is pushed, the
• control of the load control tuggers is from
• motor of the tugger stops the control pendants
• tugger motor brake engages • the load control tugger controls located on
the control console in the operator’s cab do
The tugger EMERGENCY STOP switch is a not function
maintained push-pull switch. Before the tugger • the TUGGER CONTROL indicator light illu-
can be operated, the knob of the switch must minates yellow
be pulled all the way out. See Tugger Emer-
gency Stop Procedure, paragraph 4.5.3.
4.4.3 START and STOP Push Buttons
There are also EMERGENCY STOP switches
located on the corresponding drive control The START push button (see table 4–1) and
panel for the tugger. Pushing the knob of an STOP push button control the electric motor
EMERGENCY STOP switch located on a that drives the corresponding tugger. The push
tugger drive control panel only stops the corre- buttons are momentary-contact push buttons.
sponding tugger. Before a tugger can be oper-
ated, the knob of the EMERGENCY STOP Push the START push button to start the motor.
switch must be pulled all the way out and the The push button illuminates green when the
drive control panel must be reset (see para- motor is operating.
graph 4.4.8).
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Push the STOP push button to stop the motor The speed of payout depends on
and engage the tugger motor brake.
• the position of the control lever
Table 4–1. START and STOP Push Buttons • the weight of the load being controlled
FIGURE AND
To operate in the load positioning mode of oper-
LABEL LOCATION ITEM
ation, push the lever of the TUGGER control
NUMBERS
forward away from the operator to pay out the
Right control figure 4–1, wire rope. Pull the lever back toward the opera-
panel item 5 tor to inhaul the wire rope. The speed of the
START
Pendant figure 4–2, drum increases as the lever is moved away
control item 3 from its neutral position. To decrease the
speed, move the lever toward its neutral posi-
Right control figure 4–1,
tion. To stop the drum, return the lever to its
panel item 4
STOP neutral position. The control system slows the
Pendant figure 4–2, motor of the tugger to a stop and engages the
control item 2 tugger motor brake.
To operate in the constant tension mode of

operation, use the inhaul direction only. The
4.4.4 TUGGER Control
drum will inhaul or pay out as necessary to
maintain the adjusted line tension. The farther
!WARNING the control lever is pulled back toward the oper-
ator, the faster the drum will rotate.
• Do not use a tugger for load lifting.
foundation, and reeving system,
resulting in damage to the crane, the 4.4.5 PAYOUT/NEUTRAL/INHAUL
load, and death or serious injury to Switch
personnel.
The PAYOUT/NEUTRAL/INHAUL switch (figure
The TUGGER control (figure 4–1, item 2), 4–2, item 7), located on the control pendant,
located on the right control console in the oper- controls the direction of rotation of the tugger.
ator’s cab, controls the direction and speed of The switch is a three-position selector switch.
the corresponding tugger wire rope. The
TUGGER control is a stepless electrical master In the PAYOUT position, the tugger will pay out
switch with a friction-controlled operating lever. the wire rope.
To move the lever, first lift up on the control
handle. The lever will stay in any position. The In the NEUTRAL position, the tugger drum is
neutral (center) position is detented. stopped.
The speed of inhaul depends on In the INHAUL position, the tugger will inhaul
the wire rope.
• the position of the control lever
• the position of the TENSION control (see
paragraph 4.4.7)
• the weight of the load being controlled
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4.4.6 SPEED Control To decrease the linepull, turn the knob of the
TENSION control counterclockwise.
The SPEED control (figure 4–2, item 6), located
on the control pendant, controls the drum Table 4–2. TENSION Controls
speed (linespeed) of the tugger.
FIGURE AND ITEM
LOCATION
The speed of inhaul depends on the NUMBERS
Right control panel figure 4–1, item 6
• position of the knob of the SPEED control
• position of the knob of the TENSION Pendant control figure 4–2, item 5
control (see paragraph 4.4.7)
• weight of the load being controlled
The speed of payout depends on the 4.4.8 RESET Push Button
The RESET push button (figure 4–2, item 4),

• position of the knob of the SPEED control
located on the control pendant, resets the
• weight of the load being controlled
corresponding tugger drive control panel.
Turn the knob of the SPEED control clockwise
to increase the speed of the tugger. The speed NOTICE
of the wire rope increases the farther the knob
• There is also a RESET push button on
is turned clockwise.
each tugger drive control panel located
in the electrical house. Pushing a
Turn the knob of the control counterclockwise to
RESET push button on a drive control
decrease the speed of the tugger. The speed of
panel resets that panel only. The
the wire rope decreases the farther the knob is
READY indicator light located on the
turned counterclockwise. Turn the knob all the
panel illuminates green when the panel
way counterclockwise to stop the tugger.
is ready for operation.
4.4.7 TENSION Control
The TENSION control (see table 4–2) controls

the linepull developed by the tugger when the
lever of the corresponding TUGGER control
(see paragraph 4.4.4) or the PAYOUT/
NEUTRAL/INHAUL switch (see paragraph
4.4.5) is in a position for inhaul. When the
tension on the tugger wire rope equals the
adjusted linepull as determined by the position
of the TENSION control knob, the drum of the
tugger stops. If the load moves, the drum
inhauls or pays out and stops automatically to
maintain the adjusted linepull.
To increase the linepull, turn the knob of the

TENSION control clockwise.
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4.5 Tugger Operation 1. Complete the tugger pre-start procedure

(see paragraph 4.5.1).
4.5.1 Pre-Start Procedure 2. Check that the
The following inspections are considered • lever of each TUGGER control (figure
mandatory by National Oilwell Varco. They 4–1, item 2) is in its neutral (center)
make sure the equipment is in a safe operating position
condition. Other inspections can be required by • knob of the TENSION control (item 6)
local regulations and must also be made. is turned all the way counterclockwise
3. The tugger(s) is now ready for normal oper-

4.5.1.1 Each Workday ation.
Do the following at the beginning of each work-

day: 4.5.3 Tugger EMERGENCY STOP
Procedure
• Check the preventive maintenance records
to make sure that the scheduled lubrication
(see paragraph 5.2.2) and inspections and !WARNING
maintenance (see paragraph 5.3) have • Pushing the tugger EMERGENCY
been done at the correct intervals. STOP switch will engage the brake of
the tugger. Engaging the brake of a
tugger when the wire rope of the
4.5.1.2 Before Each Start-Up tugger is connected to a load can
1. Check that all safety guards are in place. reeving system if the radius of the load
increases due to vessel list or trim or
2. Check that all personnel, tools, and other outward drift of the boom. After an
loose items are away from the tuggers, wire emergency stop, check the foundation
rope, and moving equipment parts. bolts of the tuggers.
3. The tugger equipment can now be started 1. To immediately stop all motions of a tugger,
(see paragraph 4.5.2). push the knob of the corresponding tugger
EMERGENCY STOP switch all the way
down. See Tugger EMERGENCY STOP
4.5.2 Start Procedure switch, paragraph 4.4.1, for a description of
the response of the control system to the
Do the following procedure for each tugger. emergency stop.
NOTICE 2. To resume operation of the tugger after the

reason for the tugger emergency stop has
• This procedure assumes that the crane been corrected
start procedure (see paragraph 3.4)
has been completed. A. Check the motor brake of the tugger if
the brake was used to stop the load
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during the emergency stop. Check the • knob of each TENSION control (item 6)
brake for wear, damage, and correct is turned all the way counterclockwise
adjustment. • TUGGER CONTROL OPCAB/LOCAL
switch (item 1) is in the OPCAB posi-
B. Pull the knob of the tugger tion
EMERGENCY STOP switch that was
pushed in step 1 all the way out. Before 2. For the tugger to be operated, pay out
the tugger can be operated, the knob of enough wire rope to reach the load or
the tugger EMERGENCY STOP switch block.
must be pulled all the way out.
A. Push the correct START push button
C. The tugger can now be started (see (item 5). The push button must illumi-
paragraph 4.5). nate.
B. Move the lever of the TUGGER control

4.5.4 Operation Procedure—Operator’s in the payout direction until the desired
Cab Control amount of wire rope has payed out.
C. Return the lever of the TUGGER

!WARNING control to its neutral position.
• Do not exceed the rated linepull
capacity of the tugger (see paragraph D. Push the corresponding STOP push
6.5). button (item 4) to stop the tugger motor
• Do not use a tugger for load lifting. and engage the motor brake.
foundation, and reeving system, 3. Attach the wire rope from the tugger to the
resulting in damage to the crane, the load or block.
load, and death or serious injury to
personnel. 4. Repeat steps 2 and 3 as necessary for
• Do not permit the motor brake of the each additional tugger to be used for
tugger to resist the load. Doing so can controlling a load or block.
reeving system, resulting in damage to 5. Push the START push button for each
the crane, the load, and death or tugger to be operated. The push button(s)
serious injury to personnel. must illuminate.
6. Use the correct TUGGER control to take up

Use the following procedure to operate a tugger
(inhaul) slack in the tugger wire rope.
using the tugger controls in the operator’s cab.
To operate a load control tugger using the
control pendant, see paragraph 4.5.5.
1. Check that the
• lever of each TUGGER control (figure

4–1, item 2) is in its neutral (center)
position
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7. Adjust the line tension by doing one of the 11. Remove the load from the tugger and wind
following: the wire rope onto the tugger drum. To do
so, do the following:
A. To operate the tugger in the load posi-
tioning (speed-regulated payout) mode
for reeving and other maintenance !WARNING
purposes, turn the correct TENSION • In step A, turn the knob of the
control all the way clockwise (maximum TENSION control slowly, to avoid a
tension). sudden release of tension.
B. To operate the tugger in the constant A. Decrease the tension in the tugger wire
tension mode, turn the TENSION rope by slowly turning the knob of the
control all the way counterclockwise. TENSION control all the way counter-
Then, pull the lever of the TUGGER clockwise. (Alternatively, the TUGGER
control a small amount in the inhaul control can be used to pay out the wire
direction and turn the TENSION control rope in a controlled manner to
clockwise to the desired tension setting decrease the tension in the wire rope.)
(wire rope linepull).
B. Put the lever of the TUGGER control in
its neutral position.
!WARNING
• When decreasing the tension using the C. Detach the tugger wire rope from the
TENSION control, turn the knob of the load or block.
control slowly, to avoid a sudden
release of tension. D. Use the TUGGER control and a low
tension setting to wind the unattached
8. Adjust the position of the TUGGER control wire rope onto the tugger drum. (Use
lever to the desired speed setting (wire enough tension to make sure the wire
rope linespeed). The farther the control rope winds properly onto the tugger
lever is moved from its neutral position, the drum.)
faster the tugger drum will rotate. The drum
will stop when the tension on the wire rope 12. Check that the lever of the TUGGER
equals the tension setting. (In the constant control is in its neutral position.
tension mode of operation, a lower speed
setting will prevent the tugger from “surg- 13. Turn the knob of the TENSION control all
ing”—overreacting—to load movement.) the way counterclockwise.
9. If operating the tugger in the load position- 14. Push the correct STOP push button.
ing mode of operation, return the lever of
the TUGGER control to its neutral position
to stop the tugger wire rope. The control
system slows the motor of the tugger to a
stop.
10. When tugger operation is finished, continue

with step 11 to shut down the tugger.
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4.5.5 Operation Procedure—Pendant 2. Check that the

Control
• PAYOUT/NEUTRAL/INHAUL switch
(figure 4–2, item 7) is in the NEUTRAL
!WARNING position
• Do not exceed the rated linepull • knob of the SPEED control (item 6) is
capacity of the tugger (see paragraph turned all the way counterclockwise
6.5). • knob of the TENSION control (item 5)
• Do not use a tugger for load lifting. is turned all the way counterclockwise
Lifting a load can overload the tugger, • knob of the EMERGENCY STOP
foundation, and reeving system, switch (item 1) is pulled all the way out
resulting in damage to the crane, the
load, and death or serious injury to 3. Push the RESET push button (item 4).
personnel.
• Do not permit the motor brake of the 4. For the tugger to be operated, pay out
tugger to resist the load. Doing so can enough wire rope to reach the load.
reeving system, resulting in damage to A. Turn the PAYOUT/NEUTRAL/INHAUL
the crane, the load, and death or switch to the PAYOUT position.
serious injury to personnel.
B. Push the START push button (item 3).
The push button must illuminate.
When operating the load control tuggers from
the control pendant, the operators must be in
C. Slowly turn the knob of the SPEED
constant communication with each other.
control clockwise to begin pay out of
the wire rope.
Use the following procedure to operate a load
control tugger using the pendant control stowed
D. When the desired amount of wire rope
on the support beam by the tugger. To operate
has been payed out, turn the knob of
a load control tugger using the tugger controls
the SPEED control all the way counter-
in the operator’s cab, see paragraph 4.5.4.
clockwise.
NOTICE E. Push the STOP push button (item 2) to

stop the tugger motor and engage the
• Do step 1 in the operator’s cab.
motor brake.
1. Check that the TUGGER CONTROL 5. Attach the wire rope from the tugger to the
OPCAB/LOCAL switch (figure 4–1, item 1) load.
is in the LOCAL position. The TUGGER
CONTROL indicator light (item 3) must illu- 6. Repeat steps 2 through 5 as necessary at
minate. the other load control tugger.
NOTICE 7. Push the START push button for each

tugger to be operated. The push button(s)
• Do steps 2 through 22 at the control
must illuminate.
pendant.
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8. Turn the PAYOUT/NEUTRAL/INHAUL 16. Use the SPEED control to get the desired
switch to the INHAUL position. wire rope linespeed. Turn the knob of the
control clockwise to increase the linespeed.
9. To operate the tugger in the load position- Turn the knob of the control counterclock-
ing (speed-regulated payout) mode for wise to decrease the linespeed. A lower
reeving and other maintenance purposes, speed setting will prevent the tugger from
continue with step 10. To operate the “surging”— overreacting—to load move-
tugger in the constant tension mode, ment.
continue with step 13.
10. Turn the TENSION control all the way with step 18 to shut down the tugger.
clockwise (maximum tension).
18. Remove the load from the tugger and wind
11. Slowly turn the knob of the SPEED control the wire rope onto the tugger drum. To do
clockwise to begin movement of the wire so, do the following:
rope. Turn the knob of the control clockwise
to increase the linespeed. Turn the knob of
the control counterclockwise to decrease !WARNING
the linespeed. Turn the knob all the way • In step A, turn the knob of the
counterclockwise to stop the wire rope. TENSION control slowly, to avoid a
sudden release of tension.
with step 18 to shut down the tugger. A. Decrease the tension in the tugger wire
rope by slowly turning the knob of the
13. Turn the TENSION control all the way TENSION control all the way counter-
counterclockwise. clockwise.
14. Turn the knob of the SPEED control a small B. Turn the knob of the SPEED control all
amount clockwise. the way counterclockwise.
C. Turn the PAYOUT/NEUTRAL/INHAUL

!WARNING
switch to the NEUTRAL position.
• When decreasing the tension using the
TENSION control, turn the knob of the D. Detach the tugger wire rope from the
control slowly, to avoid a sudden load.
release of tension.
E. Turn the PAYOUT/NEUTRAL/INHAUL
15. Turn the knob of the TENSION control switch to the INHAUL position.
clockwise to increase the linepull devel-
oped by the tugger. Turn the knob of the F. Use the SPEED control along with the
control counterclockwise to decrease the TENSION control at a low tension
linepull developed by the tugger. When the setting to wind the unattached wire
load’s tension on the wire rope equals the rope onto the tugger drum. (Use
adjusted linepull developed by the tugger, enough tension to make sure the wire
the tugger will stop. rope winds properly onto the tugger
drum.)
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19. Turn the knob of the SPEED control all the 2. Check the motor brake of the tugger if the
way counterclockwise. brake was used to stop the load when the
motor overload occurred for wear, damage,
20. Push the correct STOP push button. and correct adjustment.
21. Turn the knob of the TENSION control all 3. If operating the tugger from the operator’s
the way counterclockwise. cab, push the RESET push button located
on the corresponding tugger drive control
22. Turn the PAYOUT/NEUTRAL/INHAUL panel. The READY indicator light located
switch to the NEUTRAL position. on the panel must be illuminated green.
If operating the tugger from the control

4.6 Tugger Motor Overload Stop pendant, push the RESET push button
(item 4).
!WARNING 4. The tugger can now be started (see para-

• A tugger motor overload stop will graph 4.5.2).
engage the brake of the tugger.
Engaging the brake of a tugger when
the wire rope of the tugger is
connected to a load can overload the
tugger, foundation, and reeving system
if the radius of the load increases due
to vessel list or trim or outward drift of
the boom. After a motor overload stop,
check the foundation bolts of the
tuggers.
The electric motors of the tuggers are protected

against overload. If a motor overload condition
occurs, the
• motor of the tugger stops

• tugger motor brake engages
1. If operating the tugger from the operator’s

cab, put the lever of the TUGGER control
(figure 4–1, item 2) in its neutral (center)
position.
If operating the tugger from the control

pendant, turn the PAYOUT/NEUTRAL/
INHAUL switch (figure 4–2, item 7) to the
NEUTRAL position.
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5 MAINTENANCE
CAUTION
• Clean the work area and lubrication
5.1 Introduction and General fittings before and after adding the
Instructions lubricant. Remove any extra lubricant
that has been forced through a
This section includes general maintenance bearing. When the equipment is
schedules and maintenance instructions for the operated, extra lubricant will work its
equipment as outlined by the table of contents. way out of the bearing. This lubricant
Reference drawings are included at the end of must be removed, especially in areas
this chapter. near the brake and clutch linings. If a
lubricant does wear into a lining, a new
Maintenance must be done at regular intervals. lining can be necessary.
Failure to do the necessary maintenance can
result in damage or failure of the equipment. Do not mix different types and brands of lubri-
The lubrication schedule (see paragraph 5.2) cants, because of possible incompatibility.
and the inspection and maintenance schedule
(see paragraph 5.3) are guides for the correct Use caution regarding the rate and pressure at
maintenance of the equipment. which lubricant is forced into a bearing, to avoid
damaging the seal of the bearing, which can
Permit only qualified service personnel who cause damage to the bearing.
have received training in the proper mainte-
nance, adjustment, and inspection of the equip- When putting new bearings into service, add
ment to do these procedures. lubricant, rotate the bearing, and add more
lubricant until a small amount of lubricant
After making a repair or adjustment, always begins to show from the bearing. This will make
check the functioning of the equipment parts sure the bearing is completely lubricated.
before putting the equipment into full operation.
At designated intervals, relubricate the bear-
Do not make modifications to the equipment ings. When relubricating a bearing, add only a
unless approved in writing by National Oilwell measured amount of lubricant. Periodic
Varco. over-lubrication is needed to remove all old
lubricant from the bearing. When to over-lubri-
cate a bearing depends on the duty cycle of the
5.2 Lubrication equipment and its severity of use.
Extra lubricant forced out from a bearing must

5.2.1 Lubrication Procedures be removed. Check the removed lubricant for
water content and particles of metal. Particles
Do not operate the equipment without proper of metal in the lubricant indicate bearing wear.
lubrication. Lubricants that do not meet the
requirements of the equipment or lubricants that If a lubricant fitting will not take lubricant (too
have deteriorated to a level of unacceptable much pressure) the problem must be found and
service must not be used, or must be replaced corrected before continuing operation.
with acceptable lubricants before operating the
equipment.
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5.2.2 Lubrication Schedule Qualified person—A person who, by posses-

sion of a recognized degree in an applica-
See Lubrication Guide, drawing 1595432 at the ble field or certificate of professional
end of this section for the lubrication schedule, standing, or who, by extensive knowledge,
lubrication points, and quantities and types of training, and experience, has successfully
lubricant. demonstrated the ability to solve or resolve
problems relating to the subject matter and
See Application of Asphaltic Base Open Gear work.
Lubricant, drawing 1525532 at the end of this Standby crane—A crane that is not in regular
section for the procedure to apply Open Gears service, but one that is used occasionally or
Lubricant (National Oilwell Varco p/n 310310). intermittently as required.
5.3 Inspection and Maintenance 5.3.3 Inspection Intervals

Schedule
Inspections must be done at regular intervals.
The intervals are dependent on the degree of
5.3.1 Introduction and Purpose exposure of the crane equipment parts to criti-
cal and/or severe loads, wear, deterioration, or
The basic document for inspection and mainte- malfunction. The usage of the crane, both in
nance of vessel-mounted cranes is the current hours and severity, must be considered when
publication of American National Standard for determining inspection intervals. Detailed
Floating Cranes and Floating Derricks, observation of the equipment parts over time by
ANSI/ASME B30.8, Chapter 8-2, “Inspection, experienced maintenance personnel will help
Testing, and Maintenance” published by the establish a pattern of required maintenance and
American Society of Mechanical Engineers, inspection.
Three Park Avenue, New York, NY 10016-5990,
USA. 1. As Necessary—These items must be done
as necessary (see manufacturer’s information
The purpose of the following paragraphs is to if applicable).
supplement the above basic documents, to
provide additional detailed information where 2. Frequent Inspections—These items must
deemed helpful and/or necessary to help be done daily to monthly depending on
assure the complete and thorough inspection severity of use, or as specifically recom-
and maintenance of all equipment parts. mended by the manufacturer of a particular
crane part.
5.3.2 Definitions 3. Periodic Inspections—These items must be

done in one to twelve month intervals
Appointed person—A person assigned specific depending on severity of use, or as specifi-
responsibilities by the employer or the cally recommended by the manufacturer of
employer’s representative. a particular crane part.
Designated person—A person selected or
assigned by the employer or the employer’s
representative as being competent to
perform specific duties.
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5.3.4 Inspection Records • All hoist drum pawls and all brakes
engaged.
Dated records must be made on critical items • All controls in the shutdown position.
such as hoisting machinery, brakes, clutches,
sheaves, hooks, wire ropes, and other lifting 2. Means of starting means rendered inopera-
devices. Records must be maintained and tive, or main switch locked in open position.
available to appointed personnel. For wire rope
inspection record requirements, see “Inspection 3. “Do Not Use” signs or tags placed on the
Records,” in the corresponding ANSI/ASME crane, including: on the control console, at
publication section B30.8-2004, 8-2.4.5 or latest the entrance to the machinery house, at the
revision. entrance to the operator’s cab, at the main
electrical switches, and on the hoists and
tuggers. Lockouts must be installed by
5.3.5 Maintenance Procedure each maintenance person at each electrical
power area following industry-standard
lockout/tag out procedures.
!WARNING
• Failure to do the necessary 4. Procedures for repairs by welding must be
maintenance can result in damage or approved by a qualified person, with guid-
failure of the crane. ance as necessary from the National
• Permit only qualified service personnel Oilwell Varco Service Department. Do not
who have received training in the weld on hooks or shackles.
maintenance, inspection, and
adjustment of the equipment to do 5. Release air pressure from all air circuits
these procedures. and equipment parts before loosening or
• Use caution when doing maintenance removing air system parts.
on or near electrical equipment.
Electrical equipment must be 6. After adjustments and repairs have been
maintained and operated according to made, the crane must not be put back in
applicable standards. operation until all guards have been rein-
stalled, safety devices reactivated, and
maintenance equipment removed.
Do not permit any maintenance or adjustment
to the equipment before taking the following
precautions:
1. Equipment shut down (see paragraph 3.6):
• Load removed from the equipment.

• Crane positioned where it will cause
the least interference with other equip-
ment or operations in the area and
secured from movement.
• Boom lowered to the boom rest, if
possible, or otherwise secured against
inadvertent lowering.
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5.3.6 Adjustments and reshaping on hooks or shackles is not

Repairs—General Precautions permitted.
• pitted or burned electrical contacts
should be corrected only by replace-
!WARNING ment in sets. Controller parts must be
• Always look for equipment damage or lubricated only as recommended by the
abnormal functioning during manufacturer.
operation. If found, safely shut down
the equipment and correct the problem 4. All replacement and repaired parts must
before continuing operation. meet the manufacturer’s current specifica-
• Correct any condition that is not safe tions.
before operating the equipment.
• After making a repair or adjustment
check the functioning of the
equipment parts before putting the
equipment into operation.
• Do not make modifications to the
equipment unless approved in writing
by National Oilwell Varco.
1. Any hazardous conditions observed must

be corrected before operation is resumed.
Adjustments and repairs must be done only
by designated personnel.
2. Adjustments must be maintained to ensure

correct functioning of all equipment parts.
Examples include but are not limited to:
functional operating mechanisms, control
systems, braking systems, clutch systems,
pawl system, foundations or other anchor-
ages, safety devices, and signal systems.
3. Repairs or replacements must be provided

as needed for operation. Examples include
but are not limited to:
• critical parts of functional operating

mechanisms that are cracked, bent,
broken, corroded, or excessively worn
• critical parts of the structure that are
cracked, bent, broken, or excessively
corroded
• hooks showing indications must be
discarded if examination determines
they constitute a hazard. Welding or
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5.3.7 As Necessary
Interval Item
o Paint any damaged paint surfaces to prevent corrosion. Damaged paint
can indicate an underlying structural hazard (see “structural members and
welds” in “Periodic Inspection”)—determine whether further inspection is
required before repairing paint damage. Notify appropriate inspection
personnel if necessary.
o PLC Battery—replace as necessary to avoid data loss. For the instructions
to replace the battery, see the Vendor Data Manual, Allen-Bradley.
o Ventilation filters (on electrical panels, motor blowers, ventilation fans, air
conditioning, etc.)—clean or replace the filter elements.
As necessary or as o Shutters or louvers (machinery house louvers, etc.)—remove debris.
recommended by o Air reservoir and filters—drain the water condensation.
the manufacturer, o Air filters—clean or replace the filter element as applicable. See manufac-
whichever is more turer’s information.
frequent o Air system desiccant dryer—replace the desiccant.
o See the manufacturer’s information for additional maintenance informa-
tion for items not manufactured by National Oilwell Varco. If the information
is not in the Vendor Data Manual, contact the National Oilwell Varco Service
Department. Examples include but are not limited to:
• Resistor bank • Refrigerated air dryer
• Electric motor • Air system lubricator
• Gear reducer • Air system anti-freezer
• Motor brake • Air conditioning
• Air compressor • Anemometer
Before every o Resistor bank—remove debris from the intake side.
startup
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5.3.8 Frequent Inspections (Daily to Monthly Depending on Severity of Use)
ANSI/ASME Reference
(publication, paragraph)
Item
(B30.8-2004, 8-2.3.1 (a)
unless otherwise noted)
o Hooks—visually check before and during operation for: B30.10-2005, 10-1.2.1.2
• distortion, such as bending, twisting, or increased throat opening
• wear
• cracks, nicks, or gouges (see ANSI/ASME B30.10-1.2.3 (e) for
repair guidelines)
• safety latch for engagement, damage, and proper functioning (if
provided)
• hook attachment and securing means
• check self-locking hooks for proper operation and locking
If a problem is found, a designated person must determine whether it
or a combination of problems found constitute a hazard and whether
a more detailed inspection is required.
o Reeving—check for correct wire rope reeving. B30.8-2004, 8-2.1.2 (a) (7)
o Chords and lacing (including boom chords and lacing)—visually B30.8-2004, 8-2.1.2 (a) (2)
check all for damage, distortion, cracks, corrosion, and loose or miss-
ing parts.
o Lighting—check for correct operation. B30.8-2004, 8-2.1.2 (a) (8)
o Machinery house, electrical house, and operator’s cab—check

for damage, corrosion, leaks, broken glass, and cleanliness including
proper storage of tools and equipment. Check for correct operation of
doors, vents, windows, and window wipers.
o Fire protection equipment—monthly inspection per National Fire B30.8-2004, 8-2.1.2 (a) (4)
Protection Association (NFPA) Publication NFPA 10 and local regula- NFPA 10
tions.
o Safety guards—check that the safety guards are in place. Replace B30.8-2004, 8-2.1.2 (a) (4)
all damaged or missing safety guards.
o Electrical equipment (wiring, panels, junction boxes, motors, motor B30.8-2004, 8-2.1.2 (a) (8)
brakes, collector rings, anti-condensation and other heaters,
etc.)—check for malfunctioning, signs of excessive deterioration, dirt
or moisture accumulation, signs of excessive heating or arcing, and
legibility of labels.
o Air systems—check for visible deterioration or leakage. B30.8-2004, 8-2.1.2 (a) (5)
o Hoist brakes and brake operating levers—check for proper function- B30.8-2004, 8-2.1.2 (a) (11)
ing before beginning operation. Check daily when the crane is in use.
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ANSI/ASME Reference
Item
(B30.8-2004, 8-2.3.1 (a)
o Hoist motor brakes, tugger motor brakes, and swing motor B30.8-2004, 8-2.1.2 (a) (8)
brakes—see manufacturers’ recommendations for adjustment check
intervals and procedures. Check the motor brakes daily for correct
operation and visually inspect as in “electrical equipment” item
above.
o Hoist clutches and clutch operating levers (main hoist)—check for B30.8-2004, 8-2.1.2 (a) (11)
proper functioning before beginning operation. Check daily when the
crane is in use.
o Hoist pawls and mating drum flange—check for damage, distortion, B30.8-2004, 8-2.1.2 (a) (4)
and excessive wear. Check for correct operation and adjustment.
o Capacity chart—check daily when crane is in use for presence of B30.8-2004, 8-1.1.3
durable capacity chart viewable from operator’s seat.
o Load monitoring system (LMS) and other operator’s cab safety B30.8-2004, 8-2.1.2 (a) (4)
devices such as horn, communication devices, etc.—check for
correct operation. Check daily when the crane is in use. See “Peri-
odic Inspection” for LMS calibration check.
o Operator’s control mechanisms—check daily when the crane is in B30.8-2004, 8-2.1.2 (a) (1), (3)
use for:
• maladjustment interfering with proper operation
• excessive wear of parts and contamination by lubricants or other
foreign matter
• indicator light function using the LAMP/ALARM TEST push
button
• missing or damaged control labels
o Proximity switches, limit switches and encoders—check for B30.8-2004, 8-2.1.2 (a) (4)
correct operation. Check the electrical and mechanical parts and
mountings.
o Wire ropes—make an inspection per the corresponding ANSI/ASME B30.8-2004, 8-2.4.1
B30.8-2004, 8-2.4.1 or latest revision
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5.3.9 Periodic Inspections (Monthly to Annually Depending on Severity of Use)
ANSI/ASME Reference
Item
(B30.8-2004, 8-2.3.1 (a)
o Wire ropes—make an inspection per the corresponding ANSI/ASME B30.8-2004, 8-2.4.2 and 3
publication section B30.8-2004, 8-2.4.2 and 3 or latest revision
See the Parts Manual, Section 3 for wire rope specifications (size,
grade, construction, strength rating, etc.).
o Hooks—A designated person must make a visual inspection with B30.10-2005, 10-2.2.1.3
records kept of apparent external conditions to provide a basis for
continuing evaluation. Inspection items include the same inspection
items as in “Frequent Inspection” for hooks. Hooks having any of the
following conditions must be removed from service until repaired or
replaced:
• cracks, nicks, or gouges (see ANSI/ASME B30.10-1.2.3 (e) for
repair guidelines)
• distortion—any visually apparent bend or twist from the plane of
the unbent hook
• throat opening—any distortion causing an increase in throat
opening of 5 percent or more than 6.35 mm (0.25 in) (or as
otherwise recommended by the hook manufacturer)
• wear—any wear exceeding 10 percent (or as otherwise recom-
mended by the hook manufacturer) of the original section dimen-
sion of the hook or its load pin
• inability to lock—any self-locking hook that does not lock
• inoperative latch—any latch that does not close the throat of the
hook.
o Load blocks—check for wear, damage, distortion, cracks, corrosion,
and loose or missing parts.
o Structural members and welds including boom, A-frame, backlegs, B30.8-2004, 8-2.1.3 (a) (1)
rotating machinery deck frame, etc.—check for damage, distortion,
cracks, corrosion, and loose or missing parts. Check the welds
100 percent visually. Cracked paint with a rust line at the weld is an
indication that the weld may be cracked. Check any such area by
magnetic particle testing after removal of paint. All welds must be
free of cracks. All non-destructive testing must conform to the latest
edition of AWS D1.1, Sections 1 through 9.
o Foundations and supports—check for continued ability to support B30.8-2004, 8-2.1.3 (a) (12)
the imposed loads (examples for cranes: rail circle, machinery foun-
dations, elevated boom support structure, etc.).
o Handrails, stairs, ladders, walkways, and safety guards—check
for damage, distortion, cracks, corrosion, and loose or missing parts.
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ANSI/ASME Reference
Item
(B30.8-2004, 8-2.3.1 (a)
o Fasteners—check for tightness, corrosion, etc. B30.8-2004, 8-2.1.3 (a) (2)
o Sheaves and hoist and tugger drums—check for cracked or worn B30.8-2004, 8-2.1.3 (a) (3)
surfaces.
o Chain drive sprockets—check for excessive wear and chain for B30.8-2004, 8-2.1.3 (a) (8)
stretch.
o Pins, bearings, bushings, shafts, gears, couplings, rollers, lock- B30.8-2004, 8-2.1.3 (a) (4)
ing devices (swing lock, etc.), and clamping devices—check for
wear, cracks, and distortion, and for excessive noise and vibration.
o Safety labels (see paragraph 1.6 for label locations)—clean the Z535.4-1998 (Product Safety Signs
labels for good legibility. Replace all damaged or missing safety and Labels), 10.2.1 and 10.2.2
labels.
o Hoist and tugger serial number and load rating name- B30.7-2006, 7-1.1.3
plate—replace all damaged or missing nameplates.
o Electrical equipment (control contactors, limit switches, master
switches, push button stations, etc.)—check for contact pitting or any
deterioration.
o Air hose, fittings, and tubing—check for: B30.8-2004, 8-2.1.3 (a) (13)
• evidence of leakage at the surface of the flexible hose or its junc-
tion with the end fittings
• blistering or abnormal deformation of the outer covering of the
air hose
• leakage at threaded or clamped joints that cannot be eliminated
by normal tightening or recommended procedures
• evidence of excessive abrasion or scrubbing on the outer surface
of a hose, rigid tube, or fitting. Means must be taken to eliminate
the interference of elements in contact or otherwise protect the
components.
o Air pumps and motors (including air compressor unless the manu- B30.8-2004, 8-2.1.3 (a) (14)
facturer’s information gives different guidelines)—check for:
• loose fasteners • unusual noises or vibration
• leaks at joints between • loss of operating speed
sections • loss of pressure
• shaft seal leaks
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ANSI/ASME Reference
Item
(B30.8-2004, 8-2.3.1 (a)
o Air valves—check for: B30.8-2004, 8-2.1.3 (a) (15)
• cracks in valve housing • failure of relief valves to

• improper return of spool to attain correct pressure
neutral position setting
• leaks at spools or joints • check automatic drain valves
• sticking spools of air reservoir and air filters
for correct operation
o Air cylinders—check for: B30.8-2004, 8-2.1.3 (a) (16)
• drifting caused by air leaking • scored, nicked, or dented

across the piston cylinder rods
• rod seal(s) leakage • dented cylinder barrel
• leaks at welded joints • loose or deformed rod eyes
or connecting joints
o Hoist drum clutches (main hoist)—check for correct adjustment and B30.8-2004, 8-2.1.3 (a) (5)
for excessive wear of clutch system parts including the clutch linings.
The machined friction surface of the drum clutch flange must not be
rust pitted or have rust laminations. If necessary, use a power wire
brush to remove all rust, scale, dirt, etc. If machining of the friction
surface is necessary, contact the National Oilwell Varco Service for
instructions.
o Hoist drum brakes—check for correct adjustment and for excessive B30.8-2004, 8-2.1.3 (a) (5)
wear of brake system parts including the brake linings. The machined
friction surface of the drum brake flange must not be rust pitted or
have rust laminations. If necessary, use a power wire brush to
remove all rust, scale, dirt, etc. If machining of the friction surface is
necessary, contact the National Oilwell Varco Service for instructions.
o Wire rope remaining on hoist drums. Check for correct amount B30.8-2004, 8-1.6.1 and 8-1.6.2
when corresponding boom or load block is lowered to lowest possi-
ble position (boom) or extreme lower position (load blocks). At least
one-half layer of wire rope must remain on the boom hoist drum at all
times during operation, and at least three wraps of wire rope on each
of the other hoist drums.
o Load, boom angle, and other indicators including system air pres- B30.8-2004, 8-2.1.3 (a) (6)
sure indication gauges—check these devices over their full range, for
any significant inaccuracies. Annually check calibration.
o Load testing. Although not required by the ANSI/ASME crane stan- Check applicable specifications or
regulations.
dards except for new or reinstalled machines and sometimes
repaired, altered, or modified machines, some regulatory authorities
(ABS, DNV, API etc. if applicable) may specify periodic load testing.
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ANSI/ASME Reference
Item
(B30.8-2004, 8-2.3.1 (a)
o Fire extinguishers—annual inspection by an approved fire equip- NFPA 10
ment maintenance facility per publication NFPA 10 and local regula-
tions. Additionally, fire extinguisher testing may be required at 5-, 6-,
and/or 12-year intervals inspection by an approved fire equipment
maintenance facility per the applicable NFPA text based on the type
of extinguisher (see publication NFPA 10 and local regulations for
details).
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5.3.10 Cranes Not in Regular Use stalled cranes and provides guidelines for the
procedure (contact National Oilwell Varco if you
A crane that has been idle for a period of one desire the National Oilwell Varco load test
month or more, but less than six months, must procedure for your crane). The need for load
be given an inspection conforming with the testing a repaired, altered, or modified crane
requirements of “As Necessary,” “Frequent must be determined by a qualified person.
Inspections,” and “Periodic Inspections” before
being placed in service. The wire rope must be 5.4 Electrical System
inspected following “Ropes Not in Regular
Use,” per the corresponding ANSI/ASME publi- The electrical schematic shows the relationship
cation section B30.8-2004, 8-2.4.4 or latest of the electrical system equipment. See the
revision. following drawings in the Parts Manual,
Section 13:
A crane that has been idle for a period of over
six months must be given a complete inspec- 1589577 One Line Diagram
tion conforming with the requirements of “As 1589820 Electrical Schematic, Crane Power
Necessary,” “Frequent Inspections,” and “Peri- 1589821 Electrical Schematic, Crane Control
odic Inspections” before being placed in
service. The wire rope must be inspected 5.5 Electrical System Maintenance
following “Ropes Not in Regular Use,” per the
corresponding ANSI/ASME publication section Use caution when doing maintenance on or
B30.8-2004, 8-2.4.4 or latest revision. near the electrical system equipment. Before
working on the electrical system, a lockout must
Standby cranes must be inspected at least be installed by each maintenance person at
twice a year in accordance with the require- each electrical power source following indus-
ments of “As Necessary” and “Frequent Inspec- try-standard lockout/tag out procedures. Electri-
tions.” The wire rope must be inspected at least cal equipment must be maintained and
twice a year as in “Periodic Inspections.” operated according to applicable standards. For
Cranes exposed to adverse environments information about electrical system equipment
and/or severe use should be inspected more not manufactured by National Oilwell Varco,
frequently. see Vendor Data Manual.
5.3.11 Testing Clean the work area before installing and

removing electric wires from the equipment.
The ANSI/ASME B30.8 standards require an When removing electric wires, check that the
operational test prior to initial use for new or wires are correctly labeled and install caps on
reinstalled cranes and provides guidelines for all the connectors to prevent corrosion.
the procedure (contact National Oilwell Varco if
you desire the National Oilwell Varco procedure 5.5.1 Calibration Procedures
for your crane). Prior to use, repaired, altered,
or modified cranes must also be tested (testing The calibration screens of the load monitoring
may be limited to the function(s) affected by the system (LMS) display (see paragraph 2.4.5) are
repair). for instrument calibration procedures. The LMS
must be calibrated before it can display accu-
The ANSI/ASME B30.8 standards also require rate load or radius information. The principal
a load test prior to initial use for new or rein- calibration screens of the LMS display are listed
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below and shown in figure 5–1. The screens

are described in more detail in the following
NOTICE
paragraphs: • The boom angle calibration procedure
(see paragraph 5.5.1.3) must be
• CALIBRATION DATA screen (see para- completed before the main, auxiliary,
graph 5.5.1.2) and whip hoist calibration procedures.
• Hoist calibration screens: HOOK HEIGHT
• The load zero calibration procedure
CALIBRATION screens (see paragraph
5.5.1.5), ZERO POINT CALIBRATION
completed for the corresponding hoist
screens (see paragraph 5.5.1.6), SPAN
before doing the load span calibration
POINT CALIBRATION screens (see para-
for the hoist.
graph 5.5.1.7), and SHUNT CALIBRATION
screens (see paragraph 5.5.1.8)
• Heel and cross angle calibration screens: 2. All of the following parameters must be cali-
CROSS ANGLE CALIBRATION screen brated for correct functioning of the LMS.
(see paragraph 5.5.1.10) and HEEL To do the calibration, follow the instructions
ANGLE CALIBRATION screen (see para- on the calibration screens of the LMS
graph 5.5.1.11) display and follow the corresponding proce-
• BOOM ANGLE CALIBRATION screens dures listed below:
(see paragraph 5.5.1.3) • boom angle calibration (see paragraph
5.5.1.3)
5.5.1.1 How to Calibrate the Load • fall hook height calibration (see para-
Monitoring System (LMS) graph 5.5.1.5)
• hoist load zero calibration (see para-
1. Before calibrating the load monitoring graph 5.5.1.6)
system (LMS), go to the CALIBRATION • hoist load span calibration (see para-
DATA screen (see paragraph 5.5.1.2). graph 5.5.1.7)
Record all of the calibration values shown, • hoist load shunt calibration (see para-
on the Calibration Data Table form provided graph 5.5.1.8)
at the end of this section. An up-to-date • cross angle calibration (see paragraph
written record of the calibration values is 5.5.1.10)
helpful if the LMS calibration becomes • heel angle calibration (see paragraph
suspect or is changed by mistake. If that 5.5.1.11)
happens, the correct values can be
re-entered into the LMS from the 3. After completing the calibration procedures,
CALIBRATION DATA screen. If there is no go to the CALIBRATION DATA screen and
record, the corresponding calibration proce- record all of the calibration values shown,
dure would need to be done again. on the Calibration Data Table form provided
at the end of this section for future refer-
!WARNING ence.
• Calibration settings are stored in the
crane programmable logic controller
(PLC). If hoist operating parameters
change, the affected LMS functions
must be calibrated again so that the
LMS can provide accurate information.
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START
START
Screen
CALIBRATION
Screen
CALIBRATION
DATA
Screen
MAIN HOIST
CALIBRATION
Screen
MAIN MAIN MAIN

HOOK HEIGHT ZERO POINT SPAN POINT MAIN SHUNT
CALIBRATION CALIBRATION CALIBRATION CALIBRATION
MAIN MAIN MAIN

HOOK HEIGHT ZERO POINT SPAN POINT MAIN SHUNT
MAIN MAIN
HOOK HEIGHT ZERO POINT
CALIBRATION CALIBRATION
Screen Screen
AUX HOIST
CALIBRATION
Screen
AUX AUX AUX

HOOK HEIGHT ZERO POINT SPAN POINT AUX SHUNT
AUX AUX AUX

HOOK HEIGHT ZERO POINT SPAN POINT AUX SHUNT
AUX AUX
Screen Screen
WHIP HOIST
CALIBRATION
Screen
WHIP WHIP WHIP

HOOK HEIGHT ZERO POINT SPAN POINT WHIP SHUNT
WHIP WHIP WHIP

HOOK HEIGHT ZERO POINT SPAN POINT WHIP SHUNT
WHIP WHIP
Screen Screen
HEEL AND
CROSS ANGLE
CALIBRATION
Screen
CROSS ANGLE HEEL ANGLE

Screen Screen
BOOM ANGLE BOOM ANGLE BOOM ANGLE BOOM ANGLE BOOM ANGLE
CALIBRATION CALIBRATION CALIBRATION CALIBRATION CALIBRATION
Screen Screen Screen Screen Screen
A3700
Figure 5–1. LMS Display Calibration Screens Organization
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5.5.1.2 CALIBRATION DATA Screen
Calibration data can be viewed or entered from

the CALIBRATION DATA screen (see figure
5–2). Each displayed value consists of a
number and a label describing which calibration
value the number represents. If the calibration
of the load monitoring system (LMS) is suspect
or has been changed inadvertently, the calibra-
tion values should be compared to the recorded
values from the last calibration procedure.
!WARNING
• Incorrectly modifying calibration data Figure 5–2. CALIBRATION DATA Screen
can cause the load monitoring system
(LMS) to not function correctly and 6. To change a value, touch the value to be
prevent the safety warning messages modified. A data entry keypad is brought
and overload automatic stop from up.
operating correctly. Damage to the
equipment and death or serious injury 7. Enter the new value. Touch the numeric
to personnel can result. buttons of the data entry keypad (see para-
graph 2.4.5.10) to enter the new value.
1. On the START screen (see paragraph Then touch the OK button to return to the
2.4.5.1) of the LMS display, touch the normal screen.
CALIBRATE command button. A logon
dialog box is brought up. 8. Record the new calibration value on the
Calibration Data Table form provided at the
2. On the logon dialog box, touch the end of this section.
command button next to the password field.
A data entry keypad is brought up for enter- 9. To exit the screen and return to the previ-
ing the password. ous screen, touch the EXIT command
button at the bottom of the screen.
3. Enter the password using the data entry
keypad. Touch the numeric buttons to enter 10. If any of the calibration values were
the password. Then touch the OK button to changed using the CALIBRATION DATA
return to the logon dialog box. screen, verify afterward that the calibration
is accurate. For example, if a load calibra-
4. Touch the OK button to continue to the tion value was changed, lift a test weight to
CALIBRATION screen. verify the calibration. If a boom angle cali-
bration value was changed, compare the
5. On the CALIBRATION screen, touch the displayed angle to a measured boom angle.
CAL DATA command button to go to the
CALIBRATION DATA screen (see figure
5–2).
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5.5.1.3 Boom Angle Calibration
1. Position the boom near maximum boom

angle.
2. Using a calibrated measuring device,

measure the angle of the centerline of the
boom, with respect to horizontal.
3. On the START screen (see paragraph

2.4.5.1) of the load monitoring system
(LMS) display, touch the CALIBRATE
command button. A logon dialog box is
brought up.
Figure 5–3. BOOM ANGLE CALIBRATION
4. On the logon dialog box, touch the Screen
A data entry keypad is brought up for enter- 11. On the same screen, touch the CONTINUE
ing the password. command button.
5. Enter the password using the data entry 12. Position the boom near horizontal.
keypad. Touch the numeric buttons to enter
the password. Then touch the OK button to 13. Using a calibrated measuring device,
return to the logon dialog box. measure the angle of the centerline of the
boom, with respect to horizontal.
6. Touch the OK button to continue to the
CALIBRATION screen. 14. On the next screen, touch the ENTER CAL
POINT #2 command button.
7. On the CALIBRATION screen, touch the
BOOM ANGLE CAL command button. 15. On the next screen (see figure 5–4) touch
the PRESS TO ENTER BOOM ANGLE
8. On the BOOM ANGLE CALIBRATION POINT 2 indicator. A data entry keypad is
screen, touch the SET 1ST POINT brought up.
command button.
16. Enter the true boom angle, to the nearest
9. On the next screen (see figure 5–3), touch tenth of a degree, that was measured in
the PRESS TO ENTER BOOM ANGLE step 12. Touch the numeric buttons of the
POINT 1 indicator. A data entry keypad is data entry keypad to enter the new value.
brought up. Then touch the OK button to return to the
normal screen.
10. Enter the true boom angle, to the nearest
tenth of a degree, that was measured in 17. On the same screen touch the CONTINUE
step 2. Touch the numeric buttons of the command button.
data entry keypad (see paragraph 2.4.5.10)
to enter the new value. Then touch the OK 18. On the next screen touch the SAVE / EXIT
button to return to the normal screen. command button to return to the
CALIBRATION screen.
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3. Position the hook to be calibrated so it just

touches the vessel deck. Completely stop
the hoist drum.

desired MAIN HOIST CAL, AUX HOIST
CAL, or WHIP HOIST CAL command
button.
5. On the HOIST CALIBRATION screen,

touch the HOOK HEIGHT CAL command
button.
6. With the hook positioned at the vessel

Figure 5–4. BOOM ANGLE CALIBRATION deck, on the HOOK HEIGHT
Screen CALIBRATION screen, touch the
CONTINUE command button.
5.5.1.4 Main, Auxiliary, and Whip Hoist 7. On the next screen (see figure 5–5), touch
Calibration the ENTER LAYER indicator. A data entry
keypad (see paragraph 2.4.5.10) is brought
up.
NOTICE
• For the following calibration screens, 8. Enter the number of layers of wire rope on
the main hoist screens are shown. The the corresponding hoist drum. Touch the
auxiliary and whip hoist screens are numeric buttons of the data entry keypad to
similar. enter the new value. Then touch the OK
button to return to the normal screen.
5.5.1.5 Hook Height Calibration
!WARNING
• The boom angle calibration procedure
completed before doing the hook
height calibration procedure.
1. Complete the boom angle calibration proce-

dure (see paragraph 5.5.1.3).
2. Position the boom at or near 60 degrees

boom angle. Figure 5–5. MAIN HOOK HEIGHT
CALIBRATION Screen
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9. On the same screen, touch the ENTER # 5.5.1.6 Load Zero Calibration
OF WRAPS indicator. A data entry keypad
is brought up.
!WARNING
10. Enter the number of wraps of wire rope on • The boom angle calibration procedure
the top layer of the corresponding hoist (see paragraph 5.5.1.3) must be
drum. Touch the numeric buttons of the completed before doing the load zero
data entry keypad to enter the new value. calibration procedure.
Then touch the OK button to return to the
normal screen. 1. Complete the boom angle calibration proce-
dure (see paragraph 5.5.1.3).
11. On the same screen, touch the CONTINUE
command button. 2. Remove the load from the block of the fall
to be calibrated.
12. On the next screen (see figure 5–6), check
that the ENCODER RAW COUNTS value 3. Position the block so the elevation of the
(output from the drum encoder) matches block is at or near the height of the boom
the ENCODER PRESETS COUNTS value foot pin.
(calculated).
13. Touch the SAVE / EXIT command button at desired MAIN HOIST CAL, AUX HOIST
the bottom of the screen to return to the CAL, or WHIP HOIST CAL command
HOIST CALIBRATION screen. button.

touch the LOAD ZERO CAL command
button.
6. With the block positioned at or near the

height of the boom foot pin, on the ZERO
POINT CALIBRATION screen, touch the
YES command button.
7. On the next screen, touch the YES

command button.
8. Touch the EXIT command button at the

Figure 5–6. Figure MAIN HOOK HEIGHT bottom of the screen to return to the HOIST
CALIBRATION Screen CALIBRATION screen.
9. Record the new zero calibration value

shown on the CALIBRATION DATA screen
(see paragraph 5.5.1.2). on the Calibration
Data Table form provided at the end of this
section.
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5.5.1.7 Load Span Calibration
!WARNING
• Before doing a load span:
• Complete the boom angle
calibration procedure (see
paragraph 5.5.1.3).
• Complete the load zero calibration
procedure (see paragraph 5.5.1.6).
A known (calibrated) load must be used to cali-

brate the span point. For best results, the
known load should be 70 to 100 percent of the
Figure 5–7. MAIN SPAN POINT CALIBRATION
rated load capacity of the corresponding fall.
screen
1. Complete the boom angle calibration proce-
dure (see paragraph 5.5.1.3). 8. Enter the weight of the known load, accu-
rate to the nearest metric ton. Touch the
2. Complete the load zero calibration proce- numeric buttons of the data entry keypad to
dure (see paragraph 5.5.1.6) for the fall to enter the new value. Then touch the OK
be calibrated. button to return to the normal screen.
3. Lift the known load within the rated load 9. Touch the EXIT command button at the
capacity of the crane and allow it to hang bottom of the screen to return to the HOIST
for several minutes or until stabilized. CALIBRATION screen.
4. On the CALIBRATION screen, touch the 10. Record the new span calibration value
desired MAIN HOIST CAL, AUX HOIST shown on the CALIBRATION DATA screen
CAL, or WHIP HOIST CAL command (see paragraph 5.5.1.2), on the Calibration
button. Data Table form provided at the end of this
section.
touch the LOAD SPAN CAL command
button. 5.5.1.8 Load Shunt Calibration
6. With the known load suspended from the 1. Remove the load from the fall to be cali-
fall, on the SPAN POINT CALIBRATION brated.
screen, touch the YES command button.
7. On the next screen (see figure 5–7), touch 2.4.5.1) of the load monitoring system
the KNOWN WEIGHT ENTRY indicator. A (LMS) display, touch the CALIBRATE
data entry keypad (see paragraph 2.4.5.10) command button. A logon dialog box is
is brought up. brought up.
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3. On the logon dialog box, touch the

A data entry keypad is brought up for enter-
ing the password.

the password. Then touch the OK button to
return to the logon dialog box.
5. Touch the OK button to continue to the

CALIBRATION screen.

desired MAIN HOIST CAL, AUX HOIST Figure 5–8. MAIN SHUNT CALIBRATION
CAL, or WHIP HOIST CAL command Screen
button.
7. On the HOIST CALIBRATION screen, 5.5.1.9 Cross and Heel Angle

touch the LOAD SHUNT CAL command Calibration
button.
8. With the load removed from the fall, on the 5.5.1.10 Cross Angle Calibration
SHUNT CALIBRATION screen, touch the
YES command button.
NOTICE
9. On the next screen (see figure 5–8), • Positive cross angle is when the left
compare the value of the new shunt calibra- side of the crane is lower than the right
tion load with the value of the last saved side.
shunt calibration, which was saved after the
last zero and span calibration. If the differ- 1. On the START screen (see paragraph
ence between the values is more than 5 2.4.5.1) of the load monitoring system
percent, the fall should be re-calibrated with (LMS) display, touch the CALIBRATE
a known load. command button. A logon dialog box is
brought up.
If this is the first load shunt calibration
following a zero and span calibration, save 2. On the logon dialog box, touch the
the value by touching the YES command command button next to the password field.
button. A data entry keypad is brought up for enter-
ing the password.
10. Touch the EXIT command button at the
bottom of the screen to return to the HOIST 3. Enter the password using the data entry
CALIBRATION screen. keypad. Touch the numeric buttons to enter
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4. Touch the OK button to continue to the screen to return to the HOIST

CALIBRATION screen. CALIBRATION screen.
5. On the CALIBRATION screen, touch the 11. Record the cross angle offset value shown
CROSS/HEEL CAL command button. on the CALIBRATION DATA screen (see
paragraph 5.5.1.2), on the Calibration Data
6. On the HEEL AND CROSS ANGLE Table form provided at the end of this
CALIBRATION screen, touch the CROSS section.
ANGLE command button.
7. On the CROSS ANGLE CALIBRATION 5.5.1.11 Heel Angle Calibration

screen (see figure 5–9), touch the PRESS
TO ENTER CROSS ANGLE indicator. A
data entry keypad is brought up (see para- NOTICE
graph 2.4.5.10). • Positive heel angle is when the front
(boom side) of the crane is lower than
the rear.

2.4.5.1) of the load monitoring system
(LMS) display, touch the CALIBRATE
command button. A logon dialog box is
brought up.
2. On the logon dialog box, touch the

A data entry keypad is brought up for enter-
ing the password.

Figure 5–9. CROSS ANGLE CALIBRATION
Screen
8. Enter the actual cross angle, to the nearest
tenth of a degree. Touch the numeric 4. Touch the OK button to continue to the
buttons of the data entry keypad to enter CALIBRATION screen.
the new value. Then touch the OK button to
return to the normal screen. 5. On the CALIBRATION screen, touch the
CROSS/HEEL CAL command button.
9. Touch the SAVE / EXIT command button at
the bottom of the screen to return to the 6. On the HEEL AND CROSS ANGLE
HEEL AND CROSS ANGLE CALIBRATION CALIBRATION screen, touch the HEEL
screen. ANGLE command button.
10. On the HEEL AND CROSS ANGLE

CALIBRATION screen, touch the EXIT
command button at the bottom of the
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7. On the HEEL ANGLE CALIBRATION 5.6 Air System

screen (see figure 5–10), touch the PRESS
TO ENTER HEEL ANGLE indicator. A data The air schematic shows the relationship of the
entry keypad is brought up (see paragraph air system equipment. See the Parts Manual,
2.4.5.10). Section 12, drawing 1590496, Air Piping Sche-
matic.
5.6.1 Air System Maintenance
Release pressure from the air system (see

paragraph 5.6.2) before doing maintenance to
the air system equipment. Residual pressure
can remain in the air piping. Use caution when
removing any piping or hose. Accidentally
releasing air at high pressure can cause injury
to you and others, and can damage the equip-
ment.
Figure 5–10. HEEL ANGLE CALIBRATION For information about air system equipment not
Screen manufactured by National Oilwell Varco, see
the Vendor Data Manual.
8. Enter the actual heel angle, to the nearest
tenth of a degree. Touch the numeric Regular inspection and maintenance of the air
buttons of the data entry keypad to enter system is necessary for reliable performance of
the new value. Then touch the OK button to the equipment. A good preventive maintenance
return to the normal screen. program will help prevent condensation and air
system failures.
9. Touch the SAVE / EXIT command button at
the bottom of the screen to return to the Cleanliness is very important in the operation
HEEL AND CROSS ANGLE CALIBRATION and maintenance of the air system. No dirt or
screen. abrasive particles can be permitted to enter the
system.
10. On the HEEL AND CROSS ANGLE
CALIBRATION screen, touch the EXIT Some contaminants enter the system when it is
command button at the bottom of the opened. Do everything you can to keep the
screen to return to the HOIST system as clean as possible. Clean the work
CALIBRATION screen. area and tools before opening any part of the
system. Install caps on all open air piping and
11. Record the heel angle offset value shown hoses. Install plugs in all open air ports. Do not
on the CALIBRATION DATA screen (see leave the air system open to dust and other
paragraph 5.5.1.2), on the Calibration Data airborne particles. Do not accept replacement
Table form provided at the end of this parts that are not in their original protective
section. packages. Wash parts according to the manu-
facturer’s instructions and permit them to dry
before assembly.
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5.6.2 Releasing Pressure from Air 5.7.1 Check and Adjustment of Hoist
System Drum Brake
1. Shut down the crane (see paragraph 3.6).

!WARNING
2. Close the valve for the supply of air to the • When adjusting the hoist drum brake,
air reservoir. Open the manual drain valve always adjust both the left brake and
on the bottom of the air reservoir (see the right brake for the drum before
figure 2–2). Release pressure from the air putting the hoist back into operation.
reservoir until the pressure gauge located Unequal brake adjustment can cause
on the reservoir reads 0 psi. reduced brake holding capacity.
1. Keep other people from operating the hoist.

!WARNING
Put “Do Not Use” signs or tags on the
• Residual pressure can remain in the control console to prevent operation of the
air piping. Read and understand the air hoist.
schematic to identify possible areas of
residual pressure in the air system. 2. Engage the drum brake. Put the lever of the
Use caution when removing any air corresponding BOOM or HOIST control
piping or hose. Accidentally releasing (figure 2–9, item 5, or figure 2–12, item 4)
air at high pressure can cause injury to in its neutral (center) position. The corre-
you and others, and can damage the sponding BOOM, MAIN/AUXILIARY or
equipment. WHIP brake pedal (see figure 2–8) must be
in its “released” position. Air pressure is
released from the parking brake air cylinder
5.7 Hoist Drum Brakes (see figure 5–11), permitting the spring to
engage the brake.
!WARNING
• Keep the hoist drum brakes in correct
!WARNING
adjustment at all times. A brake that is • Keep away from moving and hot
not adjusted correctly can have equipment parts.
reduced holding capacity. Without
periodic adjustment, normal brake 3. Check that the brake lining is tight against
lining wear can cause the brake lever the brake flange of the drum.
to contact the stop, which can cause
reduced brake holding capacity. 4. Measure the distance between the brake
lever and the stop. This is dimension A of
Check the hoist drum brakes of the boom, figure 5–11. The distance must be more
main, auxiliary, and whip drums for correct than the corresponding “minimum” permit-
operation and adjustment as directed in the ted dimension listed in figure 5–11 and less
inspection and maintenance schedule (see than or equal to the “maximum” permitted
paragraph 5.3). The brakes will need adjust- dimension. If the distance measured is
ment to compensate for normal brake lining within the correct range, the brake does not
wear and after replacement of the lining, a need adjustment. If the distance measured
brake actuator, or a brake linkage part. is not within the correct range, note the
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distance measured and continue with 9. Draw a reference mark (see figure 5–11)
step 5 to adjust the brake. across the brake lever and the hub. The
reference mark will help for adjusting the
brake.
!WARNING
• Do step 5 to prevent the load or boom
from falling when the brake is released NOTICE
in step 11. Not following this • Step 10 is done to permit release of the
procedure can cause the load or boom brake in step 11.
to fall or unexpected drum movement,
resulting in death or serious injury and 10. Connect an external source of air pressure
equipment damage. (from a portable air compressor) through a
• The pawl must be engaged all the way control valve to the pressure port of the
into the ratchet pocket of the drum. parking brake air cylinder for the drum
brake being adjusted. The source of air
5. Engage the corresponding drum pawl. The pressure must be able to supply
pawl must be engaged all the way into the 7.23–8.61 bar (105–125 psi). The control
ratchet pocket of the drum before continu- valve will be used during this procedure to
ing with step 6. The drum brake must not
be supporting a load or the weight of the • release the brake (by supplying air
corresponding lower block or boom. Other- pressure to the parking brake air cylin-
wise, damage to the hoist can occur or the der)
load or boom may fall when the brake is • engage the brake (by exhausting air
released during adjustment. If practical, pressure from the parking brake air
also lower the corresponding main, auxil- cylinder)
iary, or whip fall lower block to the vessel
deck. Initially the control valve should be in the
“brake engaged” position (air pressure
6. Measure the thickness of the brake lining at exhausted from the parking brake air cylin-
both ends and at the middle of the brake der).
band. The thickness of the lining must be
more than 11.5 mm (0.45 in). If the thick- 11. With the pawl engaged all the way into the
ness of the lining is more than 11.5 mm ratchet pocket of the drum to hold the hoist
(0.45 in), continue with step 7. If not, drum from rotating, release the brake. To
replace the lining (see paragraph 5.7.2.2). do so, operate the control valve installed in
step 10 to supply full air pressure of
7. Subtract the measurement found in step 4 7.23–8.61 bar (105–125 psi) to the parking
from the “maximum” permitted dimension brake air cylinder.
listed in figure 5–11. The difference is the
amount of adjustment needed. Divide this 12. With the brake released, loosen the clamp
number by four (4). Note the resulting bolt of the brake lever.
value. It is the distance you will need to
rotate the hub in relation to the brake lever 13. Apply a small amount of lubricant to the
in step 15. threads of the bolt. Make sure that the lubri-
cant does not get into the area of contact
8. Clean the brake lever and the exposed between the brake lever and the hub.
surfaces of the hub.
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Parking Brake Air Cylinder
Parking Brake Engage Spring
Stop
Brake Lever
Clamp Bolt
DIMENSION “A”
Gap in the Split of
MAXIMUM MINIMUM the Brake Lever
BRAKE ENGAGED— ENGAGED—
NEW ADJUSTMENT
ADJUSTMENT REQUIRED Hub
115 mm 20 mm
Main
(4 12 in) (1316 in) A Brake Shaft
Auxiliary, 57 mm 19 mm
Whip (2 14 in) (34 in) Reference Mark
Boom 44 mm 19 mm
(134 in) (34 in) S861
Service Brake Air Cylinder
Figure 5–11. Hoist Drum Brake Adjustment–Typical
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18. Release the brake.

!WARNING
• Paint, rust, dirt, or lubricant between 19. Adjust the brake band lifters so the brake
the contact surfaces of the brake lever lining does not contact the brake flange of
and the hub can cause the lever to slip the drum with the brake released. A feeler
on the hub while the brake is engaged. gauge must fit freely all the way around the
This will cause the brake to have drum between the brake lining and the
reduced holding capacity. brake flange.
14. Check the surface of contact between the 20. Engage the brake.
brake lever and the hub. If there appears to
be any paint, rust, dirt, or lubricant between 21. Check the brake adjustment by repeating
the lever and the hub, remove the lever steps 2 through 4. If the adjustment is not
from the hub and clean the surfaces of the correct, return to step 5. If the brake adjust-
hub and lever that contact each other. ment is correct, continue with step 22.
Remove any paint, rust, dirt, or lubricant.
22. With both the left brake and the right brake
15. Observe the reference mark made in for the drum engaged, remove the external
step 9. Using a wrench, turn the brake shaft source of air pressure and the control valve
in the direction of the arrow as shown in that were installed in step 10. Then recon-
figure 5–11 (brake “engage” direction), until nect the original air piping—refer to the
the mark on the hub and the mark on the following drawings in the Parts Manual,
brake lever are offset by the distance calcu- Section 12:
lated in step 7.
• 1590496 Air Piping Schematic
• 1590499 Air Piping, Main Hoist
!WARNING • 1590870 Air Piping, Boom Hoist
• Make sure the clamp bolt of the brake
lever is tight. If the brake lever is not 23. Replace all covers and guards.
clamped tight on the hub, the lever can
slip on the hub when the brake is 24. Test the brake to make sure it can hold a
engaged. This will cause the brake to full load before putting the hoist into opera-
have reduced holding capacity. tion.
• Replace the brake lever if there is no
gap in the split of the lever or if the
lever is damaged.
16. Tighten the clamp bolt of the brake lever.

Check that a gap remains in the split of the
lever as shown in figure 5–11.
17. Engage the brake. To do so, operate the

control valve installed in step 10 to exhaust
the air pressure from the parking brake air
cylinder.
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5.7.2 Hoist Drum Brake Lining • Missing, cracked, or damaged lining

sections. If any of these conditions are
found, replace the lining.
5.7.2.1 Inspection of Hoist Drum Brake • Lubricant worn into the lining. If this occurs,
Lining replace the lining. See the notice below.
• Loose rivets. Replace the lining only if the
holes in the lining are damaged. Otherwise,
!WARNING just replace the loose rivets.
• Keep away from moving and hot
equipment parts.
NOTICE
• Use only cleaning materials that are
made for brake linings. The wrong • For glazed lining or minor
cleaning solvent can severely damage contamination by lubricants, sanding
the lining, which will cause the brake the lining (see paragraph 5.7.2.3) can
to have reduced holding capacity. be a temporary method to extend the
life of the lining. Replace the lining as
soon as a maintenance shutdown can
Rivets fasten the lining to the brake band. The
be scheduled. If sanding does not
heads of the rivets are countersunk into the
result in acceptable control of the
lining.
hoist, do not operate the hoist until the
lining is replaced.
Check the brake lining as directed in the
inspection and maintenance schedule (see
paragraph 5.3). Check the brake lining for
5.7.2.2 Replacement of Hoist Drum
• Lining wear. Do not permit the lining to Brake Lining (National Oilwell
wear down to the heads of the rivets. This Varco Standards 1525333,
can result in damage to the brake flange of 1525334)
the drum from the rivet heads coming into
contact with the brake flange. Measure the 1. Keep other people from operating the hoist.
thickness of the lining at both ends and at Put “Do Not Use” signs or tags on the
the middle of the brake band (lining will control console to prevent operation of the
typically wear more at the dead (fixed) hoist.
end). Lining worn to 11.5 mm (0.45 in) or
less at any point must be replaced.
• Lining contact. With the brake engaged, the
!WARNING
lining must have continuous wrap (length- • Do step 2 to prevent the load or boom
wise) contact with the brake flange of the from falling when the brake is released
drum and must make a minimum of 85 for brake lining replacement. Not
percent total area contact with the brake following this procedure can cause the
flange. If the total area contact is less than load or boom to fall or unexpected
85 percent or there are gaps with no drum movement, resulting in death or
contact, the lining can be sanded (see serious injury and equipment damage.
paragraph 5.7.2.3) to correct for the • The pawl must be engaged all the way
out-of-round shape of the brake band and into the ratchet pocket of the drum.
to get the required contact.
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2. Engage the corresponding drum pawl. The

pawl must be engaged all the way into the !WARNING
drum ratchet pocket before continuing with • Support the sections of the brake band
step 3. The drum brake must not be and use appropriate lifting equipment
supporting a load or the weight of the corre- while removing and installing the
sponding lower block or boom. Otherwise, brake band. The brake band is heavy
damage to the hoist can occur or the load and is a crushing hazard.
or boom may fall when the brake is • Use extreme caution when reaching
released. If practical, also lower the corre- into the brake area.
sponding main, auxiliary, or whip fall lower • This procedure makes airborne dust
block to the vessel deck. that can be harmful if inhaled. For your
protection wear proper respiratory
safety equipment.
NOTICE
• Step 3 is done to permit release of the
brake in step 4. NOTICE
• Store the sections of the brake band
3. Connect an external source of air pressure from the same brake together. Do not
(from a portable air compressor) through a exchange parts between different
control valve to the pressure port of the brakes.
parking brake air cylinder for the drum
brake whose lining is being replaced. The 5. Remove equipment parts from the hoist as
source of air pressure must be able to necessary to avoid equipment damage
supply 7.23–8.61 bar (105–125 psi). The when removing the brake band.
control valve will be used during this proce-
dure to 6. Remove the brake band from the hoist.
• release the brake (by supplying air 7. Check the pivot pins and pin holes of the
pressure to the parking brake air cylin- brake band and linkage for damage, wear,
der) cracks, and corrosion. Replace parts if
• engage the brake (by exhausting air necessary.
pressure from the parking brake air
cylinder) 8. Completely clean the machined friction
surface of the drum brake flange. The
Initially the control valve should be in the machined friction surface must not be pitted
“brake engaged” position (air pressure or have rust laminations. If necessary, use
exhausted from the parking brake air cylin- a power wire brush to remove all rust,
der). scale, dirt, paint, etc. Check the surface for
damage such as scoring from rivet heads
4. With the pawl engaged all the way into the and warping. If machining of the friction
ratchet pocket of the drum to hold the drum surface is necessary, contact the National
from rotating, release the brake. To do so, Oilwell Varco Service Department for
operate the control valve installed in step 3 instructions.
to supply full air pressure of 7.23–8.61 bar
(105–125 psi) to the parking brake air cylin-
der.
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9. Move the brake band to a clean work area. 16. Use the brake band as a template to drill
Note the position of the old lining on the holes in the new lining. For drilling dimen-
band. This information is needed in step 15 sions see figure 5–12.
to correctly position the new lining on the
band. 17. Drill countersink holes in the lining. For drill-
ing dimensions see figure 5–12.
10. Drill out the rivets that hold the lining to the
brake band from the band side, opposite 18. Chamfer the ends of the lining (four places
the lining. per brake). For chamfering dimensions see
figure 5–12.
11. Use a chisel to remove any remaining
turned-over rivet heads. 19. Install the rivets. Start at the middle of the
lining. Work outward toward the ends, alter-
12. Use a punch to drive out the rivets. nating on each side working away from the
Remove the old lining from the brake band. middle.
13. Completely clean the mounting surface for 20. Use long feeler gauges to check the lining
the lining on the brake band. Remove all for surface contact with the brake band.
rust, scale, and dirt, but do not remove the
zinc primer. • The lining must make a minimum of 85
percent total area contact with the
14. Check the brake band for damaged, worn, band.
cracked, or corroded parts, welds, and rivet • The lining must make continuous wrap
holes. Apply zinc primer if bare metal is (lengthwise) contact with the band.
showing.
If the total area contact is less than 85
percent or there are gaps with no contact,
CAUTION remove the rivets and start with step 14
• If the brake band must be repaired or again.
corrected, contact the National Oilwell
Varco Service Department for 21. Check the lining for cracks or other damage
instructions. Do not try to correct caused during installation. Replace the
distortion with heat. lining if it is damaged.
NOTICE !WARNING
• To help during fitting of the new lining • Support the sections of the brake band
to the brake band, the lining can be and use appropriate lifting equipment
softened and made more pliable by while installing the brake band. The
warming the lining in a bonding oven brake band is heavy and is a crushing
to between 150–180°C (302–356°F) for hazard.
sufficient time for the heat to penetrate • Use extreme caution when reaching
the fabric. into the brake area.
15. Put the new lining on the brake band in the

position noted in step 9. Use clamps to hold
the lining on the band.
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1
2 in
150°
9.6 mm (0.38 in)

Brake Band Connection Bolt
Spacer Plate (Quantity 4)
17 Lining Chamfer
64 in
Lining Rivet Installation: Typical
Brake Band
Lining
16.0 mm (0.63 in)
6.3 mm (0.25 in)
Lining Chamfer Lining Chamfer: 4 Places
A2892
Figure 5–12. Hoist Drum Brake Lining Installation
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22. Assemble the brake with 50.8 mm (2 in) of • Check for high spots, areas of the lining
spacer plates in the connection joint of the that are not contacting the brake
band sections. Connect the sections of the flange.
brake band together using new bolts, nuts, • Check for low spots, areas where a
and washers. Tighten the nuts to 873 N·m small amount of the lining is contacting
(644 ft·lb). Apply lubricant to the band dead the brake flange and the surrounding
(fixed) end and live (moving) end pivot pins. lining is not contacting the brake flange.
• Check that the band moves easily on Mark all high and low spots.
the dead-end and live-end pivot pins.
• Check that the band is centered on the
friction surface of the drum brake
CAUTION
flange. • To prevent damage to the lining, do not
heavily hammer the brake band when
removing high spots.
!WARNING
• Tighten the bolts that connect the 27. To remove a high spot:
brake band sections together to the
correct value. Loose bolts will cause A. Engage the brake.
the brake adjustment to change and
cause the brake to have reduced B. Carefully hammer the high spot on the
holding capacity. steel brake band to bring the lining into
contact with the brake flange of the
drum.
CAUTION
• Remove any extra lubricant from the 28. To remove a low spot, use a “brake band
pivot pins to keep it from wearing into spoon” (see figure 5–13):
the brake lining. If lubricant does wear
into the lining, a new lining may be A. With the pawl engaged all the way into
necessary. the ratchet pocket of the drum to hold
the drum from rotating, release the
23. Engage the brake. To do so, operate the brake.
control valve installed in step 3 to exhaust
the air pressure from the parking brake air B. At the low spot in the brake band, care-
cylinder. fully tap the spoon in between the lining
and the brake flange of the drum.
24. Adjust the brake (see paragraph 5.7.1).
C. Engage the brake.
25. Engage the brake.
D. Release the brake. Remove the spoon.
26. With the brake engaged, check the brake
band for an out-of-round shape. Use long E. Engage the brake again. Check the
feeler gauges to check the lining for surface contact of the lining to the brake flange.
contact with the brake flange of the drum. If there is a new high spot, carefully
hammer the high spot on the steel
brake band to bring the lining into
contact with the brake flange.
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CAUTION
• Burnish a new brake lining before
At Least Band putting the hoist into operation.
Width
33. Burnish the lining (see paragraph 5.7.2.4)
to get the design coefficient of friction
Tapered between the lining and the friction surface
of the drum brake flange.
25.4 mm
(1 in) 34. Check the brake adjustment (see para-
graph 5.7.1). Adjust the brake as neces-
4.8 mm ( 316 in) sary.
A618
Figure 5–13. Brake Band Spoon 35. With both the left brake and the right brake
for the drum engaged, remove the external
29. Check the edges of the lining for cracks or source of air pressure and the control valve
other damage caused by incorrect actions that were installed in step 3. Then recon-
during the above steps. Replace the lining if nect the original air piping—refer to the
it is damaged. following drawings in the Parts Manual,
Section 12:
30. Check the brake adjustment (see para-
sary. • 1590496 Air Piping Schematic
• 1590499 Air Piping, Main Hoist
31. Engage the brake. • 1590870 Air Piping, Boom Hoist
32. With the brake engaged, use long feeler 36. Replace all covers and guards.
gauges to check the lining for surface
contact with the brake flange of the drum. 37. Test the brake to make sure it can hold a
full load before putting the hoist into opera-
• The lining must make a minimum of 85 tion.
brake flange.
• The lining must make continuous wrap
(lengthwise) contact with the brake
flange.

the lining can be sanded (see paragraph
5.7.2.3) to correct for the out-of-round
shape of the brake band and to get the
required contact.
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5.7.2.3 Sanding Hoist Drum Brake 2. Connect an external source of air pressure
Lining (National Oilwell Varco (from a portable air compressor) through
Standards 1525332, 1525335) pressure graduating control valves to the
pressure port of the parking brake air cylin-
With the hoist drum brake engaged, the lining ders of both the left brake and the right
must have continuous wrap (lengthwise) brake for the drum. The source of air pres-
contact with the brake flange of the drum and sure must be able to supply 7.23–8.61 bar
must make a minimum of 85 percent total area (105–125 psi). The control valves will be
contact with the brake flange. If the total area used during this procedure to
contact is less than 85 percent or there are • release the brakes (by supplying air
gaps with no contact, the lining can be sanded pressure to the parking brake air cylin-
to correct for the out-of-round shape of the ders)
brake band and to get the required contact. • engage the brakes (by exhausting air
pressure from the parking brake air
!WARNING cylinders)
• provide graduated control of the air
• Do this sanding procedure only when pressure to the parking brake air cylin-
there is no wire rope on the drum, or if ders, so that the brake to be sanded
all the wire rope is completely wound can be partially engaged during this
on the drum and the free end of the procedure
wire rope is secured to the drum. The
wire rope for the drum must not be Initially the control valves should be in the
reeved to the lower block or the boom. “brake engaged” position (air pressure
• Keep away from moving and hot exhausted from the parking brake air cylin-
equipment parts. ders of both the left brake and the right
• This procedure makes airborne dust brake).
which can be harmful if inhaled. For
your protection, wear proper 3. With no wire rope wound on the drum or
respiratory safety equipment. with all the wire rope on and secured to the
drum, release both the left brake and the
right brake for the drum. To do so, operate
NOTICE the control valves installed in step 2 to
supply full air pressure of 7.23-8.61 bar
• The hoist drum has two drum brakes.
(105-125 psi) to both parking brake air
This procedure requires separate
cylinders for the drum.
control of the left brake and the right
brake, including graduated control of
4. Apply a piece of self-adhesive abrasive
the brake whose lining is being
tape (National Oilwell Varco p/n 827581) to
sanded. The brake not being sanded
the friction surface of the drum brake flange
remains released while the other brake
for the brake to be sanded. Apply the tape
is partially engaged to sand the brake
from the inside edge of the friction surface
lining.
to the outside edge. Put the adhesive side
of the tape on the brake flange, with the
1. Keep other people from operating the hoist. abrasive side facing the lining. The surface
Put “Do Not Use” signs or tags on the temperature of the brake flange must be
control console to prevent operation of the 10-37°C (50-100°F) for the best hold of the
hoist. tape to the brake flange.
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5. With both the left brake and the right brake 11. If the brake lining is new, burnish the lining
for the drum released and the drum pawl (see paragraph 5.7.2.4) to get the design
released, rotate the drum at a slow speed coefficient of friction between the lining and
in the inhaul direction. the friction surface of the drum brake
flange.
6. Engage the brake to be sanded a small
amount to sand the lining. To do so, oper- 12. Engage both the left brake and the right
ate the control valve installed in step 2 to brake for the drum. To do so, operate the
reduce the air pressure to the correspond- control valves installed in step 2 to exhaust
ing parking brake air cylinder. If the brake the air pressure from both parking brake air
band starts to vibrate, decrease the speed cylinders for the drum.
of rotation until the vibration stops.
13. Check the brake adjustment (see para-
CAUTION sary.
• Prolonged vibration of the brake band
can cause damage to the equipment. 14. With both the left brake and the right brake
for the drum engaged, remove the external
7. Sand the lining until source of air pressure and the control
valves that were installed in step 2. Then
• the lining makes continuous wrap reconnect the original air piping—refer to
(lengthwise) contact with the brake the following drawings in the Parts Manual,
flange Section 12:
• the lining makes a minimum of 85
percent total area contact with the • 1590496 Air Piping Schematic
brake flange • 1590499 Air Piping, Main Hoist
• 1590870 Air Piping, Boom Hoist
Use long feeler gauges to check the lining
for surface contact with the brake flange. 15. Replace all covers and guards.
Multiple applications of abrasive tape can
be necessary to get the required contact. 16. Engage the corresponding drum pawl if this
was not already done.
8. Stop rotating the drum.
17. Test the brake to make sure it can hold a
9. With the brake released, remove the abra- full load before putting the hoist into opera-
sive tape from the brake flange. Thoroughly tion.
clean the friction surface of the brake
flange with acetone or M.E.K. (methyl ethyl
ketone). (Do not use carbon tetrachloride,
because of possible personal physical
harm.)
10. Use air pressure free of moisture to clean

the dust and debris from between the brake
flange and the lining.
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5.7.2.4 Burnishing Hoist Drum Brake pressure graduating control valves to the
Lining (National Oilwell Varco pressure port of the parking brake air cylin-
Standard 1525336) ders of both the left brake and the right
brake for the drum. The source of air pres-
Burnish the drum brake lining on a new hoist sure must be able to supply 7.23–8.61 bar
and after installing a new brake lining to get the (105–125 psi). The control valves will be
design coefficient of friction between the lining used during this procedure to
and the friction surface of the drum brake
flange. • release the brakes (by supplying air
pressure to the parking brake air cylin-
ders)
!WARNING • engage the brakes (by exhausting air
• Do this burnishing procedure only pressure from the parking brake air
when there is no wire rope on the cylinders)
drum, or if all the wire rope is • provide graduated control of the air
completely wound on the drum and the pressure to the parking brake air cylin-
free end of the wire rope is secured to ders, so that the brake to be burnished
the drum. The wire rope for the drum can be partially engaged during this
must not be reeved to the lower block procedure
or the boom.
• Keep away from moving and hot Initially the control valves should be in the
equipment parts. “brake engaged” position (air pressure
• This procedure makes airborne dust exhausted from the parking brake air cylin-
which can be harmful if inhaled. For ders of both the left brake and the right
your protection, wear proper brake).
respiratory safety equipment.
3. With no wire rope wound on the drum or
with all the wire rope on and secured to the
NOTICE drum, release both the left brake and the
right brake for the drum. To do so, operate
• The hoist drum has two drum brakes.
the control valves installed in step 2 to
This procedure requires separate
supply full air pressure of 7.23–8.61 bar
control of the left brake and the right
(105–125 psi) to both parking brake air
brake, including graduated control of
cylinders for the drum.
the brake whose lining is being
burnished. The brake not being
burnished remains released while the CAUTION
other brake is partially engaged to
• Do not glaze the brake lining. Too
burnish the brake lining.
much heat generated too quickly
causes glazing. If the lining is glazed,
1. Keep other people from operating the hoist. it will not hold correctly. Sand the
Put “Do Not Use” signs or tags on the lining (see paragraph 5.7.2.3) to
control console to prevent operation of the remove the glazing before putting the
hoist. hoist into operation.
2. Connect an external source of air pressure

(from a portable air compressor) through
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8. Stop rotating the drum.

!WARNING
• The lining will release a gas during the 9. Engage the brake. To do so, operate the
heating from the burnishing process. control valve installed in step 2 to exhaust
the air pressure from the parking brake air
4. With both the left brake and the right brake cylinder. Do not release the brake until the
for the drum released and the drum pawl lining and brake flange have cooled.
released, rotate the drum at a slow speed
in the inhaul direction. 10. After the lining and brake flange have
cooled, release the brake.
5. Engage the brake to be burnished as much
as possible without stalling the motor or 11. Use air pressure free of moisture to clean
generating excessive temperature in the the dust and debris from between the brake
brake flange of the drum. To do so, operate flange and the lining.
the control valve installed in step 2 to
reduce the air pressure to the correspond- 12. Engage both the left brake and the right
ing parking brake air cylinder. If the brake brake for the drum.
band starts to vibrate, decrease the speed
of rotation until the vibration stops. 13. Check the brake adjustment (see para-
sary.
CAUTION
• Prolonged vibration of the brake band 14. With both the left brake and the right brake
can cause damage to the equipment. for the drum engaged, remove the external
source of air pressure and the control
6. Apply the brake ten times, at 10 seconds valves that were installed in step 2. Then
on, 20 seconds off, allowing the tempera- reconnect the original air piping—refer to
ture in the brake flange of the drum to the following drawings in the Parts Manual,
increase gradually. The first ten applica- Section 12:
tions should not increase the soak temper-
ature of the brake flange to more than 66°C • 1590496 Air Piping Schematic
(150°F). Check the soak temperature of the • 1590499 Air Piping, Main Hoist
brake flange with an infrared temperature • 1590870 Air Piping, Boom Hoist
measuring instrument or a welder's temper-
ature stick. Measure the soak temperature 15. Replace all covers and guards.
on the contact surface of the brake flange
between the ends of the brake band or 16. Engage the corresponding drum pawl if this
beside the band, whichever is hotter. To was not already done.
prevent excessive heating, release the
brake and permit the brake flange to cool. 17. Test the brake to make sure it can hold a
full load before putting the hoist into opera-
7. Repeat steps 4 through 6 several times. tion. If the brake slips while holding a full
The soak temperature of the brake flange load, repeat the above steps until the brake
may be allowed to reach the maximum will hold a full load.
temperature of 149–176°C (300–350°F)
only after 2 or 3 cycles.
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5.8 Hoist Drum Clutches 2. Release the drum clutch. Check that the
corresponding MAIN, AUXILIARY, or WHIP
SELECT push button (figure 2–12, item 1,
!WARNING 2, or 3) is not illuminated. Air pressure is
• Keep the hoist drum clutches in released from the clutch air cylinders (see
correct adjustment at all times. A figure 5–14), permitting the springs inside
clutch that is not adjusted correctly the air cylinders to release the clutch.
can have reduced holding capacity.
The clutch is self-equalizing after the
first adjustment, but adjustment for
!WARNING
lining wear is necessary. Without • Keep away from moving and hot
periodic adjustment, normal lining equipment parts.
wear can cause the pistons of the air
cylinders to travel to the end of their 3. For each clutch band, measure the
stroke, which can cause reduced distance from the center of the clevis pin for
clutch holding capacity. the outermost clutch air cylinder to a refer-
ence surface of the air cylinder bracket.
Check the hoist drum clutches of the main, This is dimension A of figure 5–14. Note
auxiliary, and whip drums for correct operation this value for each clutch band; it will be
and adjustment as directed in the inspection needed in step 6.
and maintenance schedule (see paragraph
5.3). The clutches will need adjustment to 4. Engage the clutch. Push the corresponding
compensate for normal brake lining wear and MAIN, AUXILIARY, or WHIP SELECT push
after replacement of the lining, a clutch actua- button. The push button must illuminate.
tor, or a clutch linkage part. Full air pressure (7.23–8.61 bar (105–125
psi)) must be supplied to the clutch air
cylinders.
5.8.1 Check and Adjustment of Hoist
Drum Clutch 5. Check that the clutch band linings are tight
against the clutch flange of the drum.
!WARNING 6. For each clutch band, measure again the

• The drum clutch has two clutch bands, distance from the center of the clevis pin for
each with its own clutch lever and air the outermost clutch air cylinder to the
cylinder(s). When adjusting the drum reference surface of the air cylinder mount-
clutch, always adjust both clutch ing bracket. This is dimension A of
bands before putting the hoist back figure 5–14. Subtract the corresponding
into operation. Unequal clutch measurement found in step 3 from this
adjustment can cause reduced clutch measurement. The difference in the travel
holding capacity. of the pin must be equal to or more than the
“minimum” permitted dimension and less
1. Keep other people from operating the hoist. than the corresponding “maximum” permit-
Put “Do Not Use” signs or tags on the ted dimension listed in figure 5–14. If the
control console to prevent operation of the difference calculated is within the correct
hoist. range, the clutch does not need adjust-
ment. If the difference calculated is not
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See Table Below
Released
A Engaged
Position
Air Cylinder Position
Adjustment
Nut
Trunnion
Locknut Air Cylinder

Clevis Pin
Eyebolt
Eyebolt
Air Cylinder
Clevis Pin Locknut
Trunnion
Adjustment Nut
Engaged
Position
Released
Position
Air Cylinder
A
CLEVIS PIN (PISTON) TRAVEL

MAXIMUM MINIMUM
CLUTCH (NEW (ADJUSTMENT
ADJUSTMENT) REQUIRED)
Main, 77 mm 97 mm
Auxiliary (3 in) (31316 in)
64 mm 84 mm S805
Whip S201
(2 12 in) (3516 in) S202
Figure 5–14. Hoist Drum Clutch Adjustment—Typical
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within the correct range, continue with step is not correct, return to step 7. If the clutch
7 to adjust the clutch. adjustment is correct, continue with step 9.
9. Replace all covers and guards.

NOTICE
• If the clutch lining was not in full 10. Test the clutch to make sure it holds a full
contact with the clutch flange of the load before putting the hoist into operation.
drum in step 4 and full air pressure
had been applied to the air cylinders,
this means the pistons of the air 5.8.2 Hoist Drum Clutch Lining
cylinder have bottomed in the
cylinders at the mounting bracket end. 5.8.2.1 Inspection of Hoist Drum Clutch
The travel of the air cylinder clevis Lining
pins (see figure 5–14) will also be more
than the “maximum” permitted
dimension listed in figure 5–14. To !WARNING
correct this, loosen the locknut and • Keep away from moving and hot
tighten the adjustment nut on both equipment parts.
eyebolts the same number of turns • Use only cleaning materials that are
until the lining comes into full contact made for clutch linings. The wrong
with the clutch flange. Tighten and cleaning solvent can severely damage
lock the nuts securely against the the lining, which will cause the clutch
trunnions. If the clutch lining was not to have reduced holding capacity.
in full contact with the clutch flange
and the travel of the air cylinder clevis Rivets fasten the lining to the clutch band. The
pins is less than the “maximum” heads of the rivets are countersunk into the
permitted dimension listed in figure lining.
5–14, the clutch band could be
out-of-round or twisted. Contact the Check the clutch lining as directed in the
National Oilwell Varco Service inspection and maintenance schedule (see
Department for instructions. paragraph 5.3). Check the clutch lining for:
• Lining wear. Do not permit the lining to
!CAUTION
wear down to the heads of the rivets. This
• Both air cylinder clevis pins (pistons) can result in damage to the clutch flange of
must have equal travel. the drum from the rivet heads coming into
contact with the clutch flange. Measure the
7. Turn the adjustment nut and locknut on thickness of the lining at both ends and at
both eyebolts as necessary until the differ- the middle of the clutch band (lining will
ence in the travel of the air cylinder clevis typically wear more at the middle). Lining
pins equals the “minimum” permitted for the main drum worn to 15.3 mm (0.6 in)
dimension listed in figure 5–14. Tighten and or less at any point must be replaced.
lock the nuts securely against the trun- Lining for the auxiliary drum worn to
nions. 7.6 mm (0.3 in) or less at any point must be
replaced. Lining for the whip drum worn to
8. Check the clutch adjustment by repeating 5.6 mm (0.23 in) or less at any point must
steps 2 through 6. If the clutch adjustment be replaced.
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• Lining contact. With the clutch engaged, 5.8.2.2 Replacement of Drum Clutch
the lining must have continuous wrap Lining (National Oilwell Varco
(lengthwise) contact with the clutch flange Standard 1525333)
of the drum and must make a minimum of
85 percent total area contact with the clutch 1. Keep other people from operating the hoist.
flange. If the total area contact is less than Put “Do Not Use” signs or tags on the
85 percent or there are gaps with no control console to prevent operation of the
contact, the lining can be sanded (see hoist.
paragraph 5.8.2.3) to correct for the
out-of-round shape of the clutch band and
to get the required contact. NOTICE
• Missing, cracked, or damaged sections. If • The pawl must be engaged all the way
any of these conditions are found, replace into the ratchet pocket of the drum.
the lining.
• Lubricant worn into the lining. If this occurs, 2. Engage the corresponding drum pawl and
replace the lining. See the notice below. drum parking brake.
• Loose rivets. Replace the lining only if the
holes in the lining are damaged. Otherwise, 3. Loosen the adjustment nut (see figure
just replace the loose rivets. 5–15) for each clutch band until the clutch
lining is released from (not in contact with)
NOTICE the clutch flange of the drum.
• For glazed lining or minor
contamination by lubricants, sanding !WARNING
the lining (see paragraph 5.8.2.3) can
be a temporary method to extend the • Support the sections of the clutch
life of the lining. Replace the lining as band and use appropriate lifting
soon as a maintenance shutdown can equipment while removing and
be scheduled. If sanding does not installing the clutch band. The clutch
result in acceptable control of the band is heavy and is a crushing
hoist, do not operate the hoist until the hazard.
lining is replaced. • Use extreme caution when reaching
into the clutch area.
• This procedure makes airborne dust
that can be harmful if inhaled. For your
protection wear proper respiratory
safety equipment.
NOTICE
• Store the sections of the clutch band
from the same clutch together. Do not
exchange parts between different
clutches.
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Revision 01
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4. Remove equipment parts from the hoist as 13. Completely clean the mounting surface for
necessary to avoid damage when removing the lining on the clutch band. Remove all
the clutch band. rust, scale, and dirt, but do not remove the
zinc primer.
5. Remove the bolts that connect the sections
of the clutch band together. 14. Check the clutch band for damaged, worn,
cracked, or corroded parts, welds, and rivet
6. Remove the dead-end and live-end pivot holes. Apply zinc primer if bare metal is
pins (see figure 5–15) from each clutch showing.
band section. Using extreme caution, lift
and remove each section of the clutch band
out between the spokes of the drum gear.
CAUTION
• If the clutch band must be repaired or
7. Check the pivot pins and pin holes of the corrected, contact the National Oilwell
clutch band and linkage for damage, wear, Varco Service Department for
cracks, and corrosion. Replace parts if instructions. Do not try to correct
necessary. distortion with heat.
8. Completely clean the machined friction 15. Put the new lining on the clutch band in the
surface of the drum clutch flange. The position noted in step 9. Use clamps to hold
machined friction surface must not be pitted the lining on the band.
or have rust laminations. If necessary, use
a power wire brush to remove all rust, 16. Use the clutch band as a template to drill
scale, dirt, paint, etc. Check the surface for holes in the new lining. For drilling dimen-
damage such as scoring from rivet heads sions see figure 5–15.
and warping. If machining of the friction
surface is necessary, contact the National 17. Drill countersink holes in the lining. For drill-
Oilwell Varco Service Department for ing dimension see figure 5–15.
instructions.
18. Chamfer the ends of the lining (two places
9. Move the clutch band to a clean work area. per clutch band). For chamfering dimen-
Note the position of the old lining on the sions see figure 5–15.
clutch band. This information is needed in
step 15 to correctly position the new lining 19. Install the rivets. Start at the middle of the
on the band. lining. Work outward toward the ends, alter-
nating on each side working away from the
10. Drill out the rivets that hold the lining to the middle.
clutch band from the band side, opposite
the lining. 20. Use long feeler gauges to check the lining
for surface contact with the clutch band.
11. Use a chisel to remove any remaining
turned-over rivet heads. • The lining must make a minimum of 85
12. Use a punch to drive out the rivets. band.
Remove the old lining from the clutch band. • The lining must make continuous wrap
(lengthwise) contact with the band.
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Revision 01
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CAUTION
remove the rivets and start with step 14 • Remove any extra lubricant from the
again. pivot pins to keep it from wearing into
the clutch lining. If lubricant does wear
21. Check the lining for cracks or other damage into the lining, a new lining may be
caused during installation. Replace the necessary.
lining if it is damaged.
23. Adjust the clutch (see paragraph 5.8.1).
!WARNING 24. Engage the clutch.
• Support the sections of the clutch
band and use appropriate lifting 25. With the clutch engaged, use long feeler
equipment while installing the clutch gauges to check the lining for surface
band. The clutch band is heavy and is contact with the clutch flange of the drum.
a crushing hazard.
• Use extreme caution when reaching • The lining must make a minimum of 85
into the clutch area. percent total area contact with the
clutch flange.
• The lining must also make continuous
22. Assemble the clutch. Apply lubricant to all
wrap (lengthwise) contact with the
the pivot pins.
clutch flange.
Tighten the bolts that connect the sections If the total area contact is less than 85
of the clutch band together hand tight. percent or there are gaps with no contact,
Engage the clutch band all the way against the lining can be sanded (see paragraph
the clutch flange of the drum. To do so, 5.8.2.3) to correct for the out-of-round
push the corresponding MAIN, AUXILIARY, shape of the clutch band and to get the
or WHIP SELECT push button (figure 2–12, required contact.
item 1, 2, or 3). The push button must illu-
minate. Full air pressure (7.23–8.61 bar CAUTION
(105–125 psi)) must be supplied to the
• Burnish a new clutch lining before
clutch air cylinders. Carefully tap the back
putting the hoist into operation.
face of the clutch band on both sides of the
band section connection joints for the best
possible contact of the lining with the clutch 26. Burnish the drum clutch lining (see para-
flange. Tighten the connection bolts. graph 5.8.2.4) to get the design coefficient
of friction between the lining the friction
• Check that the band moves easily on surface of the drum clutch flange.
the dead-end and live-end pivot pins.
• Check that the band is centered on the 27. Check the clutch adjustment (see para-
friction surface of the drum clutch graph 5.8.1). Adjust the clutch as neces-
flange. sary.
29. Test the clutch to make sure it holds a full

load before putting the hoist into operation.
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Revision 01
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1
2 in
150°
Main Drum:
12.7 mm (0.5 in)
Auxiliary Drum:
Clutch Band Connection Bolt 6.35 mm (0.25 in)
Whip Drum:
Lining 4.76 mm (0.1875 in)
Clutch Band 17
64 in
Lining Rivet Installation: Typical
Adjustment
Nut
Lining
Chamfer Lining Chamfer
Live-End Pin Dead-End Pin
Dead-End Live-End Pin

Pin
Adjustment Nut
Lining
Chamfer
Main, Auxiliary Drum
19.0 mm
(0.75 in)
Lining
12.7 mm (0.5 in)
Clutch Band
Clutch Band Connection Bolt

Lining Chamfer: 4 Places
Whip Drum
12.7 mm
(0.5 in)
4.76 mm (0.1875 in)
S805
A2898
A2899
Figure 5–15. Hoist Drum Clutch Lining Installation—Typical
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5.8.2.3 Sanding Hoist Drum Clutch Initially the control valve should be in the
Lining (National Oilwell Varco “clutch released” position (air pressure
Standards 1525332, 1525335) exhausted from the clutch air cylinders,
drum clutch released).
With the drum clutch engaged, the lining must
have continuous wrap (lengthwise) contact with 4. Add a “jumper wire” across the pressure
the clutch flange of the drum and must make a switch in the air piping for the clutch air
minimum of 85 percent total area contact with cylinders. The switch must continuously be
the clutch flange. If the total area contact is less in the “closed” position (corresponding to
than 85 percent or there are gaps with no air pressure supplied to the clutch air cylin-
contact, the lining can be sanded to correct for ders).
the out-of-round shape of the clutch band and
to get the required contact. 5. Remove the wiring from the solenoid air
valve for the corresponding parking brake.
The valve must continuously be in the
!WARNING “parking brake engaged” position (corre-
• Keep away from moving and hot sponding to air pressure exhausted from
equipment parts. the parking brake air cylinders).
• This procedure makes airborne dust
that can be harmful if inhaled. For your
protection, wear proper respiratory
!WARNING
safety equipment. • Support the sections of the clutch
band and use appropriate lifting
1. Keep other people from operating the hoist. equipment while removing and
Put “Do Not Use” signs or tags on the installing the clutch band. The clutch
control console to prevent operation of the band is heavy and is a crushing
hoist. hazard.
• Use extreme caution when reaching
2. Engage the corresponding drum parking into the clutch area.
brake.
6. In step 7, a piece of abrasive tape will be
3. Connect an external source of 7.23–8.61 applied to the friction surface of the drum
bar (105–125 psi) air pressure (from a clutch flange. With the clutch released,
portable air compressor) with a control remove clutch parts and the bolts that
valve to the air piping for the clutch air connect the sections of the clutch band
cylinders. The control valve will be used together as necessary and reposition or
during this procedure to: remove the band sections as necessary to
permit access to the friction surface of the
• engage the clutch (by supplying air drum clutch flange.
pressure to the clutch air cylinders)
• release the clutch (by exhausting air 7. Apply a piece of self-adhesive abrasive
pressure from the clutch air cylinders) tape (National Oilwell Varco p/n 827581) to
• provide proportional control of the air the friction surface of the drum clutch
pressure to the clutch air cylinders, so flange. Apply the tape from the inside edge
that the clutch can be partially engaged of the friction surface to the outside edge.
during this procedure Put the adhesive side of the tape on the
clutch flange, with the abrasive side facing
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Revision 01
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the lining. The surface temperature of the 12. Release the clutch.
drum clutch flange must be 10–37°C
(50–100°F) for the best hold of the tape to
the clutch flange. !WARNING
• Support the sections of the clutch
8. Assemble the clutch. Tighten the bolts that band and use appropriate lifting
connect the sections of the clutch band equipment while removing and
together hand tight. Rotate the clutch so the installing the clutch band. The clutch
connection joint is 180 degrees from the band is heavy and is a crushing
abrasive tape. Engage the clutch all the hazard.
way against the clutch flange of the drum. • Use extreme caution when reaching
To do so, operate the control valve installed into the clutch area.
in step 3 to supply full air pressure
(7.23–8.61 bar) 105–125 psi)) to the clutch 13. The abrasive tape must be removed from
air cylinders. Carefully tap the back face of the drum in step 14. Remove clutch parts
the clutch band on both sides of the band and the bolts that connect the sections of
section connection joint for the best possi- the clutch band together as necessary and
ble contact of the lining with the clutch reposition or remove the band sections as
flange. Tighten the connection bolts. necessary to permit access to the abrasive
tape on the drum clutch flange.
9. Release the clutch. To do so, operate the
control valve installed in step 3 to release 14. Remove the abrasive tape from the clutch
the air pressure from the clutch air cylin- flange and thoroughly clean the friction
ders. surface of the drum clutch flange with
acetone or M.E.K. (methyl ethyl ketone).
10. With the drum clutch released, rotate the (Do not use carbon tetrachloride because
hoist drive at a slow speed and engage the of possible personal physical harm.)
clutch to be sanded a small amount by
supplying air pressure to the clutch air 15. Use air pressure free of moisture to clean
cylinders. the dust and debris from between the clutch
flange of the drum and the lining.
11. Sand the lining until:
16. Assemble the clutch. Tighten the bolts that
• the lining makes a minimum of 85 connect the sections of the clutch band
percent total area contact between the together hand tight. Engage the clutch all
lining and the drum clutch flange the way against the clutch flange of the
• the lining makes continuous wrap drum. Carefully tap the back face of the
(lengthwise) contact with the clutch clutch band on both sides of the band
flange section connection joint for the best possi-
ble contact of the lining with the clutch
Use long feeler gauges to check the lining flange. Tighten the connection bolts.
for surface contact with the clutch flange.
Multiple applications of abrasive tape can
be necessary to get the required contact.
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17. With the clutch released, remove the exter- 5.8.2.4 Burnishing Hoist Drum Clutch
nal source of air pressure that was installed Lining (National Oilwell Varco
in step 3. Then reconnect the original air Standard 1525336)
piping—refer to the following drawings in
the Parts Manual, Section 12: Burnish the drum clutch lining on a new hoist
and after installing a new clutch lining to get the
• 1590496 Air Piping Schematic design coefficient of friction between the lining
• 1590499 Air Piping, Main Hoist and the friction surface of the drum clutch
• 1590870 Air Piping, Boom Hoist flange.
18. Remove the “jumper wire” from the pres-

sure switch in the air piping for the clutch !WARNING
air cylinders that was installed in step 4. • Keep away from moving and hot
equipment parts.
19. Connect the wiring from the solenoid air • This procedure makes airborne dust
valve for the corresponding parking brake that can be harmful if inhaled. For your
that was removed in step 5. protection, wear proper respiratory
safety equipment.
20. If the clutch lining is new, burnish the lining
(see paragraph 5.8.2.4) to get the design
1. Keep other people from operating the hoist.
coefficient of friction between the lining and
Put “Do Not Use” signs or tags on the
the friction surface of the drum clutch
control console to prevent operation of the
flange.
hoist.
21. Check the clutch adjustment (see para-
2. Engage the corresponding drum parking
graph 5.8.1). Adjust the clutch as neces-
brake.
sary.
3. Connect an external source of 7.23–8.61
bar (105–125 psi) air pressure (from a
portable air compressor) with a control
23. Test the clutch to make sure it holds a full
valve to the air piping for the clutch air
load before putting the hoist into operation.
cylinders. The control valve will be used
during this procedure to:
• engage the clutch (by supplying air

pressure to the clutch air cylinders)
• release the clutch (by exhausting air
pressure from the clutch air cylinders)
• provide proportional control of the air
pressure to the clutch air cylinders, so
that the clutch can be partially engaged
during this procedure
Initially the control valve should be in the

“clutch released” position (air pressure
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Revision 01
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exhausted from the clutch air cylinders, lining. To keep the temperature from rising
drum clutch released). above 176°C (350°F), release the drum
clutch and permit the clutch flange to cool.
4. Add a “jumper wire” across the pressure
switch in the air piping for the clutch air 9. Repeat steps 7 and 8 several times.
cylinders. The switch must continuously be
in the “closed” position (corresponding to 10. Stop the hoist drive and engage the corre-
air pressure supplied to the clutch air cylin- sponding drum pawl. Release the drum
ders). brake and engage the drum clutch. Do not
release the clutch until the lining and clutch
5. Remove the wiring from the solenoid air flange have cooled.
valve for the corresponding parking brake.
The valve must continuously be in the 11. After the lining and clutch flange have
“parking brake engaged” position (corre- cooled, engage the drum parking brake and
sponding to air pressure exhausted from release the drum clutch.
the parking brake air cylinders).
12. Use air pressure free of moisture to clean
the dust and debris from between the clutch
CAUTION flange of the drum and the lining.
• Do not glaze the clutch lining. Too
much heat causes glazing. If the lining 13. Check the clutch adjustment (see para-
is glazed, it will not hold correctly. graph 5.8.1). Adjust the clutch as neces-
Sand the lining (see paragraph 5.8.2.3) sary.
to remove the glazing before putting
the hoist into operation. 14. With the clutch released, remove the exter-
nal source of air pressure that was installed
in step 3. Then reconnect the original air
!WARNING piping—refer to the following drawings in
• The lining will release a gas during the the Parts Manual, Section 12:
heating from the burnishing process.
• 1590496 Air Piping Schematic
6. With the drum clutch released, rotate the • 1590499 Air Piping, Main Hoist
hoist drive at a slow speed. • 1590870 Air Piping, Boom Hoist
7. Engage the clutch to be burnished as much 15. Remove the “jumper wire” from the pres-
as possible. To do so, operate the control sure switch in the air piping for the clutch
valve installed in step 3 to supply air pres- air cylinders that was installed in step 4.
sure to the clutch air cylinders. Do not over-
load the motor or permit the drum brake to 16. Connect the wiring from the solenoid air
slip. valve for the corresponding parking brake
that was removed in step 5.
8. To prevent glazing, check the soak temper-
ature of the clutch flange with an infrared 17. Replace all covers and guards.
temperature measuring instrument or a
welder’s temperature stick. The tempera- 18. Engage the corresponding drum pawl if this
ture must be 148–176°C (300–350°F) on was not already done.
the surface of the clutch flange opposite the
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19. Test the clutch to make sure it holds a full 5. Start the hoist and slowly inhaul wire rope
load before putting the hoist into operation. from the spool onto the drum. Make sure
If the clutch slips while holding a full load, that the first wrap of wire rope is against the
repeat the above steps until the clutch will drum flange. Wind the wire rope tight with
hold a full load. no spaces between the wraps (maintain a
drag on the spool at all times).
5.9 Wire Rope Installation
Wire Rope Hole in Drum Flange
!WARNING Wire Rope
Clamp
• Installing the wire rope wrong can
cause the wire rope to be severely
damage during operation. Damaged
wire rope cannot be used. The
damaged wire rope must be removed.
NOTICE A1522
Figure 5–16. Wire Rope Installation—Typical

• See the Wire Rope User’s Manual at
the end of this section for additional
information about installing wire rope. 5.10 Welding Instructions
1. Position the spool of wire rope so the wire Using the wrong weld procedures on any part of
rope will be wound on the drum as shown the equipment can weaken the material and
on page 19 of the Wire Rope User’s cause material failure resulting in equipment
Manual. damage, injury to personnel or both. Contact
the National Oilwell Varco Service Department
2. Reeve the wire rope as necessary, passing for instructions before welding any part of the
the end of wire rope through the hole in the equipment.
drum flange and through the wire rope
clamps (see figure 5–16). The end of the When welding, attach the electric grounding
wire rope must extend beyond the last wire cable directly to the part or area being welded.
rope clamp. Not following this procedure can cause damage
to the bearings, bushings, or spacers.
3. Apply anti-seize compound (National
Oilwell Varco p/n 1812613) to the threads Proper precaution must be taken to avoid
of the studs or bolts and the face of the damage to electronic parts when welding.
nuts for the wire rope clamps. Examples of electronic parts include program-
mable logic controllers (PLCs) and electronic
4. Tighten the nuts for the wire rope clamps of drive control systems, load pins, etc.
the boom, main, and auxiliary hoist drums
to 861 N·m (635 ft·lb). Tighten the nuts for !WARNING
the wire rope clamps of the whip hoist and
tugger drums to 466 N·m (344 ft·lb). • Do not weld on hooks or shackles.
Welding on these items can weaken
the material, causing failure.
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Calibration Data Table
AmClyde Model 52 Crane, serial number BP5376
Date
Main dead end zero
Main lead in zero
Main dead end span
Main lead in span
Aux load link zero
Aux load link span
Whip load pin zero
Whip load pin span
Boom angle slope
Boom angle offset
Cross angle offset
Heel angle offset

Revision 01
Page 6-1
6 SPECIFICATIONS
6.1 Crane
Serial Number:
• BP5376
Model:
• 52
Boom Length (from center of boom foot pin):

• Length to main fall upper block sheaves—70.1 m (230 ft)
• Length to auxiliary fall upper block sheaves—79.3 m (260.2 ft)
• Length to whip fall jib tip sheave—84.7 m (277.9 ft)
Tailswing:
• 13.96 m (45.8 ft)
Operating Radius:
• Main fall—21.3–70.1 m (69.8–229.9 ft)
• Auxiliary fall—22.9–79.2 m (75.1–259.8 ft)
• Whip fall—23.8–83.8 m (78–274.9 ft)
Top of vessel deck to centerline of boom hinge:

• 10.4 m (34.1 ft)
6.2 Wire Rope and Reeving
Wire Rope—Main, Auxiliary, Whip, Boom, and Tuggers

MAIN LOAD
MAIN AUXILIARY WHIP BOOM BLOCK CONTROL
TUGGERS TUGGERS
Parts of line 1 @ 32 parts 1 @ 10 parts 1 @ 2 parts 1 @ 16parts 1 @ 1 part 1 @ 1 part
Wire rope:
Part number 1593259 1593260 1593261 1593262 1593263 1593264
Diameter 44 mm 44 mm 36 mm 44 mm 26 mm 26 mm
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6.3 Hoists
Hoists—Main, Auxiliary, Whip, and Boom

Hoist MAIN AUXILIARY WHIP BOOM
Serial number BP5376-0001 BP5376-0002
Model Frame 20 Frame 16 Frame 14 Frame 16
366,680 N single 337,927 N single 263,019 N single 323,666 N single
Rated linepull at linepull at linepull at linepull at
performance 106 m/min on 107 m/min on 134 m/min on 98 m/min on
layer 13 layer 8 layer 3 layer 7
Internal expanding band type (1 per drum),
Drum clutch
air-engaged/spring-release
External contracting band type (2 per drum),
Drum brake Parking brake function: spring-engaged/air-released,
Service brake function: air-engaged/spring-released
Drum dog Last position type (1 per drum), air-engaged/air-released
Electric motor:
Voltage 660 VAC
Power 649 kW at 800 rpm 649 kW at 800 rpm
Electric motor
Caliper disc type, spring-engaged/air-released
brake
6.4 Swing Drives
Number of Swing Drives:

• Three
Serial Numbers:
• BP5376-0004
• BP5376-0005
• BP5376-0006
Model:
• 52
Rated Performance:
• Swing speed—0.50 rpm
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Motor:
• Voltage—660 VAC
• Horsepower of each motor—149 kW (200 hp)
Motor Brake:
• Disc type
• Spring-engaged/air-released
6.5 Tuggers
Serial Numbers:
• BP5376-0055
• BP5376-0056
• BP5376-0057
Model:
• RW126
Rated performance
• 25 MT single linepull at 13 m/min on layer 1
Electric Motor:
• Voltage—660 VAC, 3 ph, 60 Hz
• Horsepower—111 kW (150 hp)
6.6 Power Generation and Distribution
6.6.1 Air System
Operating Pressure:
• 7.23–8.61 bar (105–125 psi)
Air Compressor (two—one continuous run, one standby):

• 14.9 kW (20 hp), 400 VAC, 3 ph, 50 Hz each
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6.6.2 Electric System
Supply Power (from vessel):

• 400 VAC, 3 ph, 50 Hz (vessel)
• 400 VAC, 3 ph, 50 Hz (vessel ancillary feed)
Voltage supplied to Drive Control Panels (hoist drive, boom drive, swing #1, #2, and #3 drive, load
tugger #1 and #2 drive, block tugger drive, and brake chopper #1 and #2):
• 660 VAC, 3 ph, 50 Hz (Transformer T205 (supplied by others) converts 400 VAC power to 690 VAC
power.)
Voltage supplied to Distribution Panel DP1:

• 400/230 VAC, 3 ph, 50 Hz from vessel ancillary feed (Transformer T221 converts 400 VAC power
to 400/230 VAC power.), or
• 400/230 VAC, 3 ph, 50 Hz
Source selection controlled through transfer switch XS226
Voltage supplied to drive control power:

• 230 VAC, 1 ph, 50 Hz (Transformer T461 converts 400/230 VAC power to 230 VAC power.)
Voltage supplied to crane control power:

• 230 VAC, 1 ph, 50 Hz (Transformer T457 converts 400/230 VAC power to 230 VAC power.)
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Page 6-5
6.7 Inch to Millimeter Equivalents
INCH INCH INCH INCH

FRACTIONAL DECIMAL MILLIMETER FRACTIONAL DECIMAL MILLIMETER
1 33
64 0.0156 0.397 64 0.5156 13.097
1 17
32 0.0312 0.794 32 0.5312 13.494
3 35
64 0.0469 1.191 64 0.5469 13.891
1 9
16 0.0625 1.588 16 0.5625 14.288
5 37
64 0.0781 1.984 64 0.5781 14.684
3 19
32 0.0938 2.381 32 0.5938 15.081
7 39
64 0.1094 2.778 64 0.6094 15.478
1 5
8 0.1250 3.175 8 0.6250 15.875
9 41
64 0.1406 3.572 64 0.6406 16.272
5 21
32 0.1562 3.969 32 0.6562 16.669
11 43
64 0.1719 4.366 64 0.6719 17.066
3 11
16 0.1875 4.762 16 0.6875 17.462
13 45
64 0.2031 5.159 64 0.7031 17.859
7 23
32 0.2188 5.556 32 0.7188 18.256
15 47
64 0.2344 5.953 64 0.7344 18.653
1 3
4 0.2500 6.350 4 0.7500 19.050
17 49
64 0.2656 6.747 64 0.7656 19.477
9 25
32 0.2812 7.144 32 0.7812 19.844
19 51
64 0.2969 7.541 64 0.7969 20.241
5 13
16 0.3125 7.938 16 0.8125 20.638
21 53
64 0.3281 8.334 64 0.8281 21.034
11 27
32 0.3438 8.731 32 0.8438 21.431
23 55
64 0.3594 9.128 64 0.8594 21.825
3 7
8 0.3750 9.525 8 0.8750 22.225
25 57
64 0.3906 9.922 64 0.8906 22.622
13 29
32 0.4062 10.319 32 0.9062 23.019
27 59
64 0.4219 10.716 64 0.9219 23.416
7 15
16 0.4375 11.112 16 0.9375 23.812
29 61
64 0.4531 11.509 64 0.9531 24.209
15 21
32 0.4688 11.906 32 0.9688 24.606
31 63
64 0.4844 12.303 64 0.9844 25.003
1
2 0.5000 12.700 1 1.0000 25.4
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6.8 Millimeter to Inch Equivalents
MILLIMETER INCH MILLIMETER INCH MILLIMETER INCH

1 0.0394 36 1.4173 71 2.7953
2 0.0787 37 1.4567 72 2.8346
3 0.1181 38 1.4961 73 2.8740
4 0.1575 39 1.5354 74 2.9134
5 0.1969 40 1.5748 75 2.9528
6 0.2362 41 1.6142 76 2.9921

7 0.2756 42 1.6535 77 3.0315
8 0.3150 43 1.6929 78 3.0709
9 0.3543 44 1.7323 79 3.1102
10 0.3937 45 1.7717 80 3.1496
11 0.4331 46 1.8110 81 3.1890

12 0.4724 47 1.8504 82 3.2283
13 0.5118 48 1.8898 83 3.2677
14 0.5512 49 1.9291 84 3.3071
15 0.5906 50 1.9685 85 3.3465
16 0.6299 51 2.0079 86 3.3858

17 0.6693 52 2.0472 87 3.4252
18 0.7087 53 2.0866 88 3.4646
19 0.7480 54 2.1260 89 3.5039
20 0.7874 55 2.1654 90 3.5433
21 0.8268 56 2.2047 91 3.5827

22 0.8661 57 2.2441 92 3.6220
23 0.9055 58 2.2835 93 3.6614
24 0.9449 59 2.3228 94 3.7008
25 0.9843 60 2.3622 95 3.7402
26 1.0236 61 2.4016 96 3.7795

27 1.0630 62 2.4409 97 3.8189
28 1.1024 63 2.4803 98 3.8583
29 1.1417 64 2.5197 99 3.8976
30 1.1811 65 2.5591 100 3.9370
31 1.2205 66 2.5984 101 3.9764

32 1.2598 67 2.6378 102 4.0157
33 1.2992 68 2.6772 103 4.0551
34 1.3386 69 2.7165 104 4.0945
35 1.3780 70 2.7559 105 4.1339
www.nov.com
Revision 01
Page 6-7
6.9 U.S. to Metric Conversions
TO CONVERT INTO MULTIPLY BY

Length foot (ft) meter (m) 0.3048
foot (ft) centimeter (cm) 30.48
inch (in) meter (m) 0.0254
inch (in) centimeter (cm) 2.54
inch (in) millimeter (mm) 25.4
Area square foot (ft2) square meter (m2) 0.0929

square inch (in2) square meter (m2) 0.000645
square inch (in2) square centimeter (cm2) 6.4516
square inch (in2) square millimeter (mm2) 645.16
Volume cubic yard (yd3) cubic meter (m3) 0.7646

cubic foot (ft3) cubic meter (m3) 0.02832
cubic inch (in3) cubic centimeter (cm3) 16.3871
Liquid Volume gallon (gal) liter (L) 3.7854

quart (qt) liter (L) 0.9464
pint (pt) liter (L) 0.4732
ounce (oz) milliliter (mL) 29.5735
Mass/Weight long ton (LT) (2240 lb) metric ton (MT) 1.1016
short ton (ST) (2000 lb) metric ton (MT) 0.9072
pound (lb) kilogram (kg) 0.4536
ounce (oz) gram (g) 28.3495
Pressure pounds/sq. in. (psi) kilopascal (kPa) 6.8947

pounds/sq. in. (psi) bar 0.06895
Velocity feet/minute (ft/min) meters/minute (m/min) 0.3048
Liquid Flow gallons/minute (gal/min) liters/minute (L/min) 3.7854
Force kip (kip) (1000 lb) newton (N) 4448.2216

pound (lb) newton (N) 4.4482
ounce (oz) newton (N) 0.278
Torque foot×pound (ft×lb) newton×meter (N×m) 1.3558

inch×pound (in×lb) newton×meter (N×m) 0.1129
step 1. subtract 32°

Temperature Fahrenheit (°F) Celsius (°C) step 2. multiply by 0.56
www.nov.com
Revision 01
Page 6-8
6.10 Tightening Procedures for ASTM, Contact Surface

SAE, and ISO Bolts Material
Contact
6.10.1 Tightening Procedure for ASTM Surface
A325 and ASTM A490
A156
High-Strength Structural Coarse Contact Surface
Thread Bolts and Hex Nuts
Figure 6–1. Material Contact Surfaces
(National Oilwell Varco Standard
1525179)
All paint, except organic and inorganic zinc
A325 primer, must be removed from all the joint
A325 ASTM A325 identification marking surfaces, including the material contact
surfaces and the surfaces under the bolt head,
A490 ASTM A490 identification marking nut, and washers. All the joint surfaces must be
A490 free of scale, oil, grease, dirt, pits, burrs, etc.
that could prevent the correct joining of the
Use the following procedure to tighten ASTM
parts.
A325 and ASTM A490 high-strength structural
coarse thread bolts and hex nuts. Unless speci-
Turn-of-the-nut method with plain manual
fied on the drawing, washer requirements are
wrenches or impact wrenches:
as specified in the latest edition of AISC Speci-
fication for Structural Joints Using ASTM A325
1. Pull the parts together by tightening all the
or A490 Bolts, “Washer Requirements.” When
bolts of the connection “snug tight,” to make
A490 bolts are used and the specified yield
sure the material contact surfaces of the
point of the material to be joined is less than
connection are tight against each other.
40,000 psi, use a hardened washer under both
The material contact surfaces must be tight
the nut and the bolt head. When an outer face
around each bolt by a radius of not less
of the
8.8 parts bolted together has a slope of more
than one bolt diameter measured from the
than8.8 1:20 with respect to a plane normal to the
bolt centerline.
bolt centerline, use a hardened beveled washer
to 10.9
compensate for the lack of parallelism.
10.9 NOTICE
CAUTION • “Snug tight” is defined as the
12.9 tightness existing when the material
• Do not retighten ASTM A325 bolts
12.9 contact surfaces of the connection are
more than two times. If ASTM A325
in firm contact. This can be made by a
bolts become loose after being
316 few impacts of an impact wrench or the
tightened two times, they must be
316 maximum effort of a person using an
replaced. Retightening bolts that have
ordinary spud wrench.
become loose by the tightening of
adjacent bolts is not considered a
reuse. Do not reuse A490 or 2. Tighten completely all the bolts in the
galvanized A325 bolts. connection by the amount of nut rotation
listed in the following table:
Visually check the bolts for tightness every six
months after installation. Check for cracked
paint or new rust at the contact surface.
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Revision 01
Page 6-9
NOTICE
• Impact wrenches must have enough capacity and receive enough air (volume and
pressure) to perform the correct tightening of each bolt in approximately 10 seconds.
Tightening of bolts in a connection must start at the fixed or stiffest point and progress
toward the free edges for both “snugging up” and final tightening. Parts not turned by the
wrench must not rotate.
• When an outer face of the parts bolted together has a slope greater than 1:20 with respect
to a plane normal to the bolt centerline, a hardened beveled washer must be used to
compensate for the lack of parallelism.
Nut Rotation (A) from “Snug Tight” Condition

DESCRIPTION OF OUTER SURFACE OF BOLTED PARTS
Bolt length (measured One surface normal to Both surfaces sloped not
from underside of head bolt centerline. Other more than 1:20 from
Both surfaces normal
to extreme end of point) surface sloped not more normal to bolt centerline.
to bolt centerline
than 1:20. (Beveled (Beveled washer not
washer not used) used)
Up to and including 4 1 1 2
3 turn 2 turn 3 turn
diameters
Over 4 diameters but not 1 2 5
more than 8 diameters
Over 8 diameters but not 2 5
more than 12 diameters
(A) Nut rotation is relative to the bolt, whether the bolt or nut is turned. For bolts installed by 12 turn and
less, nut rotation tolerance is ±30 degrees. For bolts installed by 2 3 turn or more, nut rotation toler-
ance is ±45 degrees.
Fastener Tension
ASTM A325 REQUIRED ASTM A490 REQUIRED
DIAMETER MINIMUM FASTENER MINIMUM FASTENER
(in) TENSION (lb) TENSION (lb)
1
2 12,050 15,000
5
8 19,200 25,000
3
4 28,400 35,000
7
8 39,000 49,000
1 51,000 64,000
1 18 56,450 80,000
1 14 71,700 102,000
13 8 85,450 121,000
1 12 104,000 148,000
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A325 Revision 01
Page 6-10
6.10.2
A490 Tightening Values for SAE Grade 2 Coarse Thread Bolts
(National Oilwell Varco Standard 1525177)
SAE Grade 2 identification marking (none)
SAE J429 Grade 2 Coarse Thread Bolts

DIAMETER–
TIGHTENING TORQUE (ft×lb) (D) TIGHTENING TORQUE (N×m) (D)
THREADS/in
THREAD
LUBRICANT MoS2 (A) 30W (B) DRY (C) MoS2 (A) 30W (B) DRY (C)
TORQUE
K=0.13 K=0.15 K=0.20 K=0.13 K=0.15 K=0.20
COEFFICIENT (K)
1
8.8 4 –20 3.5 4 5 4.7 6 7
5
16 –18 7.3 8 11 10 11 15
3
8 –16 13 15 20 18 20 27
10.9
7
16 –14 21 24 32 28 32 43
1
2 –13 32 37 49 43 50 66
12.9
9
16 –12 46 53 70 62 72 95
5
316
8 –11 63 73 97 85 99 132
3
4 –10 112 129 172 152 175 234
7
8–9 108 125 167 146 170 226
1–8 162 187 250 220 254 339

1 18–7 230 266 354 312 360 480
1 14–7 325 375 500 441 508 678
3
1 8–6 426 491 655 578 666 888
1 12–6 565 652 870 766 884 1179
13 4–5 891 1029 1372 1206 1395 1860
2–4 12 1341 1547 2063 1818 2098 2797

2 14–4 12 1961 2262 3017 2659 3068 4091
1
2 –4 2 2681 3094 4126 3635 4195 5595
3
2 4–4 3635 4194 5594 4929 5688 7585
3–4 4802 5541 7389 6512 7513 10,020
(A) Torque for threaded parts that are clean, with no rust and contamination and are well lubricated with molybdenum
disulfide (MoS2) (National Oilwell Varco p/n 1511574).
(B) Torque for threaded parts that are clean, with no rust and contamination and are well lubricated with 30W motor oil.
(C) Torque for threaded parts that are clean, with no rust and contamination and are dry of lubricant.
(D) ft×lb = 0.7375 x torque in N×m, N×m = 1.356 x torque in ft×lb
www.nov.com
A325

A490
Revision 01
Page 6-11

SAE Grade 5 identification marking

DIAMETER–
TIGHTENING TORQUE (ft×lb) (E) TIGHTENING TORQUE (N×m) (E)
THREADS/in
THREAD
LUBRICANT MoS2 (A) 30W (B) ANTI-SEIZE (C) DRY (D) MoS2 (A) 30W (B) ANTI-SEIZE (C) DRY (D)
8.8
TORQUE
K=0.13 K=0.15 K=0.13 K=0.16 K=0.20 K=0.13 K=0.15 K=0.13 K=0.16 K=0.20
COEFFICIENT (K)
1
4 –20 5.5 6 5.5 7 8 7.5 8 7.5 9 11
10.9
5
16 –18 11.3 13 11.3 14 17 15.3 18 15.3 19 24
3
8 –16 20 23 20 25 31 27 31 27 34 42
7
12.9
16 –14 32 37 32 40 49 43 50 43 54 67
1
2 –13 49 57 49 60 75 66 77 66 81 102
316
9
16 –12 71 81 71 87 109 96 111 96 118 148
5
8 –11 98 113 98 120 150 133 153 133 163 204
3
4 –10 173 200 173 213 266 235 271 235 289 361
7
8–9 279 322 279 344 430 378 437 378 466 583
1–8 419 483 419 515 644 568 655 568 698 873
1 18–7 516 595 516 635 794 700 807 700 861 1077
1
1 –7 4 728 840 728 896 1120 987 1139 987 1215 1520
3
1 8–6 955 1102 955 1175 1469 1295 1494 1295 1593 1992
1 12–6 1267 1462 1267 1560 1949 1718 1983 1718 2115 2643
3
1 4–5 1486 1714 1486 1829 2286 2015 2324 2015 2480 3100
2–4 12 2234 2578 2234 2750 3438 3029 3496 3029 3729 4662
1 1
2 –4 4 2 3268 3771 3268 4022 5027 4431 5113 4431 5454 6817
1
2 –4 2 4469 5156 4469 5500 6875 6060 6991 6060 7458 9323
3
2 4–4 6059 6991 6059 7457 9321 8216 9480 8216 10,112 12,639
3–4 8004 9235 8004 9851 12,313 10,853 12,523 10,853 13,358 16,696
(C) Torque for threaded parts that are clean, with no rust and contamination and are well lubricated with Bostik Never-Seez
(K=0.13) or Loctite C5-A (K=0.16) anti-seize compound (National Oilwell Varco p/n 1812613).
(D) Torque for threaded parts that are clean, with no rust and contamination and are dry of lubricant.
(E) ft×lb = 0.7375 x torque in N×m, N×m = 1.356 x torque in ft×lb
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A490

Revision 01
Page 6-12

(National Oilwell Varco Standards 1525177 and 1525515)
SAE Grade 8 identification marking

DIAMETER–
8.8
THREADS/in
PTFE PTFE
THREAD
10.9
LUBRICANT 30W (A) ANTI-SEIZE (B) DRY (C) THREAD 30W (A) ANTI-SEIZE (B) DRY (C) THREAD
COATING (C) COATING (C)
TORQUE
K=0.15 K=0.13 K=0.16 K=0.20 K=0.15 K=0.15 K=0.13 K=0.16 K=0.20 K=0.15
COEFFICIENT (K)
12.91
4 –20 9 8 9.5 12 12 11 12.9 16
5
16 –18 18 16 20 25 25 22 27 33
3163
8 –16 33 28 35 44 33 44 38 47 59 44
7
16 –14 52 45 56 70 52 71 61 76 94 71
1
2 –13 80 69 85 106 80 108 94 115 144 108
9
16 –12 115 100 123 154 115 156 136 167 208 156
5
8 –11 159 138 170 212 159 215 187 230 287 215
3
4 –10 282 244 301 376 282 382 331 408 510 382
7
8–9 455 394 485 606 455 617 534 658 822 617
1–8 682 591 727 909 682 924 801 986 1233 924
1 18–7 966 837 1030 1288 966 1309 1135 1397 1746 1309
1
1 –7 4 1363 1181 1454 1817 1363 1848 1601 1971 2464 1848
13 8–6 1787 1548 1906 2382 1787 2423 2099 2584 3231 2423
1
1 2–6 2371 2055 2529 3162 2371 3215 2787 3429 4288 3215
134–5 3741 3242 3990 4988 3741 5072 4396 5410 6763 5072
2–4 12 5625 4875 6000 7500 5625 7628 6611 8136 10,170 7628
1 1
2 –4 4 2 8227 7130 8775 10,969 8227 11,155 9668 11,899 14,874 11,155
1
2 2–4 11,250 9750 12,000 15,000 11,250 15,255 13,221 16,272 20,340 15,255
3
2 4–4 13,346 11,566 14,235 17,794 13,346 18,097 15,684 19,303 24,129 18,097
3–4 17,630 15,280 18,806 23,507 17,630 23,906 20,720 25,500 31,875 23,906
(A) Torque for threaded parts that are clean, with no rust and contamination and are well lubricated with 30W motor oil.
(B) Torque for threaded parts that are clean, with no rust and contamination and are well lubricated with Bostik Never-Seez
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Revision 01
Page 6-13

8.8
ISO CLASS 8.8 identification marking
ISO 898/1 Class 8.8 Metric Thread Bolts

DIAMETER–
10.9 TIGHTENING TORQUE (ft×lb) (E) TIGHTENING TORQUE (N×m) (E)
THREADS/in
THREAD
12.9
TORQUE
K=0.13 K=0.15 K=0.13 K=0.16 K=0.20 K=0.13 K=0.15 K=0.13 K=0.16 K=0.20
COEFFICIENT (K)
M5 x 0.8 3 3.4 3 3.6 4.6 4 4.6 4 4.9 6.2
316
M6 x 1 5 5.8 5 6.2 7.7 6.8 7.9 6.8 8.4 10.4
M8 x 1.25 12.2 14.1 12.2 15.0 18.8 16.6 19.1 16.6 20.4 25.5
M10 x 1.5 24.2 27.9 24.2 29.8 37.2 32.8 37.8 32.8 40.4 50.5
M12 x 1.75 42 49 42 52 65 57 66 57 70 88
M14 x 2 67 77 67 83 103 91 105 91 112 140

M16 x 2 105 121 105 129 161 142 164 142 175 219
M20 x 2.5 211 244 211 260 325 287 331 287 353 441
M(22 x 2.5) 288 332 288 354 442 390 450 390 480 600
M24 x 3 366 422 366 450 562 496 572 496 610 762
M(27 x 3) 535 617 535 658 823 725 837 725 892 1115
M30 x 3.5 726 838 726 894 1117 985 1136 985 1212 1515
M(33 x 3.5) 988 1140 988 1216 1520 1340 1546 1340 1649 2061
M36 x 4 1269 1464 1269 1562 1952 1721 1985 1721 2118 2647
M(39 x 4) 1642 1895 1642 2021 2526 2227 2569 2227 2741 3426
M42 x 4.5 2029 2342 2029 2498 3122 2752 3175 2752 3387 4234
M48 x 5 3044 3513 3044 3747 4683 4128 4763 4128 5080 6350
M(52 x 5) 3949 4556 3949 4860 6075 5354 6178 5354 6589 8237
M56 x 5.5 4905 5659 4905 6036 7546 6650 7673 6650 8185 10,231
M(60 x 5.5) 6109 7049 6109 7519 9399 8284 9558 8284 10,195 12,744
M64 x 6 7400 8538 7400 9108 11,385 10,034 11,578 10,034 12,349 15,437
M(68 x 6) 8977 10,358 8987 11,049 13,811 12,173 14,045 12,173 14,982 18,727
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Revision 01
Page 6-14
6.10.6
8.8 Tightening Values for Metric ISO Class 10.9 Bolts
(National Oilwell Varco Standards 1525314 and 1525516)
10.9

DIAMETER–
12.9
THREADS/in
PTFE PTFE
THREAD
316
TORQUE
K=0.15 K=0.13 K=0.16 K=0.20 K=0.15 K=0.15 K=0.13 K=0.16 K=0.20 K=0.15
COEFFICIENT (K)
M5 x 0.8 4.9 4.2 5.2 6.5 6.6 5.7 7.1 8.8
M6 x 1 8.3 7.2 8.9 11.1 11.3 9.8 12.0 15.0
M8 x 1.25 20.1 17.5 21.5 26.9 27.3 23.7 29.2 36.5
M10 x 1.5 39.9 34.6 42.6 53.3 54.2 46.9 57.8 72.2
M12 x 1.75 70 60 74 93 70 94 82 101 126 94
M14 x 2 111 96 118 148 111 150 130 160 200 150
M16 x 2 173 150 185 231 173 235 203 250 313 235
M20 x 2.5 337 292 360 450 337 458 397 488 610 458
M(22 x 2.5) 459 398 490 612 459 622 539 664 830 622
M24 x 3 583 506 622 778 583 791 686 844 1055 791
M(27 x 3) 853 740 910 1138 853 1157 1003 1234 1543 1157
M30 x 3.5 1159 1004 1236 1545 1159 1572 1362 1676 2095 1572
M(33 x 3.5) 1577 1367 1682 2103 1577 2138 1853 2281 2851 2138
M36 x 4 2025 1755 2160 2701 2025 2746 2380 2929 3662 2746
M(39 x 4) 2621 2272 2796 3495 2621 3554 3080 3791 4739 3554
M42 x 4.5 3239 2807 3455 4319 3239 4392 3807 4685 5856 4392
M48 x 5 4859 4211 5183 6479 4859 6589 5710 7028 8785 6589
M(52 x 5) 6302 5462 6723 8403 6302 8546 7406 9115 11,394 8546
M56 x 5.5 7828 6785 8350 10,438 7828 10,615 9200 11,323 14,153 10,615
M(60 x 5.5) 9751 8451 10,401 13,002 9751 13,222 11,459 14,103 17,629 13,222
M64 x 6 11,812 10,237 12,599 15,749 11,812 16,016 13,880 17,083 21,354 16,016
M(68 x 6) 14,329 12,419 15,285 19,106 14,329 19,429 16,839 20,725 25,906 19,429
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Revision 01
8.8
Page 6-15

10.9
12.9

316
DIAMETER–
THREADS/in
PTFE PTFE
THREAD
TORQUE
K=0.15 K=0.13 K=0.16 K=0.20 K=0.15 K=0.15 K=0.13 K=0.16 K=0.20 K=0.15
COEFFICIENT (K)
M5 x 0.8 5.7 5 6.1 7.6 7.7 6.7 8.3 10.3
M6 x 1 9.7 8.4 10.3 12.9 13.2 11.4 14.0 17.5
M8 x 1.25 23.6 20.4 25.1 31.4 32.0 27.7 34.1 42.6
M10 x 1.5 46.7 40.5 49.8 62.2 63.3 54.9 67.5 84.4
M12 x 1.75 81 71 87 109 81 110 96 118 147 110
M14 x 2 130 112 138 173 130 176 152 187 234 176
M16 x 2 202 175 216 270 202 274 238 292 365 274
M20 x 2.5 394 342 421 526 395 535 463 570 713 535
M(22 x 2.5) 536 465 572 715 536 727 630 776 970 727
M24 x 3 682 591 727 909 682 925 801 986 1233 925
M(27 x 3) 997 864 1064 1330 997 1352 1172 1443 1803 1352
M30 x 3.5 1354 1174 1145 1806 1355 1837 1592 1959 2449 1837
M(33 x 3.5) 1843 1597 1966 2458 1843 2499 2166 2666 3332 2499
M36 x 4 2367 2051 2525 3156 2367 3210 2782 3424 4279 3210
M(39 x 4) 3063 2655 3268 4085 3064 4154 3600 4431 5538 4154
M42 x 4.5 3786 3281 4038 5048 3786 5133 4449 5475 6844 5133
M48 x 5 5679 4921 6057 7572 5679 7700 6673 8213 10,266 7700
M(52 x 5) 7366 6383 7857 9821 7365 9987 8656 10,653 13,316 9987
M56 x 5.5 9149 7929 9759 12,199 9149 12,405 10,751 13,232 16,540 12,405
M(60 x 5.5) 11,396 9876 12,156 15,195 11,396 15,452 13,392 16,482 20,603 15,452
M64 x 6 13,804 11,963 14,724 18,405 13,804 18,717 16,222 19,965 24,956 18,717
M(68 x 6) 16,746 14,513 17,863 22,328 16,746 22,707 19,679 24,221 30,276 22,707
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8.8

Revision 01
10.9 Page 6-16
6.10.8
12.9
Tightening Values for 316 Stainless Steel Coarse Thread Bolts
316 316 stainless steel identification marking
316 Stainless Steel Coarse Thread Bolts

DIAMETER–
THREADS/in
THREAD
TORQUE
K=0.13 K=0.15 K=0.13 K=0.16 K=0.20 K=0.13 K=0.15 K=0.13 K=0.16 K=0.20
COEFFICIENT (K)
1
4 –20 3.9 4.5 3.9 4.8 6 5.3 6.1 5.3 6.5 8.1
5
16 –18 8 9.2 8 9.8 12.3 10.8 12.5 10.8 13.3 16.7
3
8 –16 14.2 16.3 14.2 17.4 21.8 19.2 22.2 19.2 23.6 29.6
7
16 –14 23 26 23 28 35 31 35 31 38 47
1
2 –13 35 40 35 43 53 47 54 47 58 72
9
16 –12 50 58 50 61 77 68 78 68 83 104
5
8 –11 69 79 69 85 106 93 108 93 115 144
3
4 –10 82 94 82 100 125 111 128 111 136 170
7
8–9 131 152 131 162 202 178 205 178 219 274
1–8 197 227 197 242 303 267 308 267 329 411
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8.8

Revision 01
10.9 Page 6-17
6.10.9
12.9
Tightening Values for Metric ISO Type A4 316 Stainless Steel Bolts
316 ISO TYPE A4 316 stainless steel identification marking
ISO Type A4 316 Stainless Steel Metric Thread Bolts

DIAMETER–
THREADS/in
THREAD
TORQUE
K=0.13 K=0.15 K=0.13 K=0.16 K=0.20 K=0.13 K=0.15 K=0.13 K=0.16 K=0.20
COEFFICIENT (K)
M5 x 0.8 2 2.4 2 2.5 3.1 2.8 3.2 2.8 3.4 4.3

M6 x 1 3.5 4 3.5 4.3 5.3 4.7 5.4 4.7 5.8 7.2
M8 x 1.25 8.4 9.7 8.4 10.4 13 11.4 13.2 11.4 14.1 17.6
M10 x 1.5 16.7 19.2 16.7 20.5 25.7 22.6 26.1 22.6 27.8 34.8
M12 x 1.75 29 34 29 36 45 39 46 39 49 61
M14 x 2 46 53 46 57 71 63 72 63 77 97
M16 x 2 72 83 72 89 111 98 113 98 121 151
M20 x 2.5 141 163 141 173 217 191 221 191 235 294
M(22 x 2.5) 129 149 129 159 199 175 202 175 216 270
M24 x 3 164 190 164 202 253 223 257 223 274 343
M(27 x 3) 241 278 241 296 370 326 376 326 402 502
M30 x 3.5 327 377 327 402 503 443 511 443 545 682
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Revision 01
Page 6-18
www.nov.com

Amclyde Crane Operation Maintenance Manua

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Amclyde Crane Operation Maintenance Manua

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Operation and Maintenance Manual

Serial Number BP5376

REFERENCE REFERENCE DESCRIPTION

DOCUMENT NUMBER REV

Rev Date (dd.mm.yyyy) Reason for Issue Prepared Checked Approved

Revision Change Description

2.4.5.2 HOIST Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2.6.4 WHIP Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

3.10.1.1 Engaging the Boom Hoist Pawl . . . . . . . . . . . . . . . . . . 3-15

4.4.3 START and STOP Push Buttons . . . . . . . . . . . . . . . . . . . . . . . 4-5

5.3.10 Cranes Not in Regular Use . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.8.2.1 Inspection of Hoist Drum Clutch Lining . . . . . . . . . . . . . . 5-39

6.6.2 Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

National Oilwell Varco

Accessory Sales For replacement parts, retrofits, upgrades,

• Erection Manual, document number BP5376–MAN-001

This page intentionally left blank.

1 SAFETY damage to equipment, high maintenance costs,

1.1 Safety: Warning Any performance ratings and specifications for

Not using the equipment according to these

Correct training, inspection, and maintenance

1.3.1 General Safety Rules

7. Before making a heavy lift, make a test lift

5. Do not make modifications to the equip-

Figure 1–1. Wire Rope Wound Wrong on Drum

1.4 Planning Lifts

The signal person must be visible to the opera-

Carefully plan your lifts to prevent accidents. If

The operator must check the following before

1. The shape of the object to be lifted.

2. The rated load capacity of the equipment.

3. The weight and center of gravity of the

4. The limits of the slings.

5. The crane tailswing and swing path of the

6. The position the load will take when it is

7. How high the load will have to be lifted.

1.5 Crane Signals

Move Slowly. Use one Raise the Boom and

Dog Everything. Clasp

Figure 1–2. Crane Signals

1.6 Safety Labels

WARNING Install the equipment using National Oilwell Varco

WARNING Do not enter this area unless authorized to do so.

WARNING To protect your hearing, wear ear protection when

Only qualified, trained maintenance personnel must

WARNING Only qualified, trained maintenance personnel must

DANGER High voltage will remain in the 600 VAC conductors

FIRE Indicates that a fire extinguisher is located inside

2 DESCRIPTION OF CRANE AND 2.2 Equipment Description

Boom Wire Rope

Obstruction Light (see

Main Wire Rope

A-Frame Boom Walkway

Backleg Boom Stop

Operator’s Cab (see figures 2–7 and 2–8)

Figure 2–1. Crane

Auxiliary Fall Jib Obstruction Light

Figure 2–1. Crane (continued)

Electrical House Air Conditioning and

Main Hoist (see Figure 2–3) S S

Louver Ventilation Fan

Symbol Legend Louver

Figure 2–2. Machinery Plan

Load Control Tugger #2