Dongnam Marine Crane Co., Ltd. Rev.

0
Provision & Hose Handling Crane 2009-07-09

OPERATING PROCEDURE

1. Inspection prior to operation

※ Trained staff must inspect all parts of the crane and required / necessary cleaning is to be
carried out before the crane is put into operation.

1> The inspection should at least contain the following item ;

● Check the crane for visible damages.

● Apply to grease at necessary points.
● Special attention should be paid to all of the hydraulic system. Check for damage.
● Check oil leakage on hydraulic hoses, tubes and fittings.
● Ensure that all hydraulic valves are in normal position.
● Check return filter (filter indicator).
● Check that wire rope runs correctly in the sheaves and that the ends of wire ropes are securely
clamped.
● Ensure that the wire rope for hoisting is in perfect condition.
● Check the oil level gauge of hoisting and slewing reducer gears and the oil tank of hydraulic unit.
● Check the crane is capable to move freely in its operation area.

2> Preparation before operation.

● Check the oil level gauge of hoisting and slewing reducer gears and the oil tank of hydraulic unit.
● Apply to grease at necessary points.
● Switch "ON" on the remote push button switch and "MCB" of main starter panel.
● Release locking devices for hook.
● Raise jib without load.
● Ensure that each limit valve is property operating without load.
● Ensure that there is nothing wrong with each motor, brake and hyd. cylinder.

3> Crane operation

※ The crane can be operated by means of the main control valves on operation platform.
All motions have step-less speed control from 0 to maximum.
Two(2) motions can be operated at the same time with maximum load, but with reduced speed.

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Installation operating instructions Designed by T. H. Kim

 Dongnam Marine Crane Co., Ltd. Rev.0
Provision & Hose Handling Crane 2009-07-09

ⅰ) Hoisting operation : Right lever

● Hoisting : Put the control lever in operating "HOOK UP" position.
● Lowering : Put the control lever in operating "HOOK DOWN" position.
Attention ! Operate the control lever softly and slowly only winch is valid for hoisting and
lowering on the deck.

ⅱ) Luffing operation : Middle lever

● Jib up : Put the control lever in operating "JIB UP" position.
● Jib down : Put the control lever in operating "JIB DOWN" position.
Attention ! Operate the control lever softly and slowly.
A jerk is very dangerous, because it may cause a big shock to the crane
especially when load is suspended under the jib.

ⅲ) Slewing opertion : Left lever

● Slewing to right : Put the control lever in operating "SLEWING RIGHT" position.
● Slewing to left : Put the control lever in operating "SLEWING LEFT" position.
Attention ! Operate the control lever softly and slowly.
A jerk is very dangerous, because it may cause rolling of load especially
when load being suspended.

< MAIN CONTROL VALVE ON OPERATION PLATFORM >

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Installation operating instructions Designed by T. H. Kim

 Dongnam Marine Crane Co., Ltd. Rev.0
Provision & Hose Handling Crane 2009-07-09

4> After operation

After operation, park jib on the jib rest.

● Turn the jib to the position above the jib rest.

● Put the control lever in operating position of down and lowering and can be parked on the jib rest.
This work should be carried out with no load.
● Park hook.
● Lock hook with hook lashing device by hoisting of hook as much as slightly to protect it from
moving due to pitch and roll of the hull.
● Switch "OFF" on the R.P.B box and MCB of main starter panel.

5> Emergency stop

Emergency stop is done manually by using one of the following methods ;

● Pressing the "STOP" button on main starter panel.

● Pressing the "STOP" button on remote on/off switch.
● Turning "EMERGENCY STOP" valve, fitted close to operating platform.

6> Start after emergency stop, Due to system failure

The following procedure is to be adhere to ;

● Emergency operation instructions.

● Fault finding/trouble shooting to be initiated,
possible findings are to be rectified.

● "Inspection prior to operation" procedure to be

carried out.

● Starter after emergency stops. Due to hazardous

situations ;
- Clear the area for unauthorized personnel.
- Normal start.

< EMERGENCY VALVE ON OPERATION PLATFORM >

World best marine & offshore crane www.dongnam-crane.co.kr

Installation operating instructions Designed by T. H. Kim

 Dongnam Marine Crane Co., Ltd. Rev.0
RESEARCH & DEVELOPMENT INSTITUTE 2009-10-14

MAINTENANCE PROGRAM
1. Introduction
The maintenance program has been developed by DMC in accordance to our supplier's own maintenance
program for each component. Conforming to this maintenance program will ensure long-time, trouble-free

operation and eliminate unexpected occurrences.

2. Description of maintenance actions

The maintenance program entails the following actions :
- Lubrication - Inspection

- Overhaul - Replace

Lubrication : Lub.
Lubrication is identified with following :

▲ Apply grease to grease nipples.

▲ Apply lubricant or oil onto surfaces due to friction or corrosion.

▲ Refill or change oil to system or component.

Inspection : Insp.
Inspection is identified with the following :

▲ Check component for any damage.

▲ Check for correct function of each component.

▲ Check for any unfamiliar noise from each component.

▲ Check for any abnormal vibration from rotating components.

▲ Check for correct oil quantity.

▲ Check paint condition on all components.
▲ Check for leaks.
▲ Check for corrosion.

▲ Check lifting wire for wear.

Overhaul : Ovhl.
Overhaul is identified with the following :
▲ Remove the component from the unit.
▲ Disassemble the component and inspection each part.

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Installation operating instructions

 Dongnam Marine Crane Co., Ltd. Rev.0
RESEARCH & DEVELOPMENT INSTITUTE 2009-10-14

▲ Repair if necessay :
- Bearings

- O-rings, gaskets and seals.

- Hydraulic valves fittings and hoses.
- All bolts, nuts and washers.
▲ Clean all components before mounting assembly.

▲ Replace or components if required, before mounting assembly.

▲ Repair damaged painted areas.

Replace : R
Replace is identified with the following :

▲ Remove original component and exchange with a new component.

World best marine & offshore crane www.dongnam-crane.co.kr

Installation operating instructions

 Dongnam Marine Crane Co., Ltd. Rev.0
RESEARCH & DEVELOPMENT INSTITUTE 2009-10-14

3. Maintenance Program.

● M=Months Y=Year W=Week, H=Hours.

PERIODIC MAINTENANCE PROGRAM

Equipment Lub. Insp. Ovhl. R. Action
General inspection for leaks in hydraulic system
Quantity of oil, to be in top of level glass
Crane functionality
General
1W Emergency (operation) (if applicable)
Inspection
Accumulator oil pressure (if applicable)
Check for w ire damage
Check for damage of lifting equipment (hook etc.)
Apply grease to all grease nipples.
1M/100H
Include w ire sheaves, cylinders, elec.motor and docking head.
Grease nipples
Inspect for proper function, damage, corrosion.
(General) 3M/100H
Remove excess grease.
! Replace if damaged.
1M/100H Apply special grease to drive pinion and ring tooth.
Winch / slew
1Y/500H Check for w ear / abnormal tooth clearance.
gear drive pin
! Replace if damaged.
3M/200H Apply grease onto w ire.
Inspect due to corrosion & w ear.
1M/200H
Rub length of w ire w ith a cloth to detect broken atrands.
Wire
Inspect w ire secured to w inch drum.
3M/100H
Check torque.
! Replace if damaged.
Inspect for corrosion, w ear, cracks.
6M/200H Check bolts.
Wire sheave
Inspect that w ire sheave rotates freely.
! Replace if damaged.
Inspect general condition.
6M/200H
Accumulators Check nitrogen pressure value according to flow diagram.
(if mounted) Overhaul or replace if unable to hold the necessary charge.
! !
Contact DMC. After Sales.
Inspect all exposed cylinder rods.
6M/200H Must be free of dirt damage and other foreign contaminants.
Cylinders
Check condition.(paint, leak, corrosion)
! Overhaul / replace if damaged.
Inspect for any abnormal noise, vibration, leak.
3M/100H
Winch / slew Inspect valve.(paint, leaks, corrosion)
motor 5Y Overhaul component.
! Replace if damaged.

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Installation operating instructions

 Dongnam Marine Crane Co., Ltd. Rev.0
RESEARCH & DEVELOPMENT INSTITUTE 2009-10-14

● M=Months Y=Year W=Week, H=Hours.

PERIODIC MAINTENANCE PROGRAM

Equipment Lub. Insp. Ovhl. R. Action
Inspect for any abnormal noise, vibration,
3M / 100H Tighten bolts if required.
Inspect general condition.(paint, leaks, corrosion)
Winch / slew
3M/50H Check gear oil level.
gearbox
1Y Change oil.
5Y Overhaul component.
! Replace if damaged.
Electric motor 3M/200H Inspect for any abnormal noise, vibration, corrosion, leaks.
and hydraulic 5Y Check for w ear / abnormal tooth clearance.
pump ! Replace if damaged.
Apply grease.
Sliding
3M/200H 3M/200H Check for w ear.
surfaces
Adjust sliding pads.
Hydr.hose, 6M/200H Check condition of hoses.
fitting,couplings ! Replace if damaged.
Inspect for any abnormal noise or function.
Inspect condition(paint, leak, corrosion).
Hydraulic 6M/200H
Apply grease to the valve levers(the rubber cap must be
valves
removed )
! Replace if damaged.
Inspect the entire crane for structural damage.
Mechanical 6M/200H Check for corrosion.
components Inspect paint condition.
! Replace if damaged.
Hydraulic Take oil sample for analyse.
1Y
system oil Change if necessary.
Hydraulic 6M/500H Inspect filter for abnormal contamination.
oil filter 6M/500H Replace.
Inspect all bolts and nuts on crane.
Bolts and nut 6M/500H
Foundation bolts especially.

Futher information
Contact : Customer service department
Tel : +82-(0)55-720-3095
Fax : +82-(0)55-720-3099
E-mail : cs@dongnam-crane.co.kr

World best marine & offshore crane www.dongnam-crane.co.kr

Installation operating instructions

 Dongnam Marine Crane Co., Ltd. Rev.2
RESEARCH & DEVELOPMENT INSTITUTE 2009-05-06

Measurement Instruction the Wear of Slewing bearing for Deck crane

1. General information

Following this instruction, slewing bearing rocking test should be done periodically for recording the

wear of slewing bearing and maintenance it.

While operating crane continually, periodic checkup of wear of slewing bearing will prevent

accidents to confirm whether or not it exceeds the max. allowable deviation.

2. Measurement of wear

There are two check points including the inside and outside of pedestal, but we'd like to recommend

to take the outside check point of pedestal considering safety.

To reduce wear of the inside of slewing bearing ball and race, it should be charged with gear oil

recommended periodically.

The max. allowable deviation(Table.1) are ones for single row ball type slewing bearing.

Table.1 : Max. allowable deviation in slewing bearing

Slew ing bearing Ball diameter (mm)
Ball P.C.D 25.4 31.75 34.925 39.688 44.45 50.8
(mm) Max . allowable dev iation in slewing bearing (mm)
1250 below 1.2 1.2 1.3 1.4 1.5 1.6
1500 below 1.3 1.4 1.4 1.5 1.6 1.7
1750 below 1.6 1.7 2.0 2.1 2.2
2000 below 1.7 1.7 2.0 2.2 2.5
2250 below 1.8 2.0 2.4 2.5
2500 below 1.9 2.1 2.4 2.7

3. Interval of measurement

After delivery of ship, wear of slewing bearing should be checked in the basic three(3) months, and

after then, every six(6) months.

World best marine & offshore crane www.dongnam-crane.co.kr

Rocking Test Procedure-DMC Designed by T. H. Kim

 Dongnam Marine Crane Co., Ltd. Rev.2
RESEARCH & DEVELOPMENT INSTITUTE 2009-05-06

Measurement Instruction the Wear of Slewing bearing for Deck crane

4. Check procedure

1. When rocking testing, a checkpoint on the pedestal part should be chosen at the place to
interference, revolving sideshell or crane.
2. Measurement position should be chosen at four(4) directions by equivalent degree on the
fixed post(pedestal) parts.
3. If there is restriction of revolving area when the crane revolves, make sure to divide all angles
able to revolve into four(4) equal parts.
4. Extra red paint should be marked on the bolt checked on the fixed post(pedestal).
5. Record on the check sheet after checking regularly at the same point and direction as equipvalent
degree marked on the status of no-load and max. working radius of the crane.
6. The tool(depth gauge) which is used to check can measure like photo of Fig.1.
7. The result of periodic measurement record should be compared with the max. allowable deviation
provided by the manufacturer.
8. If new check dimension is larger than the prior record of wear, the gear oil charging cycle should
be short.
9. Please contact to customer service department of DMC if it is measured over the max. allowable
deviation of Table.1.

WARNING !
Be cautious not to operate crane as checking dimension during rocking test.

< Wear measurement method of slewing bearing >

[ Fig.1 ]

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Rocking Test Procedure-DMC Designed by T. H. Kim

 Dongnam Marine Crane Co., Ltd. Rev.2
RESEARCH & DEVELOPMENT INSTITUTE 2009-05-06

Measurement Instruction the Wear of Slewing bearing for Deck crane

5. Slewing bearing wear measurement record table

SHIPYARD : ITEM :
HULL No. : MFG. No. :
Measurements to be Max. allowable deviation [mm] Tolerance : Max. Mm
made every six(6)
1 2 3 4
month from date of Check position
basic measurement Front Rear Front Rear Front Rear Front Rear
Basic measurement Measurement
Date : Deviation 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Basic measurement Measurement
Date : Deviation
Basic measurement Measurement
Date : Deviation
Basic measurement Measurement
Date : Deviation
Basic measurement Measurement
Date : Deviation
Basic measurement Measurement
Date : Deviation
Basic measurement Measurement
Date : Deviation
Basic measurement Measurement
Date : Deviation
Basic measurement Measurement
Date : Deviation
Basic measurement Measurement
Date : Deviation

Futher information

Contact : Customer service department

Tel : +82-(0)55-720-3095
Fax : +82-(0)55-720-3099
E-mail : cs@dongnam-crane.co.kr

World best marine & offshore crane www.dongnam-crane.co.kr

Rocking Test Procedure-DMC Designed by T. H. Kim

 Dongnam Marine Crane Co., Ltd. Rev.0
Provision & Hose Handling Crane 2009-07-09

[TIGHTENING SEQUENCE]

[TIGHTENING TORQUE]

Bolt Strength Class Strength Class Strength Class

Dimension 8.8 10.9 12.9
d kN Nm kN Nm kN Nm
M12 38 80 56 117 66 135
M14 53 130 77 185 90 220
M16 72 200 106 280 124 340
M18 91 275 129 380 151 460
M20 117 390 166 560 194 650
M22 146 525 208 750 243 875
M24 168 670 239 960 280 1150
M27 221 990 315 1400 370 1700
M30 270 1350 385 1900 450 2250
M33 335 1850 480 2600 560 3000
M36 395 2350 560 3300 660 3900
M39 470 3050 665 4290 800 5150

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TIGHTENING METHOD Designed by T. H. Kim