SEATRAX Vol-1

Seatrax (UK) Limited
Portland Wharf, Southtown Rd, Gt. Yarmouth, Norfolk, NR31 0J J

Tel: +44 (0) 1493 651311 Fax: +44 (0) 1493 604900
Emergency Contact Tel No: 07736957803 (Out of Hours)

OPERATIONS &
MAINTENANCE MANUAL
N.P.C.C. MAERSK OIL QATAR
AL SHAHEEN FIELD DEVELOPMENT PROJECT
MOQ Equipment Title : ED Crane

P.O. No. 6048-07-70033-AC

1 No. Seatrax S9028 Tag No. ASEDA-A-6101

Customer Document No. ASEDA-10-70033-0008
NPCC Document No. 6048-70033A-A003-001
Seatrax Document No. H00301 (SXOMM4527)

Seatrax Contract No: 4527-UK
NPCC MAERSK OIL QATAR
AL SHAHEEN BLOCK 5 PROJECT
1 No. S9028 Tag No. ASEDA-A-6101
SEATRAX JOB NOS 4527-UK

SEATRAX (UK) LIMITED
PORTLAND WHARF, SOUTHTOWN RD, GT.YARMOUTH, NORFOLK, NR31 0J J
TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900
EMERGENCY CONTACT TEL NO: 07736957803 (OUT OF HOURS)

Operations and Maintenance
Manual Index
(A003 / A009)

SECTION A INTRODUCTION AND DESIGN FEATURES

Fail Safe
Support and Slew
Anti-Two Block

SECTION B BASIC OPERATING INSTRUCTIONS

Basic and Specific Operating Instructions
Tag Line Winch Operating Instructions for GA Platform only
Hydraulic Starter System

SECTION C INSPECTION AND MAINTENANCE

Initial Start-Up and Commissioning Procedure (W009)
Commissioning Check List (W008)
Inspection Check List (Daily, Monthly and Yearly Recommended) (G017)
Bolt Installation and Inspection Procedure
Specifications for Large Diameter Nuts and Bolts
Load Block and Overhaul Ball Inspection
Wedge Sockets
Boom Lock Operation
Hydraulic Boom Hoist Limit System
Hydraulic System Adjustments
Brake Inspection, Adjustment and Replacement
Boom Butt Bushing Replacement
Swing Bearing Replacement Procedure
Emergency Slewing Procedure
Emergency Load Lowering Procedure
Start Up & Commissioning Spares Listing (A004)
2 Year Spare Parts List (A004/W004/W005)

SECTION D LUBRICATION (G025 / G026 / J037)

Comprehensive Information, Diagrams and Charts
Hydraulic Oil Chart

SECTION E ERECTION & INSTALLATION PROCEDURE

Shipping & Handling Procedure (G019 / F008 / W001)
Erection & Installation Procedure (W002 / W007)
General Arrangement Drawing (J036 / L001)
Kingpost Interface & Boom Rest Details (G060)
Storage & Preservation Procedure (W003)

Vol. 1

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION F RIGGING

Standard Information
Wire Rope Specifications
Reeving Diagrams

SECTION G PERFORMANCE DATA

Load Charts (G002)
Commentary on Load Testing
Load Test Procedures
Load Test Report (Completed on Site)
Clients Data Sheets (G001)

SECTION H HYDRAULIC SCHEMATICS AND BILL OF MATERIALS (B003, J022)

Primary & Control Circuit Schematics
Hydraulic System Bill of Materials

SECTION I PNEUMATIC SCHEMATIC AND BILL OF MATERIALS (J015, J022)

Pneumatic System Schematics c/w Bill of Materials

SECTION J ELECTRICAL SCHEMATICS AND BILL OF MATERIALS (J001, J021, J022)

Electrical Schematics (J020)
One Line Diagram (P009)
Wiring Diagram (P021)
Cable Schedule (J002, P002)
Bill of Materials and General Notes (J003, J005)
Electrical Load Calculations (P001)

SECTION K GENERAL BILL OF MATERIAL AND COMPONENT DATA

Seatrax Bill of Materials
Seatrax Component Data

SECTION L ENGINE MAINTENANCE MANUAL

Zone 2 Caterpillar Maintenance Manual

SECTION M SAFE LOAD INDICATOR / OLM

Safe Load Indicator Operations & Maintenance Manual
OLM System Operating Instructions

SECTION N FREE ISSUE ITEMS (BY OTHERS)

Motorola Battery Charger (Installed by Seatrax)
Footswitch (Installed by Seatrax)
VHF/FM Radio (Installed by NPCC)
Auteldac Telephone with Integral Speaker (Installed by NPCC)
Goose Neck Microphone (Installed by NPCC)
DNH make Careex-6(T) 2 nos of Loudspeaker (Installed by NPCC)

Vol. 1
Vol. 2
OPERATIONS & MAINTENANCE MANUAL

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION A INTRODUCTION AND DESIGN FEATURES

Fail Safe
Support and Slew
Anti-Two Block

P.O. Box 840687, Houston, Texas 77284
Phone: 713 896 6500 Fax: 713 896 6611

April 28, 2004
Introduction

Read instruction manual and safety rules carefully.

This manual has been compiled to give the operator and maintenance personnel information
regarding the care, operation, and maintenance of SeaTraxmarine hydraulic cranes.

Load rating charts, mounted near the operators console, define the lifting limitations of this
particular crane. It should be understood that on a pedestal mounted lifting crane, the maximum
loads listed on the load rating plate are limited by factors other than tipping, such as structural
strength, wire rope, etc. Even though the machine may appear capable of lifting loads greater
than those listed on the load rating charts, never exceed the loads and/or conditions stated on
these plates.

For convenience, this instruction manual has been written in sections. Familiarize yourself with
this manual so you can easily locate any needed information.

The safety rules included with this manual represent a minimum set of standards for safe
operation. Every operator should be familiar with these rules and follow them at all times.
Written rules however, cannot cover all situations that might occur on the job. Consequently,
operators must supplement the rules with good judgement and experience.

Operation
This is the most important area relative to safety since it involves the greatest frequency of
exposure to hazards. The operator should be of sound mind and body and able to understand
and apply established operating safety rules. Additionally, the operator should be able to
exercise good judgment in dealing with the many situations that cannot be anticipated and
covered herein. Since the manufacturer has no direct control over machine application or
operation, compliance with good safety practice in this area is the responsibility of the user and
operating personnel.

Capacity Ratings
Never exceed manufacturer's ratings. The stipulations pertinent to these ratings must always be
carefully observed. If required conditions are not present, the full standard capacity ratings
cannot be used and ratings must be adjusted downward to compensate for special hazards.

Ratings Based on Hydraulic or Structural Competence
All of the ratings shown on the load rating charts are based on machine's hydraulic or structural
competence rather than stability. It is unsafe to apply any load that is greater than the rated load
shown on the chart for that radius and condition.
Intro Rev.1.doc Page 1 of 14

Inspection and Maintenance
Components on any machine are subject to wear, deterioration, or damage, which limit their
useful life. When new, all parts have built-in reserve strength against unknown conditions and
reasonable loss of strength due to gradual deterioration. However, if maintenance and
lubrication are neglected, these parts can eventually reach a condition where they become a
safety hazard. Failure to maintain correct adjustments of the various mechanisms to assure
proper performance of the crane can also be a safety hazard. Hydraulic relief valve settings
should never exceed specified pressure without the consent of the manufacturer. Re-adjustment,
when necessary, should be performed by a competent and qualified person. Since the
manufacturer has no direct control over field inspection and maintenance, safety in this area is
the responsibility of the user and his operating personnel.

A regular schedule of inspection and preventive maintenance should be established so that any
apparent troubles are discovered and corrected before extensive damage is done to the crane.
Guidelines are provided in the Inspection and Maintenance section of this manual, but the wide
variation in usage and ambient conditions makes it impossible for us to develop a standard
inspection procedure applicable to all cranes. Therefore it is the responsibility of the owner to
assign experienced personnel the task of developing and implementing an inspection and
maintenance program suitable for each particular crane.

Lubrication
Regular and systematic lubrication must be maintained in accordance with the lubrication charts
and general recommendations contained in this manual. Stop all machinery while lubricating
except in cases where the machinery is in motion and the instructions so state. Before resuming
operations, replace any guards or panels that must be removed for access to some points for
lubrication or inspection.

Adjustments, Replacements, and Repairs
Any conditions disclosed by the inspection requirements above which are considered to
constitute safety hazards, must be corrected before operation of the machine is resumed.

Replacement Parts
All replacement parts should be obtained from the original equipment manufacturer in order
that the strength and quality of the original machine may be maintained.

Maintenance Tools
Routine maintenance tools should be available at all times and should be clean and in good
repair.


Phone: 713 896 6500 Fax: 713 896 6611

SeaTrax
Design Features
Fail-Safe Features, for Hoists with Contracting Band Drum Brakes

SeaTrax hoists are driven by individual hydraulic motor units consisting of the following
major components:

High Speed, Low torque Hydraulic Motors, either of the "Gear", "Vane", or "Axial Piston"
type depending on crane and hoist models.

Connected to the inlet port of each Hydraulic Motor is a "Fail Safe" spring applied,
pressure released Dynamic Brake Valve direct.

Planetary Gear Reduction connecting the Hydraulic Motor to the Drum Shaft.

One piece, solid Drum Shaft supported on both ends by Anti-Friction Bearings and
driving the Hoist Drum through a hardened spline connection.

"Fail Safe" spring applied, pressure released Static Parking Brake acting directly on the
Hoist Drum.

SeaTrax cranes use Open Loop hydraulic systems. The Hoist portion of this hydraulic system
schematic is shown in Figure 1. The entire system consists of the following major components.

Fixed or Variable displacement Pumps. Individual pumps are provided for each of the three
primary crane motions of Hoist, Luff, and Slew. The hydraulic oil passes through the "Inlet
Strainers" in the Hydraulic Tank on its way to the Pumps. Depending on the pump, the oil
will be discharged to the Directional Control Valves, for the main system, or the pressure
relief valve, for the control (pilot) system.

4 way, 3 position, spring centered, spool type Directional Control Valves are provided to
control each primary motion. These valves select either "Up" or "Down depending on
control input. Lack of control input causes the springs to automatically center the valve to the
"Neutral or stopped position. Therefore these Directional Control Valves are "Fail Safe".
These valves are equipped with "Motor Spools" which connect both "up" and "down" hoist
lines to each other and to the Hydraulic Reservoir whenever the spool is in "Neutral".

Pressure Relief Valves are built into each Directional Control Valve. Whenever the preset
pressure is exceeded, the relief valve direct surplus pump flow to the Hydraulic Reservoir.

The "Slew Directional Control Valve" discharge port flows to the Return Line Filter. Fluid
continues to the "Oil Cooler", then to the Hydraulic Reservoir. The discharge ports of both
"Hoist Directional Control Valves" are connected directly to the Hydraulic Reservoir.

Hoist dynamic braking on a SeaTrax

hoist is accomplished by the Dynamic
Brake Valve. This 2 way, 2 position,
normally closed, spring offset, throttling
spool valve is directly bolted to the "Up"
port of the Hydraulic Motor. The
following are major components of this
valve:

Free flow Check Valve
Throttling Spool
Return Spring
Pilot Orifice
Spring Cavity Vent

The Dynamic Brake Valve functions as
follows:

When the Directional Control Valve
spool moves into the "Up" or "Hoist"
position, fluid flows from the
Directional Control Valve through
the Dynamic Brake Check Valve,
and rotates the Hydraulic Motor in
the "Up" or "Hoisting" direction.
The Check Valve allows fluid to
bypass the Throttling Spool and the
system behaves as if the Dynamic
Brake Valve is not present.

When the Directional Control Valve
spool is returned to "Neutral", the
"Up" and "Down" hydraulic lines
are connected together inside the
valve, and fluid is sent to the
Reservoir. Pressure in these hydraulic lines equalizes to a very low value. The load on the
hoist cable will now try to fall (we will ignore the Static Parking Brake for now). The
Hydraulic Motor attempts to rotate in the "Down" direction as the load drives the drum.
In order for this rotation to occur, fluid must escape past the Dynamic Brake Valve. Both
the Check Valve, and the Throttling Spool, prevent escape of fluid, or reverse flow, when
closed.

Figure 1

When the Directional Control Valve spool is moved into the "Down" or "Lowering"
position, the Pump attempts to force fluid to flow through the Directional Control
Valve and Hydraulic Motor. However the Hydraulic Motor cannot rotate because of
the Check Valve and Throttling Spool. Pressure in the "Down" side of the circuit will
then increase. Pressure is transmitted through the small pilot line connecting the
"Down" side of the circuit to the Pilot Orifice. The Pilot Orifice permits the pressure
signal to push the end of the Throttling Spool, compressing the Return Spring, and
open the Dynamic Brake Valve. As the Throttling Spool opens, the load on the hoist
cable rotates the Hydraulic Motor in the "Down" direction permitting the load to lower.
Rotation speed will increase as the load tries to fall. As this happens, the load will try to
"Overrun" the system by attempting to force more fluid through the Hydraulic Motor
than is being supplied by the Pump through the Directional Control Valve. This action
will cause pressure in the "Down" side of the circuit to decay as the Hydraulic Motor
tries to suck more fluid than is supplied. This reduction in pressure allows the Return
Spring to move the Throttling Spool toward it's closed position, thereby retarding the
rotation of the Hydraulic Motor by reducing fluid flow from the Dynamic Brake Valve
and thus, the speed of descent of the load.

This "Modulation" action of the Dynamic Brake Valve then keeps the speed of descent
of the load "in step" and proportional to the flow rate of the fluid passing through the
Directional Control Valve. Energy absorbed by retarding the speed of descent of the
load is converted to heat in the hydraulic fluid as fluid is forced past the Throttling
Spool. The Oil Cooler then removes this heat from the hydraulic fluid.

The Dynamic Brake Valve is "Fail Safe" because it is bolted directly to the port of the
Hydraulic Motor without the use of pipes, tubes, or hoses. If pressure in the "Down"
side of the circuit is lost for any reason, the Return Spring will close the Throttling
Spool and stop descent of the load.

This means the load will stop if any of the following events occur in any combination:

The spool in the Directional Control Valve is returned to the "Neutral" position for any
reason.

The prime mover stops, thus stopping fluid flow from the pump.

A hose or pipe ruptures. This applies to All hoses, pipes and tubes in the system.

A pressure-containing device, other than the Hydraulic Motor or the Dynamic Brake
Valve, ruptures.

If the Dynamic Brake Valve or other system components are contaminated by dirt or
other foreign materials.

The Dynamic Brake Valve is "Fail Safe" to contamination because the Pilot Orifice is
larger than the Spring Cavity Vent. If a particle cannot pass through the Pilot Orifice, then
the Throttling Spool cannot open. If a particle passes through the Pilot Orifice, then around
the Throttling Spool, but cannot fit through the Spring Cavity Vent, fluid is trapped in the
spring cavity and the Throttling Spool cannot open. Likewise, as wear increases the
clearance between the Throttling Spool and body of the valve, more fluid will flow into the
spring cavity than can be evacuated through the Spring Cavity Vent. Then the Throttling
Spool cannot open because the fluid pressure helps the Return Spring keep the Throttling
Spool closed.

The design and construction of the Dynamic Brake Valve also makes it impervious to
changes in temperature and fluid viscosity.

SeaTrax hoists are also furnished with a Static Parking Brake. This brake is a "Fail
Safe", spring applied, pressure released, non-self energizing, external band type of brake
acting directly on the Hoist Drum. This brake system consists of the following major
components:

Brake Band lined with conventional, non-asbestos, friction lining and constructed with a
rotary bearing on the "low tension" end and a threaded anchor on the "high tension" end.

One Piece Camshaft used to apply force to the "low tension" end of the Brake Band.

Lever Arm used to apply torque to the Camshaft.

Link Bar used to connect the Lever Arm to the Output Rod of the Brake Actuator.

Brake Actuator consisting of a Conical Spring, an Output Rod, and a Hydraulic
Release Cylinder.

Three position, spring centered, pilot operated, Shuttle Valve used to control operation
of the Brake Actuator.

This Static Parking Brake functions as follows:

When the Directional Control Valve spool is in "Neutral", pressures in both sides of
the circuit will be roughly equal and low. Pilot sections of the Shuttle Valve are
connected one to the "Up", and one to the "Down" side of the circuit. Approximately
equal pressures, acting in combination with the centering springs, hold the spool of the
Shuttle Valve in the center position. This connects the pressure side of the Hydraulic
Release Cylinder to the Reservoir. The Conical Spring in the Brake Actuator is then
able to apply it's full force to the Output Rod and the Lever Arm. This applies torque to
the Camshaft resulting in a tension load applied to the low-tension end of the Brake
Band, which sets the brake.

When the Directional Control Valve spool is moved to either the "Up" or "Down"
position, the difference in pressures between the two sides of the circuit will cause the
spool in the Shuttle Valve to shift to the low pressure side. This will cause fluid to flow
from the higher-pressure side of the circuit to the Hydraulic Release Cylinder. This
cylinder will retract caging the Conical Spring and releasing the Static Parking
Brake.

The pressure required to release the Static Parking Brake is normally less than that
required to open the Dynamic Brake Valve. This assures that the Static Parking Brake
will release first and set last. Therefore, in normal operation, this Static Parking Brake
does not operate against a moving drum. Hence, there is little or no lining wear.

However, this Static Parking Brake is capable of stopping a "runaway" load in the unlikely
event that there is a failure in the drive train connecting the drum to the Hydraulic Motor.
Because this brake is not self-energizing, it can perform this function in a controlled manner
without inducing undue shock loads into the crane structure.

This Static Parking Brake is also "Fail Safe" because the Conical Spring will
automatically set the brake whenever positive pressure is not present in the Hydraulic
Release Cylinder.

SeaTraxhoists have Dual Load Paths. It should be noted that the two "Fail Safe" braking
devices on SeaTraxhoists operate through two distinctly separate load paths. The
Dynamic Brake is connected to the Hoist Drum through the drive train. The Static Parking
Brake acts directly on the Hoist Drum.

This means that there is no mode of failure that can render both braking systems
inoperative at the same time.

Certifying Authority and Regulatory Compliance:

The above "Fail Safe" braking systems fully comply with API Spec 2C, Fourth Edition,
1988 paragraphs 6.1.1.3 and 6.1.1.4b.

Additionally, the United States Coast Guard, Eighth District, reviewed this system in 1981.
They concluded this system would be classified as "Fail Safe" and therefore our Hydraulic
System and all attendant hydraulic plumbing can be classified as a "Miscellaneous fluid
power system" under the requirements of 46 CFR Subchapter F.


Phone: 713 896 6500 Fax: 713 896 6611

SeaTraxDesign Features
Method of Support and Slew Bearing Arrangement

All SeaTraxcranes are based on the
well-proven "Kingpost" concept.
This basic design consists of a
stationary or fixed "Kingpost" and a
Revolving "Superstructure" which fits
over, and revolves around, the
stationary post. The boom, machinery
house, operators cabin, hoists and
slewing machinery are all fitted to the
Revolving Superstructure.

With this design, the Overturning
Moment is resolved by means of two
(2) vertically spaced Radial Bearing
assemblies, each carries an equal and
opposite horizontal (radial) load. All
Vertical Loads (self weight of crane
plus lifted load) are carried into the
stationary Kingpost by means of a
concentric Thrust Bearing.

One way to visualize this concept is to
consider a simple ball point pen with a
cap as shown in Figure 1. Imagine
that the "pen" is the Kingpost and that
the "cap" is the Revolving
Superstructure.

It is impossible for the "Cap" to
become detached from the "Pen" due
to the application of an Overturning
Moment and a Vertical Load. The
"Bearings" only provide a means of
support for rotating the "Cap" about
the body of the "Pen".

This analogy is translated into the patented SeaTraxmounting concept shown in Figure 2.

Figure 1
With this design, the Structural and Bearing functions are distinctly separate. In other
words, a bearing failure cannot result in separation of the Revolving Superstructure
from the stationary Kingpost.

The Kingpost is mounted to the Platform Pedestal by welding. A bolted joint is not
required.

More than 1,000 Kingpost cranes
have been installed on offshore
drilling rigs and production
platforms since 1955. In nearly 40
years of offshore service, there has
never been an incident of a
Kingpost crane detaching from its
mount due to an overload. This
cannot be said for any other
offshore crane design.

The SeaTraximplementation of
the Kingpost design has been in
continuous production since 1977
with over 700 examples installed
worldwide. An exclusive feature of
SeaTraxdesign is the patented
non-metallic upper and lower
bearing assemblies. These bearings
will several thousand hours with
minimum maintenance before
replacement is necessary. When
replacement is required, all
SeaTraxslew bearings can be
easily changed in place, using
common hand tools, and without
the assist of any other crane. It is
never necessary to dismount a
SeaTraxcrane for bearing
inspection or replacement.

SeaTraxcranes are also offered in
a slightly different configuration for use on "Liftboats" or Self Elevating Barges. In this
patented configuration, as shown in Figure 3, the Barge Jacking Tower becomes the
stationary Kingpost and the crane revolves around the Jacking Tower at an elevation above
the Jack House. This allows the leg to pass through the center of the crane without
interference. This configuration offers several advantages, not the least of which is that
valuable deck space need not be sacrificed to the crane. Another advantage of this
arrangement is the crane can easily slew 360 degrees without fouling a leg.
Figure 2
In summary, the SeaTraxSlew Bearing Arrangement offers the following advantages:

The proven Kingpost design
assures the crane cannot separate
from its mount due to slew bearing
failure.

All bolted connections between the
crane and the platform (or rig)
have been eliminated.

There is no possibility of crane
separation due to a bolt failure.

The use of non-metallic bearings
assures that the bearings cannot
wear or degrade the structural
integrity of the Kingpost or other
structures that they contact.

Slew bearings can be easily
changed in place, using common
hand tools. Assistance from
another crane is not required.

Hence, this design is exempt from
all certifying authority
requirements for periodic removal
and inspection of slew bearings.

Figure 3

Phone: 713 896 6500 Fax: 713 896 6611

SeaTraxDesign Features
Patented API 2C Anti "Two-Block" System

One of the historical causes of accidents during crane operations has been the unintentional
contact between the Hook Block or Ball and the boom point. This is sometimes referred to
as "Two-blocking" while lowering the boom or "Booming Down into the Block".

"Two-Blocking" on
most cranes in because
the hoist drum is
mounted on the
Revolving
Superstructure as
shown in Figure 1.

With this arrangement,
the distance between
the hoist drum and the
Boom Tip Sheaves
increases as the boom is
lowered. This increase
causes the Lower Block
(hook block) to drawn
closer to the Upper
Block (boom tip
sheaves).

When these two blocks
touch, "Two-blocking"
has occurred.

If the boom is lowered
past the point where
"Two-blocking" occurs, the load will transfer from the Multi-part Boom Line to the Single
Part Hoist Line. This load transfer will usually cause the Hoist Line to break and drop the
load.

Because of this, most all Crane Specifications or Regulations require that a crane be fitted
with some means to prevent "Two-blocking".

For cranes with the load hoist located as shown in Figure 2, the means to prevent Two-
blocking is most often a switch or valve which interrupts power to the load hoist and/or the
boom hoist, thus stopping the offending motion. The Hook Block actuates this switch, or
Figure 1
valve, as the Block approaches the Boom Tip Sheaves. This is usually done by means of a
weight hanging from a rope or chain. This weight normally has a hole through which one of
the lines to the Hook Block passes. When the block is hoisted to a predetermined position, it
"lifts" the hanging weight, thereby actuating the switch or valve.

In offshore service, this type of solution to the problem has proven to be marginal at best.

SeaTraxcranes
solve the problem
through
geometry, not
gadgetry. Hoists
are located in the
base section of the
Boom instead of
on the Revolving
Superstructure.

With this
arrangement, as
shown in Figure
2, the Hook Block
cannot be drawn
into the Boom Tip
Sheaves as the
boom is lowered.
The Hoist moves
with the boom,
therefore the
distance between
the Hoist and the
Boom Tip Sheaves
never changes.

Therefore the problem of "Two-Blocking" while lowering the boom cannot exist with a
SeaTraxcrane. No external power source, switches, valves, hanging weights, or other
gadgets are required to defeat this problem. This is solved by the basic design.

There is however, another way that "Two-Blocking" can occur. This can happen if the crane
operator "over hoists" the Hook Block or Auxiliary Hook regardless of the position or angle
of the boom. In other words, the operator simply runs into the boom point by accident. This
is also a serious problem.

As before, most all Crane Specifications or Regulations require fitting cranes with some
means to prevent "Two-blocking".

Most crane manufacturers accomplish this with the same "Gadgets" as previously
mentioned.

Figure 2
However, with all SeaTraxcranes, the problem is solved with our standard system shown in
Figure 3, 4, and 5.

This extremely simple system
takes advantage of the fact
that all hoists on SeaTrax
cranes are powered by
hydraulic motors. Therefore
the maximum line pull
developed by the hoist is
limited to a safe value by the
hydraulic system pressure
relief valves. In other words,
the hoist just cannot produce
sufficient pull to break the
line, even when stalled.
Therefore, rather than
attempting to prevent the
operator from "running into"
the boom if the blocks are
over hoisted, the SeaTrax
system provides "bumpers"
allowing this to happen in a
controlled manner without
causing any damage.

This simple system includes a
special "Swinging Bumper
Frame" which follows the
angle of the Main Block and a
mating "vee" shaped "Bumper Frame" fixed to the Main Block. This allows the Main
Block to come into contact with the "Swinging Bumper Frame" as shown in Figure 3
without causing damage to any component.

In a similar manner, a "Bumper Frame" is provided on the Jib to receive the Auxiliary Hook
Weight as shown. The wedge socket is enclosed inside of, and protected by, the special
"Overhaul Ball".

A hoist location that completely eliminates the possibility of increasing tension in the hoist
ropes by lowering the boom, coupled with the patented SeaTraxBumper Frame, solves
all "Two-Blocking" problems associated with offshore crane operations.

Again, the solution is accomplished by Design and Geometry, not Gadgetry.

In summary, the optional, patented, SeaTraxAnti Two-Block System provides the
following operational advantages:

Prevents damage to any component in the event that the Auxiliary Hook is over hoisted.
Figure 3

Prevents damage to any component in the event that the Main Block is over hoisted.

Provides a "parking place" for the Auxiliary Hook and positively prevents fouling of the
Auxiliary Hook with the Main Block when the Auxiliary Hook is not in use.

Provides a "parking place" for the Main Block and positively prevents fouling of the
Auxiliary Hook with the Main block when the Main block is not in use.

Permits raising or lowering the boom without regard to the position of either the Auxiliary
Hook or Main Block. No damage can occur during this operation because the hoist
drums are mounted in, and move with, the boom.

Provides a "caged" path for both the Main and Auxiliary lead lines, hence protecting the
operator and other personnel in the event of wire rope breakage.

Allows checking of the Weight Indicator and maximum lift capability of the crane prior to
each lift by pulling the Main Block into it's "parking place".

Performance of the engine and hydraulic system can be checked in the same manner, as
this action will cause the hydraulic pressure to rise to the relief valve setting and safely
place the machinery under full load.

This Seatrax Patented Anti Two-Block System has been used since 1977 and is accepted by
international Certifying Authorities, including ABS, DNV, and Lloyds. Additionally, this system
meets the requirements of API Spec 2C, 5
th
edition paragraph 12.6.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION B BASIC OPERATING INSTRUCTIONS



TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SEATRAX
W
.Sll_----------------
Phone: 713 896 6500 Fax: 713 896 6611
Apnl 28, 2004
Basic Operating Instructions
Applicable to all SeaTrax Marine Cranes
Crane Operator:
Cranes should be operated only by the following personnel:
Operators designated by the employer.
Trainees under the direct supervision of designated operators.
Maintenance 1 Test personnel or Inspectors in performance of their duties.
Crane Operator Qualifications:
Operators should be able to read and understand instructions.
Operators should be fully qualified through training and experience.
Operators should pass a practical examination.
Operators should have 20/30 - 20/50 vision and have good depth perception.
Operators should be able to distinguish red, green, and yellow.
Operators should have hearing adequate for the specific operation.
A history of epilepsy or a disabling heart condition should be sufficient reason for
disqualification.
Operator Cab:
Necessary clothing and personal belongings should be stored in such a manner as to not
interfere.
All loose articles should be properly stored.
There should be no obstructions to clear vision.
SOl-SOl STANDARD CRANES Rev.! Page 1 of 14
Refueling
Cranes should not be refueled with the engine running.
Fuel tanks should be filled in a manner that fuel spills or overflow will not run onto
engine, exhaust, or electrical equipment on the rig.
Fire Extinguisher:
Charged fire extinguishers should be in the cab or vicinity of the crane.
Operating and maintenance personnel should be familiar with the use and care of the fire
extinguisher provided.
Pre Start-Up Inspection
This inspection should be performed every time the crane is started up. It does not take the
place of the required Levell inspection (see Section C, Inspection Checklist). A pre-startup
inspection should take less than ten minutes to perform.
The Operator should visually check for damaged or sub-standard items as follows:
At boom tip:
Slings to be used.
Load block and shackle.
Wire rope on sheaves at block and boom tip.
Wedge socket and corresponding wire rope.
Boom tip for any loose or hanging items.
Along full length of boom:
Loose or hanging items.
Loose or missing boom connection bolts.
Leaks on Main / Aux assembly
On gantry:
Cracked or worn sheaves.
Broken sheave thrust washers.
Wedge socket and corresponding wire rope.
At base of crane:
Disconnected utilities such as electrical or pneumatic lines.
Cracks or stressed paint areas in the Kingpost or Platform Pedestal.
Oil spills.
BOl-SOl STANDARD CRANES Rev.l Page 2 of 14
On Crane Deck:
Oil spills.
Out of service signs.
At engine:
Engine oil.
Engine emergency shutdown.
Pump Drive Oil Level.
Oil spills.
Start engine:
Check engine oil pressure.
Check Control circuit pressure.
Crane Operating Practices:
Operator should familiarize himself with the equipment and its proper care.
An operator should not operate when physically or mentally unfit.
An operator should not start crane if a "warning sign" is located on crane.
Before starting engine, operator should see that all personnel are in the clear.
Operator will test all controls at the start of a new shift.
An operator must never divert attention while operating.
The operator must have the authority to stop and refuse to handle the load until safety has
been assured. The operator is ultimately responsible for safe operation.
Before leaving cab, operator should:
Land any attached load.
Set the slew (swing) brake.
Pull up the "Hydraulic ControlsD knob in the console.
Stop prime mover and reset kill cable (if equipped).
Operator should report defects, adjustments, or repairs required to supervisor and next
operator upon changing shifts.
When extensions are added to the boom, the Load Rating Charts must be changed.
To reduce unnecessary stress, boom up to maximum angle before stopping the prime
mover. The boom rest should only be used during transportation or in high winds.
BOI-SOI STANDARD CRANES Rev.l Page 3 of 14
When setting the boom in the rest, lower the boom until it barely touches the rest.
DO NOT slacken the cables! Easing the cables risks =bird nesting'= the rope on the
drum.
Hand Signals
A hand signal chart, similar to the one included in this section, should be posted
conspicuously.
One designated person should be assigned to give signals before the load is lifted.
The operator should respond to signals only from the appointed signalman, but should
obey an "emergency stop" signal at anytime, no matter who gives it.
No response should be made unless signals are clearlv understood.
For operations not covered by standard signals or for special conditions, additions or
modifications to the standard signals may be required. In such cases these signals should
be agreed on in advance by operator and signalman and should not be in conflict with
standard signals.
If instruction must be given to the operator by other than by the established signal system,
crane motions should be stopped.
Operator should never start machine movement until signalman or complete load is within
his range of vision.
Attaching the Load:
Do not wrap hoist rope around the load.
Load should be attached to hook by means of slings or other approved devices.
All hooks should have safety latches.
Inspect slings daily.
Immediately remove defective slings from service.
Provide protection between sling and sharp surfaces.
Provide proper storage for slings while not in use.
Do not choke slings in a splice.
Unused legs of a multi-leg sling should be secured.
BOI-SOI ST AL'IDARD CRANES Rev.! Page 4 of 14
Moving the Load:
Before the lift, the person directing the lift should determine that:
Hook is brought over load in such a manner as to minimize swinging.
Hook is centered over load
Multiple part lines are not twisted.
Rope is properly seated on sheaves if there is a slack rope condition.
Load is secured and properly balanced.
Lift and swing paths are clear.
Load is free to be lifted.
During lift, Crane Operator should insure:
Crane is NOT used to drag load.
Acceleration and deceleration of moving load is accomplished in a smooth manner.
Controls are engaged smoothly to avoid excessive stress on crane components.
Load, boom, or other parts of crane do not contact any obstruction.
No external force side loads the boom.
No personnel ride on the load unless in a personnel carrier.
NEVER carry a load over personnel.
Hoist brakes are tested each time a load approaching the rated load is to be handled.
A minimum of five full wraps of wire rope should remain on all hoist drums at all
times.
Sudden starts and stops are avoided when rotating. This will reduces stress on the
structure and avoids swinging the load.
Tag lines are used to control the load.
BOI-SOI STANDARD CRANES Rev.! Page 5 of 14
Holding the Load:
The operator will not leave his position at the controls while the load is suspended.
Do not permit personnel to stand or pass under a suspended load.
Personnel Transfer:
All hooks should have a safety latch and latch should be closed securely.
Load should be under power both up and down.
Crane should not be operated until proper pre-determined hand signals have been given.
If crane operators' view of primary signal person is obstructed, an additional signal person
should be provided to relay signals to crane operator.
While transferring personnel, raise personnel carrier just high enough to clear all
obstructions, swing over the water in such a manner as to minimize swinging, raise or
lower it smoothly, position it slightly above the landing area and gently lower it to the
deck.
Do not raise or lower a loaded personnel carrier directly over a vessel.
Personnel carriers should be designed for the intended purpose.
Personnel to be lifted on a personnel carrier should use an approved personnel flotation
device.
Personnel riding on a net type personnel carrier should stand on the outer rim facing
inward.
Loaded personnel carrier weight must not exceed:
1/3 the static rated load at the specific radius.
III 0 the braking strength of the hoist rope times the parts ofline used.
Load blocks and overhaul balls are stamped with the rated personnel capacity.
BOISOI STANlJARD CRANES Rev.! Page 6 of 14
On-Platform Lift Procedure
Center load block over load
Use Static Load Chart to verify crane capacity at the required working.
Lift load slowly (about 6 to 12 inches) off deck, stop and check hoist brake
Lift load a safe height (about 3 to 4 feet) off deck
Make sure path is clear, never move load over personnel.
Move load slowly across deck
When load reaches an obstacle, lift load high enough to clear the obstacle, swing over the
obstacle and lower the load to a safe height. This will reduce the possibility of excessive
damage to the load, deck, or other items if a failure were to occur.
Move load to final position
Slowly lower load to deck
Platform to Boat Lift Procedure
Check load charts to verify crane capacity at the required working radii by Dynamic Rated
Load Chart applicable to the current operating condition.
Lift load slowly (about 6 to 12 inches) off deck, stop and check winch brake.
Lift load to a height sufficient to clear any nearby obstructions.
Make sure path is clear - never move load over personnel.
Slowly move load across deck.
Once load clears edge of platform, lower load to 20 feet above water (never lower load
over boat).
Swing load to deck of boat.
Lower load to deck.
Make sure slings have sufficient slack to avoid jerking the load back off deck in swells.
Boat to Platform Lift Procedure
Verify weight of load
Set boom angle to safe crane capacity by using the appropriate Dynamic Rated Load Chart
applicable to the current operating condition.
Increase engine speed to maximum
When boat hits valley of wave, take slack out of slings.
Increase hook speed as boat rises to peak of wave
Lift load off boat about 15 feet
Swing load clear of boat.
Lift load only high enough to safely clear edge of platform deck.
Make sure path is clear.
Swing slowly over platform
Lower load to safe height off deck.
Swing load slowly into position.
Boom out to the required radius without exceeding the maximum radius for the specific
load as indicated on Static Rated Load Chart.
Lower load slowly to deck
Bor-sOl STA-''''UARD CRANES Rev 1 Page 8 of 14
...
SEATRAXl!)
-----------..
Phone: 713 896 6500 Fax: 713 896 6611
APIQR
ISO 9001
Hand Signals for Crane Operators
,,'. I.'SE LOAD LL'iE
list Oil head. then
D"" ... , .....
Tap dbm, wilh
b;ul\J. then use
:.:ignals
r-;

..
I; '" R.\ISE LU ill \
SI ()\H.Y LOWER LO.ill
I '-) SLo\VLY
Extend thnmb upward
and llox fingers in and
out as long as movetut;!ut
is ,k,lr"d.
SWING THIS DIRECTION
ExtcnoJ ann with forefingers
indicating diro,!ction of s.wing.
and Hex fingers in and Oul
as long as load mO\'"menl
is desired.
STOP
EXf<!noJ forearm and hand
in horizontal po,;ilion and
s.licing. Jnotiotl...'l.
The above signals are basic for operating boom equipment. Any other signals to be used
during operation should be agreed upon by the operator and signalman beforehand. These
signals should not be in conflict with the basic signals.
Anyone-hand signal can be modified to indicate slow or cautious movement by placing
the palm of the unused hand a short distance in front of the direction-indicating finger. No
response should be given to unclear signals.
The operator is ultimately responsible for the safety and operation of the crane.
.... . ....
Phone: 713 896 6500 Fax: 713 896 6611

Specific Operating Instructions
For Cranes with Console Mounted Instruments
Please refer to the Console Arrangement drawing at the back of this section.
Primary Motion Controls:
This crane is equipped with low pressure, hydraulic remote Control Levers (Joysticks)
mounted in the armrests of the Operator's chair.
These controllers are spring loaded to the neutral (center) position and provide
independent, proportional, infinitely variable speed control for all of the primary crane
motions.
When performing simultaneous operations involving two or more of the primary motions,
the diesel engine should be operated at a constant speed between 1,800 and 2,200 rpm.
Individual joysticks should be used to independently control the speed of the various crane
motions.
The "Left Hand" controller is a dual axis "Joystick" and controls the Swing (slew) and
Boom Hoist (luff) motions.
The "Right Hand" controller has two independent single axis "Joysticks." The inside
Control Lever controls the Auxiliary Hoist. The outside Control Lever controls the Main
Hoist.
Swing (slew) Motion:
The Left Hand Joystick is moved to the left of center to "Swing Left" (counterclockwise),
or moved to the right of center to "Swing Right" (clockwise).
Speed of rotation is proportional to the amount of Control Lever movement from the center
position.
Start and stop swing motion as slowly and smoothly as possible to avoid possible damage
to equipment or injury to personnel from a wildly swinging load.
The crane is free to swing or drift when the joystick is in the center position, provided the
swing brake pedal, free slew valve is activated and swing lock lever are not engaged.
BOISOl STANDARD Rev.l Page 10 of 14
Boom Hoist (Luff) Motion:
The Left Hand Joystick is "pulled" back to Raise the Boom (reduce the radius) or "pushed"
forward to Lower the Boom (increase the radius).
Boom Hoist motion is always under the control of the hydraulic system and cannot overrun
or freewheel in the lowering mode. Please refer to our Description of Fail-Safe Features in
Section A for more information on this subject.
The speed of movement, in both directions, is proportional to the engine speed and amount
of Control Lever movement from the center position.
The Boom Hoist brake(s) automatically set and lock the boom in position when the Control
Lever is centered.
Simultaneous operation of both above motions is accomplished by moving the left hand
joystick diagonally. Speed of operation of both motions is independently proportional to
the displacement of the Control Lever from the center position. For example, it is possible
to raise the boom at maximum speed while the crane swings very slowly to the left.
Main and Auxiliary Hoist Motions:
The appropriate Right Hand Joystick is "pulled" back to Raise the Main or Whip Line (take
in cable) or "pushed" forward to Lower the Main or Whip Line (payout cable).
Hoist motion is always under the control of the hydraulic system and cannot overrun or
freewheel in the lowering mode. Please refer to our Description of Fail-Safe Features in
Section A for more information on this subject.
The speed of movement, in both directions, is directly proportional to the amount of
Control Lever movement from the center position.
Hoist brakes automatically set and lock Drums when the joysticks are centered. In
case of a mechanical failure, releasing the controls will set the brakes and stop drum
rotation.
Swing (slew) Brake(s):
Dynamic braking is accomplished by "Cross Controlling" the Left Hand Joystick. For
example; if the crane is swinging to the left at high speed and the joystick is then centered,
the crane will continue to "coast" to the left. Moving the joystick away from center to the
right will apply a "braking torque" to the crane motion, hence stopping rotation more
quickly.
The crane and its associated Swing System machinery are protected from damage during
this operation by means of a torque limiting hydraulic valves. These valves will limit the
amount of swing torque available during acceleration and deceleration ofthe crane.
However, it is strongly recommended that swing motion should start and stop as slowly and
smoothly as possible to avoid possible damage to equipment or injury to personnel from a
wildly swinging load.
The crane and load can be held in position against the wind by means of the Foot Pedal
Brake (if equipped) or centering of the joystick, when equipped with the hydrostatic drive.
"Cross controlling", as described above, is the preferred method for stopping rotation.
The crane may be locked in position indefinitely by means of the Swing Lock Brake Lever
mounted in the control console. When this lever is in the "Engaged" position, the crane is
locked against rotation. Any attempt to rotate the crane by means of the swing control
lever, while the lock is engaged, will result in the hydraulic swing motor being stalled
against the lock. This is not harmful and will not damage any portion of the Swing
Machinery.
Console Mounted Instruments and Controls:
The "Air Pressure" gauge indicates accessories.
The "Pilot Circuit Pressure" gauge displays hydraulic pressure in the Control Circuit.
The "Swing Motor Pressure" gauge shows hydraulic pressure in the Swing Circuit.
The "Boom Hoist Pressure" gauge shows hydraulic pressure in the Boom Hoist Circuit.
The "Load Hoist Pressure" gauge shows hydraulic pressure in the Main or Auxiliary hoist
circuit depending on which is in use.
The "Swing Lock" Brake lever is used to engage and release the slew shaft brake. This
lever should be placed in the "engaged" position whenever the operator leaves the cab.
This lever must be placed in the "released" position to rotate the crane.
The "Hydraulic Controls knob disables the hydraulic controls. The Hydraulic control
should be disengaged when crane operations cease to prevent accidental use of the
main/auxiliary controls and the boom/swing controls. To immobilize the controls,
simply pull up on the Hydraulic Control knob.
The "Hydraulic Gauge" denotes the level of hydraulic oil in the reservoir.
The "Fuel Gauge" shows the amount of diesel available to fuel the prime mover.
The Upper Wiper control valve is used to start and stop the upper pneumatic windshield
wiper on the upper window (option).
The Lower Wiper control valve is used to start and stop the lower pneumatic windshield
wiper on the main window.
When the black "Hom" button is depressed, the hom, mounted below the cab, will sound.
The "Hyd. Oil Temp." gauge shows temperature of the hydraulic oil in the suction pipes.
The "Water Temp." gauge displays diesel engine coolant temperature.
The "Oil Pressure" gauge shows diesel engine lubricating oil pressure.
The LAJarm Reset Control silences the diesel engine low oil pressure alarm. The latch must
be reset immediately after the engine is shut down to prevent the hom from sounding as oil
pressure subsides.
The green Engine "Start" Button energizes the pneumatic starting motor for the diesel
engine. The button is pressed to start the engine.
The "Tachometer" indicates diesel engine rpm.
The "Boom Lock" is used to engage the locking pawl against the ratchet wheel of the boom
hoist drum. The pawl is engaged whenever the "T handle" is pushed in (cable style), when
the knob on the console is turned (pneumatic style) or manual latch is activated at the hoist.
The Boom Lock is designed to lock the boom hoist drum during maintenance and
repairs to the Boom Hoist gearbox and brake assemblies. DO NOT engage the boom
lock while booming down! DO NOT use the boom lock to test luffing pressure.
Damage to the lock, gearbox, and shaft could occur as well as damage to the boom. Injury
to personnel is also possible!
The Emergency Stop Handle shuts down intake airflow to the diesel engine turbo
charger(s), thus choking the engine. This will render all of the Primary Control Levers
inoperative and lock all Hoist Brakes. The Emergency Stop Handle should only be used in
the event of an emergency. Pull the handle to apply. Reset turbo(s) after use.
The Engine Stop Handle is used to stop the diesel engine. When pulled out, this prevents
fuel from flowing to the intake system properly stopping the engine and disengaging the
hydraulic controls. Return handle to its original position after engine has stopped.
Foot Operated Secondary Controls:
The Right Side Foot Operated Throttle Pedal controls the speed of the diesel engine.
SeaTrax recommends an engine speed between 1,800 and 2,200 rpm while performing
simultaneous operation of the primary crane motions.
ZQ
S E T R X ~
Phone: 713 896 6500 Fax: 713 896 6611
-
The Swing Brake Pedal (if so equipped) is used to hold the crane against the wind. Do not
apply this brake suddenly, while crane is rotating.
On the cab floor to the left of the swing brake pedal is the Emergency Hoist Brake. If there
is a failure in some part of the hoist mechanism and the load or boom begins to free-fall,
the operator should REMOVE their hands from the controls. This automatically sets the
brakes and can slow/stop the falling load.
In case of a falling load, operators have a tendency to pull back on the controls. This is the
WRONG action, Pulling the controls back signals to the brakes to release, To set the
brakes, an Emergency Hoist Brake knob has been fitted to the cab floor. Stepping on this
knob down dumps pilot system pressure and automatically applies all hoist brakes. The
valve must be reset before crane operations can resume. To do this, simply reach down and
pull the knob up (it will only move %").
BOI-SOI STANDARD CRA.l'lES Rev.! Page 14 of 14

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Hyd Starter.doc Page 1 of 18

Phone: 713 896 6500 Fax: 713 896 6611


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STARTER MOTOR

DISASSEMBLY

1. Clamp the motor assembly in a vise. Remove the pinion housing and the mounting flange which
are fastened to the motor housing by four screws. Knock out the housing welsh plug, loosen the
set screw and slide the drive assembly off the shaft. Remove the two Woodruff keys from the
shaft.

2. Before removing the port plate put an indexing mark on the port plate and the motor assembly to
enable proper position of the port plate at re-assembly.

3. Remove the port plate fastening screws and lock washers that hold the port plate to each
assembly. There is a slight spring load on this plate and upon loosening the screws, any fluid left
in the housing will drain out. Remove the port plate.

4. Remove the barrel assembly by turning the housing upside down and allowing the barrel and
pistons to slide off the spline of the shaft. Remove the pistons from the barrel.

5. Remove the retaining ring. Press the shaft out of the housing from port plate end. The seals, seal
holder and ball bearing will come out with shaft.

CAUTION
DO NOT APPLY EXCESSIVE HEAT
Do not remove thrust bearing unless it is to be replaced.

6. To remove the thrust bearing, press against thrust bearing housing with a little pressure and the
bearing housing with thrust bearing assembly will come out of the port plate end as an assembly.
Remove the thrust bearing plate. To remove the thrust bearing from the thrust bearing housing,
apply heat to the housing and press out the thrust bearing.

EXAMINATION OF PARTS

All parts should be cleaned and free of fluid or grease before attempting inspection. Care should be
taken to assure that machined surfaces of parts are not nicked or scratched by careless handling.

Pinion Housing: Visually check the housing for cracks or other damage. Examine the bearing for
damage or wear. Replace if necessary.

Drive Assembly: Examine the pinion gear to be sure that the teeth are not worn excessively or
chipped from interference with the ring gear. Check to insure that the compressing
springs are not damaged or broken.

Port Plate: The port plate face, where the barrel rides, must be smooth and free of scoring. Slight
scuff marks can be removed by lapping on surface plate. (See Note C). Check the
needle bearing for wear or damage. Replace if necessary. To remove the bearing,
apply even heat to the port plate.

CAUTION
DO NOT APPLY EXCESSIVE HEAT.
Do not remove bearing unless it is to be replaced.

Bearing will fall out when port plate is tapped against wooden block or bench.
Caution must be used when tapping the plate, so as not to damage the lapped surface.
Check threads on inlet and outlet ports.

Barrel and Pistons: Examine the ported face of the barrel for scratching or scoring. Slight scuff marks
can be removed by lapping on a surface plate. The bores of the barrel should be
smooth and free of scoring.

The diameter of the pistons should be smooth and free of scoring. The closed end of
the pistons may show brinnelling where they contact the thrust bearing plate, but no
burrs or flat spots are permissible.

Drive Shaft: Check the ends of the shaft for wear or scoring. The splines should be smooth and
free of nicks. Check the ball bearing and replace if necessary.

Check Bearing: Replace if necessary.

Motor Housing: Visually check housing for cracks or other damage. Be sure that the thrust bearing
rolls free and smooth. Inspect tapped holes for thread damage.

Seal Holder (O Rings & Slipper Seal): Replace the "O" rings with new "O" rings. Replace the
slipper seal. If the seal holder did not contain a slipper seal, replace the seal holder.
(See Note A and B.)
RE-ASSEMBLY

1. Be sure all parts are clean and free of burrs before starting re-assembly.

2. Install the thrust bearing housing with bearing and plate assembly into motor assembly with slight
pressure. Press in until it has bottomed against motor assembly. Be sure dowel pin is in place.
Install thrust bearing plate into thrust bearing.

3. Install the bail bearing on the drive shaft. Install the retaining ring. Press the drive shaft with ball
bearing and retaining ring into motor assembly. Install seat assembly on the drive shaft. (See Note
C.)

4. Install the barrel with pistons on the drive shaft. Be sure that the barrel spring in the barrel in
place. Assemble the port plate to the motor assembly. Torque the screws to 300 in./lbs. There
should be a slight pre-compression of the barrel with the port plate. If not, replace the barrel
spring in the barrel.

TEST PROCEDURE

1. Mount the hydrotor in a suitable fixture and connect all hoses to appropriate fittings as illustrated
in the System Schematic Section.

2. Open the external control valve, start the engine pump to circulate fluid through the complete
system with the control valve remaining open, thus purging the system of air. Examine the
hydrotor and all fittings for possible leaks before releasing the control valve.

3. Allow system pressure to build up to 3000 psi (207 bars), at which pressure the unloading valve
by-passes fluid to the reservoir. Again examine for leaks in the system. Should pressure fail to
rise rapidly to accumulator pre-charge pressure and then build up gradually to 3000 psi (207
bars), it indicates system was not purged completely. Purge again if necessary.

NOTE: If at anytime, leaks occur externally, the unit must be disassembled to correct leakage before
proceeding with test.

CAUTION
ALWAYS RELEASE ALL HYDRAULIC PRESSURE
BEFORE DISCONNECTING ANY LINES

4. After it has been determined that the unit is not leaking, open the control valve, permit the unit to
operate until the accumulator fluid volume has been exhausted. Release the control valve. The
system will now recharge to 3000 psi (207 bars). Repeat charge and discharge cycle several
times to determine that the hydrotor functions properly.

5. Attach TSE 8603 Lock Testing Tool to the motor assembly. This can be accomplished by
inserting two pinion gear housing fastening screws finger tight 180 apart. The lock test tool can
now be slipped over these fastening screws and spline in tool engaged with spline on drive shaft.

6. Open the control valve slowly to the full open
position. Hold it open for 3 seconds before
closing. While control valve is in open position,
a pressure drop to 500 psi (35 bars) maximum is
permissible.

7. Proceed to test each of the pistons in the matter
described above by rotating the lock test tool in
increments as provided until all pistons have
been tested. Should the pressure drop faster than specified when testing at one particular
position, it indicates internal leakage. This could be a piston requiring replacement.

NOTE: Turn lock test tool and shaft one full turn and retest before replacing any one particular piston.
A pressure drop at all pistons indicates that the port plate fastening screws are not properly torqued or
that there is insufficient spring tension to keep motor barrel against the port plate. It may be necessary
to lap the port plate and barrel on a lapping plate or replace the barrel spring to eliminate leakage. (See
Note C).

8. After the preceding test is complete, remove the lock testing tool and install the drive assembly
on the drive shaft.

9. Install the pinion housing and mounting flange and tighten the four fastening screws with lock
washers.

10. Open the control valve to the full open position, allowing the accumulator to discharge
completely. Hydraulic pressure gage should now read 0 psi (0 bars).

CAUTION
DO NOT DISCONNECT ANY LINES UNTIL HYDRAULIC PRESSURE IS
COMPLETELY EXHAUSTED. REMOVE THE HYDROTOR FROM THE TEST
CIRCUIT. DRAIN REMAINING QUANTITY OF FLUID FROM THE HYDROTOR
AND CLOSE ALL, OPENINGS WITH SUITABLE PLUGS TO PREVENT
ENTRANCE OF FOREIGN MATTER DURING STORAGE OR SHIPMENT.

NOTES

NOTE A: On newer models the outer and O ring seals, slipper shaft seal, and the seal holder have
been replaced by a one piece seal. Replace that seal.

NOTE B: INSTRUCTIONS FOR INSTALLATION OF SLIPPER SHAFT SEALS

1. Install the inner O ring seal in the seal holder. Deform the slipper seal and install it
on top of inner O ring seal. Push the tool EHS 41-2858 through the holder once in
each direction to smooth out the deformed slipper seal.

2. Place the tool EHS 41-2858 over the drive shaft and against the installed ball bearing.
Slide the holder containing the O rings and slipper seal over the tool until holder is in
place against the bearing. Hold the seat holder in position and remove tool.

EHS 41-2858

NOTE C: Port plates are lapped at the factory with the straight fittings installed in both ports. Fittings
are torqued to 25 lb.ft. Leave these fittings in the port plate when testing or lapping. If they have been
removed, replace with new fittings when testing or lapping.

HAND PUMP SERVICE

Service Kit

QTY DESCRIPTION
1 Bleed screw O" ring
1 Inlet fitting O" ring (outer)
1 Inlet fitting back-up ring
1 Inlet fitting O" ring (inner)
1 Check valve seat O" ring
1 Plunger back-up ring

1 Plunger O" ring
1 Check valve spring
1 Plunger gland O" ring (inner)
1 Plunger gland back-up ring
1 Plunger gland O" ring (outer)


DISASSEMBLY

1. Disconnect the lever from the housing and the plunger. Remove the retaining ring and the clevis
pin before removing the link assembly.

2. Remove the plunger gland retaining ring from the housing. The plunger gland will come out oil
the plunger when the plunger is pulled from the housing. Remove the plunger gland from the
plunger.

3. Remove the discharge check valve seat from end of the plunger. Discharge check ball valve and
discharge check valve spring will drop out of the plunger.

4. Remove the inlet fitting from the end of the housing. Inlet check ball valve and the inlet check
valve spring will drop out of the housing.

5. Back out the bleeder screw and remove the ball.


Housing: Check for cracks and other visible damage. Bore of cylinder must be smooth with no
pitting or scoring. All threads should be checked. (It is not necessary to remove the
pipe plug unless there has been leakage at threads). Bleed ball valve and its seat in
housing must be checked. Replace ball valve if damaged. Replace the bleed screw
"O" ring with a new one.

Inlet Fitting: Examine internal and external threads. Inspect inlet check valve seat for nicks or
scratches. Replace the inner and outer inlet fitting "O" rings and back up rings with
new ones. Examine inlet check ball valve and spring. Replace if damaged.

Plunger: Check plunger for scoring on large diameter and on plunger shank where it rides in
plunger gland. A wear pattern may be evident but no scores or scratches should be
present. Replace the plunger "O" ring and back-up ring and the discharge check valve
seat "O" ring with new ones. Examine discharge check ball valve and spring and
discharge check valve seat. Replace any damaged parts.

Lever: Check link assembly for wear or damage. Replace if necessary.

Plunger Gland: With the inner plunger gland "O" ring and back-up ring removed, check gland on
plunger shank to be sure it does not bind. Inner and outer plunger gland "O" rings and
back-up rings should be replaced with new ones.

ASSEMBLY

NOTE: Make sure that all parts are clean before assembling. To facilitate assembly, use light oil or
grease on O rings and back-up rings.

1. Install inlet check valve spring and ball into housing. With the inner and outer inlet fitting "O"
rings and back-up ring oil the inlet fitting, install the fitting into the housing. Tighten the inlet
fitting securely being sure that the inlet check ball valve seats property in end of the inlet fitting.

2. Install discharge check valve spring and ball into plunger. With discharge check valve "O" ring
in place, thread discharge check valve seat into plunger and tighten securely.

3. Insert the plunger into the housing, bottoming plunger in pump bore. Install the plunger gland
being sure that the inner "O" ring is closest to the leading edge (see illustration). Press the
plunger gland in until groove for the retaining ring is uncovered, then insert the retaining ring.

4. Drop bleed ball valve into place and with bleed screw "O" ring in position insert bleed screw.
Tighten the bleed screw securely.

5. Install the link assembly to the plunger and the lever. Place the lever into position and insert the
clevis pin and the retaining ring. Put other side of link on and secure with clip.

TEST PROCEDURE

1. Mount hand pump in suitable holding fixture and connect all hoses to appropriate fittings as
illustrated in Hydraylic Schematic (see page 2) leaving the discharge connection loose. Slowly
operate the hand pump until all the air is expelled. Re-tighten connection. This operation will
also assure that the plunger is free in the housing. With high-pressure valve open, operate the
hand pump long enough to sufficiently purge the system.

2. Close the high-pressure valve. Operate the hand pump until the system pressure is approximately
1800 psi (124 bars). Check for external leakage.

3. Operate the hand pump until system pressure is 3000 psi (207 bars). Observe the pressure gage
closely to determine if the unit is pumping on each stroke. (Pump is double acting.)

4. Locate the pump plunger is mid-position and release the operating handle. Any movement of
handle indicates leakage past inlet check ball valve or "O" rings on inlet fitting. (There should not
be any perceptible drop in pressure gage reading.)

5. Move the plunger in the full extent of its travel until the plunger bottoms in housing. Disconnect
inlet line from pump. A steady pressure reading of 3000 psi (207 bars) indicates that the
discharge check valve plunger "O" rings and bleed valve are sealing properly. If leakage occurs
at this point it will be necessary to correct and retest as required.

6. Slowly open high-pressure valve and release pressure to 0 psi.

CAUTION
DO NOT DISCONNECT ANY HIGH PRESSURE LINES
UNTIL HYDRAULIC PRESSURE IS COMPLETELY EXHAUSTED.

7. Remove the hand pump from the test circuit. Drain the remaining quantity of oil from the hand
pump and close all openings with a suitable plug to prevent entrance of foreign matter during
shipment or storage.

HYDRAULIC CRANKING SYSTEM TEST CIRCUIT

TheTest Circuit Schematic for Hydraulic Cranking System Components illustrated in this section
shows the approximate position of the equipment required for testing purposes. This may be altered to
meet the individual requirements of shop lay-out and components to be tested.

Reservoir: The reservoir should be mounted high enough so that the outlet at the bottom of
the reservoir is above the oil inlet to the engine pump. The reservoir should be
filled to approximately 3/4 of its maximum oil volume. (This pertains to a test
circuit only and does not refer to actual application specifications.) This will
provide sufficient space above the oil level for the return oil to surge back into
the reservoir when components are being tested without the hydrotor in the
circuit.

Accumulator: The capacity of the accumulator should be 230 cu. in. (1 gal.) for the time factor
used when testing the engine pump. It also provides a sufficient volume of oil
for testing other components.

Electric Motor: The electric motor should be at least 1 HP and have a speed of 1750 RPM. This
speed and HP are required when testing and operating the engine pump at the
high pressures attained.

Hand Pump: The hand pump is not required in the circuit unless it is one of the components
to be tested.

High Pressure Valve: [3000 psi (207 bars)] The high pressure valve is used in the circuit when
components other than hydrotors are being tested. It is to be inserted between
the accumulator and reservoir to provide a means of returning the high pressure
oil to the reservoir. A Crane #222 H, Steel, 1/2" valve, or equal should be used.

Fittings and Hoses: All return hoses from components to the reservoir should be larger (#10 or
larger recommended) than the inlet hoses (#8 recommended). This will
eliminate back pressure within the unit. Hose should be as shown as possible to
prevent surging. All fittings and hoses should be inspected periodically to
insure that they are in good condition. If there is any doubt about a fitting or
hose it should be replaced.

CAUTION
ALWAYS RELEASE ALL HYDRAULIC PRESSURE IN THE SYSTEM
BEFORE DISCONNECTING ANY HOSES.

Clean all hose assemblies before installing. Do not use sealing compound when installing fittings.

Unloading Valve: Most engine pumps include an integral unloading valve. When testing such pumps,
set the system unloading valve at approximately 3500 psi (241 bars) so as not to
interfere with the integral unloading valve in the pump under test.

Hydraulic Oil Recommendation: Clean, high quality hydraulic oil, appropriate for all seals should be
used in the test circuit. Test oil temperature should be maintained at 75 to 80F
(24 to 27C), during testing.

High Pressure Filter: Follow instructions as outlined in components catalog HF- 1.

ALWAYS PURGE THE SYSTEM BEFORE ATTEMPTING ANY TEST

Purging:
A. Open valve at reservoir outlet.

B. To purge the hand pump (if used), loosen the discharge connection and slowly operate the hand
pump until all the air is expelled. Retighten connection.

C. To purge the complete system open the control valve if a hydrotor is installed or the high
pressure valve if this is being used. Start the engine pump to circulate the oil through the system.
Allow the pump to operate for a period sufficient to completely purge the system of air, After
purging, close the appropriate valve and proceed with the test.

TROUBLESHOOTING

CAUTION
Before servicing any part of the hydraulic cranking system, the accumulator pressure
must be released to prevent possible injury to personnel.

A. NO SYSTEM PRESSURE

1. Air in engine driven pump.
All pumps are self-bleeding. Check for dirt in the pump piston bleed hole. See that the bleed
hole is facing the inlet port. To assist the pump in, expelling air, fill the pump with fluid
through the return port.

2. Hand pump bleed valve open.
Check to insure that the hand pump bleed screw (located above the inlet port) is tight. (See
Low System Pressure Item 2)

3. Drive belt slipping (belt driven pump)
Adjust belt for proper tension.

4. Drive gear loose (direct drive pump)
Secure gear to drive shaft.

5. Unloading valve by-passing fluid to the reservoir.
Fluid will be passing through the return port indicating the unloading valve spindle in the
RPA model pumps is stuck in the open position or the pressure adjusting screw is backed off.
Check to insure the unloading valve spindle is free. Turn the adjusting screw CW to move
the spindle into the closed position.

6. Suction line plugged
Remove and clean. Make sure the swivel ends are correctly attached.

B. LOW SYSTEM PRESSURE

1. Unloading valve set too low.
Turn adjusting screw on 0 RPA model pumps CW to increase system pressure to desired
level.

2. Hand pump bleed valve leaking.
Remove the bleed screw and ball. Use ball to re-coin seat.

3. Engine pump valve(s) leaking
Replace inlet valve or re-coin seats of the three ball checks.

4. Low fluid level
Add fluid to the reservoir.
C. CRANKING SPEED TOO LOW

1. System fluid too heavy.
Check fluid in the system. Use MIL-H-5606 hydraulic fluid or equivalent. Fluid must be
compatible with Buna-N seals.

2. Engine fluid too heavy.
Replace fluid with proper viscosity grade. Refer to the engine lubrication fluid specifications.

3. Control valve not fully open.
Types VCA. Valve body sticking in valve housing. Replace valve cage and valve assembly.

4. Inlet line restricted.
Check plumbing from accumulator to hydrotor to insure hoses are riot collapsed and are free
of obstructions.

5. Excessive internal leakage in hydrotor.
Examine hydrotor internally for broken thrust bearing plate, scored port, plate, frozen piston
or broken barrel spring.

6. Line size too long and/or too small.
Discharge line from the hydrotor to the reservoir causing high back pressure. Discharge hose
should be at least one size larger than inlet hose. Eliminate elbows and reducers where
possible. Insert a tee containing a gage in the hydrotor discharge port. Attach the discharge
hose and measure back pressure which should not exceed 75 psi (5 bars).

D. LOSS OF FLUID FROM RESERVOIR

1. External leaks.
With pressure in system, check all hoses and fittings for leaks. Tighten or replace fittings and
any defective parts.

2. Hydrotor shaft seal leaking.
Remove the hydrotor inspection cover or welsh plug and look for signs of hydraulic fluid on
the drive shaft, the hydrotor shaft and inside the pinion housing. Replace the shaft seal
assembly.

3. Engine pump shaft seat leaking.
Replace shaft seal using proper tool to prevent seal damage.

4. Hand pump seal leaking.
Remove plunger gland and replace inner and outer "O" rings.

E. LOSS OF PRESSURE WHEN ENGINE IS NOT RUNNING

1. Ambient temperature decrease.
A small decrease in pressure is normal due to decrease in temperature. Pressure will decrease
approximately 3 psi (0.2 bars) per degree F. temperature change.

2. Engine pump check valve leaking
Examine unloading valve spool for damaged "O" rings. Re-coin ball check seats in
unloading valve portion of the engine drive pump.

3. Hand pump leaking
Disconnect inlet fine from reservoir. Leakage from inlet fitting means that either the relief
valve alone or both the inlet and outlet check valves are defective. Clean ball seats in pump
body and replace balls and springs if necessary. (See Low System Pressure, Item 2 and Loss
of Fluid from Reservoir, Item 4.)

4. Control valve leaking
To test for leakage, disconnect plumbing at inlet to hydrotor. If seepage is present replace
"O" rings in type VA 202180 valves or replace valve assembly in type, VCA valves.

5. External leakage in system
Visually locate source of fluid leakage and tighten applicable connection. Use of liquid
teflon on pipe threads is permissible if properly applied.

6. Loss of accumulator pre-charge (nitrogen)
Test for pre-charge after opening bleed screw on hand pump. Install a gage assembly on the
accumulator gas valve. Open valve and read nitrogen pressure. Correct nitrogen pressure
appears on the accumulator name plate, usually one half the system working pressure.

F. HAND PUMP FAILS TO RAISE SYSTEM PRESSURE

1. Bleed valve open or leaking
(See No System Pressure, Item 2 and Low System Pressure, Item 2)

2. Check valves leaking
Hand pump handle will not stay in neutral position but will move to one end of the stroke.
Examine for broken ball check springs or damaged check valve seats. Re-coin seats using the
ball checks. Make sure there are no foreign particles in the pump.

Remove and clean.

4. Fluid level low
Add fluid to reservoir.

5. Piston seal damaged
(See Loss of Fluid from Reservoir, Item 4)

G. HYDROTOR TURNS BUT ENGINE DOES NOT

1. Pinion not, engaging flywheel ring gear.
Incorrect flange to ring gear dimension. Change pinion gear housing and flange assembly.

2. Drive broken.
Replace drive. Operator should disengage hydrotor as soon as engine starts. Prolonging the
period during which clutch overruns will reduce clutch life.

3. Incorrect drive.
Hydrotor may be assembled for LH rotation but with a RH drive. Change to correct hydrotor
drive.

H. LOSS OF ACCUMULATOR PRECHARGE (NITROGEN)

1. Damaged seat on piston.
Overhaul the accumulator

CAUTION
Release all hydraulic pressure before removing the accumulator from the system
and release all nitrogen pressure before disassembling the accumulator.

2. Defective gas valve
Release pressure in system by opening bypass valve on hand pump. Then open gas valve to
release remaining pre-charge before attempting to remove valve from the accumulator.
Replace gas valve.

3. Damaged seal on end cap.
Apply liquid soap on accumulator end cap. Bubbling of soap indicates a leak past the end
cap seal. Release nitrogen pre-charge; before removing cap to replace seals.

4.Defective safety fuse.
Replace safety fuse assembly after releasing all nitrogen pressure.

I. HIGH PRESSURE IN SYSTEM

1. Defective gage.
Replace gage.

2. Unloading valve not operating properly.
Clean and adjust to specified working pressure. Check that the plunger is not binding or
sticking. There is a 500 lb. differential between cutout and cut-in.

J. FLUID EMERGES FROM RESERVOIR FILLER CAP WHEN ENGINE IS CRANKED.

1. Filter element in filler cap loaded with dirt.
Replace filler cap

2. Excess fluid in reservoir.
Check fluid level when the accumulator is empty. The fluid level should be approximately 2-
1/2" from the top of the tank.

K. FLUID EMERGES AROUND PISTON ON HAND PUMP

1. Damaged piston seal
(See Loss of Fluid from Reservoir, Item 4.)

L. CRANKING CYCLE TOQ SHORT

1.Insufficient accumulator capacity.
Add more and/or larger accumulator(s).

2.Faulty pressure gage.
If gage is reading higher than actual system pressure, fluid volume in the accumulator will be
less. Replace gage.

3.Excessive internal leakage in hydrotor.
(See Cranking Speed too Low, Item 5)

4.Hydrotor too small.
Check engine cubic inch displacement to determine that the hydraulic cranking motor is the
correct size.

5. Accumulator pre-charge too high.
With the fuel shut off to prevent engine from starting, crank the engine until all fluid is used.
If the gage then registers zero pressure, install a gage assembly on the gas valve and drop the
pre-charge to 1250 psi (86 bars). Repeat cranking cycle. If gage will still drop to zero at end
of cranking cycle, reduce pre-charge to 1000 psi (69 bars).

6. Accumulator pre-charge too low.
Open the bypass valve on the hand pump to discharge fluid from the accumulator. Install a
gage assembly on the accumulator gas valve. If pre-charge is less than 1500 psi (103) bars,
add nitrogen. Make sure pre-charge holds by testing for nitrogen leakage per Loss of
Accumulator Pre-charge (Nitrogen).

M. IMPROPER DRIVE ENGAGEMENT

1. Insufficient depth of tooth engagement.
Standard dimension from flange to ring gear is 2.00" (50.8mm). Measure with depth gage. If
greater than 2.00" (50.8mm), depth of engagement will not be adequate.

2. Tooth engagement too deep.
The collar behind the teeth will be marked by the ring gear. Insert spacer between the
hydrotor flange and the ring gear housing.

3. Improper drive and ring gear mesh.
Use bluing or other marking fluid on the pinion. Install the hydrotor and crank the engine
one or two turns. Remove the hydrotor and check contact areas for proper mesh.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION C INSPECTION AND MAINTENANCE

Wedge Sockets
Boom Lock Operation


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Phone: 713 896 6500 Fax: 713 896 6611

11 October 2004
Initial Start-up and Commissioning Procedure

Initial Start-Up:

The testing of all functions will commence upon satisfactory completion of all fit-out
activities. (Complete all check sheets contract preferred items attached).

Crane Operation:

SLEW DRIVE:

1. Verify the slew and Kingpost gears have been lubricated.

2. Verify lube oil reservoir tank is full.

BOOM:

1. Verify that the Boom Point Sheaves have been lubricated.

2. Verify main hoist wedge socket is installed properly and the condition of the wire rope.

3. Verify the Anti Two Block Frame swings without excess force.

4. Verify all electrical connections on boom have been made.

5. Verify all boom connection bolts have been tightened to the correct torque using the
correct torque values. (See Bolt Installation and Inspection Procedure, Section C)

6. Verify gearbox lube levels. Refer to Section D, Lubrication.

7. Lubricate shaft bearing on hoist ends.

8. Verify that cable anchor H blocks are tight on hoist drums.

9. Verify that all tools and debris have been removed from the Boom.

Commiss Procedure Rev.2.doc Page 1 of 4
10. Verify that the Boom Butt Pins have been greased and that the Safety Bolts have been
installed.

GANTRY:

1. Verify Gantry Sheaves have been lubricated.

2. Verify all ladders, safety gates, and platforms have been fitted correctly and secured.

3. Verify Upper Bearing bolts have been tightened to the correct torque using the torque
values in Section C.

4. Verify all tools and debris have been removed from the Gantry.

UPPERWORKS:

1. Verify Boom Hoist gearbox lube level.

2. Verify fuel and hydraulic tank levels.

3. Lubricate shaft bearing on hoist end.

4. Verify lower bearing shoes are installed and greased.

5. Verify Hoist drum cable anchors are tight.

6. Verify the Access Ladder has been fitted correctly and is secure.

7. Verify all walkways have been cleared of tools and debris.

RIGGING:

1. Verify luffing rope is reeved correctly, lubricated, and wire rope is undamaged.

2. Verify that Load & Aux rope is reeved correctly, lubricated, and wire rope is not
damaged.

3. Verify the Main block is reeved with the correct number of falls (2,4,6, etc.).

4. Check the Bridle Block Assembly sheaves are lubricated and reeved correctly (if
fitted).

5. Check Pendant Lines (if fitted) to insure hairpins are installed and cables are in
satisfactory condition.

6. Verify Main Block Sheaves, Main Block Bearing, and Aux swivel have been
lubricated.

Engine/Cab Area:

PRE-START UP:

Before starting the engine the following checks must be made:

1. Verify the coolant in the radiator is to the correct level and that the water contains the
correct amount of Anti-freeze for adverse climatic conditions.

2. Verify the engine oil is to the correct level.

3. Verify multi pump drive lube oil level.

4. Check air filter for cleanness and the plastic wrapper has been removed.

CAB:

1. Check control mechanisms including function levers, throttle, engine start and stop, and
brakes for freedom of movement and for proper operation.

2. Verify horn function.

3. Verify cab mounted electrical systems perform as required.

Commissioning:

This procedure details the specific actions to be performed prior to placing the crane into
service for first use. Note: It is essential to verify all fluid levels before initial start-up
(See Lubrication, Section D).

1. Verify initial start-up sections are fully complete.

2. Visually check for leakage or damage in the hydraulic system.

3. Check the air and non-mechanical systems for leakage and contamination.

4. Verify available air supply is of sufficient pressure and volume for safe operation.

5. Visually check wire rope for evident deterioration and damage, or improper reeving.
Verify installed rope is of the correct diameter, type and properly lubricated.

6. Visually check for loose or missing components such as walkway sections, ladders and
supports, bolts, pins, keepers or cotter pins.

7. Perform a 'walk-around' visual examination of the crane; crane boom, and support
structure to ensure no damage exists and that structural installation has been
completed.

8. Ensure the correct load rating charts for the current configuration and all required
alternate configurations are available for use by the crane operator at the primary
control station.

9. Check boom hoist limit and anti-two block devices for proper operation. Care should
be exercised to prevent damage to crane components.

10. Visually check condition of loose gear to be used, such as slings, sling hooks and
shackles.

11. Check all control locks and emergency controls.

12. Hi-Low Boom Kickout: High: Adjust to 12" from boom stops.
Low: Adjust to platform requirements, Horizontal, 12 below
boom rest. NEVER disconnect this system.

13. Check boom angle/radius indicators (mechanical and electronic if equipped) over full
range and verify accuracy (see Load Indicator System, Section M).

14. Inspect sheaves for damage, rope path alignment, and freedom of movement.

15. Correct deficiencies as required by the above prior to use.


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Phone: 713 896 6500 Fax: 713 896 6611

Commissioning Checklist
DESCRIPTION: CRANE AND RIGGING LINES SYSTEM: MECH./HYD.

Item No. Item Description Yes No N/A
A) Slew Area
1 Slew Pinion Grease
2 Lube Oil Tank Full
B) Boom
3 Boom Point Sheaves
4 Anti Two Block Frame
5 Boom Butt Pins
6 Connection Bolts
7 Gearbox lube levels. Refer to Section D, Lubrication
8 Shaft bearing greased
9 Tool & Debris Removal
C) Gantry
10 Gantry Sheaves
11 Ladders, Safety Cages & Platforms
12 Connection Bolts

COMMENTS:

Commiss Checklist Rev.1.doc Page 1 of 5
COMPLETED BY CLIENT APPROVED C.A. APPROVED
SIGNATURE
DATE

Phone: 713 896 6500 Fax: 713 896 6611

DESCRIPTION: CRANE AND RIGGING LINES SYSTEM: MECH./HYD.

Item No Item Description Yes No N/A
D) Upperworks

14 Ensure Hydraulic Tank suctions are open (overhead tanks)

15 Gearbox lube levels. (Refer to Section D, Lubrication)
16 Hyd. Tank Level (2 3 below top of tank)
17 Fuel Tank Level
Full

18 Lower Bearings
19 Drum Anchors
20 Access Ladder
21 Handrails (removable)
E) Rigging
23 Luffing Rope
24 Load & Auxiliary rope
25 Main Block Assembly
26 Headache Ball Assembly
27 Release Lines
28 Hold Lines

COMMENTS:

SIGNATURE
DATE

Phone: 713 896 6500 Fax: 713 896 6611

DESCRIPTION: ENGINE / CAB AREA SYSTEM: MECH./HYD.

A) Pre-Start Up
1 Radiator Coolant Full
2 Engine Oil Level (Check Dip Stick)
3 Pump Drive Fluid Level (Check Dip Stick)
B) Cab
4 Slew Left
5 Slew Right
6 Main Hoist Lever Pull, Load Up
7 Main Hoist Lever Push, Load Down
8 Auxiliary Hoist Lever Pull, Load Up
9 Auxiliary Hoist Lever Push, Load Down
10 Slew Brake Parking Brake (console mounted)
11 Slew Brake Dynamic (foot pedal)
12 Engine Start Switch
13 Engine Throttle Control
14 Engine Stop Handle
15 Horn Function
16 Up and Down Limit Switches, Main
17 Up and Down Limit Switches, Aux

COMMENTS:

SIGNATURE
DATE

Phone: 713 896 6500 Fax: 713 896 6611

DESCRIPTION: PREFERRED ITEMS SYSTEM: MECH./E & I

1 Slew Pinion Guard
2 Bridle Block Assembly
3 Pendant Lines
4 Multi-Pump Drive oil level
5 Air Receiver
6 Windshield Wipers
7 Engine Overspeed Shut Down
8 Safe Load Indicator Function
9 Hoist Limit Switch Function
10 Slew Limit Switch Function
11 Machinery Guards
12 Safety Guards
Electrical System
13 Telephone/Alarm System Function
14 Radio Antennas Damage
15 UHF Radio Function
16 Loud Hail Amp Function
17 Deck Lighting
18 Flood Lights
19 Aircraft Warning Lights

COMMENTS:

SIGNATURE
DATE

Phone: 713 896 6500 Fax: 713 896 6611

DESCRIPTION: PREFERRED ITEMS SYSTEM: MECH./E & I

20 Emergency Lights
21 Cab Lights
22 Engine Compartment Lights
23 Power Supplies
24 Circuit Breakers, Function
25 Heater Fan, Function
26 Hydraulic Oil Heater
27 Annunciator Function
28 Audible Alarm Function
29 Fire Alarm System
30 Fire System
31 Smoke Detector
32 Fire Detector
33 Earth Connections
34 Earth Continuity Test
35 A/C Unit Function
36 Load indicator Function

COMMENTS:

SIGNATURE
DATE


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Inspection Checklist.doc Page 1 of 7

25 April 2001
Inspection Checklist

Inspection Frequency:

The "Duty Cycle," or frequency of operation of Offshore Cranes varies from almost continuous
use (MODUS) to sitting idle for months at a time (unmanned production platforms). Therefore it is
not possible or practical for the crane manufacturer to provide universal inspection programs,
based on frequency of use, which are applicable to all possible situations.

Therefore, the following Inspection Checklist is to assist owners and operators in development of
an appropriate Preventative Maintenance Program applicable to their unique application.

All items should be checked by a qualified inspector. Records of every inspection, modification,
or repair, should be kept to formulate any maintenance trends that may develop. These records are
to be kept for at least two years.

NOTES: This list does not include items covered in Section D, Lubrication.
Cracked/chipped paint or rust can signify hidden structural deterioration.

Level 1 Regular Inspection (Pre-Use)

Level 2 Periodic Inspection (Monthly), Level 1 plus these items

Level 3 Intensive Inspection (Quarterly), Levels 1 and 2 plus these items

Level 4 Annual Inspection (Yearly), Levels 1-3 plus these items

Inspect or verify the following:

Cab Area:
Level 1:
Remove any obstructions to clear operator vision (includes cleaning windows if necessary).
All instruments function properly
All engine instruments operate properly.
Crane functions for proper operation.
Throttle operates smoothly, from idle (950 rpm) to WOT (2,000 rpm).
Control levers operate freely and return to neutral when released.
All hoists operate smoothly.

Portland Wharf Support Base, Southtown Road,
Great Yarmouth, Norfolk, NR31 0JJ, ENGLAND
Tel: +44 1493 651311 Fax: +44 1493 604900
Seatrax UK Limited
Level 2:
Document console mounted Hour Meter reading and verify function (if equipped).
Load charts are in place and legible.
Fire extinguisher is accessible and charged.
Air conditioner / heater function (if equipped).
Cab lights and electrical equipment (if equipped).
Safety alarms for proper function.
Windshield wipers function and condition (if equipped).
Window pivot mechanism (if equipped).
Crane functions for proper operation:
Swing brake pedal holds.
Boom limit system set at the correct positions.
Console mounted controls operate as described.
Floor mounted Emergency Hoist Brake disables all hydraulic controls (if equipped).
Load indicator display (if equipped).
Emergency kill handle rapidly stops engine when pulled. (Reset after test)

Level 3:
Remove inspection plate behind seat and check for leaks.
Joysticks and console controls for leaks

Level 4:
Load Indicator accuracy
Vibration dampeners in good shape.

Rear / Wing Deck:
Level 1:
Hydraulic or fuel leaks / spills.
Fuel level.

Level 2:
Boom hoist cable.
Boom dog function.
Brake band wear and condition.
Clevis pin on brake linkage and eccentric shaft.
Gearbox oil level(s) and condition ( full).
Hose abrasion.

Level 3:
Gearbox mounting bolts.
Motor mounting bolts.
Hoist frame to upperworks mounting bolts.
Frame, drum, and turntable structure for deterioration.
Brake to brake drum core welds.
Inside of brake drum area (where cable anchors are located).
Spline hub to drum weld.
Complete hoist frame.
Boom hoist platform.
Wire rope H blocks on hoist drum are tight.
Brake and boom lock retaining bolts.
Bearings and seals for visible wear.
Eccentric shaft and bushings for visible wear.
Proper adjustment of brake linkage and condition.
Hoist brake test:
Disconnect brake actuator pressure to release line.
Run hoist in the down direction at full power to ensure brake holds.
While testing brake, check the maximum hoist pressure.
Upperworks welds at gantry splice flange.
Welds down gantry beams to base of crane structure.
Structure welds from gantry beams out to boom connections.

Level 4:
Remove outer bearing cover to inspect bearings and seals.
Welds and structure for deterioration.
Fuel and hydraulic level gauges for accuracy (if equipped).
Fuel and hydraulic tanks for water.
Grating condition and loose or missing retainers.
Handrail connections.

Valve Cabinet: (42 and 60 Series only)
Level 1:
Valves, hoses, and filter for leaks.
Filter indicator is green.

Level 2:
Motor cooling needle valves are locked on gold setting (2 turns)(6,000 psi systems).
Electrical cable or hose abrasion.

Level 3:
No additional inspection required

Level 4:
No additional inspection required

Engine House:
Level 1:
Engine oil level.
Pump Drive fluid level (if applicable).
Suction pipes are completely open (if applicable).
Fuel, oil, or coolant leaks.

Level 2:
Document Hour Meter reading and verify function (if equipped).
Condition of engine oil.
Condition of pump drive lubricant.
Condition and level of engine coolant.
Air cleaner condition.
Drain air filter/separator
Filter indicator is green.
Hose abrasion.
Motor cooling needle valves are locked on gold setting (2 turns) (6,000psi 72/80 Series).
Hydraulic oil is approximately 2 inches below top of tank.

Level 3:
Engine mounting bolts.
Engine belt tightness and condition.
Engine mounted emergency kill operation.
Engine mounted starter button operation.
Drain air line dryer of water accumulation (if equipped).
Air line lubricator level (if equipped).
Exhaust system for leaks.

Level 4:
Pump drive vent for contamination.
Suction pipe deterioration or leaks
Engine shut-down linkage and operation.
Engine emergency shut-down linkage and operation.
Engine mounted kill operation.
Oil cooler and radiator and clean as required to ensure proper airflow.
Vibration dampners for deterioration.
Air receiver for water, leaks, or corrosion (if equipped).
Handrail connections.

Swing Area:
Level 1:
Hydraulic leaks around swing motor and boom hoist limit assembly.
Condition of front shoe bearings and retainers.

Level 2:
Boom butt pin bushings and retainers.
Condition of all shoe bearings.
Lube oil level in reservoir ( - full).
Boom Kick-out for leaks.
Hose abrasion.

Level 3:
Pinion gears, sprocket retainer, and bolts.
NOTE: Pinion gears rarely require replacement and wear- in during the first 250 hours. Inspect the
external splines with a vertical straight edge after de-burring; there should be less than of wear.

Level 4:
Lower Pinion gear partially to lubricate and inspect splines.
Slew retaining bolts (clean bolt and threads, apply loctite 271, and torque to 600 ft.lbs.)

Main and Auxiliary Hoists:
Level 1:
Hydraulic leaks.

Level 2:
Hoist wire rope for wear or damage.
Brake band wear and condition.
Proper adjustment of brake linkage and condition.
Clevis pin on brake linkage and eccentric shaft.
Gearbox oil level and condition ( full).
Hose abrasion.

Level 3:
Gearbox mounting bolts.
Motor mounting bolts.
Hoist frame to boom mounting bolts.
Wire rope H blocks on hoist drum are tight.
Seals for visible wear.
Eccentric shaft and bushings for visible wear.
Hoist brake test:
Disconnect brake actuator pressure to release line.
Run hoist in the down direction at full power to ensure brake holds.
While testing brake, check the maximum hoist pressure.

Level 4:
Remove outer bearing cover to inspect bearings and seals.
Brake retaining bolts.
Frame, drum, and boom butt structure for deterioration.
Brake to brake drum core welds.
Inside of brake drum area (where cable anchors are located).
Spline hub to drum weld.
Complete hoist frame.

Boom Base and Straight Sections:
Level 1:
Visually inspect for attachment flanges that do not touch.
Missing bolts or nuts.

Level 2:
No additional inspection necessary.

Level 3:
Boom chords and lacing for damage or deformation.
Bolts torqued to correct values without stretching.

Level 4:
Welds at connection plates (between boom sections).
Boom base vertical foot plates (plates where pivot pins attach).
Rub rails have at least 1/8 material remaining.
Walkways/grating condition and mounting bolts (if equipped).

Boom Point and Jib Extension:
Level 1:
Loose gear (slings, hooks, and shackels).
Main rope at dead end for broken strands.

Level 2:
All sheaves in point area for obvious damage or split thrust washers.
Boom suspension and load support plates for deformation or deterioration.
Bridle and bridle sheaves are in acceptable condition (if equipped).
Pendant lines and spelter sockets for deterioration (if equipped).
Load block:
Sheaves for obvious damage.
Shackle for missing hairpin or nut (if equipped).
Shackle, or hook, for excess wear or deformation.
Grease seal is undamaged.
Hook eyelet (stinger pin), or hook, rotates freely.
Latch closing properly (if equipped).
Aux line:
Auxiliary hook for cracks in throat or deformation.
Hook safety latch for damage and proper operation.
Stinger cable for broken strands or deterioration.
Free rotation of swivel joint.
Latch closing properly.

Level 3:
Point rub rails have at least 1/8 material remaining.
Bolts torqued to correct values without stretching.
Suspension wire rope.
Unbolt and lift overhaul ball to inspect dead end, bushing, swivel, and pins.
Anti-two block frame for damage and freedom of movement.
Aircraft warning light illuminates (typically with engine running).

Level 4:
Jib extension structure.
Dead-end connection welds.
Remove shafts and sheaves on point and load block to clean and inspect bearings.

Gantry:
Level 1:
Gantry sheaves for obvious damage
Air swivel for damage or leakage (if equipped).
Electric swivel for freedom of movement and damage (if equipped).
Boom hoist cable dead end.

Level 2:
Dead end plate connection.
Sheaves for damage, wear, cracks, or split thrust washers.
All gantry mounted electrical equipment working properly.
Upper bearing for excessive wear.
Jib crane is secured (if equipped).

Level 3:
Gantry to upperworks flange bolts.
Lower flanges
Bearing area
Sheave area
Rear beam splices at angle
Boom spring stops in good condition (if equipped).

Level 4:
Ladder and handrails for damage or missing bolts.
Walkways/grating condition and mounting bolts.
Remove shaft and sheaves to clean and inspect bearings.

Kingpost:
Level 4 Only:
Welds and structure.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Phone: 713 896 6500 Fax: 713 896 6611
STDFM-43 Rev. 1 01/31/01

31 July 2003

Installation
Insure all Bolts, Nuts & Flat Washers comply with SeaTrax Specification for Large Diameter
Nuts & Bolts.
Visually check that boom section connector pads are flush (N/A on SB Series). These are
designed as heavy, non-precision joints. The components have been welded out using jigs,
which hold the fabrications in position, but due to weld draw, the bolted splice connections may
not be an exact fit. Although a majority of the pad will be touching, small gaps are common.
These gaps are NOT critical and do not affect the stability of the connection provided the bolts
have been torqued to the correct value.

Install all bolts with the threads down so water will not collect between the threads and nuts.
Boom bolt heads must face the boom point.

Place a hardened flat washer under the nut of each bolt that complies with SeaTrax Specification
for Large Diameter Nuts & Bolts. Torque all bolts according to size & grade (see chart on next
page).

Subsequent Inspections:
Visually check that boom connector pads are flush. There may be some gap due to uneven
surfaces between the two pads, but the gap should not be continuous throughout the entire pad
area. A good way to check the bottom bolts is to raise the boom slightly out of the boom cradle
before checking for gaps. Check to see if gap closes when boom is set back in the cradle.

Check the torque by applying proper torque with a torque wrench. If the nut turns, record this
condition and recheck after 12 - 24 hours of operation. If the nut turns again, change the bolt,
nut and hardened flat washer.
POINT
POINT
Bolt Inspection Procedure R2 Page 1 of 2

Recommended Torque

GRADE 8
* TEFLON

COATED (BLUE)
BOLT SIZE
DRY TORQUE
FT-LBS
WET TORQUE
FT-LBS
DRY TORQUE
FT-LBS
2 10,000 6,400 7,500
2 7,300 4,700 5,500
2 5,000 3,235 3,750
1 3,325 2,152 2,500
1 2,185 1,414 1,600
1 1,200 777 900
1
1
/
8
860 557 650
1 600 388 450
7
/
8
400 260 300
275 175 190
5
/
8
160 100 110
80 50 -
3
/
8
32 20 -
* DO NOT USE LUBRI CANT ON TEFLON COATED BOLTS
All bolts 1 and larger must comply with SeaTrax Specification for Large Diameter Nuts &
Bolts. All others are Grade 8.

NOTES:
1. For wet torque, Molybdenum Disulfide Greaseis the only approved lubricant. Other lubricates
require different torque values. DO NOT USE ANY LUBRICANT ON TEFLON COATED BOLTS)

2. The torques listed above are lower than maximum allowable for each respective bolt size due
to the low load requirement in this particular application.

3. Stainless steel bolts are typically used on non-structural items where specific torque is not
required, therefore they are not included in this table.

Please direct all questions concerning this procedure to:

Service Manager
SeaTrax Inc.
13223 Spencer Rd. (FM 529)
Houston, Texas 77041 U.S.A.
tel.: (713) 896-6500
Bolt Inspection Procedure R2 Page 2 of 2
fax: (713) 896-6611

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Phone: 713 896 6500 Fax: 713 896 6611

Bolt Specifications R1.doc Page 1 of 1
8 May 2001
For Hoist Mounting, Gantry Connections, & Boom Connections

All nuts & bolts 1 diameter and larger must to be ordered as follows:

Bolts:
ASTM A 354 (current issue) Grade BD Hex Head Bolts
Dimensions to be in accordance with ANSI/ASME B18.2.1
Threads to be Unified National Coarse per ANSI B1.1
Finish to be Fluorokote #1, blue.
Grade Marking to be six (6) radial lines on the head per ASTM A 354 section 15
Certification per ASTM A 354, section 14 is required. (Includes Mill Certs)

Nuts:
ASTM A 194 (current issue) Grade 2H Heavy Hex Nuts
Dimensions to be in accordance with ANSI/ASME B18.2.2 for Heavy Hex Series
Grade Marking to be 2H per ASTM A 194 section 11
Certification per ASTM A 194, section 13 is required. (Includes Mill Certs)

Washers:
ASTM F 436 Hardened Flat Washers (1 ea. under each nut)

Acceptable alternative for bolts with 1 to 1 diameters is as follows:

Bolts:
SAE J 429 (current issue) Grade 8 Hex Head Bolts
Dimensions to be in accordance with ANSI/ASME B18.2.1
Grade Marking to be six (6) radial lines on the head per ASTM A 354 section 15
Mill Certs are required

Nuts and Washers:
No Acceptable alternative

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Phone: 713 896 6500 Fax: 713 896 6611

Load Block and Overhaul Ball.doc Page 1 of 1
4 April 2001

General

Never use a hook whose throat opening has increased, or whose tip has bent to the point the
locking pin can not be inserted through the locking latch and hook body. Inspect the
shackle eyelet in the hook for deformation or damage. If it is significantly deformed, the
hook should be taken out of service. Latches will not work properly on hooks with bent
or worn tips.

Always visually inspect any shackle before using and verify it is the correct rating (tons)
for that load , and that it is not visibly deformed or missing the nut or cotter pin. Inspect
the bolt of the shackle to insure it is not bent or damaged.

Never repair, alter, rework, or reshape a hook by welding, heating, burning, or bending.
Non-conforming hooks should be replaced.

Load Block Inspection

Visibly verify that the load block sheave(s) have been properly greased, are in good
condition, and rotate freely. There should be no visible cracks in the load block weldment.
The load block bearing should be properly greased and rotate freely.

During the annual inspection, the shaft and sheaves must be removed, cleaned, and
thoroughly inspected.

Overhaul Ball Inspection

Visually inspect the Astinger line@(from overhaul ball to hook) checking for broken wires,
damaged hook, or loose/missing bolts/pins.

During the quarterly inspection, remove the bolts at the bottom of the overhaul ball and
slide it up. Inspect the bushing (at the top of the block), swivel, pins, wedge socket, and
wire rope

See Section F, Rigging, for proper methods of inspecting wire rope (stinger cable).


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Wedge Sockets
Phone: 713 896 6500 Fax: 713 896 6611

Wedge Sockets.doc Page 1 of 2
1 August 1999
Wedge Sockets

Securing rope dead end in a wedge socket

Wedge socket will be installed with the live load side of the wire rope in line with the wedge socket
pin. One wire rope clamp is to be used in conjunction with the wedge socket (on the Terminator
style).

This style wedge socket is assembled by attaching a clamp through the wedge, and securing to the dead
end of the line.

Wherever a cable clamp is used, it MUST be torqued to the manufacturers specifications.
Phone: 713 896 6500 Fax: 713 896 6611

Wedge Sockets.doc Page 2 of 2
Other allowable methods for securing dead ends
(per API RP2D)

Cable Clips
Crosby G-450
Rope
Diameter
SeaTrax
Part No.
Clip Torque
(Ft.Lbs)
5
/
8
- 95
3
/
4
10005 130
7
/
8
10006 225
1 10007 225
1
1
/
8
10019 225
1
1
/
4
10025 360
1
3
/
8
10049 360
NOTE: Torque values shown are based upon the
threads being clean, dry, and free of lubricant.
Use wire to loosely
attach rope
Maximum 3 times
rope diameter
Minimum 7 times
rope diameter

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Boom Lock Operation
Boom Lock Handle.doc Page 1 of 1

Phone: 713 896 6500 Fax: 713 896 6611

1 May 2001
Boom Lock
Boom Lock Function:

The Boom Lock has been designed to hold the boom in place during service of the motor or
gearbox. DO NOT engage the Boom Lock while the drum is turning, it is not designed as a
brake. DO NOT engage the Boom Lock and drive the hoist in the down direction. This can
damage the lock assembly and gearbox.

Boom Lock Operation:

The new boom lock has been specifically designed to require two people to operate because crane
operators tend to use it for more than a maintenance tool and forget it is engaged.

To engage the Boom Lock, have a maintenance person stand on the gearbox side of the boom hoist
and locate the handle for the Boom Lock. With one hand, push the handle forward. As the handle
moves forward, the latch will release. With the other hand, pull the latch up against the handle.
Allow the handle and latch to move to the back under the pressure of the spring. The operator can
now very gently boom down until the boom lock is fully engaged and the boom stops lowering (the
boom point may move less than a foot). DO NOT continue to drive into the locking pawl, it is not
designed to take the immense force generated by a motor and gearbox. Visually verify that the
pawl is fully engaged in the ratchet mechanism.

To release the Boom
Lock, the operator must
boom up slowly as the
maintenance person
holds the latch and
pushes the Boom Lock
Handle forward until
the latch can drop over
the pin. Slowly lower
boom to ensure the pawl
has fully released.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Phone: 713 896 6500 Fax: 713 896 6611
Boom Limit, Hydraulic Page 1 of 1
10 February 2000
GENERAL:
SeaTrax cranes are equipped with a mechanically operated hydraulic Boom Hoist Limit system,
which limits the maximum, and minimum angles to which the boom can be moved.
The boom limit system consists of a "boom kick-out" weldment which rotates about the boom
pivot point, with an extension lever which attaches to the boom, so it moves up and down
exactly as the boom does. On the circular section of the kick-out are mounted two Cam Plates
with a ramped surface on each. Each plunger slide actuates a piston, which operates a cartridge-
mounted hydraulic control valve. These valves are mounted inside the valve body, which is
bolted to the upperworks at the boom pivot point.
OPERATION:
When the left hand joystick is pulled back, hydraulic oil from the control circuit is sent to the up
side of the boom control valve. Between these two points is the boom kick-out. As the boom is
raised, the arm of the kick-out raises also until Plunger Slide "A" contacts its piston. This
actuates the cartridge valve and dumps pressure from the joystick to the tank; therefore, the
control valve no longer receives the signal to boom up. As the boom is lowered, the arm of the
kick-out moves down until Plunger Slide "B" contacts its piston, again causing oil pressure to
dump back to the tank.
ADJUSTMENT: (Refer to Boom Kick-out drawing in Bill of Materials. and Component
Data Section)
Each Plunger Slide plate has two curved slots, which allow the plate to move back and forth
along a fixed radius, corresponding to a range of different boom positions. The "A" plunger
slide should be adjusted to provide a minimum of 12" of clearance between the boom and the
boom stops when the valve kicks out at maximum angle. If the distance is not correct, loosen
the two bolts attaching the plunger slide, and move it in the proper direction to produce the
desired result.
The Boom Hoist Kick-out should be tested several times while raising the boom, first low speed
and then full speed, to ensure that the boom does not contact the boom stops with excessive
force. The next step is to adjust the low angle limit on the kick-out system. The "B" plunger
slide should be adjusted so that the valve kicks out when the boom is horizontal, 12 below the
boom cradle. Adjust the plunger slide as necessary, and re-tighten the bolts. The kick-out will
require periodic readjustment throughout the life of the crane.
This system is a SAFETY FEATURE and should NEVER be disconnected.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Hydraulic Adjustments, HP Page 1 of 4
Phone: 713 896 6500 Fax: 713 896 6611
11 November 1999
Hydraulic System Adjustments for
High Pressure Cranes
Pressure Relief Valves:
Pressure relief valves are installed in a circuit to make certain that system pressure does not
exceed safe pre-set limits. Relief valves are intended to relieve occasional excess pressures
arising during the course of normal operation. Excess fluid is allowed to return to the
reservoir through an outlet port in the valve while full adjusted pressure is maintained in the
system.
Check pressure by observing gauge located on the operator's console.
NOTE: All hydraulic system adjustments should be performed only when the engine and
hydraulic system are at normal operating temperature. If the crane is cold and has not been
run, start the engine and run the crane to allow the hydraulic oil to warm to near normal
operating temperature.
Main/Auxiliary and Boom Hoist (Refer to Control Valve and Pump Drawings)
1. Locate the pump and corresponding control valve and brake actuator.
2. On the brake actuator, disconnect and plug the line running from the brake release
valve to the brake release actuator (brake line closest to hoist frame).
3. Look at the pump from the back. Find the regulator assembly (this is located 90
clockwise from the suction pipe). There are two adjustment screws on the backside
(there may be a cone shaped cover over them that must be removed. Only adjust the
one furthest clockwise. Loosen the jam nut and turn this screw all the way in. DO
NOT adjust the other screw.
4. On the control valve, locate the pressure relief valve (this may be covered by a
disposable orange cap). Loosen the jam nut and back out the screw one full turn.
5. Start the engine and let it run for five minutes.
6. Have the operator drive the corresponding hoist in the full down position at full throttle.
This should be held during the complete adjustment process. (Since the brake release
line has been disconnected the hoist should not move.)
7. Read the pressure on the corresponding pressure gauge in the cab. It should be about
2000 psi.
8. On the control valve, slowly turn the screw in until the pressure reaches 5,800 psi.
Lock the jam nut at this pressure.
9. Return to the pump and back out on the adjustment screw until the pressure drops to
5,400. Lock down the jam nut.
10. Reconnect the brake release line. Pressure adjustment on the pump and valve is now
complete. For Safety, DO NOT set operating pressures above 5,400 psi.
NOTE: Since the main hoist and auxiliary hoist share the same pump, control valve,
and relief valve, all auxiliary hoist relief valve adjustments are completed using the
main hoist, as detailed above.
Swing System Relief Valve
NOTE: All adjustments are done at full throttle with the slew joystick full right or left.
1. Start engine and let run for five minutes.
2. Engage swing brake on console. Slew
gears must not turn during adjustment.
3. Move left-hand joystick right and increase
engine speed to maximum RPM.
4. Read pressure relief valve setting on
Swing System pressure gauge in console.
Pressure should read 2500 psi 50 psi.
Repeat step (3) but to the left.
5. If pressure is not correct, locate the
crossover relief valve bolted atop the
swing motor. Remove the plugs in the
end of the relief valve cartridges (fluid
will slowly leak out, this is normal).
6. Insert an Allen wrench into the end of the
cartridge and screw the plunger into the
cartridge (clockwise) until it bottoms out. Do this for all cartridges. Now the crossover
relief valves are closed.
7. Slowly move the left-hand joystick fully to the left or right while increasing engine
speed to maximum. The Slew Pressure should read 2,800 psi 50. If the pressure is
correct, move to step 11. If pressure needs adjustment, continue to step 8.
8. Locate the slew control valve (usually on the floor of the valve cabinet or engine
house).
9. Remove the acorn nut and brass washer if equipped. Loosen the jam nut and slowly
turn the set screw into valve (clockwise) to increase pressure, or unscrew (counter
clockwise) to reduce pressure.
10. Once 2800 psi has been achieved, lock the jam nut. Replace the brass washer and
acorn nut if removed. NOTE: 2,800 psi may not be achievable on worn pumps. In
this case, turn the set screw in a few turns. Next, watch the pressure as the screw is
backed out. Once the pressure starts to drop, stop and set the jam nut. Replace the brass
washer and acorn nut.
11. Return to the slew area and locate the front cartridge in each crossover relief valve.
12. With the joystick in the full right position and the throttle fully depressed, slowly
unscrew the plunger in the front cartridge until the pressure drops to 2,500 psi. For
single slew motor units move to step (14), for multiple slew motor units continue to
step (13).
13. Move to the next motor assembly and front cartridge. Unscrew the plunger until the
pressure drops below 2,500 psi then screw it in slightly. Repeat this step for any
remaining front cartridges.
14. Move the joystick to the full left position and repeat steps (12) and (13) for the rear
cartridges.
15. Replace all plugs into the cartridge ends.
Control System Relief Valve
1. Start the engine and let it idle for five minutes.
2. Allow the engine to warm up and the engine to idle (about 925 RPM). Read the
Control System pressure gauge while the engine is idling. The gauge should read
approximately 600 psi 50 psi with the crane at normal operating temperature.
3. If the pressure is not correct, find the control system pressure relief valve. Loosen the
rear knurled jam nut and screw the front knob into valve (clockwise) to raise pressure,
or unscrew (counter-clockwise) to lower pressure until gauge reads 600 psi. If pressure
will not come up to 600 psi, close the three motor cooling needle valves near the
control system relief valve. If the pressure still does not increase, the control system
filter may require replacement if installed in the line before the relief valve (refer to
hydraulic schematic).
4. If pressure now raises above 600, lower it to 600. Slowly open all three needle valves
equally until pressure just starts to drop. Lock down all adjustment knobs. Pressure is
now set. NOTE: The needle valves are typically set at 2 turns (gold).
5. Raise engine to maximum RPM and check pressure gauge. Gauge should read no
higher than about 700 psi. If the pressure is substantially higher, this may indicate a
problem with the relief valve. Long term usage in this condition can artificially shorten
the life of seals in the control system. Contact SeaTrax for assistance in resolving this
problem.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Brake Inspection 60 500-500.doc Page 1 of 5

Phone: 713 896 6500 Fax: 713 896 6611

28 June 2007
Drum Brake Inspection, Adjustment, and Replacement

General
Seatrax cranes are equipped with drum type brakes with external brake bands. The brake is tightened
around the drum by the force of the brake actuator.

The actuator holds tension on the brake band by use of an internal spring(s). To release the brake,
hydraulic pressure is applied to the actuator forcing the internal piston to retract the piston rod and
compress the spring(s).

NOTE: All adjustments and testing should be done with no load unless otherwise stated.

Inspection
The brake band and associated components should be periodically inspected for wear or deformation.
When inspecting the components, insure that:
? The band material is sufficiently thick (rivets are not wearing into drum).
? There are no cracks or deformation of band weldment.
? All nuts are tight.
? The brake band bushing (over eccentric pin) is in good condition (most commonly worn part).
? The eccentric pin is in good condition (damage occurs once brake band bushing wears through).
? Brake arm is within 5 of vertical (approximately).
? The eccentric pin is in a position either nearest or farthest from the drum (depending on the
application).
? The actuator and associated hoses are not leaking.
? All shoulder bolts and cotter pins are in good condition.
? The brake holds when tested.

Testing
To test that a brake will hold when applied:
? Disconnect brake actuator pressure to release line.
? Run hoist in the down direction at full power to ensure brake holds.
? If brake squeals or does not hold, see Adjustment.
? If the drum does not turn, re-attach all hoses, testing is complete.

Adjustment
NOTE: If the joystick is gently moved forward, the brake will release before the motor has enough
pressure to turn. This will make it easier to adjust the nuts holding the brake band.

Follow these steps to adjust the tension on a drum brake:
1. Inspect the brake assembly as noted in Inspection above.
2. If the eccentric pin, or brake arm, is not in the correct position, this must be corrected first.
3. Loosen the jam nut several turns.
4. Back out the band nut until it is at the end of the threads.
5. Release the joystick to reset the brake.
6. At this point there should be no tension on the brake band.
7. Adjust the eccentric pin and brake arm to the point nearest their correct position (the brake actuator
should be fully extended).
8. Gently push joystick in the down direction while tightening the brake nut.
9. Periodically release the joystick and check the angle of the brake arm (it should be near vertical).
10. Tighten the jam nut and test the brake in the down direction.
11. If the brake holds, adjustment is complete, if not, go to the next step.
12. Loosen jam nut, release brake, and tighten the bad nut 1 turns.
13. Tighten jam nut and test brake.
14. If brake fails to hold, repeat steps 12 and 13 only one more time.
15. If the brake fails again, either the brake band or actuator is faulty (assuming the all parts are
installed correctly).
16. Remove the brake band and inspect the lining.
17. If the rivets are not wearing against the drum and the band is not oil soaked, reinstall band.
Otherwise, replacement is necessary.
18. Remove the brake actuator and disassemble. The most common causes of failure are worn seals or
broken springs. If the piston cylinder is not scarred, the actuator can be rebuilt, but replacement is
suggested.

New Brake Band Installation
If the brake band is replaced, it is necessary to burn- in the new band to prepare the brake lining for
operation and to conform the band assembly to that particular drum. NOTE: Once a band is burned- in
to a drum, do not use it on a different drum, it MAY NOT HOLD.
NOTE: If the joystick is gently moved forward, the brake will release before the motor has enough
pressure to turn. This will make it easier to adjust the nuts holding the brake band.

1. Remove band nut and flat washer.
2. Remove cotter pin from eccentric pin.
3. Slide the threaded end of the brake band out of the hoist frame.
4. Remove band eyelet hole from eccentric pin.
5. Remove bolt and retainer cap from brake arm.
6. Remove eccentric pin from hoist frame.
7. Inspect the complete eccentric pin for groves or excessive wear. A pin should be replaced if there
are any groves in the small pin portion.
WARNING: Keep body parts and clothing away from rotating drum.
8. Inspect the two eccentric pin bushings in the hoist frame. Replace as needed.
9. Clean and install eccentric pin (do not lubricate pin or bushings).
10. Rotate eccentric pin to correct position and install brake arm, retaining cap, and bolt with lock
washer. Coat bolt threads with loctite 242.
11. Remove the jam nut and lock washer from the old band and install them on the new band (if new
parts are not supplied). If new nuts or washers are installed, they must adhere to the SeaTrax
Specifications for Large Diameter Bolts and Nuts.
12. Install brake band over drum and insert the eyelet over the eccentric pin.
13. Insert cotter pin through the eccentric pin, and threaded portion of band through the hoist frame.
14. Release tension from the brake actuator and install the flat washer and band nut.
15. Now you MUST burn-in the new band.

New Band Burn-in
When burning- in a new band, the hoist must rotate in the UP direction only.

1. Lower the hoist to its lowest position.
2. While raising the hoist at wide-open throttle, tighten the band nut until the hoist begins to strain but
does not stop. For cranes with gear pumps, pressure should be 1,800-2,000 psi. Variable volume
crane pressure should be approximately 3,500 psi.
3. When the hoist is at its highest point, loosen the nut slightly.
4. Repeat steps 1-3 until the band starts to smoke.
5. Once the band is smoking, leave the band nut tight and wait until the band cools down.
6. After the band has cooled, follow the steps on Adjustment.

Typical Brake Assembly

Phone: 713 896 6500 Fax: 713 896 6611

Drum Brake Linkage Adjustment
Typical Hoist

1.0 ADJUST DRUM BRAKE LINKAGE:

1.1 On both brake eccentric shafts, the pin that engages the brake band MUST be at the
point nearest the drum when the brake is engaged.

1.2 Loosen jam nuts on brake bands. Tighten or loosen adjusting nuts as necessary until the
brake lever is in the vertical position and the eccentric pin is oriented as shown.

1.3 Tighten the jam nuts.

NOTE: The brake band should have a nut and lock washer on the inside and a flat washer and
nut on the outside. Brakes should look as shown when engaged.

Phone: 713 896 6500 Fax: 713 896 6611

Boom Drum Brake Linkage

2.0 ADJUST DRUM BRAKE LINKAGE:

2.1 Loosen jam nuts on brake band, tighten or loosen adjusting nuts as necessary until the
brake lever arm is 90? to the brake push rod when the brake is engaged.

2.2 On the Boom brake eccentric shaft, the pin for the brake band should be at a point
nearest the drum.

2.3 Having the eccentric pin in the wrong position can cause the brake to apply improperly. Excessive wear
and eventual failure could also occur.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Boom Butt Bushing Replacement.doc Page 1 of 2

Phone: 713 896 6500 Fax: 713 896 6611

28 June 2001

This procedure describes the replacement of boom butt bushings on all Seatrax cranes.

1. Lay boom into boom rest.
2. Remove all tension from boom suspension.
3. Tightly secure boom to boom rest with strap, or other adequate method, to keep boom from
shifting in boom rest.
4. Disconnect boom high/low angle kickout assembly from upper works.
5. Remove keeper bolts from boom butt pins.
6. Connect adequate means of support to boom butt section and first straight section of boom.
(Figure 1) Note: Adequate support would require support of 75 % of boom estimated weight.
7. Lift boom butt slightly to remove all tension on pins.
8. Once tension has been removed, drive out boom butt pins.
9. Lift, or lower, boom to gain easy access to the bushings. Drive out boom butt bushings (old
bushings can be cut with a hacksaw to ease removal).
10. From the outside of the boom, install new bushings with a large soft face hammer.
11. Lubricate bushing with the appropriate grease.
12. Perfectly align hole in upper works with hole in boom butt.
13. Drive boom butt pins into boom.
14. Install keeper bolts.
15. Assemble boom high/low angle kickout assembly back onto upper works.
16. Lubricate the pins with at an appropriate amount of grease.
17. Remove strap securing boom to boom rest.
18. Tighten boom suspension and raise boom out of boom rest.
19. Ensure the boom high/low kickout is adjusted properly.

Boom Butt Bushing Replacement.doc Page 2 of 2

Phone: 713 896 6500 Fax: 713 896 6611

Figure 1


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Phone: 713 896 6500 Fax: 713 896 6611

S Series Swing Bearing Replacement .doc Page 1 of 3
May 5, 2005
Swing Bearing System Replacement Procedure
For S Series Cranes

Introduction
The SeaTrax Marine Crane uses a unique swing bearing system, which allows inspection or
replacement with hand tools only. A separate crane is not required to lift a SeaTrax crane
completely off the fixed Kingpost.

Operation
The SeaTrax bearing system consists of two sets of bearings. The upper bearing is a circular
bushing block, which is located at the top of the Kingpost. A circular steel frame at the top of
the gantry surrounds the bearing. Above this is the bearing thrust plate and collector ring
assembly. The vertical force component due to the crane and horizontal force component (the
overturning moment) of the crane and load is transferred to the fixed Kingpost through the
cylindrical section of the upper bearing at the top, and through the bearing shoes at the bottom.
The lower bearing shoes pin directly to the turntable at the base of the Upperworks.

Bearing Wear
The upper bearing should be replaced if " of the 1" thick material has worn away from its
inside diameter, or from the horizontal surface. The lower bearing shoes should be replaced
when no more than " of the thick material has worn away from the middle of the shoe. If
the plastic bearing material wears away to the point of metal-to-metal contact, the crane will
make a dragging noise or may refuse to swing, especially with a heavy load. If metal-to-metal
contact occurs, the crane should be stopped immediately and the problem corrected. Continued
use of the crane can damage the kingpost-bearing surface and require extensive repairs.

Tools Required for Bearing Replacement
Three 50-ton hydraulic pancake jacks
Four 1-8 x 5 Large UNC Bolts
4x4x8 Hardwood Timbers

Lower Bearing Shoe Replacement

1 Put the boom in the boom rest with slacked lines to decrease the load on the bearing shoes.

2 Remove rear shoes to allow movement.

3 Center the Upperworks on the Kingpost by placing 50-ton pancake jacks at base of Upperworks
arranged with equal spacing.

4 Remove the front shoe retaining pins and pull the shoe assemblies straight up.

5 Remove the four sheet metal screws, which mount the plastic shoe to the steel shoe
support.

6 Install the new shoes to the steel shoe support and tighten the mounting screws.

7 Apply a liberal amount of EP multi-purpose grease to the bearing surface of the new shoe
and the bearing surface of the Kingpost.

8 Install thefront shoe assemblies to the turntable and reinstall the retaining pins.

9 Release hydraulic jack to allow the Front Shoes to come to rest against the Kingpost.
Install the Rear shoes.

10 Grease each bearing with a grease gun. The crane is now ready to operate.

NOTE: The side and rear shoes do not wear
out like the front shoes and in an emergency
they can be rotated with the front shoes until
new ones arrive.

Upper Bearing Replacement

1 Lower the boom to the boom rest and
slacken the boom suspension lines slightly.

2 Place hardwood timbers between the bull
gear and the bottom of the turntable. Shim
between hardwood and bottom of turntable
to achieve best fit. Place three 50 ton
pancake jacks under turntable in a manner
to allow adjustment of upper bearing
housing front to rear and left to right in
relation to the upper bearing block. These
jacks will allow centering of upper bearing
for removal and reinstallation of the upper
bearing block. Loosen the upper bearing
thrust plate bolts in order to lower the upper
works onto the timbers.
Place pancake jacks around the
kingpost in this position

Phone: 713 896 6500 Fax: 713 896 6611


3 Unbolt and remove the bearing retainer blocks and the bearing thrust plate.

4 If the top of the Kingpost is resting against the front of the bearing, use the jacks to make
adjustments. Boom suspension lines need to have some slack in them.

5 If the top of the Kingpost is resting against the back of the bearing, use the jack to make
adjustments.

6 Use the three 50-ton pancake jacks to center the Upperworks about the Kingpost if any
more adjustment is needed.

7 Mark the orientation of the bearing assembly so it can be replaced in the same direction.
Remove the upper bearing assembly by placing 4 bolts (with 1-8 x 5 unc threads) in the
top of the bearing and lifting straight up.

8 These cranes have a 2 piece upper bearing. Lift out the worn synthetic radial / thrust
bearing and press in the new ones. It is important to replace both pieces of this bearing at
the same time.

9 Lubricate the new bearings with EP grease and set them into the gantry in their original
position. Bolt the bearing thrust cover plate and the retaining blocks down and torque to
specs.

10 Remove the timbers and release and remove the three 50 ton pancake jacks from beneath
the Upperworks.


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Phone: 713 896 6500 Fax: 713 896 6611
Emer Slew All Rev.2.doc Page 1 of 1
April 28, 2005
for All Series Cranes
This crane is capable of being rotated without power from the prime mover. The emergency
slewing process is very slow and should only be used if no other method is available.
1. Remove all slew motors and all but one brake from slew gearboxes (the brake assembly
is directly below the motor). In most instances, you can leave all hoses connected.
2. On the remaining brake, locate the top hose fitting. Disconnect the existing hose and
attach a hand pump with gauge to the brake.
3. Insert a splined hand crank (available from SeaTrax parts dept.) into the spline on top of
each gearbox.
4. Release the slew brake by pumping 300 to 500 psi into the line.
5. Turn all hand cranks clockwise for slewing to right, and counterclockwise to slew left.
6. Number of revolutions required to rotate the crane 90 degrees:
36SB Series 491
42SB Series 491
42 Series 491
60 Series 592
72 Series 826
7200 DR 1468
80 Series 826
90 Series
105 Series 2000*
115 Series 1020
126 Series 2367*
S72 Series 805
S90 Series 944
7. The required torque in mild conditions will be approximately 25-50 ft. lbs. In high wind
or listing conditions, a slew torque of 75 to 100 ft. lbs. could be required.
NOTE: Removing part no. 20078 pancake gear reducer will lower the number of turns
required, but significantly increase the torque.
8. When the desired position is reached, release the pressure at the hand pump to set the
slew brake.
9. Reinstall and check all items that were removed once slewing becomes possible.
* Due to the high number of revolutions required to rotate 90, SeaTrax suggests the use of an auxiliary
hydraulic power unit attached to one motor and removing the remaining motors and brakes.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Phone: 713 896 6500 Fax: 713 896 6611

Emer Load Lowering_Rev.2 Page 1 of 1
18 April 2006
Variable Displacement System

In the event of power loss and a load is left suspended, the SeaTrax crane hoists are equipped to allow
emergency load lowering.

Retrieve the Brake Release Tool attached to the lower left side of the boom hoist frame. NOTE:
If tool is missing, a " UNC threaded rod about 1 foot long with a flat washer and nut can be
substituted.
Tools needed: (2x) 1 1/8 & (1x) 1 1/2 wrench, (1) hammer, (2) 10mm allen wrench (hex key),
and Proper Safety Equipment

1. Close all hydraulic suction shut off valves.
2. Go to hoist that need to be lowered.
3. Remove spring side cap of motor control valve. (on rear of hyd. motor)
4. Remove spool assembly from motor control valve.
5. Reinstall spring side cap.
6. Insure that all hydraulic hoses are connected. (Plugged hoses or fittings can
be harmful to personnel or equipment).
7. Open all hydraulic suction shut off valves.
8. Remove Boss plug in top of brake actuator cylinder.
9. Install nut and flat washer on Brake Release Tool. Insert brake release tool
into brake cylinder and thread into hole in top of brake piston.
10. Slide down flat washer, and thread nut down until snug.
11. Hold rod from rotating while turning nut clockwise. This will pull piston
and rod up, therefore releasing the brake. CAUTION: During this step, tap
brake band with a hammer to avoid a sudden release.
12. As hoist begins to turn, turn nut counterclockwise to slow it down or stop.
Turn it clockwise to release or increase the speed. Do not lower load fast.
Lower it slowly. (about 1 to 3 drum revolutions a minute)
13. When load has been lowered and released, remove tool and replace Boss
plug.
14. Close all hydraulic suction shut off valves.
15. Remove spring side cap of motor control valve and reinstall spool assembly.
16. Reinstall spring side cap of motor control valve.
17. Open all hydraulic suction shut off valves.
18. Once the crane is back in service insure that there are no hydraulic leaks.

Brake Release Tool
Boss plug
Flat washer
and nut


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Page 1 of 2

MAERSK OIL QATAR AS
AL SHAHEEN FIELD DEVELOPMENT 2005
GA Wellhead Module, ED, GD and GB Platforms
MOQ CONTRACT C-01226

NPCC Purchase Order Number : 6048-07-70033-AC
Equipment / Material : PEDESTAL CRANE
MOQ Equipment Tag No : ASEDA-A-6101/ ASGDA-A-6102/ ASGAA-A-6101 / ASGDA-A-6101
MOQ Equipment Title : ED Crane, GD East & West Cranes & GA Crane

PRE-COMMISSIONING / COMMISSIONING & START-UP SPARES LIST

MOQ DOC. No.: ASYYY-10-70033-0047
NPCC DOC. No.: 6048-70033A-W004-001
VENDOR DOC. No. : G001 SXCSL4527/4528/4529/4530

NATIONAL PETROLEUM CONSTRUCTION COMPANY
P.O. BOX 2058, ABU DHABI, UNITED ARAB EMIRATES

SEATRAX UK LTD

2 18-Mar-08 Revised incorporating customer comments for review and approval
1 27-Nov-07 Revised incorporating customer comments for review and approval
0 09-NOV-07 Issued for approval
REV DATE REMARKS CHK REVD APVD
ROGER MATTIS
Project Commissioning Manager
23/03/2008
Vendor to add names
Based on 100 hours per month

Portland Wharf, Southtown Road, Gt Yarmouth,
Norfolk, NR31 OJ J , England
Phone: 44 (0) 1493 651311 Fax: 44 (0) 1493 604900

Start Up & Commissioning Spares List

Date: 18
th
March 2008 Model No.: 3 No. S7226 Cranes & 1 No. S9028 Crane
Project: NPCC Maersk Oil Qatar Packages 17 & 18 Crane Serial No: 4527 / 4528 / 4529 / 4530-UK
Equipment: Seatrax Marine Crane 4 No. Contact: Dave Abel

Item

Description

Part No.

Qty
Unit Price
($s)
Ext. Price
($s)

Remarks
1 Seal Kit SK001 4 F.O.C. F.O.C. Delivery with Crane
2
Gasket Kit GK001 4 F.O.C. F.O.C. Delivery with Crane
3 EP90 Gear Oil EP90 4 x 50ltr F.O.C. F.O.C. Delivery with Crane
4 Hydraulic Oil HV68 4 x 205ltr F.O.C. F.O.C. Delivery with Crane
5 Main Hydraulic Filter 40133 4 F.O.C. F.O.C. Delivery with Crane
6 Control Circuit Filter 40135 4 F.O.C. F.O.C. Delivery with Crane
TOTAL COST = NIL

NOTE: 1) Above quantities are the totals for all 4 cranes and shall be delivered with the cranes
2) Item 5 & 6 Filters cannot be cleaned up and reused.
3) See Lubrication Schedule for recommended types of Oil to be used on the Seatrax crane
4) The Operations & Maintenance Manual (including Cabin Equipment) details all the cranes equipment. This list is purely for Start-up and Commissioning
Spares.
5) Item 1 is a selection of O Rings for the hydraulic hose connections
6) Item 2 is CAFF Gasket Paper for pumps and motor gaskets
7) Please note that the seal kit and gasket kit will probably not be required as system will have been pressurised and commissioned at our factory.
8) The 2 year Operating Spares List has been submitted as a separate document.
2

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


1f
VENDOR
DOCU ... ENT STATUS
18l '
""""'"
o 8 . CO/.'IUENTS .o.s MARKED
Dc. NOT ACCI;:PTEO
o D
.. IXllI N01 ..,..,fCl-OO::-
LWlt.I1lU UIO llEiPCtISD.1TEli A811'fF1.V,1'(O
Wlml<THE f'IIACl our
IIHDoet<cnlCNl-
I VHlOCRM..-JDJNF."'Ml'OU
couwt:m1 VI1IL IE MXRIORATED
8EFORS I'ROCEf:DIttQ;
t .ou. DClCIJtoEH'IB .... ' OII.l_ ..

MAERSK
,-

Cl\TIFlCA T10N ENGIrEER
MAERSK OIL QATAR AS

Ow.! 00lIt 08.01.2008 1
GA Wellhead Module, ED, GO and GB Platforms
NPCC Purchas e Order Number : 6048-07-70033-AC
Equipment I Materi al : PEDESTAL CRANE
MOQ Equipment Tag No : ASEDA-A-6101! ASGDA-A-6102! ASGAA-A-6101 ! ASGDA-A-6101
MOQ Equipment Title : ED Crane, GO East & West Cranes & GA Crane
2 YEAR SPARES LISTINGS
MOQ DOC. No.: ASYVY10-70033-0012
NPCC DOC. No.: 6048-70033A-AOO4-001
VENDOR DOC. No. : G002 - SXOSL4527/4528/4529/4530

..
NPI:I:
SEATRAX
- "'ARIN e

NATIONAL PETROLEUM CONSTRUCTION COMPANY SEATRAX UK LTD
BOX 2058, ABU DHABI, UNITED ARAB EMIRATES
2 07-Jan-08 Revised incorporating customer comments for revi ew and approval
1 03-Jan-08 Revised incorporating customer comments for revi ew and approval
0 09-Nov-07 Issued for approval
Page 1 of 2

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION D LUBRICATION (G025 / G026 / J037)

Comprehensive Information, Diagrams and Charts
Hydraulic Oil Chart

Page 1 of 12

MAERSK OIL QATAR AS


LUBRICATION SCHEDULE

MOQ DOC. No.: ASYYY-10-70033-0033
NPCC DOC. No.: 6048-70033A-G025-001
VENDOR DOC. No. : G003 SXLS4527/4528/4529/4530


SEATRAX UK LTD

1 27-Oct-08 Revised incorporating customer comments (oil capacities)
Nadarajan Ganapathy
Sr Project Engineer
Tel. 0097125023698
13-11-08

Phone: 713 896 6500 Fax: 713 896 6611

Lubrication
General Information

It is recommended that a periodic lubrication schedule be established for the crane and that
this schedule be carefully followed. All lubrication intervals recommended in the section
represents minimum safe intervals for normal conditions.
Lubrication must be preformed more frequently when the crane is subjected to extreme
temperature changes, prolonged operation, and severe weather. Lubrication periods may
be extended during periods of inactivity.

Keys to Lubrication:

Use the correct type and quantity of lubricant, applied properly, at appropriate
intervals.
Clean grease gun and grease fittings to avoid forcing grit into zerk. Bearings are best
greased while rotating.
Drain oil cases when oil is hot so the drained oil will carry off any sludge.
Keep funnels, plugs, and oil spouts clean. Wipe off oil covers before using.
Watch for signs of incorrect lubrication, neglected areas, or excess grease accumulation.
The frequency of lubrication, as given in the charts, is intended as a guide. This does
not mean that under certain operating conditions some points may not require more
frequent lubrication or other special attention. Use good judgement and common
sense in lubricating.
Oiling points should not be overlooked when lubricating. A few drops of oil should be
periodically applied to all metal parts subject to wear.

NOTE: Synthetic oils may offer a practical option for all cranes, especially those operated
in extremely high or low temperature environments. Most brands of synthetic oils provide
improved flow at low temperature and greater stability at high temperature.

CAUTION: Because of the high cost of synthetic oils, combined with large reservoir
quantities in the hydraulic circuit, there is an understandable reluctance to change the oil
once it becomes contaminated. Contaminated oil is the leading cause of hydraulic
problems, and the main contributor to component failures.

As with any oil or lube being considered, compatibility with components and seals in the
system must be verified prior to use.

Phone: 713 896 6500 Fax: 713 896 6611

Lubricant Types

EO Engine Oil, see engine manufacturer's recommendations
MPG Multi-purpose type grease with EP (extreme pressure) additive; must have a high
resistance to water washout.
MPL Multi-purpose gear lubricant, SAE-90 with EP additive
HO Hydraulic oil, per chart
WRL Wire rope lubricant, see wire rope manufacturer's recommendations
MAS Molybdenum based Anti-Seize
NOTE: All above lubricants are available in synthetic.

* Change engine oil & filter according to manufactures recommendations (See Section L OP
manual) If oil annalists is run then change as required.
** See location point Diagram attached
*** Gearbox (pump drive, planetary, etc.) oil should be changed after the first 50 hours of
operation, then at 1000 hours, or 1 year, whichever comes first. Change if there are any
traces of contamination, particles, or discoloration.

Lubrication Chart
Duty Cycles
Heavy Duty: Crane is used more than 50 hours a week
Medium Duty: Crane is used 21 to 50 hours a week.
Light Duty: Crane is used less the 20 hours a week

Heavy Medium Light Point** # of Points Lube Type Description

Daily Daily Daily H 4 MPG (8 Shots) King Post Upper
I 8 MPG (8 Shots) Lower Bearing Shoes
C 1 ea MPG (4 Shots) Boom Foot Pins
K MLP (Brush on) Bull Gear.
F 5-6 MPG (4 Shots) Bridle System (if Equipped)
D 1 EO Engine oil Level *
1 MPL Pump Drive Oil Level
4 MPL (near Full) Pump Drive Pad Oil Level

Daily Daily Weekly G 5-6 MPG (2 Shots) Gantry Sheaves
E MPG (2 Shots) Boom Point & Jib:
5 Main Hoist Sheaves
2 Aux. Hoist Sheaves
6 Boom Hoist Sheaves
(No Bridle)
A 1-3 MPG (2 Shots) Load Block Sheaves &
1 Swivel Bearings
Inspect: All Wire Ropes.
Check: Hydraulic Oil Levels

Heavy Medium Light Point** # of Points Lube Type Description
Daily Weekly Weekly B 1 MPG (2 Shots) Headache Ball Swivel
L 2ea MPG (2 Shots) Boom Stops (Spring)
D 1 MPG (2 Shots) Fan Pulley (Engine)
MPG (1 Shot) Door Hinges
J 4 MPG (2 Shots) Main, Aux & Boom
Hoist Shaft Bearing

Weekly Weekly Weekly MPG (1 Shot) Pump Drive Pad Input Shaft
H 2 MPG (1 Shot) Electric Swivel
M MPG (1 Shot) Swing Light Brackets
Check & lube Load, Boom & Aux
Wire Rope:( Section F)
K MAS (3 Shots) Pinion Gear(s)

Daily Daily Weekly Check Gearboxes: ***

6 Months Yearly Yearly Hyd. Oil Tank: Drain & Fill (See Chart)

1000hrs. Yearly Yearly Service Gearboxes:
Main Hoist: See Figure 1
Aux. Hoist: See Figure 1
Boom Hoist: See Figure 1 (Fill to Arrow)
Swing Drive: Slew Tank - Full
Pump Drive: Full on Dipstick

WARNING: Failure to lubricate the machine properly in accordance with this manual and
general good practice may cause a failure due to excessive wear or overheating, resulting in a
dangerous and costly accident.

Figure 1
Main & Aux
Hoist
Fill Point
Fill 2 Below
Plug
Boom
Hoist
Note: Each Gearbox must
be filled individually. Refer
to Service Gearboxes

Lubrication Points
G
I
H
D K
L
C
J
A
J
B
E
E
M

Typical Hoist / Gearbox
Grease Points

Grease
Point
2 Grease
Points
Grease
Point
Grease
Point

PUMP DRIVE LUBRICATION

For Part No.s 20200, 20201, 20202 & 20206

The center drive shaft should have one shot of MPG EP2 grease
applied on a weekly basis.

GREASE INSERT

PUMP DRIVE LUBRICATION

For Part No.s 20135, 20156, 20173 & 20195

Each independent drive should have 2 shots of SAE 90wt oil applied from a oil can
into the breather on a monthly basis.

BREATHERS

BREATHERS

Engine Oils

The following chart of oil grades is typical for the diesel engines installed in SeaTrax
Marine Cranes. For further information on engine lubrication, see the manufacturers
Operation and Maintenance Manual.

Ambient Temperature
Minimum F (C) Maximum F (C)
Viscosity Grade
5 (-15) 122 (50) SAE 15W40
-4 (-20) 104 (40) SAE 10W30
-22 (-30) 104 (40) SAE 5W40
-22 (-30) 86 (30) SAE 5W30
-40 (-40) 50 (10) SAE 0W20

NOTE: Synthetic oils are acceptable in diesel engines because they have improved flow
characteristics especially in Arctic conditions. All oils must meet API CH-4 requirements.

Gear Oils

Gear oils are used in all hoists throughout the crane. It is imperative that these oils are
replaced at the required intervals, especially if run at high temperatures for extended
periods of time.

As with all lubricants, using the correct grade and additives is crucial to proper
performance. Any gear oil used must have an EP (Extreme Pressure) additive. EP
additives are specifically designed to prevent metal-to-metal contact in the operation of
highly loaded gears.

The most commonly used gear oils are multi-grade types. SeaTrax hoist drives are
typically filled with 80W-90 unless the customer requests a specific lubricant. This
weight is appropriate for most operating conditions. Operations in an environment that
is extremely hot (over 100F), or cold (below 0F), may require draining the gearboxes
and refilling them with a lubricant developed for these specific temperatures.

Excessively hot environments may require the use of an 80W-140 gear oil which flows
like an SAE 80 weight gear oil in cold temperatures and gives the protection of SAE
140 weight gear oil.

Arctic cold requires the use of a 75W-90 gear oil which flows like an SAE 75 weight
gear oil in cold temperatures and gives the protection of SAE 90 weight gear oil.
In either of these extreme environments, a synthetic lubricant should be used.

Because hoist gearboxes can develop extremely high temperatures during extended usage,
these oils should be checked frequently and changed when discoloration becomes
apparent. Failure to replace gearbox oil after it has discolored can significantly shorten
the life span of the gears and bearings.

Grease

SeaTrax lubricates all bearings and bushings on the crane during the assembly process.
A high quality grease with EP and Moly additives, as well as a high resistance to water
washout, is necessary to prevent metal to metal contact and premature wear. All areas
requiring grease should be attended to as shown by the Lubrication Chart.

It is also necessary to use grease rated for the expected service temperature of the crane.

Temp. Range -40 to 40F -10 to 80F 30 to 110F
Grease

NLGI Grade 0 NLGI Grade 1 NLGI Grade 2

Hydraulic Oils

A great deal of research and testing has been performed in the selection of a hydraulic
fluid that will give optimum performance, operate in a wide range of ambient
temperatures, be long lasting, and readily available at bulk stations.

It should be understood that there are several different types of fluids that are generally
used in hydraulic systems. These are engine oils, automatic transmission fluids, and
hydraulic oils.

Engine oils are designed chiefly for use in internal combustion engines to keep the
impurities from combustion "blow-by" in suspension. It is not desirable to keep impurities
in suspension in a hydraulic system due to the critical tolerances between mating parts in
the pumps and valves, and the long intervals between oil changes.

Automatic transmission fluids, although sometimes used in hydraulic systems, are
designed primarily for use in automatic transmissions and some of their additives are not
particularly desirable for use in high-pressure hydraulic systems.

For the above reasons, neither engine oils, nor automatic transmission fluids, are to
be used in the hydraulic system.

Hydraulic oils are designed specifically for use in hydraulic systems. They are purposely
made without detergents to permit water and wear particles to settle out of the oil in the
large quiet zones of the reservoir. As a result, there is less rust and wear in the pumps,
motors and valves.

Greater chemical stability against oil oxidation is built into hydraulic oils to avoid the
necessity of frequent changes in a large volume hydraulic system. They contain longer
lasting additives to give greater shear stability, anti-wear and anti-foaming properties, and
seal compatibility.

Original Fill

High quality ISO 68 hydraulic oil is typically used for the original fill in the hydraulic
system. This type of oil was chosen because it is a non-detergent, shear stable, anti-
foaming, anti-wear hydraulic oil with high resistance to rust and oxidation. The additives
used in the oil are suitable for long duration use and are compatible with the seals used in
the crane. Its exceptionally high viscosity index allows it to thin less at high temperatures

and thicken less at low temperatures. This is an important quality for cold weather
starting. This oil can be used for temperatures from 30F to 110F.

Field Fill

Whenever oil must be added to the system, or when an oil change becomes necessary,
one of the hydraulic oils shown on the chart should be used. (Full is 2 to 3 below top)

IMPORTANT NOTES:
1. The use of oil heaters in the hydraulic tank may change the oil recommended for a
particular environment.

2. When operating in an extremely cold environment, slowly rotate each hoists for one
minute to allow warmer oil from the tank to replace the cold oil in the lines and
warm the motors.

Hydraulic Oil Chart

Listed below are the recommended ISO viscosity grades for hydraulic oil for various
ambient temperature ranges when used in SeaTrax hydraulic cranes. Also included is a list
of various manufacturers who make oil conforming to the ISO specifications. Many other
oil companies also supply oil conforming to these requirements.

ISO 22 ISO 32 ISO 46 ISO 68
Allowable Ambient
Temperature Range
-10F to 60F

(-23C to 15C)
5F to 75F

(-15C to 24C)
15F to 90F
(-9C to 32C)
30F to 122F
(-1C to 50C)
Manufacturer/Brand
B.P OIL CO. Turbinol T-22 Turbinol T-32 Turbinol T-46 Turbinol T-68
CHEVRON Industrial R&O 22 GST Oil 32 GST Oil 46 GST Oil 68
CITGO Pacemaker 19 Pacemaker 32 Pacemaker 46 Pacemaker 68
CONOCO N/A Dectol R&O 32 Dectol R&O 46 Dectol R&O 68
E.F. HOUGHTON N/A HydroDrive HP-150 HydroDrive HP-200 HydroDrive HP-300
EXXON CO, USA Spinesstic 22 Teresstic 32 Teresstic 46 Teresstic 68
MOBIL OIL DTE 22 DTE 32 DTE 46 DTE 68
PENNZOIL Pennzbell 22 Pennzbell 32 Pennzbell 46 Pennzbell 68
SHELL OIL CO. Tellus 22 Tellus 32 Tellus 46 Tellus 68
SUN N/A Sunvis 932 Sunvis 946 Sunvis 968
TEXACO Rando HDZ 22 Regal R&O 32 Regal R&O 46 Regal R&O 68
UNOCAL CORP. Unax AW 22 Unax AW 32 Unax AW 46 Unax AW 68
4527/28/29/30 UK Lubrication Schedule

Oil Capacity

Engine Caterpillar 3406 = 10 Gal (38Ltr) Approx

Quad Pump Drive = 2 Gal (7.6Ltr) Approx
(1000HP, 1:1, Part No: 20259)

Slew Gearbox = 3 Gal (11.4Ltr) Approx
(S-20 Type, Part No: 20071)

Slew System = 10 Gal (45.5Ltr) Approx
(2 Gearboxes & Reservoir)

Hoist Gearbox = 24 Gal (110Ltr) Approx
(700 Series, Part No: 20165)

Hoist Gearbox = 16 Gal (75Ltr) Approx
(400 Series, Part No: 20163)

Hydraulic Oil Tank = 330 Gal (1250Ltr) Approx
(S90 Series, Part No: TC6048)

Hydraulic Oil Tank = 300 Gal (1135Ltr) Approx
(S72 Series, Part No: TC6011)

Note: These are approximate quantities of oils required. All levels should be checked
as detailed within the Lubrication Schedule.
4527_28_29_30 Lubrication Schedule

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION E ERECTION & INSTALLATION PROCEDURE


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Page 1 of 14

MAERSK OIL QATAR AS

MOQ Equipment Tag No : ASEDA-A-6101

SHIPPING & HANDLING PROCEDURE (4527-UK)

MOQ DOC. No.: ASEDY-10-70033-0042
NPCC DOC. No.: 6048-70033A-W001-001
VENDOR DOC. No.: E005 SXPP.121


SEATRAX UK LTD


4527-UK N.P.C.C. Maersk Oil Qatar AS
Al Shaheen Block 5 S9028 Crane
Date of Issue: 27/11/2007
Issue: No: 01
Title
Component Weight and C of G Calculations Including Handling
Arrangement
Contract Ref: 4527-UK
Customer Ref: N.P.C.C
Document No: SXPP.121.01
Page No: 1 of 13

Seatrax (UK) Ltd
Portland Wharf, Southtown Road, Great Yarmouth, Norfolk, NR31 0J J
Doc No: SXPP.121

1.0 GENERAL

This procedure has been issued to enable the handling of the crane equipment, during the transport of the crane from Seatrax UK to the
installation site. This includes the Centre of Gravity and slinging Arrangement for each component.

Note: The recommendations within this procedure are based on the manufacturers knowledge of the product and do not encompass
the
constraints which may be faced during installation on site which shall remain sole responsibility of the buyer.

Due to variations in equipment supply for each crane contract, sling lengths shown should be viewed as approximate only, minor
changes may be required by the addition of shackles etc to ensure a level lift.

2.0 WEIGHTS AND SIZES

METRIC
MEASUREMENTS

Description Qty
Length in
mm
Width in
mm
Height in
mm Cubic m
Total
Cubic
metres
Weight in
kilograms
Weight in
Metric
Tons
Total
Weight in
Metric
Tons
Cab Wingdeck & Turntable 1 6,011 5,730 3,328 114.6 114.6 25,673.0 25.67 25.67
Engine House 1 5,315 3,296 4,123 72.2 72.2 11,521.0 11.52 11.52
Gantry 1 13,367 3,023 4,582 185.2 185.2 17,690.0 17.69 17.69
Kingpost 1 11,328 3,505 3,505 139.2 139.2 28,055.0 28.06 28.06
Boom Butt 1 6,096 2,997 2,369 43.3 43.3 13,064.0 13.06 13.06
Boom Insert 1 6,096 2,997 2,370 43.3 43.3 2,839.0 2.84 2.84
Boom Insert 1 3,048 2,997 2,370 21.6 21.6 1,442.0 1.44 1.44
Boom Insert 2 12,192 2,997 2,370 86.6 173.2 4,354.0 4.35 8.70
Boom Point 1 12,192 2,997 2,370 86.6 86.6 8,040.0 8.04 8.04
Miscellaneous 1 13,123 2,438 2,438 78.0 78.0 5,670.0 5.67 5.67
Total 11 Total 957.2 Total 122.7

NOTES
1. Equipment listed above is for 1 (one) crane only.
2. All weights & dimensions shown above are estimates.
Shipping weights and dimensions are confirmed at the load out.
3. The Handrails are removed from the Upperworks for transportation purposes.
4. Platforms, Handrails and Ladders are removed from the Gantry for transportation purposes.
5. The Fly Jib is removed from the Boom Point for transportation.
6. The 40 Containers Nett weight = 3,500kg. 2 (two) cranes miscellaneous items could be transported inside.

3.0 CENTRE OF GRAVITY OF THE EQUIPMENT

3.1 The centres of gravity shown on the figures below are typical of the Seatrax S9028 Series Crane c/w 52m Boom.

Cab Wingdeck & Turntable See Figure No. 1
Engine House See Figure No. 2
Gantry See Figure No. 3 & Figure No. 3a
Kingpost See Figure No. 4 & Figure No. 4a
Boom Butt See Figure No. 5
Boom Insert S20 See Figure No. 6
Boom Insert 10 See Figure No. 7
Boom Insert 40 See Figure No. 8
Boom Point See Figure No. 9

Issue: No: 01
Title
Arrangement
Page No: 2 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

3.2 The details of the lifting equipment required for each crane component is detailed in the referenced figures above.
Please refer to the figures for any special requirements of the lifting equipment.

The figures detail the following information: -

a) Slinging arrangement
b) Size, length and quantity of slings and shackles

Item Quantity Reference
Wire Rope Sling, 5.0m EWL, 15T SWL 2 Figures 1 & 2.
Wire Rope Sling, 4.7m EWL, 15T SWL 2 Figures 1 & 2.
Wire Rope Sling, 8m EWL, 10T SWL 2 Figures 3 & 4.
Wire Rope Sling, 7m EWL, 10T SWL 4 Figures 3, 3a, 5, 6, 7 & 8.
Wire Rope Sling, 6m EWL, 10T SWL 2 Figures 4, 4a & 9.
Shackle, 35T 2 Figures 3 & 3a.
Shackle, 25T 2 Figures 4 & 4a.
Shackle, 12T 6 Figures 2, 3, 5, 6, 7, 8 & 9.

NOTE: All wire rope slings should be tagged with its details (length, SWL) for easy identification. The tag slip may not be
tied to the eye of the sling or marked punched on the eye of the sling.

1

Issue: No: 01
Title
Arrangement
Page No: 3 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
6011
FIGURE 1
TURNTABLE AND CAB ASSEMBLY
4.7m, 15T SWL SLING REAR
5.0m, 15T SWL SLING FRONT
I---- 4078
4.7m, 15T SWL SLING REAR
USE CONNECTION PINS AS
LIFTING POINTS TYP. 4 LOCATIONS
NOTE: SOFTEYE ON SLING NEEDS TO BE
OF SUFFICIENT SIZE TO ALLOW PIN TO
PASS THROUGH, PROTECT PIN WITH
RUBBER AROUND SOFTEYE.
5730 ------1

Issue: No: 01
Title
Arrangement
Page No: 4 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
FIGURE 2
ENGINE HOUSE ASSEMBLY
5m, 15T SWL SLING REAR
NOTE: ADDITIONAL 12T SHACKLE
REQ'O IN NEAR SIDE SLING.
4123
1670
3296
5m, 15T SWL SLING REAR
REQ'O IN NEAR SIDE SLING.
12T SHACKLE
TYP. 4- PLCS.
1184

Issue: No: 01
Title
Arrangement
Page No: 5 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
7m, 10T SWL SLING
TYP. 2 LOCATIONS
12T SHACKLE
o
FIGURE 3
GANTRY WELDMENT
8m, 10T SWL SLING
TYP. 2 LOCATIONS
35T SHACKLE
3023
I I
4582
l5 I
~
1------- 6560 -----4
1--------------13367 -------------4

Issue: No: 01
Title
Arrangement
Page No: 6 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
7m, 10T SWL SLING
35T SHACKLE
3023
6560
FIGURE 3a
GANTRY WELDMENT
7m, 10T SWL SLING
35T SHACKLE
o
"-
I
I
I
13367
432
o

Issue: No: 01
Title
Arrangement
Page No: 7 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
FIGURE 4
KINGPOST WELDMENT
6m, 10T SWL SLING 8m, 10T SWL SLING
25T SHACKLE
3505
25T SHACKLE
---I - &- - -- - -+--
-+-1*'1.
~ ~ ~
1---- 4089 ------j
1------11328 -------I

Issue: No: 01
Title
Arrangement
Page No: 8 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
FIGURE 4a
KINGPOST WELDMENT
6m, 10T SWL SLING
25T SHACKLE
6m, 10T SWL SLING
Ct. / 25T SHACKLE
i?\ /
r - ~
I
I
I
I
11328
4089
~ - - - 3 5 0 - 5 ----.J -f--'------'-

Issue: No: 01
Title
Arrangement
Page No: 9 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
FIGURE 5
BOOM Bun ASSEMBLY
7m, 10T SWL SLING
TYP. 2 LOCA nONS
REQ'D IN NEAR SIDE SLING.
7m, 10T SWL SLING
TYP. 2 LOCA1l0NS
REQ'D IN NEAR SIDE SLING.
12T SHACKLE

Issue: No: 01
Title
Arrangement
Page No: 10 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
FIGURE 6
BOOM INSERT WELDMENT
TYP.2 LOCATIONS TYP.2 LOCAlK)NS
12T SHACKLE 12T SHACKLE
I
<t. 2370
!! B5 r-
~ ~ ~ ~ = = = I l ~

Issue: No: 01
Title
Arrangement
Page No: 11 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
FIGURE 7
TYP. 2 LOCATIONS TYP.2 LOCATIONS
I
I 'l. 2997
~ ~ ~ ~
L
j
524
3048

Issue: No: 01
Title
Arrangement
Page No: 12 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
FIGURE 8
7m, lOT SWL SLING 7m, lOT SWL SLING
TYP.2 LOCATIONS TYP. 2 LOCAllONS
I
ct. 2370

1185
l
I
T "- 2997
'r
1
6096
-------I I
----------- 12192 ------------1.

Issue: No: 01
Title
Arrangement
Page No: 13 of 13

Seatrax (UK) Ltd
Doc No: SXPP.121

...
SEATRAX
FIGURE 9
7m, 10T SWL SLING
6m, 10T SWL SLING
TYP.2 LOCAllONS
TIP. 2 LOCATIONS
2997 T
l i ~ ~ ~ ~ ~
1
------- 8103 --------1
~ . -----------12192 ~

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Page 1 of 5

MAERSK OIL QATAR AS


ERECTION & INSTALLATION PROCEDURE

MOQ DOC. No.: ASEDY-10-70033-0048
NPCC DOC. No.: 6048-70033A-W007-001
VENDOR DOC. No.: E001 SXEIP4527


SEATRAX UK LTD

1 07-Dec-07 Reissued with email of 22/11/07 (4527/28/29/30-STX-E-040) attached
0 25-Oct-07 Issued for approval
Dean Barlow
From: Dean Barlow [operations@seatrax.co.uk]
Sent: 22 November 2007 17:38
To: 'Naisam Ebrahim (NPCC)'
Cc: 'Shankar Guruswamy (NPCC)'
Subject: 4527/28/29/30-STX-E-040 ~ERECTION & INSTALLATION PROCEDURE
Page 1of 1 Dean Barlow Stationery
07/12/2007
CUSTOMER : NATIONAL PETROLEUM CONSTRUCTION COMPANY
PROJECT : AL SHAHEEN FIELD DEVELOPMENT 2005
CUSTOMER P.O. NO: 6048-2007-70033-AC
SEATRAX JOB NO'S: 4527, 4528, 4529, 4530-UK
CRANE SERIAL NO'S: 1 No. S9028 & 3 No. S7226 cranes

Correspondence Ref: 4527/28/29/30-STX-E-040

Mr Naisam,

The comments we have received from NPCC reference the Erection & Installation Procedure we consider to be non-
applicable for the following reasons;

1. KINGPOST TO PEDESTAL BUTT WELD
5) NPCC requests WPS, PQR, NDT Details
Please be advised that the Kingpost to Pedestal Butt Weld will be made by NPCC in their yard. Therefore I
would assume that NPCC will utilise their WPS, PQR and NDT procedures.
NOTE: The weld prep details are shown on the Kingpost Interface drawing that Seatrax have submitted. Also
Note that Seatrax WPS, PQR & NDT procedures are submitted for your review as separate documents.
2. 1. CHECK WIRE ROPE ANCHORS ON AIR HOISTS
NPCC Requests (Wire rope initial lubrication and frequency of lubrication requirement). Please be advised that
the wire rope is supplied with factory impregnated grease. The lubrication schedule (which is a separate
document) details the further greasing of the wire rope.

As these are NPCC's only 2 comments made to the Erection & Installation Procedures I therefore request that NPCC
agree that I resubmit the Erection & Installation Procedures without any revisions for NPCC's Code A approval.

Best Regards,

Dean Barlow
Operations Manager
Seatrax UK Limited

Tel: +44 (0) 1493 651311
Fax: +44 (0) 1493 604900
Mobile: 07801 526319
Email: operations@seatrax.co.uk
Erection Pro 42-80 Page 1 of 3
Phone: 713 896 6500 Fax: 713 896 6611
9 April 2001
Erection and Installation Procedure
This procedure outlines the methods for the erection and installation of the crane on site. This
work should be carried out under the guidance of a SeaTrax service technician. Refer to the
General Arrangement drawing for the layout.
NOTE: Once the Initial Start-up and Commissioning Procedure has as been completed, the
hoists can be rotated to reeve the wire rope.
TOOLING
No special tools are required; all work can be completed using normal hand tools.
KINGPOST
1. Remove upper bearing block and thrust washer from loose gear. Grease Kingpost vertical
and horizontal surfaces where the upper bearing rides. Place upper bearing block over
Kingpost pin with the thrust bearing down.
2. Attach 2 tag lines to Kingpost at bull gear for stabilization during lift.
3. Lift Kingpost using two part sling attached to the lifting eyes atop the Kingpost.
4. Lower the Kingpost onto platform pedestal and set vertically true in the N-S and E-W to "
2 E. Ensuring the upper bearing is lined up with the boom cradle (the semi-circular
bearing guides should be to the sides).
5. Fully weld the interconnecting butt-weld and complete all necessary NDE.
GANTRY
1. Gently lay gantry back.
2. Attach upper landing platform to gantry, (bolts supplied).
3. Attach lower landing platform to gantry, (bolts supplied).
4. Attach main vertical ladder to upper/gantry, (bolts supplied).
5. Attach maintenance jib arm to gantry and secure (if equipped).
6. Attach main ladder extension to upperworks (N/A on 4220, 4224, and 6020 models).
7. Lift gantry using lifting eyes attached and position over the Upperworks assembly.
8. Lower gantry onto matching Upperworks splice plates, Connect the two units together
using the bolts supplied (refer to Bolt Installation and Inspection Procedure in Section C).
9. Tighten bolts hand tight, and then apply the required torque as specified in the table.
UPPERWORKS/GANTRY
1. Lower the Upperworks assembly over the Kingpost, aligning bearing with gantry opening,
and lower into position. Grease and install all lower bearing shoes (refer to Swing Bearing
System Replacement Procedure in Section C).
2. Lower all cables and air line through Kingpost and tie them off to keep them from falling.
Install cables and airline to collector bottom box.
3. Connect electrical/instrument cables to slip ring collector. Bolt slip-ring assembly to top of
Kingpost.
4. Attach external gantry air line (in loose gear box) to air swivel atop the collector ring.
Run the line with the cable channel down the gantry and attach to the line near the boom
winch.
5. At Kingpost base, connect electrical cables to junction boxes, airline to rig air, and access
ladder to upperworks.
BOOM SECTIONS
1. Bolt the sections of boom together as show in the general assembly. The AV@on the end
of the boom section is always toward the boom point. Insert bolts with the head toward the
boom tip. Install a hardened flat washer under the head of the bolt and under the nut. Use
only the bolts supplied or bolts that conform to SeaTrax Specifications for Large Diameter
Nuts and Bolts (Section C). Torque to correct value.
BOOM ASSEMBLY
1. Insert boom butt into boom connection plates in Upperworks. Insert boom foot pins.
Insert and tighten boom foot pin retaining bolts (Supplied).
2. Apply at least 6 shots of grease to each pin to grease bushing.
3. Connect hydraulic hoses to main/aux. winch as marked, ensuring hose is passed through
the carrier hoops provided. It is imperative dirt is kept from entering the system.
4. Complete electrical connections for boom and gantry mounted equipment
At this point, the crane can be run in accordance with Initial Start-up & Commissioning
Procedure while the rope is reeved.
RIGGING
See Section F, Rigging
ATTACHMENTS (See Section C, Initial Start-up and Commissioning Procedure)
1. Check wire rope anchors on all hoists.
2. Install slew gear(s) if not previously installed.
3. Connect all guards.
4. Complete all mechanical/hydraulic/electrical system connections.
5. Grease all bearings and sheaves (see Lubrication, Section D).
Attachments:
Initial Start-up and Commissioning Procedure (Section C)
Bolt Installation & Inspection Procedure (Section C)
Specification for Large Diameter Nuts & Bolts (Section C)
Swing Bearing System Replacement Procedure (Section C)
Wedge Sockets (Section C)
Rigging (SectionF)
Reeving Diagrams (SectionF)
Lubrication (Section D)

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Page 1 of 2

MAERSK OIL QATAR AS


GENERAL ARRANGEMENT DRAWING (4527)

MOQ DOC. No.: ASEDA-10-70033-0037
NPCC DOC. No.: 6048-70033A-L001-001
VENDOR DOC. No. : B001 4527A


SEATRAX UK LTD

5 27-Oct-08 Revised incorporating customer comments AS BUILT ISSUE
4 09-J ul-08 Revised incorporating customer comments for review and approval
3 15-APR-08 Revised incorporating customer comments for review and approval
2 02-J an-08 Revised incorporating customer comments for review and approval
364 2135
&.
r------------------------------14574
13716
r---------- 8814 BEARING SPREAD ------------1
B.F.P TO DECK,&,
BOOM HOIST I>SSY.
W/ GUARD
A/C UNIT SUSPENSION
DEAD END
DUAL PINION Llj4-.LL-'fttH
GEAR DRIVE
c/w GUARDS
&.
BOOM RADIUS
INDICATOR
SPRING
BOOM STOPS
CRANE LIFTING
POINT
GANTRY RED
AIRCRAFT WARNING
LIGHT
INDICATOR
2591
It
1753
1
1917
I 6
7328
DUAL PINION DRIVE
&. W/GUARDS
4826
OPERATORS
CAB
rmm
A CRAIE ACCEIIIII..AIlDBII'OIIIICN
t::3. fTIOU CEtfI'PE OF ROTA1ICIN OF CIWiE

'-I +.
() .
1 .....
!
oj ELECTRIC OUTLET ROUTED .,
"f': THROUGH KINGPOST SEE INTERFACE
DWG 4527L
MOQ No I>SEDA-10-70033-0019
NPCC No 6048-70033A-FOD7-0D1
MAIN / AUX.
HOIST I>SSY.
CAB I>SSY.
MAIN VERTICAL
LADDER WITH CAGE
52m BOOM ASS'y FROM
3m. 6.1m & 12.2m SECTIONS
WALKWAY NOT SHOWN FOR CLARITY
,--- UPI'ER BEARING I>SSY.
WINDSOCK
4 No PADEYES FITTED TO
EACH 800M SECTION FOR
LIFTING
&'BOOM LIGHT ASSY.
ONE EITHER SIDE
4DDW c/w 316SS
SAFETY CHAIN
MAIN BLOCK
PARKED POSITION
A A PAINTED 316L STAINLESS STEEL FUEL
Ell:. TANK FILLED FROM FUEL REEL FITTED
WITH FILLER NOZZLE c/w CUT OUT
VALVE ALL MOUNTED ON CRANE DECK.
SWING RADIUS
R4826
REMOVABLE
LOUVER
PANEL
SPARK
ARRESTING
MUFFLER
I>SME AIR
RECEIVER
HATCH
360 GAL.
SIS HYD. TANK
MOUNTED ON ROOF
OF ENG.
I--- 2616 ----j
3 TONNE
JIB MAX WORKING
RADIUS R5065
MAINTENANCE
WALKWAY.
RUNS FULL LENGTH
OF BOOM
BOOM TIP RED AIRCRAFT
WARNING LIGHT &.

" G:
z
8
SUSPENSION
SHEAVE ASSY.
ANTI-TWO
&
KINGPOST _2286 00 x
50mm WALL
&'DRIP TRAY
SINGLE BAR SELF CLOSING
POLYURETHANE SAFETY
GATES. (TYP ALL ACCESS
POINTS) &..&.&.
UPPER ASS'Y ENGINE
CONTAINING CATERPILLAR
3406 ENGINE C/W EEMUA
ZONE II T3 ENGINE PACKAGE

4205
.&.
4948 ---------I
3 TONNE MAINTENANCE JIB.
FABRICATED BEAM
SLIP RING MOUNTED
ON TOP OF KINGPOST
.&.
---y--1470D
TO DECK LEVEL
BOTTOM FLANGE = 165mm x 12mm Thk
WEB = 10mm Thk
HEIGHT BETWEEN FLANGES = 576mm TO 211 mm AT NOSE
.X .O5 MACHINING
.XX .Q1 FABRICATION -"".
.xxx .OO5 FINISH '0/
o TO 75 1.5
OVER 75 3.0
TIR
750Kg MAINTENANCE JIB
UB 254x102x28kG/m
&..&.
THIS DOCUMENT AND Tl-IE CONTENTS HEREIN MAY NOT BE
DISPLAYED, REPRODUCED OR OTl-lERWISE USED WITHOUT THE
EXPRESS WRmEN CONSENT OF SEATRAX UK
PATENT NO'S. US 4,280,628 US 5,310,067
US 5,328,040 GEl 2253604 EI GEl 2254308 EI
DRAWN
AJC 1 = 100
AUX. BLOCK
AUX. PARKED .
........... .:.w..-
National Petroleum Construction
D MAERSK OIL QATAR AS
MAERSK

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Page 1 of 3

MAERSK OIL QATAR AS


KINGPOST INTERFACE & BOOM REST DETAILS (4527)

MOQ DOC. No.: ASEDA-10-70033-0019
NPCC DOC. No.: 6048-70033A-F007-001
VENDOR DOC No: B005 4527L


SEATRAX UK LTD

4 14-J UL-08 Revised incorporating customer comments for review and approval
2 07-Feb-08 Revised incorporating customer comments for review and approval
A- ACCEPTED
B- COMMENTSASMARKED
C- NOT ACCEPTED
D- RETAINEDFORINFORMATION
E
N
G
2
0
0
7
-
0
4
E
D
.
ACCEPTANCEDOES NOT AFFECT
VENDORLIABILITIES&RESPONSIBILITIES
ASSTIPULATEDWITHINTHEPURCHASE
ORDERSPECIFICATIONS&CONDITIONS.
A
VENDORMUSTCONFIRMTHAT ALL
COMMENTSWILLBEINCORPORATED
BEFOREPROCEEDING.
B
ALLDOCUMENTSMUSTBERESUBMITTED
AFTERINCORPORATIONOFCOMMENTS.
WORKSHALL NOT PROCEED.
C
VENDOR
DOCUMENT STATUS
(")
o
z
:'J
o
'"

r
CONFIDENTIAL
PLATFORM N
C1 JB 2 - UPS POWER (1X1710) .&.
! SIS FUEL TANK'&'
JB 1 - MAIN POWER (1X1210)'&'
J
I
II
11I111i
3D'
27C1---+1f-- ---l---l9O'
FOR TERMINAL DETAILS
REF: 4527F SEE NOTE 2 .&.
II II
\

JB 3 - COMMS (1 X0910)
,
r '---.-) I- V - I /]
JB 4 - PA/GA SYSTEM 'B' (1 X081 0)
JB 5 - PA/GA SYSTEM 'A' (1 X0710)

_+1"'-+-----.-____ "'-----,f--,-----------r-r-+--------..------'-' " <t. BOOM FOOT PIN '" JB 8 -

1"-' """""' LAT=
2851
\
A I"",ft-----t ------ 1---------t---ITiiil A
_I ""KARl F" DRAIN ' ... I , 1528
VALVE I TRAY UTILITIES OUTLET
&. 432 - i'---D,IAIN SOCKETS, SEE NOTE 3, (ELECTRICAL /).
.&. CRANE
A-A. 7 SEE NOTE 2) m.
ACCESS LADDER
KINGPOST 2286mm
x 50mm WT.&,
B r --- --- SEAlRAX 605
&. SUPPLY j KINGPOST INTERFACE",
'-1\. CUSTOMER EL: +51.6OOMIr LA.T,
" SUPPLY
I TOR I I CUSTOMER I I \ I
-'------+--------=-='- I ..--- SUPPLIED 1 I \ I
I /' PEDESTAL \ I
&. --= - - - = - -t --= - - -: _-=: _ -1- -= - - - = - _/)....J
----+c:::cJ -_ ill 50 -I I-
(PEDESTAL RADII) - - - - - I - - - - - MAIN DECK - - Q' ! \
NOTES: EL: +40.200MIr &. I 3D' \
1. SET KINGPOST VERTICALLY TRUE N-S & E-W PLANES TO 1/2 DEG. 33
2. UTILITIES DETAILS: /
ELECTRICAL DRAWINGS: 4527E (6048-70033A-P009-001/ASYYY-10-70033-0041) - J
4527F (6048-70033A-J001-001/ASnY-10-70033-0034) DETAIL C &.
PNEUMATIC DRAWINGS: 4527G (6048-70033A-J022-001/ASnY-10-70033-0036)
CUSTOMER ELECTRICAL TERMINATION SEE 4527F SHT 1. (6048-70033A-J001-001/ASnY-10-70033-0034)'&' SCAl 4X.
.&.
3. (4) 2" NPT PORTS (PLUGGED) ARE PROVIDED FOR DRAINAGE,
AND CAN BE PIPED TO SUIT CUSTOMER REQUIREMENTS.
4. NO MANHOLE IS PROVIDED IN THE KINGPOST.
4 REVISED AS PER CLIENTS COMMENTS WHERE SHOW
3 REVISED AS PER CLIENTS COMMENTS WHERE SHOWN
FIRE & GAS ANALOG
INPUTS (1X0210)
SECTION B-B
C1
JB 6 - FIRE & GAS DIGITAL
OUTPUTS (1 X041 0)
JB 7 - FIRE & GAS ANALOG
INPUTS (1X0310)
SEE NOTE 3
SECllON A-A
AJC 15 05 08
DJD 04 04 08
5. AIR UTILITY STATION TO BE POSITIONED ON THE CIRCULAR /).
ACCESS PLATFORM BENEATH THE CRANE AND IS PROVIDED BY THE m.
BUYER. (SEE SHT.2 FOR SEATRAX INTERFACE SUPPLY ALONG BOOM)
SECTION B-B UPDATED NPCC MOQ DWG No's ADDED IN NOTES
2 SHT. 2 REVISED AS PER CLIENTS COMMENTS. ADDED CLIENT BORDER
1 INCREASED FROM 45mm TO 50mm THK ON KINGPOST BASE.
DJD 06/02/08
AGB 23 11 07
DRN. DATE
I. ' ... 't .::.w .tim
National Petroleum Construction Company ....
CLIENT: N.P.C.C.
PROJECT: AL SHAHEEN BLOCK 5
EQUIPMENT: OFF"SHORE PLATFORM CRANE
SEATRAX SERIAL No: 4527 UK
P.O. No: 096048-2007-70033-AC
PLATFORM: ED PLATFORM
Tog No: ASEDA-A-6101
REV. DESCRIPTION
=&
PROJECTION
UNSPECIFIED TOLERANCES
THIS DOCUMENT AND THE CONTENTS HEREIN tolAY NOT BE MONARCH-
DISPLAYED, REPRODUCED OR CJTHERWISE USED WITHOUT THE S8CiKlno- +44 (0)1493 651311
EXPRESS WRITTEN CONSENT OF SEATRAX UI( M AII I .! 0 II AN"r. +44 (O}'493 443663
I'l MAERSK OIL OATAR
SEATRAX'
MAER5K
-
.X .05 MACHINING A.5" AL SHAHEEN FIELD DEVELOPMENT 2005
AS
.XX .O' FABRlC,"ON """". PATENT NO'S. us 4,2.0,62. US 5,310,067 KINPOST INTERFACE DETAILS GA WELLHEAD MODULE. ED. GD AND GB PLATFORMS
.x" .005 "ACH. eNISH 'IY
ig I DRAWN SCALE-B- A3 GAll: awo/PART NO. SHEET 1 of 2 REV. ,ecce"""",. 6048-70033A-F007-001
nR AJC 1 = 40 19 4527L 4 "'""'"'""', ASEDA-10-70033-0019
C1
o
z
:'J
o
'"

r
&-,. & 800M FOOT PIN <t.-
EL: +53.733M1r LAT.
CONFIDENTIAL
9
1811
1--------- 3515 --------1
1-------- 2979 --------1
2184 2370
I
1----------- 4443 ------------1 270 ] 93 ]
SECllON A-A
SCALE 4X
&
CRANE
CO
TYPICAL 800M REST AT OPTIMUM REST POSITION
SCALE 4X
+--- 8484 -----II
1"' GALVANISED HARD PIPE TO REACH ACCESS PLATFORM WHICH CONTINUES
ALONG LENGTH OF BOOM TO BOOM POINT, TO CARRY THE AIR SERVICE.
THE AIR SERVICE WILL BE TERMINATED WITH A 3/4" MALE CEJN TYPE OF CONNECTION.
THE AIR SERVICE WILL BE TERMINATED
&& WITH A 3/4" FEMALE CEJN TYPE OF CONNECTION.
&
&
__ ---.I 840
4545&
1-------------------- 41707 SEATRAX OPTIMUM BOOM REST PLACEMENT -------------------1-------11741
&
Boom Rest Placement for 52m [170') Boom
SeaTrax Optimum Boom Rest Placement is 41707 From the Center of Rotation
Note: Placement of the Boom Rest at This Location will NOT Require
Additional Stiffening of the Boom.
Boom Rest Loadings
THE BOOM REST LOADING AT 41707 FROM CENTRE OF ROTATION &-,.
VERTICAL LOADING = 42.85TONNES HORIZONTAL LOADING = 20.0HONNES
Calculated with vertical acceleration of 1.89 horizontal acceleration = 0.89 and Winds peed of 65Km/h
CUENT: N.P.C.C.
PROJECT: AL SHAHEEN BLOCK 5
EQUIPMENT: OFFSHORE PLATFORM CRANE
SEATRAX SERIAL No: 4527 UK
P.O. No: 096048-2007-70033-AC
PLATFORM: ED PLATFORM
No: ASEDA-A-6101
2518

WE HAVE PROVIDED THE BOOM CROSS SECTION DIMENSIONS. WE LEAVE THE BOOM REST
DESIGN & SECURING OF THE BOOM TO THE BOOM REST TO OTHERS TO DESIGN.
THIS DOCUMENT AND THE CONTENTS HEREIN MAY NOT BE
DISPLAYED, REPRODUCED OR OTHERWISE USED WITHOUT THE
EXPRESS WRITlEN CONSENT OF SE'ATRAX UK
PATENT NO'S. US 4,280,628 US 5,310,067
US 5,328,040 G8 2253604 8 GB 2254308 B
180 = 1
..........
SEATRAX I-::
N
,::t1="":::,'..:P..:,,,,,=,=,m::.=Co:::,,,,,,=,:.:t1:=on:..C:.:om="::o'Y'-"'=-l
D MAERSK OIL QATAR AS
MAER5K

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Page 1 of 5

MAERSK OIL QATAR AS


STORAGE & PRESERVATION PROCEDURE

MOQ DOC. No.: ASYYY-10-70033-0046
NPCC DOC. No.: 6048-70033A-W003-001
VENDOR DOC.No. : E009 SXSPP4527/4528/4529/4530


SEATRAX UK LTD


Contract: 4527/28/29/30-UK
NPCC MOQ
AL SHAHEEN BLOCK 5
P.O. No. 0096048-2007-70033-AC

Revision
01

Sheet
1 of 4

Title

Sign & Date of Issue

Seatrax (UK) Limited,
Portland Wharf, Southtown Rd, Gt. Yarmouth, Norfolk, NR31 OJ J
Doc No. SXSPP4493/4494

1.0 SCOPE

1.1 This procedure outlines the requirement for unpacking and preservation.

Note: The recommendations within this procedure are based on the Manufacturers
knowledge of the product.

1.2 The Crane will be broken down & shipped to site as major component parts as listed below: -

Kingpost The Kingpost will be delivered with the Hemisphere Upper Bearing Area
heavily greased. Should the grease become contaminated by dust or any other foreign
body. The upper bearing area is to be degreased and new uncontaminated grease applied
prior to installation of the crane and upper bearing.

Upperworks The Upperworks is delivered fully assembled, inclusive of: -
Cab
Hydraulic Valve Cabinet
Boom Hoist
Diesel Tank
Hydraulic Tank
Electric Equipment
Boom Foot Pins
The Engine House is delivered as a separate item.

All Components have been fully lubricated and run up during the factory function test, prior
to delivery.

Note: The Cab and Engine Room are accessible at all times.

Gantry The Gantry will be delivered with the luffing sheaves and shaft assembled and
fully greased. Grease is fed through the middle of the shaft pushing the old grease out of
the bearing and any contamination that may have occurred during storage. Therefore it is
not necessary to dismantle, clean and reassemble these items.

Boom Butt The Boom Butt has the Main and Aux Hoist assembled within it. The Main
and Aux Hoist have been fully function tested at the factory and is greased and lubricated
prior to delivery.

Note: The Hydraulic Hoses to and from the Main and Aux Hoists are disconnected and
plugged/ blanked off, the hoses are coiled back to the Upperworks and stored.
Hydraulic hoses shall be tagged with respect to Hoist before coiling.

Boom Inserts The Boom Inserts will be delivered with the Boom Walkway and Rope
Guards.

Boom Point & Fly Jib The Boom Point and Fly J ib is delivered with the Luffing, Main
and Aux Sheaves and Shafts assembled and fully greased.

1
1
1

Contract: 4527/28/29/30-UK
NPCC MOQ
AL SHAHEEN BLOCK 5
P.O. No. 0096048-2007-70033-AC

Revision
01

Sheet
2 of 4

Title



Misc. Equipment This includes such items as follows: -
Slip Ring Boxed
Lower Bearings Boxed
Wire Ropes Reels
Electric Lights: Boom Boxed
Mipeg Sensor: Main Block Boxed
Gantry Platforms/ Ladders Loose
Boom Fly J ib Platform Loose
Gantry Davits Loose
Electric Lights: Gantry Boxed
Main & Aux Blocks

Humidity Control

The following items will have a humidity control in the form of silicon bags: -

Slip Ring x 2 Bags Replace after 3 months
Distribution Board x 2 Bags Replace after 3 months
Mipeg Control Box x 1 Bag Replace after 3 months

NOTE: These bags need to be removed prior to electrical commissioning.

The engine having been run up during the factory testing of the crane will be delivered without
preservation.

2.0 RECIEVING

2.1 Prior to unloading from vessel the customer should make arrangements for the equipment to be
inspected for any transit damage.

Note: All of the Crane components apart from the boxed goods are accessible for visual
inspection at this stage.

2.2 Special notice is to be taken on slew Gearbox Shafts on the underside front of the Upperworks.

2.3 Ensure all grillages are firmly fastened and intact.

2.4 Once inspections have been completed by the recipients yard unloading of the cranes and Kingpost
can begin.

Note 1: The customer is responsible for all transportation and off loading at site.

3.0 PREPARATION

3.1 Ensure that adequate clean/flat area is available to unload all articles from the vessel without any
chance of clashing or hindrance. Please refer to document 4.10 Component Weight & C of G
Calculation.

3.2 Temporary Supports/ Packing

The Upperworks will require 4 pieces of timber to support it under the main turntable base
plate.

The Kingpost will be shipped in the horizontal position supported on two transportation grillages.

1

Contract: 4527/28/29/30-UK
NPCC MOQ
AL SHAHEEN BLOCK 5
P.O. No. 0096048-2007-70033-AC

Revision
01

Sheet
3 of 4

Title



The Gantry is shipped in the horizontal position and can be supported on timbers at its base
and one H frame grillage at the top end.

The Boom inserts and Boom Butt need four timber supports for each section, one under
each corner.

The Boom Point can stand on two pieces of timber at its base and one piece of steel
grillage at the front end.

4.0 STORAGE

4.1 It is recommended that the boxed items i.e. electrical items along with the ropes/ blocks be
stored indoors. The Upperworks, Gantry Boom and Kingpost are large items and may have to be
stored outside.

4.2 With the Crane unable to be run and with no electrical supply the following preservation checks
are to be undertaken.

Cab
J oystick Levels operate freely and return to neutral
Fire Extinguishers in place
Check for any hydraulic leaks
Check for any water ingress

Engine House/ Valve Cabinet
Check for any hydraulic/ oil/ water leaks
Check for any water ingress

Gantry
Rotate sheaves and grease if required

Boom Point/ Fly Jib
Rotate sheaves and grease if required.

Kingpost
Rotate Upper Bearing on the Kingpost Spigot and grease if required.

Hoists/ Slew Motors
Check for oil leaks

Aux / Main Blocks
Rotate the sheave and grease if required
Operate the swivels on both blocks and grease if required
Check hooks and safety latches

Loose Items
Check the Slip Ring and Electric components for condition and moisture ingress.

4.3 Should storage exceed 14 days humidity levels within the machinery house and cab should be
monitored and in the case of high humidity A temporary electric heater be placed in the engine
house and cab to reduce the moisture content to a minimum.

Contract: 4527/28/29/30-UK
NPCC MOQ
AL SHAHEEN BLOCK 5
P.O. No. 0096048-2007-70033-AC

Revision
01

Sheet
4 of 4

Title



4.4 If the crane is to be stored in excess of 56 days it is recommended that the Main and Aux Hoists
in the Boom Butt are reconnected to the Hydraulic Hoses on the Upperworks. The Engine House
is connected to the Turntable with hydraulic hoses connection being made.

Using the engines hydraulic start system, the engine can be started and the cranes hydraulic
system and mechanical components fully operated.

The machine should be started up and run for one hour each week thereafter to circulate the oils
and to lubricate the internals as follows;

a) Ensure all valves (Suction) are fully open.
b) Start engine and idle for 5 minutes, apply approx 1700rpm for 2 minutes return to idle.
c) Operate all hoists (Without Wire Rope) in both directions for approximately 10 mins to allow
cranes systems to achieve a working temperature.
d) With the Slew Parking Brake disengaged move the J oystick Controller to the right, increase
the Engine RPM to 1700 and hold for 30 seconds return to neutral and repeat to the left.

4.5 All equipment is to be greased every 28 days making sure not to over grease and run Hoists and
Slew Motors. See the Lubrication Schedule for grease oil and type.


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION F RIGGING

Reeving Diagrams


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Rigging Standard Info.doc Page 1 of 4

Phone: 713 896 6500 Fax: 713 896 6611

29 April 2000
Rigging

General

Wire rope is used as the final link in the transmission of power from the unit to the load. It
is just as much a part of the machine as the pumps, valves, and motors and requires the same
attention to lubrication and inspection as any other major part. Failure of the wire rope in
service endangers life and property. It also shuts the crane down immediately, and all work
is held up until a new rope can be ordered and installed. Therefore, it is essential to
immediately replace any rope showing signs of weakness that could lead to failure.

Wire rope manufactures have developed many different types of wire rope. Each type of
construction has some special advantages for particular applications. A wire rope of the
wrong type is dangerous and will not give satisfactory service. Replace a worn out rope
with the exact type and diameter recommended in the specifications listed in this section.
Also ensure that the rope is cut to specified length. A rope that is too long may be damaged
by over winding and too short a rope may pull out of its attachment with serious results.

Wire ropes are anchored on the hoist drum with two special H blocks. The opposite end
is anchored with a wire rope wedge sockets. After installing a wedge socket, apply the load
gradually and make sure the wedge is fully seated. The load will do the final tightening.

Lubrication of the wire rope is critical. Rust freezes the wire not allowing the strands to
move and give as they travel over the sheaves, thus causing strands to break. Additionally,
dry wires and strands rub together and prematurely destroy a rope due to abrasive wear.
Lubrication prevents both rust and abrasion.

The manufacturer lubricates wire ropes, but the protection must be maintained in the field.
Lubricant must penetrate to the inner core of the wire rope to get an oil film between all
strands. It can be applied hot or cold, depending on the exact type of lubricant. Refer to the
wire rope distributor or manufacturer to find the best lubricant and the best application
methods. The lubricant interval depends on the service and ambient conditions. The most
commonly used interval is 100 hours, but exposure to salt air may require more frequent
lubrication.

Wire Rope Inspection

All wire ropes in active service should be visually inspected once every working day. A
thorough inspection of such ropes should be made at least once a month and date records
kept as to rope condition.

Any deterioration, resulting in appreciable loss of original strength should be carefully
examined and determination made as to whether further use of the rope would constitute a
safety hazard. The following conditions should be sufficient reason to question rope safety
and consider replacement.

Corrosion.

More than one broken wire in any one strand. Breaks occurring on crowns of outside
wires indicate normal deterioration. Breaks in valleys between strand indicate an
abnormal condition, possibly fatigue or breakage of other wires not readily visible.

More than one broken wire near attached fittings.

Heavy wear and/or broken wires in rope sections under sheaves where rope travel is
limited or at points of contact with saddles.

Extensive abrasion, scrubbing, and peening of outside wires, pitting, kink damage or
other mechanical abuse causing distortion of rope structure.

Sheaves, guards, guides, drums flanges, and other surfaces contacted by the rope during
operation should be inspected for conditions which are harmful to the rope.

Wire Rope Replacement

A fully comprehensive and precise set of rules cannot be given for determination of exact
time for rope replacement since many variable factors are involved. Safety in this respect
depends largely upon the use of good judgment by competent maintenance personnel in
evaluating remaining rope strength in a used rope after allowance for deterioration disclosed
by inspection.

According to API Recommended Practice 2D (API RP2D), wire rope should be retired if
any of the following conditions exist:

Rotation resistant rope: Four randomly distributed broken wires in one rope lay, or two
broken wires in one strand in one rope lay. (Rope lay is the length along the rope in
which one strand makes a complete revolution around the rope.)

Pendant lines: Three broken wires within one rope lay, or two broken wires at end
connection.

Abrasion, scrubbing, or peening causing wear of more than a of the original diameter of
outside wires.

Evidence of severe corrosion.

Evidence of heat damage from any cause.

Reduction from nominal diameter of more than:
3/64 (.047) for rope diameters through
1/16 (.062) for rope diameters
7
/
8
through 1
1
/
8

3/32 (.093) for diameters 13 to 12
Marked reduction in diameter indicates deterioration of the
core, resulting in lack of proper support for the load carrying
strands. Excessive rope stretch or elongation may also be an
indication of internal deterioration.

Kinks, crushing, bird caging or any other damage resulting in
distortion of the rope structure.

Noticeable rusting or development of broken wires in the
vicinity of attachments.

Boom hoist ropes should be inspected near dead end for breaks in
the heart of rope not visible from outside caused by vibrations.

When replacing ropes, do not weld ends to seize them as this can cause premature failure.
This is especially critical on the boom hoist dead end.

All rope should be of proper size, grade, and construction as recommended in following
pages of this manual.

When transferring wire rope from a storage reel to the crane drum, always reel in the same
direction. This will help the rope reeve smoothly onto the drum. It is also necessary to keep
tension on the rope at all times while reeving.

Wire Rope Installation

NOTE: The easiest way to reeve all wire ropes is to run a 5/8 or larger hemp rope in place of
the wire rope (hemp does not stretch like nylon). Attach one end of the hemp rope to the end
of the wire rope and reeve the other end through the sheaves and run three wraps onto the
respective drum. Hold tension on hemp rope at drum while pulling on wire rope with hoist.
Reeve hemp around and off the drum (this is known as cat-heading).

1. Boom Rope Reeving:

A. Set reel of rope on a stand near the right side of the boom butt. Face the stand so the
rope can be pulled from the bottom of the reel towards the point.

B. Attach two shackels together and attach one to a lifting eye on the boom butt nearest
to the reel. Run the wire rope through the shackle and attach it to the hemp rope.
From here, the rope continues across the boom and under the far right sheave.
Reeve boom suspension as per reeving diagram. Make off winch dead end on side
plate of hoist drum with H blocks supplied.

C. Make off gantry end of suspension rope using the wedge socket supplied.

2. Main Rope Reeving:

A. NOTE: When reeving the main rope, it is important to have a reeving diagram
available, and know how many parts of line the crane should have. Reeve main line
wire rope through the anti-two block and the last point sheave (the sheave before it
goes to the hoist drum), and continue to the main hoist drum. Attach wire rope to
the drum with the H blocks supplied.

B. To keep tension on the wire rope during reeving, run the wire rope between two 6
long boards (2 x 4 or similar), and tighten them against the rope with 2 C clamps.
Do this on the point side of one of the boom lacing boards. Slowly hoist the boards
against the boom lacing boards. Use the clamps on the 6 boards to keep tension on
the rope as it reeves onto the drum.

C. Leave enough rope at the point to run it through the main block, anti-two block, and
point sheaves for the appropriate number of falls. Refer to the reeving diagram for
the correct reeving pattern.

D. Run the end of the wire rope through the point towards the attachment point.

E. Use wedge socket supplied to make the dead end. NOTE: Connect MIPEG load
sensing plate, if fitted, to the wedge socket, and dead end post to tension link plates
with tension link pin. Now attach load sensor to link plates with link pin.

3. Whip Line Reeving:

A. Reeve whip line wire rope over jib sheave, load sensor sheave (if equipped),
point sheave, and onto aux. drum. Keep tension on the rope as described in 2B.

B. Slide headache ball (small end first) onto aux. rope. Attach the wedge socket
and stinger line. Bolt headache ball over wedge socket.


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


WIRE ROPE SPECIFICATION

Project: 4527-UK

Seatrax (UK) Limited
Portland Wharf, Southtown Rd, Gt. Yarmouth, Norfolk, NR31 0J J
Tel: +44 (0) 1493 651311 Fax: +44 (0) 1493 604900

MAIN HOIST ROPE

Diameter : 28mm
Tensile : 1960N/mm
Length : 455 metres
Type : Perfekt TK16 Evolution
Finish : Galvanized and factory injected grease
Lay : L.H.O.L (overwind)
MBL : 725KN =73.90 Tonnes
Ends : Plain

AUX HOIST ROPE

Diameter :
28mm
Tensile :
1960N/mm
Length :
162 metres
Type :
Perfekt TK16 Evolution
Finish :
Galvanized and factory injected grease
Lay :
L.H.O.L (overwind)
MBL :
725KN =73.90 Tonnes
Ends :
Plain

BOOM HOIST ROPE

Diameter :
28mm
Tensile :
1960N/mm
Length :
699 metres
Type :
Perfekt QS816V-3AQ
Finish :
Galvanized and factory injected grease
Lay :
R.H.O.L. (overwind)
MBL :
726KN =74 Tonnes
Ends : Plain


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Reeving Diagrams

Reeving Diagrams RH Cab.doc Page 1 of 2
Phone: 713 896 6500 Fax: 713 896 6611
Boom and Auxiliary Hoist Reeving
",
SEATRAX
Bridk or Point sm.,"tJ
r.,1 Lint

""
Boom Hoi. , Drum
Boom Pion! sn.. .... .,.
Au:\ Hut. , Drum
7ifi AP'QR
) '5110111
Reeving Diagrams RH Cab.doc Page 2 of 2
Phone: 713 896 6500 Fax: 713 896 6611
Main Hoist Reeving
SEATRAX '
6 PARTS
(6 FALLS)
4 PARTS
(4 FALLS)
2 PARTS
(2 FALLS)
7ifi ) AP'QR
~ . '5110111
Reeving Diagrams LH Cab Page 2 of 2
Phone: 713 896 6500 Fax: 713 896 6611
Main Hoist Reeving
",
SEATRAX
-
6
(6 FALLS)
4 PARTS
(4 FALLS)
2 PARTS
(2 r-ALL'
7ifi > AP'QR
"I:': 'SOIOO1

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION G PERFORMANCE DATA

Load Charts (G002)


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Load Charts (G002)

Page 1 of 97

MAERSK OIL QATAR AS


MANUFACTURERS DATA SHEETS

MOQ DOC. No.: ASEDY-10-70033-0027
NPCC DOC. No.: 6048-70033A-G001-005
VENDOR DOC. No. : D001 SXDS4527


SEATRAX UK LTD

02 07-Dec-07 Revised incorporating customer comments
01 01-Nov-07 Revised incorporating customer comments
A- ACCEPTED
B- COMMENTSASMARKED
C- NOT ACCEPTED
E
N
G
2
0
0
7
-
0
4
E
D
.
ACCEPTANCEDOESNOT AFFECT
A
BEFOREPROCEEDING.
B
C
VENDOR
DOCUMENT STATUS

Phone: 713 896 6500 Fax: 713 896 6611

Seatrax Inc.
Seatrax Crane Data Sheet
Prepared For
10-30-2007
In Compliance with
52 Meter Boom
METRIC UNITS
API Specification 2C, 6th Edition 2004
Seatrax Series 90 Model S9028
P.O. Box 840687 Houston, Texas 77284
Telephone (713) 896-6500
Fax (713) 896-6611
Developed for Installation on a
Bottom Supported Structure
Seatrax Serial No. 4527
Maersk Qatar AS
ED Platform (ASEDA-A-6101)
Al Shaheen Field Development 2005
Kingpost Marine Cranes
API General Method
Page 2 of 97 2
Significant Wave Height = 0 meters (SWH)
2
Seatrax Crane Data Sheet-Metric Units
52 Meter Boom
GENERAL CRANE DIMENSIONS
Vertical Dim Heel Pin to Gantry Sheave 'H' (meters) 13.71
Horizontal Dim CL Rot to Heel Pin 'E' (meters) 2.28
Horizontal Dim CL Rot to Gantry Sheave 'D' (meters) 2.59
Horizontal Dim CL Rot to CG of Crane & Post 'U' (meters) 1.06
Outside Diameter of Kingpost 'OD' (mm) 2286
Wall Thickness of Kingpost 'T' (mm) 44
Yield Strength of Kingpost 'YP' (N/mm^2) 345
Vertical Dim Lower Brg to Upper Brg 'GB' (meters) 9.14
Complete Crane with Boom (Tonnes) 117.0
Block(s) (Tonnes) 1
Total Dead Weight (Tonnes) 118.4
Length of the Aux. Hoist Cable (meters) 170
Diameter of Aux. Hoist Cable (mm) 28
Aux. Hoist Cable Construction Class CH
Minimum Breaking Strength of Aux. Cable (tonnes) 72
Length of Main Hoist Cable (meters) 488
Diameter of Main Hoist Cable (mm) 28
Main Hoist Cable Construction Class CH
Min. Breaking Strength of Main Hoist Cable (tonnes) 72
Diameter of Boom Hoist Cable (mm) 28
Boom Hoist Cable Construction Class BL
Min. Breaking Strength of Boom Hoist Cable (tonnes) 72
Number of Boom Suspension Parts of Line 'NB' 12
Boom Chord Square Tube Size (mm) 178
Height Between Chord Centers (mm) 2007
Width Between Chord Centers (mm) 2616
Auxiliary Hoist Model Number 463-EJA
Main Hoist Model Number 863-HJC
This crane complies with all applicable requirements of
10-30-2007
Serial or Quotation Number: 4527
Project Identification: 4527
WIRE ROPE COMPONENT DATA
PROPERTIES OF BOOM SECTION
HOIST SELECTIONS
COMPONENT STATIC WEIGHTS (Tonnes)

Phone: 713 896 6500 Fax: 713 896 6611

Page 3 of 97
2

(1) Worki ng radi us i s measured from the mai n hook to centerl i ne of rotati on
(2) S WL l etter suffi i xes i ndi cate l oad l i mi ti ng factor per API 2C, 4.1.1 (a) thru (i ).
(3) Rated l oads are NET l oads. Mai n Bl ock & Aux. Bal l wei ghts have been deducted.
(4) The S peci fi ed Boom Ti p Vel oci ty caused by Foundati on Moti ons i s N/A.
(5) The S peci fi ed Lateral Accel erati on caused by Foundati on Moti ons i s 0
(6) The S peci fi ed Verti cal Accel erati on caused by Foundati on Moti ons i s 1g.
(7) The S peci fi ed Addi ti onal S i del ead Angl e (Li st) from Foundati on Moti ons i s .5 deg.
(8) The S peci fi ed Addi ti onal Offl ead Angl e (Tri m) from Foundati on Moti ons i s .5 deg.
(9) Mai n drum cabl e i s 29 di a. Cl ass CH, 72 te. nom strength, 488 m. l ong.
(10) Aux. drum cabl e i s 29 di a. Cl ass CH, 72 te. nom strength, 170 m. l ong.
(11) The speci fi ed hook travel for thi s machi ne i s 106 m.
(12) The Mi ni mum Personnel Rated Load at any Worki ng Radi us i s 4333 kgs.
10-30-2007
52 Meter Boom
API Specification 2C, 6th Edition, 2004
I n Compliance with
Calculated for Installation on a
Notes:
API General Method
Onboard Lifts
Windspeed = 18 m/sec
Working 2 Part 4 Part Line 6 Part Single Line
Radius Main Hois t Main Hois t Main Hois t Aux Hois t
(meters ) SWL (Kgs ) SWL (Kgs ) SWL (Kgs ) SWL (Kgs )
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
Safe Working Load Chart
Onboard Lifts
Page 4 of 97
2

11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
Offboard (Supply Boat)
(4) The S peci fi ed Boom Ti p Vel oci ty caused by Foundati on Moti ons i s 0 m/sec.
Notes:
10-30-2007
I n Compliance with
API General Method
52 Meter Boom
Page 5 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Kingpost Reactions
Bottom Supporte d Structure API Ge ne ral Me thod
Winds pe e d = 18 m/s e c
Quotation / Se rial No. 4527 Ide ntification 4527
Working Boom Safe Working Vertical Primary Sideplane Tors ional
Radius Angle Load Load Moment Moment Moment
(meters ) (Degrees ) (Kgs .) (Tonnes ) (KN-m) (KN-m) (KN-m)
11 81 54,320 226 13,479 1,565 328
13 79 54,320 226 15,906 1,555 387
15 77 54,320 226 18,332 1,542 447
17 74 54,320 226 20,757 1,527 507
19 72 54,320 226 23,181 1,509 566
21 70 54,320 226 25,604 1,488 626
23 67 54,320 226 28,026 1,464 686
25 65 54,320 226 30,447 1,438 745
27 62 54,320 226 32,867 1,408 805
29 60 54,320 226 35,286 1,375 865
31 57 54,320 226 37,703 1,338 924
33 55 51,124 220 38,032 1,243 943
35 52 47,867 214 38,068 1,146 955
37 49 44,964 208 38,109 1,054 969
39 46 42,351 203 38,145 966 981
41 43 39,456 197 37,751 872 985
43 39 36,312 190 36,917 774 980
45 35 33,450 185 36,089 677 976
47 31 30,845 180 35,271 581 970
49 27 28,436 175 34,440 481 966
51 21 26,229 171 33,618 371 961
54 3 23,192 165 32,351 74 955
(1) Working Radius is measured from the center of the main hook to the center of rotation in meters.
(2) SWLs Indicate the load limiting factor referenced in AP I Spec 2C, 6th Edition, 2004, Sec. 4.1.1
(3) The P rimary Moment is the summation of moments about an axis 90 degrees to the boom centerline
(4) The Side P lane (Radial) Moment is the summation of moments about an axis parallel to the boom centerline.
(5) The P rimary Moment is the overturning moment in KN-M , with 1.5 times SWL x Cv & Resulting Horizontal Loads +dead loads.
(6) The Side P lane (Radial) Moment is the overturning moment in KN-M , with 1.5 times SWL x Cv & Resulting Horizontal Loads +dead loads.
(7) The Total Vertical Load is the summation, in TONNES, with 1.5 times SWL x Cv +dead loads.
(8) The Torsional M oment (Torque) is the rotational moment in KN-M , with 1.5 times SWL x Cv & Resulting Horizontal Loads +dead loads.
52 Me te r Boom
10-30-2007
Onboard Lifts
(In Compliance with API Specification 2C, 6th Edition, 2004)

Page 6 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
Working
Radius Spring Dynamic Spring Dynamic Spring Dynamic Spring Dynamic Boom Sus p.
(meters ) Cons tant Coef. Cons tant Coef. Cons tant Coef. Cons tant Coef. Coef. Coef.
11 590.00 1.33 1102.00 1.33 1551.00 207.00 1.33 2.06 1.03
13 579.00 1.33 1062.00 1.33 1471.00 206.00 1.33 2.18 1.18
15 568.00 1.33 1023.00 1.33 1395.00 205.00 1.33 2.29 1.31
17 558.00 1.33 986.00 1.33 1325.00 204.00 1.33 2.39 1.43
19 548.00 1.33 951.00 1.33 1259.00 203.00 1.33 2.48 1.55
21 538.00 1.33 916.00 1.33 1197.00 202.00 1.33 2.57 1.66
23 528.00 1.33 883.00 1.33 1139.00 201.00 1.33 2.65 1.76
25 518.00 1.33 851.00 1.33 1084.00 200.00 1.33 2.73 1.87
27 508.00 1.33 820.00 1.33 1031.00 199.00 1.33 2.80 1.97
29 498.00 1.33 789.00 1.33 980.00 198.00 1.33 2.87 2.07
31 488.00 1.33 759.00 1.33 931.00 197.00 1.33 2.94 2.17
33 478.00 1.33 728.00 1.33 883.00 196.00 1.33 3.01 2.27
35 467.00 1.33 698.00 1.33 837.00 195.00 1.33 3.07 2.37
37 456.00 1.33 668.00 1.33 791.00 194.00 1.33 3.13 2.47
39 444.00 1.33 638.00 1.33 746.00 193.00 1.33 3.20 2.58
41 432.00 1.33 607.00 1.33 702.00 192.00 1.33 3.26 2.70
43 419.00 1.33 576.00 1.33 658.00 191.00 1.33 3.33 2.82
45 405.00 1.33 543.00 1.33 613.00 189.00 1.33 3.40 2.95
47 389.00 1.33 509.00 1.33 567.00 187.00 1.33 3.48 3.09
49 371.00 1.33 472.00 1.33 520.00 185.00 1.33 3.57 3.26
51 349.00 1.33 431.00 1.33 468.00 182.00 1.33 3.68 3.46
54 286.00 1.33 326.00 1.33 342.00 169.00 1.33 4.04 4.11
(1) All Spiring Constants are in n/m
(2) The calculated Supply Boat Deck Velocity in m/sec is 0
(3) The avaliable 1Fall Hook Speed in m/sec is 1.682
(4) The available 2 F all Hook Speed in m/sec is .747
(6) The available 6 F all Hook Speed in m/sec is N/A
(8) The available 10 Fall Hook Speed in m/sec is N/A
(10) The Specified Boom Tip Velocity caused by F oundation Motions is N/A.
(11) The Specified Lateral Acceleration caused by Foundation Motions is 0
(12) The Specified Additional Sidelead Angle (List) from F oundation Motions is .5 deg.
(13) The Specified Additional Offlead Angle (Trim) from Foundation Motions is .5 deg.
10-30-2007
Calculated Spring Constants and Cv
52 Meter Boom
2 Falls 4 Falls 6 Falls Auxiliary. Load Coefficients
Page 7 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Total Offlead & Sidelead Forces
Onboard Lifts
Se rial or Quotation Numbe r: 4527 Proje ct Ide ntification: 4527
Working Total Offlead Equivalent Total Sidelead Equivalent
Radius Force (all caus es ) Offlead Angle Force (all caus es ) Sidelead Angle
(meters ) (Kgs .) (Degrees ) (Kgs .) (Degrees )
11 760 0.500 2,310 0.500
13 760 0.500 2,310 0.500
15 760 0.500 2,310 0.500
17 760 0.500 2,310 0.500
19 760 0.500 2,310 0.500
21 760 0.500 2,310 0.500
23 760 0.500 2,310 0.500
25 760 0.500 2,310 0.500
27 760 0.500 2,310 0.500
29 760 0.500 2,310 0.500
31 760 0.500 2,310 0.500
33 723 0.500 2,225 0.500
35 686 0.500 2,139 0.500
37 652 0.500 2,062 0.500
39 622 0.500 1,992 0.500
41 588 0.500 1,915 0.500
43 551 0.500 1,831 0.500
45 518 0.500 1,755 0.500
47 488 0.500 1,686 0.500
49 460 0.500 1,622 0.500
51 434 0.500 1,563 0.500
54 399 0.500 1,482 0.500
(1) The Effects of Offlead, Sidelead & Windspeed are calculated in accordance with API Spec 2C, Par. 4.3.2 & 4.5.1
(2) The Sidelead & Offlead Forces acting at the boom tip due to Wind Loads are 721kgs.
(3) The Specified Additional Sidelead Angle (List) from Foundation M otions is .5 deg.
(4) The Specified Additional Offlead Angle (Trim) from Foundation M otions is .5 deg.
(5) The Total Offlead Force includes the effects of Wind, Supply Boat Position, Dynamic Coefficient, Foundation Trim Angle, & Lateral Foundation acceleration.
(6) The Total Sidelead Force includes the effects of Wind, Supply Boat Position, Dynamic Coefficient, Foundation List Angle, & Lateral Foundation acceleration.
(7) The Equivalent Offlead Angle is the Angle that the Hoistline is offset from the Vertical Plane, inline with the Boom, due to Supply Boat Position and Foundation Trim.
(8) The Equivalent Sidelead Angle is the Angle that the Hoistline is offset from the Vertical Plane, to the side of the Boom, due to Supply Boat Position and Foundation List.
10-30-2007
52 Me te r Boom
Page 8 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611
Kingpost Reactions
11 81 54,320 226 13,479 1,565 328
13 79 54,320 226 15,906 1,555 387
15 77 54,320 226 18,332 1,542 447
17 74 54,320 226 20,757 1,527 507
19 72 54,320 226 23,181 1,509 566
21 70 54,320 226 25,604 1,488 626
23 67 54,320 226 28,026 1,464 686
25 65 54,320 226 30,447 1,438 745
27 62 54,320 226 32,867 1,408 805
29 60 54,320 226 35,286 1,375 865
31 57 54,320 226 37,703 1,338 924
33 55 51,124 220 38,032 1,243 943
35 52 47,867 214 38,068 1,146 955
37 49 44,964 208 38,109 1,054 969
39 46 42,351 203 38,145 966 981
41 43 39,456 197 37,751 872 985
43 39 36,312 190 36,917 774 980
45 35 33,450 185 36,089 677 976
47 31 30,845 180 35,271 581 970
49 27 28,436 175 34,440 481 966
51 21 26,229 171 33,618 371 961
54 3 23,192 165 32,351 74 955
10-30-2007
52 Meter Boom

Page 9 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Working
11 590.00 1.33 1102.00 1.33 1551.00 207.00 1.58 2.06 1.03
13 579.00 1.33 1062.00 1.33 1471.00 206.00 1.58 2.18 1.18
15 568.00 1.33 1023.00 1.33 1395.00 205.00 1.57 2.29 1.31
17 558.00 1.33 986.00 1.33 1325.00 204.00 1.57 2.39 1.43
19 548.00 1.33 951.00 1.33 1259.00 203.00 1.57 2.48 1.55
21 538.00 1.33 916.00 1.33 1197.00 202.00 1.57 2.57 1.66
23 528.00 1.33 883.00 1.33 1139.00 201.00 1.57 2.65 1.76
25 518.00 1.33 851.00 1.33 1084.00 200.00 1.57 2.73 1.87
27 508.00 1.33 820.00 1.33 1031.00 199.00 1.56 2.80 1.97
29 498.00 1.33 789.00 1.33 980.00 198.00 1.56 2.87 2.07
31 488.00 1.33 759.00 1.33 931.00 197.00 1.56 2.94 2.17
33 478.00 1.33 728.00 1.33 883.00 196.00 1.56 3.01 2.27
35 467.00 1.33 698.00 1.33 837.00 195.00 1.56 3.07 2.37
37 456.00 1.33 668.00 1.33 791.00 194.00 1.56 3.13 2.47
39 444.00 1.33 638.00 1.33 746.00 193.00 1.55 3.20 2.58
41 432.00 1.33 607.00 1.33 702.00 192.00 1.55 3.26 2.70
43 419.00 1.33 576.00 1.33 658.00 191.00 1.55 3.33 2.82
45 405.00 1.33 543.00 1.33 613.00 189.00 1.55 3.40 2.95
47 389.00 1.33 509.00 1.33 567.00 187.00 1.54 3.48 3.09
49 371.00 1.33 472.00 1.33 520.00 185.00 1.54 3.57 3.26
51 349.00 1.33 431.00 1.33 468.00 182.00 1.53 3.68 3.46
54 286.00 1.33 326.00 1.33 342.00 169.00 1.51 4.04 4.11
(10) The Specified Boom Tip Velocity caused by Foundation M otions is 0 m/sec.
(11) The Specified Lateral Acceleration caused by Foundation M otions is 0
(13) The Specified Additional Offlead Angle (Trim) from F oundation M otions is .5 deg.
10-30-2007
52 Meter Boom
Page 10 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

11 760 0.500 2,310 0.500
13 760 0.500 2,310 0.500
15 760 0.500 2,310 0.500
17 760 0.500 2,310 0.500
19 760 0.500 2,310 0.500
21 760 0.500 2,310 0.500
23 760 0.500 2,310 0.500
25 760 0.500 2,310 0.500
27 760 0.500 2,310 0.500
29 760 0.500 2,310 0.500
31 760 0.500 2,310 0.500
33 723 0.500 2,225 0.500
35 686 0.500 2,139 0.500
37 652 0.500 2,062 0.500
39 622 0.500 1,992 0.500
41 588 0.500 1,915 0.500
43 551 0.500 1,831 0.500
45 518 0.500 1,755 0.500
47 488 0.500 1,686 0.500
49 460 0.500 1,622 0.500
51 434 0.500 1,563 0.500
54 399 0.500 1,482 0.500
10-30-2007
52 Meter Boom
Page 11 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Working Bas ed Bas ed Bas ed Bas ed Bas ed Bas ed Theor. Component Ratio
Radius on on on on on Main on Aux Fail Firs t to
(meters ) Kingpos t Sus pens ion Boom Gantry Cable Cable Load to Fail Kingpos t
11 605 816 319 435 288 72 288 MAIN 2.097
13 518 714 310 367 288 72 288 MAIN 1.797
15 453 640 296 318 288 72 288 MAIN 1.571
17 402 584 279 282 288 72 279 BOOM 1.438
19 361 539 265 254 288 72 254 GANTRY 1.421
21 327 503 253 231 288 72 231 GANTRY 1.415
23 299 472 243 213 288 72 213 GANTRY 1.406
25 276 445 234 193 288 72 193 GANTRY 1.423
27 255 422 226 177 288 72 177 GANTRY 1.438
29 237 401 218 163 288 72 163 GANTRY 1.452
31 222 382 211 151 288 72 151 GANTRY 1.464
33 208 364 204 141 288 72 141 GANTRY 1.476
35 196 348 197 132 288 72 132 GANTRY 1.488
37 185 333 191 123 288 72 123 GANTRY 1.497
39 175 318 184 116 288 72 116 GANTRY 1.506
41 166 304 178 110 288 72 110 GANTRY 1.515
43 158 290 171 104 288 72 104 GANTRY 1.524
45 151 277 164 98 288 72 98 GANTRY 1.53
47 144 263 156 94 288 72 94 GANTRY 1.536
49 138 249 148 89 288 72 89 GANTRY 1.545
51 132 234 138 85 288 72 85 GANTRY 1.551
54 124 195 112 80 288 72 80 GANTRY 1.555
(1) All Loads are measured in Tonnes
(2) Loads shown are calculated in accordance with AP I Spec 2C, 2004, Section 4.6.
(3) Ratio to Kingpost is the Ratio of the Component F irst to F ail to the KingpostThe Aux line is Excluded from this Ratio.
(4) The Specified Boom Tip Velocity caused by F oundation M otions is 0 m/sec.
(5) The Specified Lateral Acceleration caused by F oundation M otions is 0
(6) The Specified Vertical Acceleration caused by F oundation M otions is 1g.
(7) The Specified Additional Sidelead Angle (List) from F oundation M otions is .5 deg.
52 Meter Boom
10-30-2007
Theoretical Component Failure Mode Analysis
Page 12 of 97
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Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
Seatrax Hoist Datasheet-Metric Units
Auxiliary Drum Performance
Seatrax Drilling-Duty Hoist Configuration
52 Meter Boom
Hoist Model 463-EJA
Serial or Quotation Number: 4527 Project Identification: 4527
Pressure (bar) 354 Drum Barrel Diameter (mm) 508
Flow (lpm) 511 Drum Flange Diameter (mm) 864
Motor Displacement (cc/rev) 160 Drum Width Between Flanges (mm) 1,600
Motor Torque (n-m) 806 Drum Torque (n-m) 39,433
Motor Speed (rpm) 3,057 Drum Speed (rpm) 60
Gear Reduction 50.99 Diameter of Aux Cable (mm) 28
Installation Dimensions
Boom Pivot Height Above Deck Level (m) 14
Deck Level to Lowest Hook Position (i.e. Water) (m) 40
Maximum Required Hook Travel (m) 106
Single Line Performance
Layer Line Line Cumulative
of Pull Speed Cable
Cable (Kgs .) (Meters /min) Capacity (m)
1 14,988 101 94
2 13,722 110 196
3 12,653 120 307
4 11,739 129 426
Auxiliary Drum Performance (Load in Kgs. @ Meters/Min)
Hook Load @ Boom Tip 13,453 Hook Speed @ Boom Tip 110
Hook Load @ Deck 14,694 Hook Speed @ Deck 101
Hook Load @ Water 14,694 Hook Speed @ Water 101
This Seatrax Drilling-Duty Hois t is Equipped with an External Contracting Drum Band Brake
Page 13 of 97
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Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
Main Drum Performance
52 Meter Boom
Hoist Model 863-HJC
Motor Displacement (cc/rev) 160 Drum Width Between Flanges (mm) 1600
Gear Reduction 78.65 Diameter of Main Cable (mm) 28
of Pull Speed Cable
1 17,629 84 121
2 16,448 90 249
3 15,415 96 387
4 14,504 102 532
5 13,694 108 688
6 12,970 114 850
Main Drum Performance- 2 Part Line (Load in Kgs. @ Meters/Min)
Main Drum Performance - 6 Part Line (Load in Kgs. @ Meters/Min)
Thi s S eatrax Dri l l i ng-Duty Hoi st i s Equi pped wi th an External Contracti ng Drum Band Brake
Page 14 of 97
2
Bottom Supported Structure API General Method
Radius Main Hoist Main Hoist Main Hoist Aux Hoist
(meters) SWL (Kgs) SWL (Kgs) SWL (Kgs) SWL (Kgs)
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
10-30-2007
Seatrax Series 90 Model S9028 52 Meter Boom
ONBOARD (DECK) LIFTS

(1) Working radius is measured from the main hook to centerline of rotation
(2) SWL letter suffiixes indicate load limiting factor per API 2C, 4.1.1 (a) thru (i).
(3) Rated loads are NET loads. Main Block & Aux. Ball weights have been deducted.
(4) T he Specified Boom T ip Velocity caused by Foundation Motions is N/A.
(5) T he Specified Lateral Acceleration caused by Foundation Motions is 0
(6) T he Specified Vertical Acceleration caused by Foundation Motions is 1g.
(7) T he Specified Additional Sidelead Angle (List) from Foundation Motions is .5 deg.
(8) T he Specified Additional Offlead Angle (T rim) from Foundation Motions is .5 deg.
(9) Main drum cable is 29 dia. Class CH, 72 te. nom strength, 488 m. long.
(10) Aux. drum cable is 29 dia. Class CH, 72 te. nom strength, 170 m. long.
(11) T he specified hook travel for this machine is 106 m.
(12) T he Minimum Personnel Rated Load at any Working Radius is 4333 kgs.

Page 15 of 97
2
NOTE: These are the load charts that
have to go inside the Cab.
It has exactly the same information as
the data sheets on Page 4, but it is an
API 2C 6th Edition requirement that the
Cab Charts go inside the Cab.
2
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
10-30-2007
OFFBOARD (SUPPLY BOAT) LIFTS

(4) T he Specified Boom T ip Velocity caused by Foundation Motions is 0 m/sec.

Page 16 of 97
2
2
1.)
2.)
3.)
4.)
Le ngth of the Aux. Hois t Cable (me te rs ) 170
Diame te r of Aux. Hois t Cable (mm) 28
Aux. Hois t Cable Cons truction Clas s CH
Minimum Bre aking Stre ngth of Aux. Cable (tonne s ) 72
Le ngth of Main Hois t Cable (me te rs ) 488
Diame te r of Main Hois t Cable (mm) 28
Main Hois t Cable Cons truction Clas s CH
Min. Bre aking Stre ngth of Main Hois t Cable (tonne s ) 72
Diame te r of Boom Hois t Cable (mm) 28
Boom Hois t Cable Cons truction Clas s BL
Min. Bre aking Stre ngth of Boom Hois t Cable (tonne s ) 72
Numbe r of Boom Sus pe ns ion Parts of Line 'NB' 12
1.) The Main and Auxiliary Hook Trave l for This Machine in Me te rs : 106
2.) Se atrax Load Charts Indicate Nominal Minimum and Maximum Working Radii
3.) Maximum Auxiliary Hook Spe e d @ Wate r Le ve l in Me te rs /Minute : 101
4.) Maximum 2 Part Main Hook Spe e d @ Wate r Le ve l-Me te rs /Minute : 45
Maximum 4 Part Main Hook Spe e d @ Wate r Le ve l-Me te rs /Minute : 21
10-30-2007
INFORMATION CHART
Seatrax Kingpost Marine Crane Operating Notes:
Wire Rope Component Data
Additional Data
This is a Se atrax Kingpos t Marine Crane . Unlike Conve ntional Crane s , It CANNOT Se parate from
its Foundation (Pe de s tal) Due to Sle w Be aring Failure .
This Se atrax Kingpos t Marine Crane has Fail-Safe Hois ts . Re le as ing the Controls Se ts all Hois t
Brake s Automatically. If a Load Slips Downward, Do NOT Pull Back on the Controls as this Action
Signals the Brake s to Re main Off. RELEASE the Controls to Se t Brake s .
This Se atrax Kingpos t Marine Crane is Equippe d with a Pate nte d Me chanical Two Block Sys te m.
Lowe ring the Boom will NOT caus e it to Contact the Hook Blocks .
For Optimum Safe ty and Se rvice Life , Follow the Ope rating, Ins pe ction and Mainte nance
Ins tructions in the Se atrax Ope ration and Mainte nce Manual or CD.

Page 17 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Seatrax Inc.
Prepared For
10-30-2007
In Compliance with
52 Meter Boom
METRIC UNITS
Telephone (713) 896-6500
Fax (713) 896-6611
Maersk Qatar AS
API General Method
Significant Wave Height = .7 meters
Page 18 of 97
2
52 Meter Boom
Block(s) (Tonnes) 1
10-30-2007
HOIST SELECTIONS

Phone: 713 896 6500 Fax: 713 896 6611

Page 19 of 97
2

10-30-2007
52 Meter Boom
I n Compliance with
Notes:
API General Method
Onboard Lifts
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39978b N/A 12999d
43 27253d 37828b N/A 12999d
45 27253d 35863b N/A 12999d
47 27253d 34066b N/A 12999d
49 27253d 32418b N/A 12999d
51 27253d 30894b N/A 12999d
54 27196e 27196e N/A 12999d
Onboard Lifts
Page 20 of 97
2

11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 51726b N/A 12999d
33 27253d 48477b N/A 12999d
35 27253d 45562b N/A 12999d
37 27253d 42945b N/A 12999d
39 27253d 40580b N/A 12999d
41 27253d 38236is N/A 12999d
43 27253d 35408is N/A 12999d
45 27253d 32755is N/A 12999d
47 27253d 30240is N/A 12999d
49 27253d 27762is N/A 12999d
51 25270is 25270is N/A 12999d
54 19694is 19694is N/A 12999d
Notes:
Significant Wave Height = .7 meters
10-30-2007
I n Compliance with
API General Method
52 Meter Boom
Page 21 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Kingpost Reactions
11 81 54,320 226 13,479 1,333 279
13 79 54,320 226 15,906 1,324 329
15 77 54,320 226 18,332 1,313 380
17 74 54,320 226 20,757 1,300 431
19 72 54,320 226 23,181 1,285 482
21 70 54,320 226 25,604 1,267 532
23 67 54,320 226 28,026 1,247 584
25 65 54,320 226 30,447 1,224 634
27 62 54,320 226 32,867 1,199 686
29 60 54,320 226 35,286 1,171 736
31 57 54,320 226 37,703 1,139 787
33 55 51,124 220 38,032 1,050 797
35 52 47,867 214 38,068 960 801
37 49 44,964 208 38,109 876 805
39 46 42,351 203 38,145 796 808
41 43 39,978 198 38,173 719 812
43 39 37,828 194 38,201 643 814
45 35 35,863 190 38,225 568 818
47 31 34,066 186 38,250 492 821
49 27 32,418 183 38,274 411 825
51 21 30,894 180 38,289 319 828
54 3 27,196 172 36,588 62 799
52 Me te r Boom
10-30-2007
Onboard Lifts

Page 22 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
Working
11 590.00 1.33 1102.00 1.33 1551.00 207.00 1.33 2.06 1.03
13 579.00 1.33 1062.00 1.33 1471.00 206.00 1.33 2.18 1.18
15 568.00 1.33 1023.00 1.33 1395.00 205.00 1.33 2.29 1.31
17 558.00 1.33 986.00 1.33 1325.00 204.00 1.33 2.39 1.43
19 548.00 1.33 951.00 1.33 1259.00 203.00 1.33 2.48 1.55
21 538.00 1.33 916.00 1.33 1197.00 202.00 1.33 2.57 1.66
23 528.00 1.33 883.00 1.33 1139.00 201.00 1.33 2.65 1.76
25 518.00 1.33 851.00 1.33 1084.00 200.00 1.33 2.73 1.87
27 508.00 1.33 820.00 1.33 1031.00 199.00 1.33 2.80 1.97
29 498.00 1.33 789.00 1.33 980.00 198.00 1.33 2.87 2.07
31 488.00 1.33 759.00 1.33 931.00 197.00 1.33 2.94 2.17
33 478.00 1.33 728.00 1.33 883.00 196.00 1.33 3.01 2.27
35 467.00 1.33 698.00 1.33 837.00 195.00 1.33 3.07 2.37
37 456.00 1.33 668.00 1.33 791.00 194.00 1.33 3.13 2.47
39 444.00 1.33 638.00 1.33 746.00 193.00 1.33 3.20 2.58
41 432.00 1.33 607.00 1.33 702.00 192.00 1.33 3.26 2.70
43 419.00 1.33 576.00 1.33 658.00 191.00 1.33 3.33 2.82
45 405.00 1.33 543.00 1.33 613.00 189.00 1.33 3.40 2.95
47 389.00 1.33 509.00 1.33 567.00 187.00 1.33 3.48 3.09
49 371.00 1.33 472.00 1.33 520.00 185.00 1.33 3.57 3.26
51 349.00 1.33 431.00 1.33 468.00 182.00 1.33 3.68 3.46
54 286.00 1.33 326.00 1.33 342.00 169.00 1.33 4.04 4.11
10-30-2007
52 Meter Boom
Page 23 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
11 760 0.500 1,858 0.500
13 760 0.500 1,858 0.500
15 760 0.500 1,858 0.500
17 760 0.500 1,858 0.500
19 760 0.500 1,858 0.500
21 760 0.500 1,858 0.500
23 760 0.500 1,858 0.500
25 760 0.500 1,858 0.500
27 760 0.500 1,858 0.500
29 760 0.500 1,858 0.500
31 760 0.500 1,858 0.500
33 723 0.500 1,773 0.500
35 686 0.500 1,687 0.500
37 652 0.500 1,610 0.500
39 622 0.500 1,540 0.500
41 594 0.500 1,477 0.500
43 569 0.500 1,420 0.500
45 546 0.500 1,367 0.500
47 525 0.500 1,320 0.500
49 506 0.500 1,276 0.500
51 489 0.500 1,235 0.500
54 446 0.500 1,137 0.500
(2) The Sidelead & Offlead Forces acting at the boom tip due to Wind Loads are 269 kgs.
10-30-2007
52 Me te r Boom
Page 24 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611
Kingpost Reactions
Significant Wave He ight = .7 me te rs Winds pe e d = 11 m/s e c
11 81 54,320 232 16,440 1,877 393
13 79 54,320 232 18,867 1,859 463
15 77 54,320 231 21,267 1,839 534
17 74 54,320 230 23,641 1,818 603
19 72 54,320 229 25,991 1,795 673
21 70 54,320 229 28,317 1,770 745
23 67 54,320 229 30,619 1,743 817
25 65 54,320 228 32,896 1,714 889
27 62 54,320 227 35,148 1,683 962
29 60 54,320 226 37,359 1,648 1,037
31 57 51,726 221 38,061 1,550 1,072
33 55 48,477 215 38,108 1,435 1,090
35 52 45,562 209 38,143 1,328 1,109
37 49 42,945 204 38,178 1,228 1,128
39 46 40,580 199 38,209 1,132 1,151
41 43 38,236 195 38,072 1,036 1,170
43 39 35,408 189 37,323 926 1,174
45 35 32,755 184 36,510 818 1,178
47 31 30,240 179 35,617 710 1,186
49 27 27,762 174 34,555 595 1,195
51 21 25,270 169 33,267 467 1,212
54 3 19,694 157 28,788 101 1,290
10-30-2007
52 Meter Boom

Page 25 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Working
11 579.00 1.46 1066.00 1.40 1481.00 206.00 1.76 2.33 1.29
13 569.00 1.45 1028.00 1.39 1406.00 205.00 1.76 2.41 1.41
15 558.00 1.45 991.00 1.38 1335.00 204.00 1.75 2.50 1.53
17 548.00 1.44 955.00 1.38 1269.00 203.00 1.75 2.58 1.63
19 538.00 1.44 921.00 1.37 1208.00 201.00 1.75 2.66 1.74
21 528.00 1.43 888.00 1.36 1150.00 201.00 1.75 2.73 1.84
23 518.00 1.43 857.00 1.35 1095.00 200.00 1.75 2.80 1.93
25 508.00 1.42 826.00 1.34 1043.00 199.00 1.74 2.87 2.03
27 499.00 1.42 796.00 1.34 993.00 198.00 1.74 2.93 2.12
29 489.00 1.41 767.00 1.33 945.00 197.00 1.74 2.99 2.21
31 479.00 1.41 737.00 1.33 899.00 196.00 1.74 3.05 2.31
33 469.00 1.40 709.00 1.33 854.00 195.00 1.73 3.11 2.40
35 458.00 1.40 680.00 1.33 810.00 194.00 1.73 3.17 2.50
37 448.00 1.39 651.00 1.33 767.00 193.00 1.73 3.22 2.60
39 436.00 1.39 622.00 1.33 724.00 192.00 1.73 3.28 2.70
41 424.00 1.38 592.00 1.33 682.00 191.00 1.72 3.34 2.81
43 412.00 1.37 562.00 1.33 640.00 189.00 1.72 3.40 2.92
45 398.00 1.37 531.00 1.33 598.00 188.00 1.72 3.46 3.05
47 383.00 1.36 499.00 1.33 555.00 186.00 1.71 3.53 3.19
49 366.00 1.35 464.00 1.33 509.00 184.00 1.71 3.60 3.34
51 345.00 1.34 425.00 1.33 460.00 180.00 1.70 3.69 3.53
54 286.00 1.33 326.00 1.33 341.00 169.00 1.67 3.96 4.11
(2) The calculated Supply Boat Deck Velocity in m/sec is .421
10-30-2007
52 Meter Boom
Page 26 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

11 3,791 2.722 2,564 1.611
13 3,780 2.730 2,557 1.615
15 3,773 2.741 2,551 1.621
17 3,769 2.754 2,547 1.627
19 3,768 2.769 2,545 1.635
21 3,771 2.787 2,545 1.644
23 3,778 2.807 2,546 1.654
25 3,789 2.831 2,550 1.666
27 3,804 2.858 2,556 1.679
29 3,822 2.889 2,563 1.695
31 3,691 2.924 2,482 1.712
33 3,516 2.964 2,376 1.732
35 3,365 3.010 2,284 1.755
37 3,237 3.063 2,204 1.782
39 3,128 3.125 2,136 1.813
41 3,024 3.198 2,071 1.849
43 2,888 3.285 1,986 1.893
45 2,768 3.391 1,911 1.946
47 2,667 3.525 1,846 2.013
49 2,582 3.703 1,789 2.102
51 2,524 3.960 1,746 2.232
54 2,599 5.191 1,753 2.849
(2) The Sidelead & Offlead Forces acting at the boom tip due to Wind Loads are 269 kgs.
10-30-2007
52 Meter Boom
Page 27 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

11 519 647 273 343 288 72 273 BOOM 1.899
13 454 592 270 303 288 72 270 BOOM 1.681
15 403 547 266 271 288 72 266 BOOM 1.516
17 362 511 253 245 288 72 245 GANTRY 1.476
19 329 480 242 225 288 72 225 GANTRY 1.461
21 301 453 232 207 288 72 207 GANTRY 1.449
23 277 430 224 193 288 72 193 GANTRY 1.435
25 257 409 216 177 288 72 177 GANTRY 1.446
27 239 390 209 163 288 72 163 GANTRY 1.461
29 223 373 202 152 288 72 152 GANTRY 1.473
31 210 358 196 141 288 72 141 GANTRY 1.482
33 198 343 190 132 288 72 132 GANTRY 1.494
35 187 329 184 124 288 72 124 GANTRY 1.503
37 177 316 178 117 288 72 117 GANTRY 1.512
39 168 304 172 111 288 72 111 GANTRY 1.518
41 160 291 166 105 288 72 105 GANTRY 1.527
43 153 279 160 99 288 72 99 GANTRY 1.533
45 146 267 153 95 288 72 95 GANTRY 1.539
47 140 255 146 90 288 72 90 GANTRY 1.545
49 134 243 138 86 288 72 86 GANTRY 1.551
51 129 229 129 83 288 72 83 GANTRY 1.555
54 124 195 104 80 288 72 80 GANTRY 1.551
52 Meter Boom
10-30-2007
Page 28 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 463-EJA
of Pull Speed Cable
1 14,988 101 94
2 13,722 110 196
3 12,653 120 307
4 11,739 129 426
Page 29 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 863-HJC
of Pull Speed Cable
1 17,629 84 121
2 16,448 90 249
3 15,415 96 387
4 14,504 102 532
5 13,694 108 688
6 12,970 114 850
Page 30 of 97
2
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39978b N/A 12999d
43 27253d 37828b N/A 12999d
45 27253d 35863b N/A 12999d
47 27253d 34066b N/A 12999d
49 27253d 32418b N/A 12999d
51 27253d 30894b N/A 12999d
54 27196e 27196e N/A 12999d
10-30-2007


Page 31 of 97
2
2
Significant Wave Height = .7 meters Windspeed = 11 m/sec
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 51726b N/A 12999d
33 27253d 48477b N/A 12999d
35 27253d 45562b N/A 12999d
37 27253d 42945b N/A 12999d
39 27253d 40580b N/A 12999d
41 27253d 38236is N/A 12999d
43 27253d 35408is N/A 12999d
45 27253d 32755is N/A 12999d
47 27253d 30240is N/A 12999d
49 27253d 27762is N/A 12999d
51 25270is 25270is N/A 12999d
54 19694is 19694is N/A 12999d
10-30-2007


Page 32 of 97
2
2
1.)
2.)
3.)
4.)
10-30-2007
INFORMATION CHART
Additional Data

Page 33 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Seatrax Inc.
Prepared For
10-30-2007
In Compliance with
52 Meter Boom
METRIC UNITS
Telephone (713) 896-6500
Fax (713) 896-6611
Maersk Qatar AS
API General Method
Significant Wave Height = 1 meters
Page 34 of 97
2
52 Meter Boom
Block(s) (Tonnes) 1
10-30-2007
HOIST SELECTIONS

Phone: 713 896 6500 Fax: 713 896 6611

Page 35 of 97
2

10-30-2007
52 Meter Boom
I n Compliance with
Notes:
API General Method
Onboard Lifts
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
Onboard Lifts
Page 36 of 97
2

11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 49830is N/A 12999d
31 27253d 45056is N/A 12999d
33 27253d 40877is N/A 12999d
35 27253d 37119is N/A 12999d
37 27253d 33708is N/A 12999d
39 27253d 30651is N/A 12999d
41 27253d 27855is N/A 12999d
43 25264is 25264is N/A 12999d
45 22876is 22876is N/A 12999d
47 20647is 20647is N/A 12999d
49 18494is 18494is N/A 12999d
51 16379is 16379is N/A 12999d
54 12161is 12161is N/A 12161is
Notes:
10-30-2007
I n Compliance with
API General Method
52 Meter Boom
Page 37 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Kingpost Reactions
11 81 54,320 226 13,479 1,565 328
13 79 54,320 226 15,906 1,555 387
15 77 54,320 226 18,332 1,542 447
17 74 54,320 226 20,757 1,527 507
19 72 54,320 226 23,181 1,509 566
21 70 54,320 226 25,604 1,488 626
23 67 54,320 226 28,026 1,464 686
25 65 54,320 226 30,447 1,438 745
27 62 54,320 226 32,867 1,408 805
29 60 54,320 226 35,286 1,375 865
31 57 54,320 226 37,703 1,338 924
33 55 51,124 220 38,032 1,243 943
35 52 47,867 214 38,068 1,146 955
37 49 44,964 208 38,109 1,054 969
39 46 42,351 203 38,145 966 981
41 43 39,456 197 37,751 872 985
43 39 36,312 190 36,917 774 980
45 35 33,450 185 36,089 677 976
47 31 30,845 180 35,271 581 970
49 27 28,436 175 34,440 481 966
51 21 26,229 171 33,618 371 961
54 3 23,192 165 32,351 74 955
52 Me te r Boom
10-30-2007
Onboard Lifts

Page 38 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
Working
11 590.00 1.33 1102.00 1.33 1551.00 207.00 1.33 2.06 1.03
13 579.00 1.33 1062.00 1.33 1471.00 206.00 1.33 2.18 1.18
15 568.00 1.33 1023.00 1.33 1395.00 205.00 1.33 2.29 1.31
17 558.00 1.33 986.00 1.33 1325.00 204.00 1.33 2.39 1.43
19 548.00 1.33 951.00 1.33 1259.00 203.00 1.33 2.48 1.55
21 538.00 1.33 916.00 1.33 1197.00 202.00 1.33 2.57 1.66
23 528.00 1.33 883.00 1.33 1139.00 201.00 1.33 2.65 1.76
25 518.00 1.33 851.00 1.33 1084.00 200.00 1.33 2.73 1.87
27 508.00 1.33 820.00 1.33 1031.00 199.00 1.33 2.80 1.97
29 498.00 1.33 789.00 1.33 980.00 198.00 1.33 2.87 2.07
31 488.00 1.33 759.00 1.33 931.00 197.00 1.33 2.94 2.17
33 478.00 1.33 728.00 1.33 883.00 196.00 1.33 3.01 2.27
35 467.00 1.33 698.00 1.33 837.00 195.00 1.33 3.07 2.37
37 456.00 1.33 668.00 1.33 791.00 194.00 1.33 3.13 2.47
39 444.00 1.33 638.00 1.33 746.00 193.00 1.33 3.20 2.58
41 432.00 1.33 607.00 1.33 702.00 192.00 1.33 3.26 2.70
43 419.00 1.33 576.00 1.33 658.00 191.00 1.33 3.33 2.82
45 405.00 1.33 543.00 1.33 613.00 189.00 1.33 3.40 2.95
47 389.00 1.33 509.00 1.33 567.00 187.00 1.33 3.48 3.09
49 371.00 1.33 472.00 1.33 520.00 185.00 1.33 3.57 3.26
51 349.00 1.33 431.00 1.33 468.00 182.00 1.33 3.68 3.46
54 286.00 1.33 326.00 1.33 342.00 169.00 1.33 4.04 4.11
10-30-2007
52 Meter Boom
Page 39 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
11 760 0.500 2,310 0.500
13 760 0.500 2,310 0.500
15 760 0.500 2,310 0.500
17 760 0.500 2,310 0.500
19 760 0.500 2,310 0.500
21 760 0.500 2,310 0.500
23 760 0.500 2,310 0.500
25 760 0.500 2,310 0.500
27 760 0.500 2,310 0.500
29 760 0.500 2,310 0.500
31 760 0.500 2,310 0.500
33 723 0.500 2,225 0.500
35 686 0.500 2,139 0.500
37 652 0.500 2,062 0.500
39 622 0.500 1,992 0.500
41 588 0.500 1,915 0.500
43 551 0.500 1,831 0.500
45 518 0.500 1,755 0.500
47 488 0.500 1,686 0.500
49 460 0.500 1,622 0.500
51 434 0.500 1,563 0.500
54 399 0.500 1,482 0.500
10-30-2007
52 Me te r Boom
Page 40 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611
Kingpost Reactions
Significant Wave He ight = 1 me te rs Winds pe e d = 18 m/s e c
11 81 54,320 242 18,005 2,407 504
13 79 54,320 241 20,578 2,382 593
15 77 54,320 240 23,115 2,354 683
17 74 54,320 239 25,620 2,325 772
19 72 54,320 238 28,093 2,294 862
21 70 54,320 237 30,535 2,260 951
23 67 54,320 236 32,946 2,224 1,042
25 65 54,320 236 35,327 2,184 1,133
27 62 54,320 235 37,668 2,142 1,225
29 60 49,830 220 35,658 1,893 1,191
31 57 45,056 211 34,847 1,724 1,191
33 55 40,877 203 34,048 1,571 1,193
35 52 37,119 195 33,206 1,429 1,191
37 49 33,708 188 32,311 1,295 1,190
39 46 30,651 182 31,414 1,170 1,189
41 43 27,855 176 30,473 1,051 1,187
43 39 25,264 171 29,471 934 1,183
45 35 22,876 166 28,427 820 1,182
47 31 20,647 161 27,323 706 1,180
49 27 18,494 156 26,083 586 1,178
51 21 16,379 152 24,662 454 1,178
54 3 12,161 142 20,776 94 1,206
10-30-2007
52 Meter Boom

Page 41 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

Working
11 578.00 1.54 1062.00 1.51 1472.00 206.00 1.85 2.37 1.33
13 567.00 1.53 1023.00 1.50 1398.00 205.00 1.84 2.44 1.44
15 557.00 1.53 987.00 1.49 1328.00 203.00 1.84 2.52 1.55
17 546.00 1.52 951.00 1.48 1263.00 202.00 1.84 2.60 1.66
19 536.00 1.52 917.00 1.47 1202.00 201.00 1.83 2.68 1.76
21 527.00 1.51 885.00 1.46 1144.00 200.00 1.83 2.75 1.86
23 517.00 1.51 853.00 1.45 1090.00 199.00 1.83 2.82 1.95
25 507.00 1.50 823.00 1.44 1038.00 198.00 1.83 2.89 2.05
27 498.00 1.49 793.00 1.43 989.00 198.00 1.82 2.95 2.14
29 488.00 1.49 764.00 1.36 941.00 197.00 1.82 3.01 2.23
31 478.00 1.48 735.00 1.37 895.00 196.00 1.82 3.07 2.32
33 468.00 1.48 706.00 1.38 850.00 195.00 1.82 3.12 2.42
35 457.00 1.47 678.00 1.38 807.00 194.00 1.81 3.18 2.51
37 447.00 1.46 649.00 1.38 764.00 193.00 1.81 3.23 2.61
39 435.00 1.46 620.00 1.38 722.00 192.00 1.81 3.29 2.72
41 424.00 1.45 591.00 1.39 680.00 190.00 1.80 3.35 2.82
43 411.00 1.44 561.00 1.39 638.00 189.00 1.80 3.40 2.94
45 397.00 1.43 530.00 1.38 596.00 187.00 1.80 3.46 3.06
47 382.00 1.42 497.00 1.38 553.00 186.00 1.79 3.53 3.20
49 365.00 1.41 463.00 1.37 508.00 183.00 1.79 3.60 3.35
51 345.00 1.48 424.00 1.36 459.00 180.00 1.78 3.69 3.54
54 286.00 1.45 326.00 1.33 342.00 169.00 1.75 3.95 4.11
10-30-2007
52 Meter Boom
Page 42 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

11 4,505 3.008 3,402 1.754
13 4,487 3.017 3,390 1.759
15 4,472 3.029 3,380 1.765
17 4,462 3.044 3,372 1.772
19 4,456 3.061 3,367 1.781
21 4,455 3.081 3,364 1.791
23 4,458 3.104 3,363 1.802
25 4,466 3.130 3,365 1.816
27 4,479 3.161 3,369 1.831
29 3,978 3.196 3,076 1.848
31 3,674 3.235 2,896 1.868
33 3,408 3.281 2,739 1.891
35 3,169 3.333 2,597 1.917
37 2,952 3.393 2,469 1.947
39 2,759 3.462 2,354 1.982
41 2,584 3.545 2,249 2.023
43 2,423 3.643 2,153 2.072
45 2,279 3.763 2,067 2.132
47 2,150 3.914 1,988 2.208
49 2,032 4.114 1,916 2.309
51 1,930 4.404 1,852 2.454
54 1,873 5.791 1,798 3.151
10-30-2007
52 Meter Boom
Page 43 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

11 510 630 260 334 288 72 260 BOOM 1.959
13 447 579 258 296 288 72 258 BOOM 1.734
15 398 537 254 266 288 72 254 BOOM 1.564
17 358 502 244 241 288 72 241 GANTRY 1.482
19 325 473 234 221 288 72 221 GANTRY 1.467
21 298 447 224 205 288 72 205 GANTRY 1.452
23 274 425 216 191 288 72 191 GANTRY 1.438
25 254 405 209 175 288 72 175 GANTRY 1.449
27 237 387 202 162 288 72 162 GANTRY 1.464
29 222 370 196 150 288 72 150 GANTRY 1.476
31 208 355 190 140 288 72 140 GANTRY 1.485
33 196 341 184 131 288 72 131 GANTRY 1.494
35 186 327 178 123 288 72 123 GANTRY 1.503
37 176 314 173 116 288 72 116 GANTRY 1.512
39 167 302 167 110 288 72 110 GANTRY 1.521
41 159 290 161 104 288 72 104 GANTRY 1.527
43 152 278 155 99 288 72 99 GANTRY 1.536
45 145 266 149 94 288 72 94 GANTRY 1.542
47 139 254 142 90 288 72 90 GANTRY 1.545
49 134 242 134 86 288 72 86 GANTRY 1.551
51 129 228 125 83 288 72 83 GANTRY 1.555
54 124 195 101 80 288 72 80 GANTRY 1.551
52 Meter Boom
10-30-2007
Page 44 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 463-EJA
of Pull Speed Cable
1 14,988 101 94
2 13,722 110 196
3 12,653 120 307
4 11,739 129 426
Page 45 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 863-HJC
of Pull Speed Cable
1 17,629 84 121
2 16,448 90 249
3 15,415 96 387
4 14,504 102 532
5 13,694 108 688
6 12,970 114 850
Page 46 of 97
2
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
10-30-2007


Page 47 of 97
2
2
Significant Wave Height = 1 meters Windspeed = 18 m/sec
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 49830is N/A 12999d
31 27253d 45056is N/A 12999d
33 27253d 40877is N/A 12999d
35 27253d 37119is N/A 12999d
37 27253d 33708is N/A 12999d
39 27253d 30651is N/A 12999d
41 27253d 27855is N/A 12999d
43 25264is 25264is N/A 12999d
45 22876is 22876is N/A 12999d
47 20647is 20647is N/A 12999d
49 18494is 18494is N/A 12999d
51 16379is 16379is N/A 12999d
54 12161is 12161is N/A 12161is
10-30-2007


Page 48 of 97 2
2
1.)
2.)
3.)
4.)
10-30-2007
INFORMATION CHART
Additional Data

Page 49 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

Seatrax Inc.
Prepared For
10-30-2007
In Compliance with
52 Meter Boom
METRIC UNITS
Telephone (713) 896-6500
Fax (713) 896-6611
Maersk Qatar AS
API General Method
Significant Wave Height = 1.5 meters
Page 50 of 97 2
52 Meter Boom
Block(s) (Tonnes) 1
10-30-2007
HOIST SELECTIONS

Phone: 713 896 6500 Fax: 713 896 6611

Page 51 of 97
2

10-30-2007
52 Meter Boom
I n Compliance with
Notes:
API General Method
Onboard Lifts
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
Onboard Lifts
Page 52 of 97
2

11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 50768is N/A 12999d
29 27253d 45768is N/A 12999d
31 27253d 41416is N/A 12999d
33 27253d 37530is N/A 12999d
35 27253d 34045is N/A 12999d
37 27253d 30904is N/A 12999d
39 27253d 28090is N/A 12999d
41 25493is 25493is N/A 12999d
43 23093is 23093is N/A 12999d
45 20881is 20881is N/A 12999d
47 18805is 18805is N/A 12999d
49 16807is 16807is N/A 12999d
51 14855is 14855is N/A 12999d
54 10890is 10890is N/A 10890is
Notes:
Significant Wave Height = 1.5 meters
10-30-2007
I n Compliance with
API General Method
52 Meter Boom
Page 53 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

Kingpost Reactions
11 81 54,320 226 13,479 1,565 328
13 79 54,320 226 15,906 1,555 387
15 77 54,320 226 18,332 1,542 447
17 74 54,320 226 20,757 1,527 507
19 72 54,320 226 23,181 1,509 566
21 70 54,320 226 25,604 1,488 626
23 67 54,320 226 28,026 1,464 686
25 65 54,320 226 30,447 1,438 745
27 62 54,320 226 32,867 1,408 805
29 60 54,320 226 35,286 1,375 865
31 57 54,320 226 37,703 1,338 924
33 55 51,124 220 38,032 1,243 943
35 52 47,867 214 38,068 1,146 955
37 49 44,964 208 38,109 1,054 969
39 46 42,351 203 38,145 966 981
41 43 39,456 197 37,751 872 985
43 39 36,312 190 36,917 774 980
45 35 33,450 185 36,089 677 976
47 31 30,845 180 35,271 581 970
49 27 28,436 175 34,440 481 966
51 21 26,229 171 33,618 371 961
54 3 23,192 165 32,351 74 955
52 Me te r Boom
10-30-2007
Onboard Lifts

Page 54 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
Working
11 590.00 1.33 1102.00 1.33 1551.00 207.00 1.33 2.06 1.03
13 579.00 1.33 1062.00 1.33 1471.00 206.00 1.33 2.18 1.18
15 568.00 1.33 1023.00 1.33 1395.00 205.00 1.33 2.29 1.31
17 558.00 1.33 986.00 1.33 1325.00 204.00 1.33 2.39 1.43
19 548.00 1.33 951.00 1.33 1259.00 203.00 1.33 2.48 1.55
21 538.00 1.33 916.00 1.33 1197.00 202.00 1.33 2.57 1.66
23 528.00 1.33 883.00 1.33 1139.00 201.00 1.33 2.65 1.76
25 518.00 1.33 851.00 1.33 1084.00 200.00 1.33 2.73 1.87
27 508.00 1.33 820.00 1.33 1031.00 199.00 1.33 2.80 1.97
29 498.00 1.33 789.00 1.33 980.00 198.00 1.33 2.87 2.07
31 488.00 1.33 759.00 1.33 931.00 197.00 1.33 2.94 2.17
33 478.00 1.33 728.00 1.33 883.00 196.00 1.33 3.01 2.27
35 467.00 1.33 698.00 1.33 837.00 195.00 1.33 3.07 2.37
37 456.00 1.33 668.00 1.33 791.00 194.00 1.33 3.13 2.47
39 444.00 1.33 638.00 1.33 746.00 193.00 1.33 3.20 2.58
41 432.00 1.33 607.00 1.33 702.00 192.00 1.33 3.26 2.70
43 419.00 1.33 576.00 1.33 658.00 191.00 1.33 3.33 2.82
45 405.00 1.33 543.00 1.33 613.00 189.00 1.33 3.40 2.95
47 389.00 1.33 509.00 1.33 567.00 187.00 1.33 3.48 3.09
49 371.00 1.33 472.00 1.33 520.00 185.00 1.33 3.57 3.26
51 349.00 1.33 431.00 1.33 468.00 182.00 1.33 3.68 3.46
54 286.00 1.33 326.00 1.33 342.00 169.00 1.33 4.04 4.11
10-30-2007
52 Meter Boom
Page 55 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
11 760 0.500 2,310 0.500
13 760 0.500 2,310 0.500
15 760 0.500 2,310 0.500
17 760 0.500 2,310 0.500
19 760 0.500 2,310 0.500
21 760 0.500 2,310 0.500
23 760 0.500 2,310 0.500
25 760 0.500 2,310 0.500
27 760 0.500 2,310 0.500
29 760 0.500 2,310 0.500
31 760 0.500 2,310 0.500
33 723 0.500 2,225 0.500
35 686 0.500 2,139 0.500
37 652 0.500 2,062 0.500
39 622 0.500 1,992 0.500
41 588 0.500 1,915 0.500
43 551 0.500 1,831 0.500
45 518 0.500 1,755 0.500
47 488 0.500 1,686 0.500
49 460 0.500 1,622 0.500
51 434 0.500 1,563 0.500
54 399 0.500 1,482 0.500
10-30-2007
52 Me te r Boom
Page 56 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611
Kingpost Reactions
Significant Wave He ight = 1.5 me te rs Winds pe e d = 18 m/s e c
11 81 54,320 259 20,844 2,967 622
13 79 54,320 257 23,669 2,930 730
15 77 54,320 256 26,446 2,892 839
17 74 54,320 254 29,174 2,851 947
19 72 54,320 253 31,859 2,808 1,054
21 70 54,320 252 34,500 2,762 1,163
23 67 54,320 251 37,097 2,714 1,271
25 65 54,320 239 36,761 2,484 1,289
27 62 50,768 232 37,320 2,332 1,335
29 60 45,768 222 36,516 2,122 1,335
31 57 41,416 212 35,716 1,933 1,336
33 55 37,530 204 34,863 1,759 1,335
35 52 34,045 196 33,968 1,597 1,332
37 49 30,904 189 33,034 1,446 1,328
39 46 28,090 183 32,094 1,305 1,325
41 43 25,493 177 31,082 1,169 1,320
43 39 23,093 171 30,007 1,038 1,315
45 35 20,881 166 28,885 909 1,309
47 31 18,805 161 27,681 780 1,304
49 27 16,807 156 26,340 646 1,297
51 21 14,855 152 24,816 499 1,293
54 3 10,890 142 20,482 102 1,305
10-30-2007
52 Meter Boom

Page 57 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Working
11 576.00 1.69 1054.00 1.71 1458.00 205.00 1.99 2.42 1.39
13 565.00 1.68 1017.00 1.70 1385.00 204.00 1.99 2.49 1.49
15 555.00 1.67 980.00 1.68 1316.00 203.00 1.99 2.57 1.60
17 544.00 1.67 945.00 1.67 1252.00 202.00 1.98 2.64 1.70
19 534.00 1.66 911.00 1.65 1191.00 201.00 1.98 2.72 1.80
21 525.00 1.65 879.00 1.64 1135.00 200.00 1.98 2.78 1.90
23 515.00 1.64 848.00 1.62 1081.00 199.00 1.97 2.85 1.99
25 505.00 1.64 818.00 1.48 1030.00 198.00 1.97 2.91 2.08
27 496.00 1.63 788.00 1.49 981.00 197.00 1.97 2.97 2.17
29 486.00 1.62 759.00 1.50 934.00 196.00 1.96 3.03 2.26
31 476.00 1.61 731.00 1.51 889.00 195.00 1.96 3.09 2.35
33 466.00 1.61 702.00 1.52 845.00 194.00 1.96 3.14 2.45
35 456.00 1.60 674.00 1.52 802.00 193.00 1.95 3.20 2.54
37 445.00 1.59 645.00 1.53 759.00 192.00 1.95 3.25 2.64
39 434.00 1.58 617.00 1.53 718.00 191.00 1.95 3.30 2.74
41 422.00 1.57 588.00 1.53 676.00 190.00 1.94 3.36 2.85
43 409.00 1.56 558.00 1.53 635.00 189.00 1.94 3.42 2.96
45 396.00 1.55 527.00 1.53 593.00 187.00 1.93 3.47 3.08
47 381.00 1.62 495.00 1.52 551.00 185.00 1.93 3.54 3.21
49 364.00 1.62 461.00 1.52 506.00 183.00 1.92 3.61 3.37
51 344.00 1.62 423.00 1.50 458.00 180.00 1.91 3.69 3.55
54 286.00 1.57 326.00 1.44 342.00 169.00 1.87 3.93 4.10
10-30-2007
52 Meter Boom
Page 58 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

11 5,856 3.473 4,127 1.987
13 5,820 3.484 4,106 1.993
15 5,790 3.498 4,087 2.000
17 5,765 3.516 4,071 2.009
19 5,747 3.536 4,058 2.019
21 5,736 3.560 4,049 2.031
23 5,730 3.587 4,043 2.044
25 5,289 3.619 3,788 2.060
27 5,040 3.655 3,643 2.078
29 4,643 3.696 3,414 2.099
31 4,297 3.743 3,213 2.122
33 3,985 3.796 3,033 2.149
35 3,705 3.858 2,871 2.180
37 3,453 3.929 2,724 2.216
39 3,228 4.012 2,593 2.257
41 3,020 4.109 2,472 2.306
43 2,830 4.225 2,360 2.364
45 2,658 4.367 2,259 2.436
47 2,501 4.546 2,167 2.525
49 2,358 4.784 2,082 2.644
51 2,234 5.127 2,006 2.817
54 2,122 6.767 1,923 3.643
10-30-2007
52 Meter Boom
Page 59 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

11 496 604 247 320 288 72 247 BOOM 2.005
13 436 560 245 286 288 72 245 BOOM 1.776
15 389 522 243 258 288 72 243 BOOM 1.602
17 351 490 235 235 288 72 235 BOOM 1.491
19 319 462 225 216 288 72 216 GANTRY 1.476
21 293 438 217 201 288 72 201 GANTRY 1.458
23 270 417 210 187 288 72 187 GANTRY 1.444
25 251 398 203 172 288 72 172 GANTRY 1.455
27 234 381 196 159 288 72 159 GANTRY 1.467
29 219 365 190 148 288 72 148 GANTRY 1.479
31 206 350 185 138 288 72 138 GANTRY 1.488
33 194 337 179 130 288 72 130 GANTRY 1.497
35 184 324 174 122 288 72 122 GANTRY 1.506
37 174 311 168 115 288 72 115 GANTRY 1.515
39 166 299 162 109 288 72 109 GANTRY 1.524
41 158 287 157 103 288 72 103 GANTRY 1.53
43 151 276 151 98 288 72 98 GANTRY 1.536
45 145 264 145 94 288 72 94 GANTRY 1.542
47 139 253 138 89 288 72 89 GANTRY 1.548
49 133 241 131 86 288 72 86 GANTRY 1.551
51 129 228 122 82 288 72 82 GANTRY 1.558
54 124 195 99 80 288 72 80 GANTRY 1.551
52 Meter Boom
10-30-2007
Page 60 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 463-EJA
of Pull Speed Cable
1 14,988 101 94
2 13,722 110 196
3 12,653 120 307
4 11,739 129 426
Page 61 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 863-HJC
of Pull Speed Cable
1 17,629 84 121
2 16,448 90 249
3 15,415 96 387
4 14,504 102 532
5 13,694 108 688
6 12,970 114 850
Page 62 of 97
2
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
10-30-2007


Page 63 of 97 2
2
Significant Wave Height = 1.5 meters Windspeed = 18 m/sec
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 50768is N/A 12999d
29 27253d 45768is N/A 12999d
31 27253d 41416is N/A 12999d
33 27253d 37530is N/A 12999d
35 27253d 34045is N/A 12999d
37 27253d 30904is N/A 12999d
39 27253d 28090is N/A 12999d
41 25493is 25493is N/A 12999d
43 23093is 23093is N/A 12999d
45 20881is 20881is N/A 12999d
47 18805is 18805is N/A 12999d
49 16807is 16807is N/A 12999d
51 14855is 14855is N/A 12999d
54 10890is 10890is N/A 10890is
10-30-2007


Page 64 of 97 2
2
1.)
2.)
3.)
4.)
10-30-2007
INFORMATION CHART
Additional Data

Page 65 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Seatrax Inc.
Prepared For
10-30-2007
In Compliance with
52 Meter Boom
METRIC UNITS
Telephone (713) 896-6500
Fax (713) 896-6611
Maersk Qatar AS
API General Method
Page 66 of 97
2
52 Meter Boom
Block(s) (Tonnes) 1
10-30-2007
HOIST SELECTIONS

Phone: 713 896 6500 Fax: 713 896 6611

Page 3 of 97
Page 67 of 97
2

10-30-2007
52 Meter Boom
I n Compliance with
Notes:
API General Method
Onboard Lifts
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
Onboard Lifts
Page 68 of 97
2

11 27253d 54320d N/A 12943c
13 27253d 54320d N/A 12971c
15 27253d 54320d N/A 12998c
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 50272b N/A 12999d
27 27253d 46277b N/A 12999d
29 27253d 42290is N/A 12999d
31 27253d 38231is N/A 12999d
33 27253d 34636is N/A 12999d
35 27253d 31407is N/A 12999d
37 27253d 28498is N/A 12999d
39 25847is 25847is N/A 12999d
41 23452is 23452is N/A 12999d
43 21236is 21236is N/A 12999d
45 19175is 19175is N/A 12999d
47 17230is 17230is N/A 12999d
49 15381is 15381is N/A 12999d
51 13541is 13541is N/A 12999d
54 9841is 9841is N/A 9841is
Notes:
10-30-2007
I n Compliance with
API General Method
52 Meter Boom
Page 69 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Kingpost Reactions
11 81 54,320 226 13,479 1,565 328
13 79 54,320 226 15,906 1,555 387
15 77 54,320 226 18,332 1,542 447
17 74 54,320 226 20,757 1,527 507
19 72 54,320 226 23,181 1,509 566
21 70 54,320 226 25,604 1,488 626
23 67 54,320 226 28,026 1,464 686
25 65 54,320 226 30,447 1,438 745
27 62 54,320 226 32,867 1,408 805
29 60 54,320 226 35,286 1,375 865
31 57 54,320 226 37,703 1,338 924
33 55 51,124 220 38,032 1,243 943
35 52 47,867 214 38,068 1,146 955
37 49 44,964 208 38,109 1,054 969
39 46 42,351 203 38,145 966 981
41 43 39,456 197 37,751 872 985
43 39 36,312 190 36,917 774 980
45 35 33,450 185 36,089 677 976
47 31 30,845 180 35,271 581 970
49 27 28,436 175 34,440 481 966
51 21 26,229 171 33,618 371 961
54 3 23,192 165 32,351 74 955
52 Me te r Boom
10-30-2007
Onboard Lifts

Page 70 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
Working
11 590.00 1.33 1102.00 1.33 1551.00 207.00 1.33 2.06 1.03
13 579.00 1.33 1062.00 1.33 1471.00 206.00 1.33 2.18 1.18
15 568.00 1.33 1023.00 1.33 1395.00 205.00 1.33 2.29 1.31
17 558.00 1.33 986.00 1.33 1325.00 204.00 1.33 2.39 1.43
19 548.00 1.33 951.00 1.33 1259.00 203.00 1.33 2.48 1.55
21 538.00 1.33 916.00 1.33 1197.00 202.00 1.33 2.57 1.66
23 528.00 1.33 883.00 1.33 1139.00 201.00 1.33 2.65 1.76
25 518.00 1.33 851.00 1.33 1084.00 200.00 1.33 2.73 1.87
27 508.00 1.33 820.00 1.33 1031.00 199.00 1.33 2.80 1.97
29 498.00 1.33 789.00 1.33 980.00 198.00 1.33 2.87 2.07
31 488.00 1.33 759.00 1.33 931.00 197.00 1.33 2.94 2.17
33 478.00 1.33 728.00 1.33 883.00 196.00 1.33 3.01 2.27
35 467.00 1.33 698.00 1.33 837.00 195.00 1.33 3.07 2.37
37 456.00 1.33 668.00 1.33 791.00 194.00 1.33 3.13 2.47
39 444.00 1.33 638.00 1.33 746.00 193.00 1.33 3.20 2.58
41 432.00 1.33 607.00 1.33 702.00 192.00 1.33 3.26 2.70
43 419.00 1.33 576.00 1.33 658.00 191.00 1.33 3.33 2.82
45 405.00 1.33 543.00 1.33 613.00 189.00 1.33 3.40 2.95
47 389.00 1.33 509.00 1.33 567.00 187.00 1.33 3.48 3.09
49 371.00 1.33 472.00 1.33 520.00 185.00 1.33 3.57 3.26
51 349.00 1.33 431.00 1.33 468.00 182.00 1.33 3.68 3.46
54 286.00 1.33 326.00 1.33 342.00 169.00 1.33 4.04 4.11
10-30-2007
52 Meter Boom
Page 71 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
11 760 0.500 2,310 0.500
13 760 0.500 2,310 0.500
15 760 0.500 2,310 0.500
17 760 0.500 2,310 0.500
19 760 0.500 2,310 0.500
21 760 0.500 2,310 0.500
23 760 0.500 2,310 0.500
25 760 0.500 2,310 0.500
27 760 0.500 2,310 0.500
29 760 0.500 2,310 0.500
31 760 0.500 2,310 0.500
33 723 0.500 2,225 0.500
35 686 0.500 2,139 0.500
37 652 0.500 2,062 0.500
39 622 0.500 1,992 0.500
41 588 0.500 1,915 0.500
43 551 0.500 1,831 0.500
45 518 0.500 1,755 0.500
47 488 0.500 1,686 0.500
49 460 0.500 1,622 0.500
51 434 0.500 1,563 0.500
54 399 0.500 1,482 0.500
10-30-2007
52 Me te r Boom
Page 72 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611
Kingpost Reactions
11 81 54,320 277 24,162 3,650 764
13 79 54,320 275 27,266 3,598 897
15 77 54,320 273 30,305 3,544 1,029
17 74 54,320 272 33,279 3,488 1,159
19 72 54,320 270 36,193 3,430 1,289
21 70 54,320 268 39,050 3,369 1,419
23 67 54,320 250 37,510 2,984 1,399
25 65 50,272 242 37,964 2,786 1,446
27 62 46,277 233 38,028 2,584 1,479
29 60 42,290 224 37,668 2,378 1,496
31 57 38,231 215 36,810 2,164 1,496
33 55 34,636 206 35,923 1,967 1,494
35 52 31,407 198 34,982 1,785 1,490
37 49 28,498 191 33,998 1,615 1,484
39 46 25,847 185 32,953 1,453 1,476
41 43 23,452 178 31,886 1,301 1,469
43 39 21,236 173 30,747 1,153 1,460
45 35 19,175 167 29,532 1,007 1,450
47 31 17,230 162 28,214 862 1,439
49 27 15,381 157 26,776 712 1,430
51 21 13,541 152 25,096 547 1,419
54 3 9,841 142 20,849 113 1,450
10-30-2007
52 Meter Boom

Page 73 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Working
11 574.00 1.86 1047.00 1.94 1444.00 205.00 2.15 2.48 1.44
13 563.00 1.85 1010.00 1.92 1372.00 204.00 2.15 2.54 1.54
15 553.00 1.84 973.00 1.90 1304.00 203.00 2.14 2.61 1.65
17 542.00 1.83 939.00 1.88 1241.00 202.00 2.14 2.68 1.74
19 532.00 1.82 906.00 1.86 1181.00 201.00 2.14 2.75 1.84
21 523.00 1.81 874.00 1.84 1125.00 200.00 2.13 2.82 1.93
23 513.00 1.80 843.00 1.62 1073.00 199.00 2.13 2.88 2.02
25 503.00 1.79 813.00 1.63 1022.00 198.00 2.13 2.94 2.11
27 494.00 1.78 784.00 1.65 974.00 197.00 2.12 3.00 2.20
29 484.00 1.77 755.00 1.66 928.00 196.00 2.12 3.06 2.29
31 474.00 1.76 726.00 1.67 883.00 195.00 2.11 3.11 2.38
33 464.00 1.75 698.00 1.68 839.00 194.00 2.11 3.16 2.47
35 454.00 1.74 670.00 1.69 797.00 193.00 2.11 3.22 2.57
37 443.00 1.73 642.00 1.69 755.00 192.00 2.10 3.27 2.66
39 432.00 1.71 614.00 1.70 713.00 191.00 2.10 3.32 2.76
41 421.00 1.70 585.00 1.70 672.00 190.00 2.09 3.37 2.87
43 408.00 1.76 556.00 1.70 632.00 188.00 2.09 3.43 2.98
45 395.00 1.77 525.00 1.69 590.00 187.00 2.08 3.48 3.10
47 380.00 1.77 493.00 1.69 548.00 185.00 2.08 3.55 3.23
49 363.00 1.77 460.00 1.67 504.00 183.00 2.07 3.61 3.38
51 343.00 1.77 422.00 1.65 457.00 180.00 2.06 3.69 3.56
54 286.00 1.76 326.00 1.62 342.00 169.00 2.01 3.90 4.10
(2) The calculated Supply Boat Deck Velocity in m/sec is 1.207
10-30-2007
52 Meter Boom
Page 74 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

11 7,510 3.949 5,013 2.226
13 7,450 3.962 4,977 2.233
15 7,397 3.979 4,946 2.241
17 7,352 3.999 4,918 2.251
19 7,316 4.022 4,895 2.263
21 7,288 4.050 4,877 2.276
23 6,476 4.082 4,417 2.292
25 6,121 4.118 4,214 2.311
27 5,758 4.160 4,006 2.332
29 5,381 4.208 3,791 2.355
31 4,980 4.262 3,563 2.383
33 4,623 4.324 3,360 2.414
35 4,300 4.396 3,176 2.450
37 4,008 4.478 3,009 2.491
39 3,741 4.574 2,856 2.539
41 3,501 4.687 2,718 2.596
43 3,280 4.822 2,591 2.664
45 3,076 4.986 2,473 2.746
47 2,888 5.193 2,365 2.850
49 2,718 5.468 2,265 2.989
51 2,563 5.866 2,174 3.189
54 2,474 7.764 2,105 4.146
10-30-2007
52 Meter Boom
Page 75 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

11 482 580 235 307 288 72 235 BOOM 2.049
13 425 541 234 276 288 72 234 BOOM 1.816
15 380 507 232 250 288 72 232 BOOM 1.639
17 344 477 227 229 288 72 227 BOOM 1.513
19 314 452 218 211 288 72 211 GANTRY 1.482
21 288 430 210 196 288 72 196 GANTRY 1.467
23 266 410 203 184 288 72 184 GANTRY 1.449
25 247 392 196 169 288 72 169 GANTRY 1.461
27 231 375 190 157 288 72 157 GANTRY 1.473
29 217 360 185 146 288 72 146 GANTRY 1.482
31 204 346 179 136 288 72 136 GANTRY 1.494
33 192 333 174 128 288 72 128 GANTRY 1.503
35 182 320 169 121 288 72 121 GANTRY 1.509
37 173 308 164 114 288 72 114 GANTRY 1.518
39 164 296 158 108 288 72 108 GANTRY 1.524
41 157 285 153 102 288 72 102 GANTRY 1.533
43 150 274 147 97 288 72 97 GANTRY 1.539
45 144 263 141 93 288 72 93 GANTRY 1.545
47 138 251 135 89 288 72 89 GANTRY 1.548
49 133 240 128 85 288 72 85 GANTRY 1.555
51 128 227 119 82 288 72 82 GANTRY 1.558
54 124 195 96 80 288 72 80 GANTRY 1.551
52 Meter Boom
10-30-2007
Page 76 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 463-EJA
of Pull Speed Cable
1 14,988 101 94
2 13,722 110 196
3 12,653 120 307
4 11,739 129 426
Page 77 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 863-HJC
of Pull Speed Cable
1 17,629 84 121
2 16,448 90 249
3 15,415 96 387
4 14,504 102 532
5 13,694 108 688
6 12,970 114 850
Page 78 of 97
2
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
10-30-2007


Page 79 of 97
2
2
11 27253d 54320d N/A 12943c
13 27253d 54320d N/A 12971c
15 27253d 54320d N/A 12998c
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 50272b N/A 12999d
27 27253d 46277b N/A 12999d
29 27253d 42290is N/A 12999d
31 27253d 38231is N/A 12999d
33 27253d 34636is N/A 12999d
35 27253d 31407is N/A 12999d
37 27253d 28498is N/A 12999d
39 25847is 25847is N/A 12999d
41 23452is 23452is N/A 12999d
43 21236is 21236is N/A 12999d
45 19175is 19175is N/A 12999d
47 17230is 17230is N/A 12999d
49 15381is 15381is N/A 12999d
51 13541is 13541is N/A 12999d
54 9841is 9841is N/A 9841is
10-30-2007


Page 80 of 97
2
2
1.)
2.)
3.)
4.)
10-30-2007
INFORMATION CHART
Additional Data

Page 81 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Seatrax Inc.
Prepared For
10-30-2007
In Compliance with
52 Meter Boom
METRIC UNITS
Telephone (713) 896-6500
Fax (713) 896-6611
Maersk Qatar AS
API General Method
Page 82 of 97
2
STRUCTURAL COMMENTS:
1.As agreed in MOM, Vendor to provide king post
reactions for all the required loads at specified radii
as listed in client data sheets.
52 Meter Boom
Block(s) (Tonnes) 1
10-30-2007
HOIST SELECTIONS

Phone: 713 896 6500 Fax: 713 896 6611

Page 83 of 97
2

10-30-2007
52 Meter Boom
I n Compliance with
Notes:
API General Method
Onboard Lifts
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
Onboard Lifts
Page 84 of 97
2

11 25102c 46005c N/A 11091c
13 25285c 46719c N/A 11119c
15 25469c 47435c N/A 11146c
17 25652c 48148c N/A 11173c
19 25834c 48868c N/A 11199c
21 26015c 48634b N/A 11223c
23 26196c 44175b N/A 11247c
25 26380c 40382b N/A 11271c
27 26566c 37139b N/A 11294c
29 26757c 34326b N/A 11317c
31 26955c 31884b N/A 11341c
33 27160c 29751b N/A 11365c
35 27210is 27210is N/A 11390c
37 24680is 24680is N/A 11416c
39 22365is 22365is N/A 11445c
41 20256is 20256is N/A 11476c
43 18309is 18309is N/A 11511c
45 16489is 16489is N/A 11551c
47 14794is 14794is N/A 11599c
49 13164is 13164is N/A 11658c
51 11542is 11542is N/A 11542is
54 8257is 8257is N/A 8257is
Notes:
10-30-2007
I n Compliance with
API General Method
52 Meter Boom
Page 85 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Kingpost Reactions
11 81 54,320 226 13,479 1,565 328
13 79 54,320 226 15,906 1,555 387
15 77 54,320 226 18,332 1,542 447
17 74 54,320 226 20,757 1,527 507
19 72 54,320 226 23,181 1,509 566
21 70 54,320 226 25,604 1,488 626
23 67 54,320 226 28,026 1,464 686
25 65 54,320 226 30,447 1,438 745
27 62 54,320 226 32,867 1,408 805
29 60 54,320 226 35,286 1,375 865
31 57 54,320 226 37,703 1,338 924
33 55 51,124 220 38,032 1,243 943
35 52 47,867 214 38,068 1,146 955
37 49 44,964 208 38,109 1,054 969
39 46 42,351 203 38,145 966 981
41 43 39,456 197 37,751 872 985
43 39 36,312 190 36,917 774 980
45 35 33,450 185 36,089 677 976
47 31 30,845 180 35,271 581 970
49 27 28,436 175 34,440 481 966
51 21 26,229 171 33,618 371 961
54 3 23,192 165 32,351 74 955
52 Me te r Boom
10-30-2007
Onboard Lifts

Page 86 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
Working
11 590.00 1.33 1102.00 1.33 1551.00 207.00 1.33 2.06 1.03
13 579.00 1.33 1062.00 1.33 1471.00 206.00 1.33 2.18 1.18
15 568.00 1.33 1023.00 1.33 1395.00 205.00 1.33 2.29 1.31
17 558.00 1.33 986.00 1.33 1325.00 204.00 1.33 2.39 1.43
19 548.00 1.33 951.00 1.33 1259.00 203.00 1.33 2.48 1.55
21 538.00 1.33 916.00 1.33 1197.00 202.00 1.33 2.57 1.66
23 528.00 1.33 883.00 1.33 1139.00 201.00 1.33 2.65 1.76
25 518.00 1.33 851.00 1.33 1084.00 200.00 1.33 2.73 1.87
27 508.00 1.33 820.00 1.33 1031.00 199.00 1.33 2.80 1.97
29 498.00 1.33 789.00 1.33 980.00 198.00 1.33 2.87 2.07
31 488.00 1.33 759.00 1.33 931.00 197.00 1.33 2.94 2.17
33 478.00 1.33 728.00 1.33 883.00 196.00 1.33 3.01 2.27
35 467.00 1.33 698.00 1.33 837.00 195.00 1.33 3.07 2.37
37 456.00 1.33 668.00 1.33 791.00 194.00 1.33 3.13 2.47
39 444.00 1.33 638.00 1.33 746.00 193.00 1.33 3.20 2.58
41 432.00 1.33 607.00 1.33 702.00 192.00 1.33 3.26 2.70
43 419.00 1.33 576.00 1.33 658.00 191.00 1.33 3.33 2.82
45 405.00 1.33 543.00 1.33 613.00 189.00 1.33 3.40 2.95
47 389.00 1.33 509.00 1.33 567.00 187.00 1.33 3.48 3.09
49 371.00 1.33 472.00 1.33 520.00 185.00 1.33 3.57 3.26
51 349.00 1.33 431.00 1.33 468.00 182.00 1.33 3.68 3.46
54 286.00 1.33 326.00 1.33 342.00 169.00 1.33 4.04 4.11
10-30-2007
52 Meter Boom
Page 87 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

Onboard Lifts
11 760 0.500 2,310 0.500
13 760 0.500 2,310 0.500
15 760 0.500 2,310 0.500
17 760 0.500 2,310 0.500
19 760 0.500 2,310 0.500
21 760 0.500 2,310 0.500
23 760 0.500 2,310 0.500
25 760 0.500 2,310 0.500
27 760 0.500 2,310 0.500
29 760 0.500 2,310 0.500
31 760 0.500 2,310 0.500
33 723 0.500 2,225 0.500
35 686 0.500 2,139 0.500
37 652 0.500 2,062 0.500
39 622 0.500 1,992 0.500
41 588 0.500 1,915 0.500
43 551 0.500 1,831 0.500
45 518 0.500 1,755 0.500
47 488 0.500 1,686 0.500
49 460 0.500 1,622 0.500
51 434 0.500 1,563 0.500
54 399 0.500 1,482 0.500
10-30-2007
52 Me te r Boom
Page 88 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611
Kingpost Reactions
11 81 46,005 289 27,357 4,626 969
13 79 46,719 289 30,996 4,609 1,149
15 77 47,435 289 34,630 4,586 1,331
17 74 48,148 289 38,257 4,560 1,515
19 72 48,868 289 41,877 4,529 1,702
21 70 48,634 259 37,892 3,772 1,589
23 67 44,175 248 37,965 3,480 1,631
25 65 40,382 239 38,026 3,221 1,671
27 62 37,139 230 38,087 2,991 1,712
29 60 34,326 223 38,135 2,781 1,751
31 57 31,884 216 38,181 2,590 1,791
33 55 29,751 210 38,225 2,413 1,833
35 52 27,210 203 37,477 2,204 1,839
37 49 24,680 195 36,375 1,990 1,829
39 46 22,365 189 35,190 1,788 1,816
41 43 20,256 182 33,948 1,595 1,801
43 39 18,309 176 32,625 1,408 1,785
45 35 16,489 170 31,194 1,226 1,765
47 31 14,794 165 29,677 1,044 1,744
49 27 13,164 159 27,989 858 1,723
51 21 11,542 154 26,069 656 1,702
54 3 8,257 146 22,662 144 1,849
10-30-2007
52 Meter Boom

Page 89 of 97 2

Phone: 713 896 6500 Fax: 713 896 6611

Working
11 569.00 2.22 1033.00 2.46 1417.00 205.00 2.50 2.60 1.56
13 559.00 2.20 996.00 2.42 1347.00 203.00 2.49 2.64 1.65
15 548.00 2.19 961.00 2.39 1282.00 202.00 2.49 2.70 1.74
17 538.00 2.17 927.00 2.35 1220.00 201.00 2.48 2.76 1.83
19 528.00 2.16 894.00 2.32 1162.00 200.00 2.48 2.82 1.92
21 519.00 2.14 863.00 1.92 1108.00 199.00 2.47 2.88 2.01
23 509.00 2.13 833.00 1.95 1056.00 198.00 2.47 2.94 2.09
25 500.00 2.11 803.00 1.97 1007.00 197.00 2.46 3.00 2.18
27 490.00 2.10 774.00 1.99 960.00 196.00 2.46 3.05 2.27
29 481.00 2.09 746.00 2.01 915.00 195.00 2.45 3.10 2.35
31 471.00 2.07 718.00 2.03 871.00 194.00 2.45 3.15 2.44
33 461.00 2.06 691.00 2.04 828.00 194.00 2.44 3.20 2.53
35 451.00 2.04 663.00 2.06 787.00 193.00 2.44 3.25 2.62
37 440.00 2.04 636.00 2.06 746.00 192.00 2.43 3.30 2.71
39 429.00 2.06 608.00 2.07 705.00 190.00 2.42 3.35 2.81
41 418.00 2.08 579.00 2.07 665.00 189.00 2.42 3.40 2.91
43 405.00 2.09 551.00 2.07 625.00 188.00 2.41 3.45 3.02
45 392.00 2.10 521.00 2.06 585.00 186.00 2.40 3.50 3.14
47 378.00 2.11 490.00 2.05 544.00 185.00 2.39 3.56 3.27
49 361.00 2.10 457.00 2.03 501.00 182.00 2.38 3.62 3.41
51 342.00 2.09 420.00 2.00 454.00 180.00 2.37 3.69 3.59
54 287.00 2.32 327.00 2.14 343.00 170.00 2.41 3.86 4.09
(2) The calculated Supply Boat Deck Velocity in m/sec is 1.807
10-30-2007
52 Meter Boom
Page 90 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

11 9,955 4.889 6,279 2.698
13 9,989 4.906 6,296 2.706
15 10,031 4.927 6,318 2.716
17 10,082 4.952 6,343 2.729
19 10,142 4.982 6,373 2.744
21 8,431 5.017 5,426 2.762
23 7,852 5.057 5,104 2.782
25 7,358 5.104 4,829 2.805
27 6,934 5.157 4,592 2.832
29 6,568 5.217 4,388 2.862
31 6,253 5.286 4,211 2.897
33 5,981 5.365 4,058 2.937
35 5,617 5.456 3,854 2.982
37 5,239 5.561 3,643 3.035
39 4,891 5.683 3,448 3.096
41 4,571 5.826 3,269 3.168
43 4,275 5.997 3,104 3.254
45 3,999 6.205 2,948 3.360
47 3,746 6.469 2,806 3.492
49 3,510 6.817 2,672 3.668
51 3,296 7.321 2,551 3.922
54 3,434 9.719 2,607 5.139
10-30-2007
52 Meter Boom
Page 91 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

11 457 536 214 283 288 72 214 BOOM 2.131
13 406 507 214 258 288 72 214 BOOM 1.89
15 365 479 213 236 288 72 213 BOOM 1.708
17 331 455 211 218 288 72 211 BOOM 1.564
19 303 433 204 202 288 72 202 GANTRY 1.497
21 279 413 197 189 288 72 189 GANTRY 1.479
23 259 396 191 177 288 72 177 GANTRY 1.461
25 241 379 185 164 288 72 164 GANTRY 1.47
27 225 364 180 152 288 72 152 GANTRY 1.482
29 212 351 175 142 288 72 142 GANTRY 1.491
31 199 338 170 133 288 72 133 GANTRY 1.5
33 189 325 165 125 288 72 125 GANTRY 1.509
35 179 314 160 118 288 72 118 GANTRY 1.515
37 170 302 155 111 288 72 111 GANTRY 1.524
39 162 291 150 106 288 72 106 GANTRY 1.53
41 155 281 145 100 288 72 100 GANTRY 1.536
43 148 270 140 96 288 72 96 GANTRY 1.542
45 142 259 134 92 288 72 92 GANTRY 1.548
47 137 249 128 88 288 72 88 GANTRY 1.551
49 132 237 122 84 288 72 84 GANTRY 1.558
51 127 225 114 82 288 72 82 GANTRY 1.558
54 125 196 92 80 288 72 80 GANTRY 1.548
52 Meter Boom
10-30-2007
Page 92 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 463-EJA
of Pull Speed Cable
1 14,988 101 94
2 13,722 110 196
3 12,653 120 307
4 11,739 129 426
Page 93 of 97
2

Phone: 713 896 6500 Fax: 713 896 6611

10-30-2007
52 Meter Boom
Hoist Model 863-HJC
of Pull Speed Cable
1 17,629 84 121
2 16,448 90 249
3 15,415 96 387
4 14,504 102 532
5 13,694 108 688
6 12,970 114 850
Page 94 of 97
2
11 27253d 54320d N/A 12999d
13 27253d 54320d N/A 12999d
15 27253d 54320d N/A 12999d
17 27253d 54320d N/A 12999d
19 27253d 54320d N/A 12999d
21 27253d 54320d N/A 12999d
23 27253d 54320d N/A 12999d
25 27253d 54320d N/A 12999d
27 27253d 54320d N/A 12999d
29 27253d 54320d N/A 12999d
31 27253d 54320d N/A 12999d
33 27253d 51124b N/A 12999d
35 27253d 47867b N/A 12999d
37 27253d 44964b N/A 12999d
39 27253d 42351b N/A 12999d
41 27253d 39456is N/A 12999d
43 27253d 36312is N/A 12999d
45 27253d 33450is N/A 12999d
47 27253d 30845is N/A 12999d
49 27253d 28436is N/A 12999d
51 26229is 26229is N/A 12999d
54 23192is 23192is N/A 12999d
10-30-2007


Page 95 of 97
2
2
11 25102c 46005c N/A 11091c
13 25285c 46719c N/A 11119c
15 25469c 47435c N/A 11146c
17 25652c 48148c N/A 11173c
19 25834c 48868c N/A 11199c
21 26015c 48634b N/A 11223c
23 26196c 44175b N/A 11247c
25 26380c 40382b N/A 11271c
27 26566c 37139b N/A 11294c
29 26757c 34326b N/A 11317c
31 26955c 31884b N/A 11341c
33 27160c 29751b N/A 11365c
35 27210is 27210is N/A 11390c
37 24680is 24680is N/A 11416c
39 22365is 22365is N/A 11445c
41 20256is 20256is N/A 11476c
43 18309is 18309is N/A 11511c
45 16489is 16489is N/A 11551c
47 14794is 14794is N/A 11599c
49 13164is 13164is N/A 11658c
51 11542is 11542is N/A 11542is
54 8257is 8257is N/A 8257is
10-30-2007


Page 96 of 97
2
2
1.)
2.)
3.)
4.)
10-30-2007
INFORMATION CHART
Additional Data

Page 97 of 97
2

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Phone: 713 896 6500 Fax: 713 896 6611
Commentary on Load Testing3.doc Page 1 of 2
March 14, 1997
Commentary on Load Testing Procedures
There has been quite a bit of confusion within the offshore crane industry concerning lifting
requirements for marine crane load tests, particularly those being performed in conjunction
with the initial installation of new crane equipment.
Surveyors and / or representatives of various certifying authorities have, on occasion, mis-
interpreted lifting requirements and insisted on performing tests in excess of the cranes
capability in one of the following ways:
Requiring a 133% X SWL overload test. It is true that the design criteria of cranes
meeting the below listed specifications are 133% of SWL. However, this does not mean
that the crane must ever be field load tested to that limit
Requiring that a 125% X SWL overload test be performed with no regard to the actual
lifting capacity of the crane when limited by the hoisting mechanism. There often has
been no distinction or even understanding on the part of surveyors of the difference
between structural limits and actual lifting capacities.
The certifying agencies and specifications that address load testing requirements for offshore
structures, MODUS and marine vessels (ships, TLPs), etc. where offshore cranes are
typically installed are:
(USCG) CFR 46, Chapter 1 Section 107.259 & 107.260. - Crane Certification.
API Spec. RP2D, Third Edition dated June 1, 1995 Recommended Practice for Operation
and Maintenance of Offshore Cranes, Appendix E - Commentary on Load Testing.
ABS Guide for Certification of Crane dated 1991, Section 5 Part 5.3.1 - Test Loads
DNV Rules for Certification of Lifting Appliances dated 1994, Section 6, Part B 300 -
Test Loads.
LLOYDS REGISTER OF SHIPPING Code For Lifting Appliances in a Marine
Environment dated January 1987, Chapter 9 section 9.1.5 & 6 - Testing of Derricks and
Cranes.
Commentary on Load Testing3.doc Page 2 of 2
No matter which certifying authority takes precedent the object of performing a load test is
basically twofold:
1. Test the cranes STRUCTURE to 125%, 110% or 100% + 10,000 lbs. depending on
the rating of the crane at the radius the crane is to be tested.
2. Test the HOISTING MECHANISMS to 100%.
All certifying authorities require structural test loads as follows:
Safe Working Load (SWL) of Crane Test Load in Tons
Up to 20 tons SWL X 1.25
Exceeding 20 tons but not exceeding 50 tons SWL + 5 tons
Exceeding 50 tons SWL X 1.1
No certifying authority requires structural load testing in excess of 125% of SWL or testing of the
hoisting mechanisms in excess of 100% of their rated capacity.
Surveyors and / or representatives of the above referenced certifying agencies have repeatedly
mis-interpreted STRUCTURAL CAPACITY with HOIST LIFTING CAPACITY. In many
cases the Safe Working Load (SWL) of a crane at close radii is limited by the hoisting
mechanism. Inspectors frequently request that the crane be tested in excess of the highest
capacity on the load chart, which obviously cannot be done if the hoisting mechanism is the
limiting factor.
There are varying degrees of reference to actual test weight requirements depending on the
certifying authority taking precedence. Basically they are summarized as follows:
API and the USCG recognize attaching the hoisting system to the deck with an in-line
dynamometer as a suitable means for load testing while ABS, DNV and Lloyds does not.
Using Moveable known weights does not mean the weights themselves have to be
certified so long as a recently calibrated (within 12 months) dynamometer is used to verify
the actual test load being applied.
ABS, DNV, and Lloyds require hoisting, booming, and slewing of the test load while API
and USCG do not.
All certifying authorities require test loads as indicated in the table above,

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Phone: 713 896 6500 Fax: 713 896 6611
Load Test Procedures.doc Page 1 of 2
March 13, 1997
SeaTrax Standard Load Test Procedures
(Suspended Weight Method)
There are other steps involved prior to and after performing the actual lifting phase. All
qualified personnel performing or overseeing a load test should be completely familiar with the
above referenced API Spec, particularly Appendix E - Commentary on Load Testing and be
knowledgeable in the reading and interpretation of crane load rating charts.
MAIN HOIST:
Lift 100% of rated load for the main hoist at any desired radius and boom out to a radius that
will overload the cranes rating by:
25% for main hoist load ratings up to 40,000 lbs.
10,000 lbs for main hoist load ratings of 40,000 lbs to 100,000 lbs.
10% for main hoist load ratings over 100,000 lbs.
Record the Following:
1. Actual Test Weight
2. Actual Maximum Test Radius
3. Cranes Load Rating at Maximum Test Radius
4. Indicated Load (If crane equipped with a SLI )
5. Hydraulic Pressure Required to Lift the Load
AUXILIARY HOIST:
Lift 100% of rated load for the auxiliary hoist and boom out to any radius up to but not
exceeding that which will overload the cranes rating (if possible) by:
25% for cranes with auxiliary hoist load ratings up to 40,000 lbs.
10,000 lbs for cranes with auxiliary hoist load ratings of 40,000 lbs to 100,000 lbs.
10% for cranes with auxiliary hoist load ratings over 100,000 lbs.
3. Cranes Auxiliary Load Rating at Maximum Test Radius
4. Indicated Load (If equipped with a SLI )
5. Hydraulic Pressure Required to Lift the Load
Load Test Procedures.doc Page 2 of 2
AUXILIARY HOIST (Optional)
Position the boom at such an angle so that the desired overload of the auxiliary rated load will
not overload the cranes structural capacity. Attach the desired overload onto the auxiliary hoist
and take all slack out of the hoist line. DO NOT RAISE THE LOAD WITH THE
AUXILIARY HOIST. Lift the load until fully suspended by the crane by raising the boom.
3. Cranes Auxiliary Load Rating at Maximum Test Radius

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Phone: 713 896 6500 Fax: 713 896 6611
Rev-2, 03-April-2008
STDFM-30 Standard Load Test Page 1 of 4
Standard Functional & Load Test Procedure / Report
General Information
Client: Test Date:
P.O. Number: Model Number:
Project: Serial Number:
Customer Tag No. Boom Length:
SDRL Code: Doc. No.:
All testing shall be completed under the guidance of a qualified SeaTrax representative and in
accordance with SeaTrax safety standards.
Complete each section and record all information where applicable. If required record
comments / punch list items on page 4. Note: sections can be run concurrently if required.
Demonstrate Primary Crane Operations
Main &Auxiliary Hoist
Functional Operation
SeaTrax
Initial
Customer
Initial
Lower main block to ground
Hoist block into two-block frame
Demonstrate anti two-block function
Lower auxiliary hoist ball to ground
Hoist auxiliary ball into boom tip
Demonstrate anti two-block function
Record Full Speed R.P.M. R.P.M. SeaTrax Initial Customer Initial
Main Hoist Drum
Auxiliary Hoist Drum
Boom Hoist Drum
Swing Full Circle
Phone: 713 896 6500 Fax: 713 896 6611
Rev-1, 30 June 2000
Demonstrate Primary Crane Operations Cont.
Boom (Luffing) Hoist
SeaTrax
Initial
Customer
Initial
Boom up @ full speed and demonstrate high angle kick-out
Boom down @ full speed and demonstrate low angle kick-out
Engage Boom Dog and demonstrate function
Swing (Slew) Mechanism
SeaTrax
Initial
Customer
Initial
Swing 360 deg. To the right, then free swing.
Swing 360 deg. To the left, then free swing.
Demonstrate foot brake
Demonstrate swing lock (parking brake)
Demonstrate cross over relief valves
Engine Functional Tests Record
SeaTrax
Initial
Customer
Initial
Engine Stop (normal)
Engine Stop (emergency)
Engine alarm, on low oil pressure
Verify Radius Indicators
Measured
Radius
Mechanical
Indicator
Safe Load
Indicator
SeaTrax
Initial
Customer
Initial
Minimum
Maximum
Phone: 713 896 6500 Fax: 713 896 6611
Rev-1, 30 June 2000
Lifting Operations Test Records
Hoist Aux. #1 Aux. #2 Main #1 Main #2 Main #3
SeaTrax
Initial
Customer
Initial
Test Radius
Rated Load (lbs.)
Test Load (lbs.)
% Overload
Hoist psi. Up
Hoist psi. Down
Luff psi. Up
Luff psi. Down
Slew psi. Right
Slew psi. Left
Air Start Test No.1 Record
SeaTrax
Initial
Customer
Initial
Tank Capacity (Gals) N/A
Gauge Pressure (Cab)
Number of Starts
Air Start Test No.2 Record
SeaTrax
Initial
Customer
Initial
Tank Capacity (Gals) N/A
Gauge Pressure (Cab)
Starter Turn-Over Time.
Phone: 713 896 6500 Fax: 713 896 6611
Rev-1, 30 June 2000
Demonstrate Customer Specified Options
Optional Feature
SeaTrax
Initial
Customer
Initial
Boom Tip, Warning Light
Gantry warning light
Boom Tip, Flood Lights
Slip Ring Heater
Upper Bearing light
Engine House lights
Rear Deck Light
Air Conditioning
Cab Light
Load Indicator System (Martin Decker, Mipeg, Wylie etc.)
Upper windshield wiper
Lower windshield wiper
Horn (steady)
Horn (intermittent)
Fuel Level Indicator
Customer Comments:
Witnessed and Accepted (subject to above comments)
SeaTrax Representative: Date:
Customer Representative: Date:

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


Page 1 of 15

MAERSK OIL QATAR AS


CLIENT DATA SHEETS (4527)

MOQ DOC. No.: ASEDA-10-70033-0023
NPCC DOC. No.: 6048-70033A-G001-001
VENDOR DOC. No. : D006 SXCDS4527


SEATRAX UK LTD

4 22-May-08 Revised incorporating customer comments in PINK for review and approval
3 14-APR-08 Revised incorporating customer comments in GREEN for review and approval
2 07-FEB-08 Revised incorporating customer comments in BLUE for review and approval
1 20-DEC-07 Revised incorporating customer comments in RED for review and approval
0 11-OCT-07 Issued for approval
A- ACCEPTED
B- COMMENTSASMARKED
C- NOT ACCEPTED
E
N
G
2
0
0
7
-
0
4
E
D
.
A
BEFOREPROCEEDING.
B
C
VENDOR
DOCUMENT STATUS
Vendor to revise the value of TOTAL
required power (page 8/12) as per the
SEATRAX e-mail attached herewith.
Abdel Hafiz Mohamad Herbawi (NPCC)
From: Shankar Guruswamy (NPCC)
Sent: Monday, J uly 07, 2008 3:58 PM
To: Syed Ahmed Hussaini Zubair (NPCC); Abdel Hafiz Mohamad Herbawi (NPCC)
Subject: FW: 4527/28/29/30-STX-E-183 : Client Datasheets (RE: NPCC PO Ref.: 6048-2007-70033-AC / Pedestal Cranes)
Page 1
12/07/2008

Please advise to the below e-mail.

Regards,

Shankar

From: Dean Barlow [mailto:operations@seatrax.co.uk]
Sent: Monday, J uly 07, 2008 3:17 PM
To: Shankar Guruswamy (NPCC)
Cc: Syed Ahmed Hussaini Zubair (NPCC); Abdel Hafiz Mohamad Herbawi (NPCC); Nadarajan Ganapathy (NPCC); Subhash
Laxman Tekale (NPCC); Sunil Issac (NPCC); J ayakrishnan T.K. (NPCC); Sekar Chennappan (NPCC); Kassem Hamad (NPCC);
Ahmed Shawki Borai (NPCC); B.moorthy (NPCC); Mohammed Sami Khan (NPCC); Balaraman Sriramulu (NPCC); Wassim
HOUCHAIMI; Venkataraman Nagarajan (NPCC)
Subject: 4527/28/29/30-STX-E-183 : Client Datasheets (RE: NPCC PO Ref.: 6048-2007-70033-AC / Pedestal Cranes)

CUSTOMER : NATIONAL PETROLEUM CONSTRUCTION COMPANY
PROJECT : AL SHAHEEN FIELD DEVELOPMENT 2005
CUSTOMER P.O. NO: 6048-2007-70033-AC
SEATRAX JOB NO'S: 4527, 4528, 4529, 4530-UK
CRANE SERIAL NO'S: 1 No. S9028 & 3 No. S7226 cranes

Correspondence Ref: 4527/28/29/30-STX-E-183

Mr Shanker,

We will revise item 212 on page 8 of the client data sheets to read 366kw.

Trusting this will meet with your requirements. Do you want us to resubmit the document for your approval?

Best Regards,

Dean Barlow
Operations Manager
Seatrax UK Limited

Tel: +44 (0) 1493 651311
Fax: +44 (0) 1493 604900
Mobile: 07801 526319
Email: operations@seatrax.co.uk

From: Shankar Guruswamy (NPCC) [mailto:shankarg@npcc.ae]
Sent: 06 J uly 2008 06:19
To: Dean Barlow - Seatrax (UK) Ltd.
Cc: Syed Ahmed Hussaini Zubair (NPCC); Abdel Hafiz Mohamad Herbawi (NPCC); Nadarajan Ganapathy (NPCC); Subhash
Laxman Tekale (NPCC); Sunil Issac (NPCC); J ayakrishnan T.K. (NPCC); Sekar Chennappan (NPCC); Kassem Hamad (NPCC);
Ahmed Shawki Borai (NPCC); B.moorthy (NPCC); Mohammed Sami Khan (NPCC); Balaraman Sriramulu (NPCC); Wassim
HOUCHAIMI; Venkataraman Nagarajan (NPCC)
Subject: NPCC PO Ref.: 6048-2007-70033-AC / Pedestal Cranes / Seatrax, UK Ref. 4527/28/29/30 - Client Datasheets

Dear Mr. Dean Barlow,

Referring to the Client datasheets rev.4 attached herewith, page no.8 line no. 212 SEATRAX mentioned that the total power
required for two simultaneous movements is 372 KW (186 KW+186KW) but the available power from the engine is only
491HP/366 KW.

The power required for two simultaneous movements was discussed before with SEATRAX and SEATRAX confirmed the two
movements that required 186 KW each i.e total 372 KW (186 KW+186KW) will not happen simultaneously (refer to the clouded
notes in attached file no. 6048-70033A-G003-001-VER-00100).

If our understanding is correct SEATRAX to revise the value as the max. actual power required for two simultaneous
movements.
Best Regards,
G Shankar
Project Expeditor - Al Shaheen Field Development 2005
National Petroleum Construction Company
P.O. Box 2058, Abu Dhabi
United Arab Emirates
Tel.: +971 2 502 3391
Fax: +971 2 554 9054
E-mail: shankarg@npcc.ae
Page 2
12/07/2008
4527-4528-4529-4530 SDL COMMENTS & REPLIES

GENERAL COMMENTS TO DATA SHEET COMMENTS

Document No. 6048-70033A-G001-001/002/003/004

1. The crane complete weight is higher than that stated on Seatrax crane data
sheets due to these being general crane series weights and the weight
declared in the client data sheets being more specific to the contract, so they
include an increase due to the Pyroban Kit etc.

2. The swing radius dimensions are correct as stated in this revision and are
consistent with those shown on the GA drawings.
MAERSK
MAERSK OIL QATAR AS
NPCC
CONTRACT C-01226
Data Sheets for
PEDESTAL CRANE (ED PLATFORM)
Tag No. : ASEDA-A-6101
MOQ DOC. No.: ASEDA-15-06601
NPCC DOC. No.: 6048-T-DS-301
Vendor Filled Datasheet
2 17/11/07 Re-Issued for Qurchase
1 27108/07 Issued for purchase
0 11/04/07 Issued for approval
REV DATE REMARKS
./
~ J l ~
~
~ H ~ ~ <
AMH \AB
KG AB
CHK REVD
~ ~
. ~
TKM
TKM
APVD
MOQ No.: ASEDA-15-06601
NPCC No.: 6048-T-DS-301

DATA SHEET
Offshore Pedestal Crane

Rev.: 2

PROJ ECT TITLE :
AL SHAHEEN FIELD DEVELOPMENT 2005 GA Wellhead Module, ED, GD and
GB Platforms

COMPANY : MOQatar AS

REQUISITION No: 6048- 07-70033 VENDOR: SEATRAX UK LIMITED

FILE: 6048-T-DS-301 - ED Crane rev2 Page 2 of 13

Applicable to: Proposal Purchase X As Built Date 23/08/07 Revision 2
Site AL SHAHEEN FIELD DEVELOPMENT 2005
Unit ED
Platform
Service Offshore Pedestal Crane Serial No.
Manufacturer SEATRAX Model S9028 No. Required 1
Stand-alone Yes/No Yes Type Kingpost Driver Diesel
Notes: Information to be completed by Manufacturer Purchaser Power 490BHP

1. Tag Nos: ASEDA-A-6101
2. Location ED Platform
3. Crane duty Group classification Dynamic coefficient 2.0 as per API 2C
4. MAIN HOIST ON PLATFORM LIFTS
5. Required Offered
6. Mode Load
(tons)
Radius
(m)
Kingpost
reaction
(tons)
Hook Speed
(m/min)
Falls Mode Load
(tons)
Radius
(m)
Hook Speed
(m/min)
Falls
7.
Static 20
47

By
Vendor

By Vendor
4 Static 30.845 47 21 4
8.
Static 30
30

By
Vendor
By Vendor 4 Static 54.320 31 21 4
9.
Static 15
53.4

By
Vendor
By Vendor 4 Static 23.192 53.4 21 4
10.
Static 40
32

By
Vendor
By Vendor 4 Static 51.124 33 21 4
11. MAIN HOIST SUPPLY BOAT (Sea Lifts)
12. REQUIRED Offered
13. Wave
Period
Sig. Wave
height (m)
Load
(tons)
Radius
(m)
Kingpost
reaction
(tons)
Hook
Speed
(m/min)
Wave
Period
Sig. Wave
height (m)
Load
(tons)
Radius
(m)
Hook Speed
(m/min)
14.
Dynamic 1.5 30 30 By Vendor

By Vendor
Dynamic 1.5 40.288 31 21
15.
Dynamic 0.7 40 32 By Vendor By Vendor Dynamic 0.7 39.82 31
16. WHIP HOIST ON PLATFORM LIFTS
17. Required Offered
18. Mode Load Radius Hook Speed Falls Mode Load Radius Hook
Speed
Falls
19.
Static
7.5

30

By Vendor 1 Static 12.999 All 1
20. WHIP HOIST SUPPLY BOAT (Sea Lifts)
22. Wave Period Sig. Wave
height
Load Radius Hook Speed Wave
Period
Sig.
Wave
height
Load Radius Hook
Speed
23.
Dynamic 1.5 7.5 30 By Vendor Dynamic 1.5 12.999 30

24. OTHER DUTY DATA
26. Slewing Speed

(all loads)
Rpm
Normal 0 to 2maximum 0 1.0 APPROX.
27. Luffing Time

(max. to min. radius)
sec
Vendor to recommend APPROX. 100 SECONDS
4527
41,416
48,477 33 21
101
31
101
1
1
1
1
1
21
21
21
21
21
21
101
101
2
2
2
2
2
2
2
2
4
4
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms



28. Degree list

(all sea lifts)
degrees
360 Continuous
Slip Ring Assembly Required
CONFIRMED
29. ENVIRONMENT
30. Area Classification Zone 2
Note: Same
applicable to
Diesel Engine
Main Crane Certified for use in
Hazardous Area
as per IEC-60079
Boom

Certified for use in
Hazardous Area as per
IEC-60079
31. Equipment Group/Gas
Group
II 2 G, IIB for all outdoor electrical
equipment and all equipment to be
remain energized during emergency.
Temperature
Class
T3
32. Temperature
o
C Normal Maximum 50 Minimum 5
33. Dry Bulb 50
o
C
34. Wind Speed m/s Maximum for Operation / Design As per API 2C, 18
m/s
Maximum for crane
Stowed
40
Note 2
35. Relative humidity (Min/Max)

60% / 100% ACCEPTABLE
36. LOAD CHART
37. Platform Lifts Sea Lifts
38. Sea State 4-5 (cb=2)
39.

Main Hoist
WP
(sec)
SWH
(m)
WP
(sec)
WP
(sec)
SWH
(m)
WP
(sec)
40. Number of Falls

41. Radius (m) SWL (tonnes)
42. 3.25
43. 10.00
44. 15.00
45. 20.00
46. 25.00
47. 30
48. 32
49. 35
50. 40
51. 47
52. Whip Hoist

53. Number of Falls
54. Radius (m)
55. 3.25
56. 10.00
57. 15.00
58. 20.00
59. 25.00
60. 30
61. 32
62. 35
63. 40
Refer to Line nos. 6-23

Note: 1. This Table to be repeated for each hoist, and fall arrangement
2. Boom shall be capable to be brought back to boom rest without load

WP: Wave Period SWH: Significant Wave Height

TOTAL HEIGHT OF LIFT FROM SEA LEVEL: 99 meters at minimum radius (to hook)
MINIMUM LIFTING RADIUS: 10.35 meters
MAXIMUM TAIL RADIUS: 4.826 meters including ladder
2
3
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms




RAM LUFFING CRANE - MAIN DIMENSIONS (VENDOR TO INSERT SKETCH)
NA

NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms



Important Note: All the values Listed bellow shall be filled by Vendor in S.I. Units
64. A Overall height above slew datum
SLEW GEAR
Forces and Moments at Slewring
(including Crane Weight Efect)
Refer to SWL
Charts
65. B Boom footpin to main hoist sheave 51.158 Maximum Static Vertical Force (kN) Refer to SWL
Charts
66. C Boom footpin to whip hoist sheave 54.053 Maximum Dynamic Vertical Force (kN) Refer to SWL
Charts
67. D Boom footpin to slew datum 53.734 Maximum Overturning Moment Static (kNm) Refer to SWL
Charts
68. E Slew datum to top A frame
Slew Gear Approx

14.0
Maximum Overturning Moment Dynamic
(kNm)
Refer to SWL
Charts
69. F Boom footpin to pedestal centre line 2.280
70. G Maximum tail radius 4.826 meters
including
ladder

71. H Weight (tonnes)
72. Hm Maximum height main hoist to boom
foot pin elevation
51.158 Crane Complete 122
73. Hw Maximum height whip hoist to boom
foot pin elevation
54.053 A frame
Approx Gantry

21.0
74. J Maximum boom width
OVER CHORDS

2.794
Main Hoist winch IN BOOM
75. K Boom footpin to LAT 51.600 Boom hoist winch IN 118
76. L LAT to lowest hook level minus 3 m 104.292 Machinery bed and house and cabin Approx 39.5
77. M Pedestal centreline to outboard cab Approx 2.70 Slew Drive units In 118
78. N Pedestal centreline to inboard cab Approx 0.30 Slew bearing In 126
79. P Width machinery house Approx 3.1 Slewing Fasteners N/A
80. Q Cab width Approx 1.8 Prime mover In 118
81. R Pump Drive unit In 118
82. Rm1 Hook radius main hoist max. 53.444 Drivers cabin In 118
83. Rw1 Hook radius whip hoist max. 56.277 Boom Approx 34
84. Rm2 Hook radius main hoist min. 10.35 Pedestal Adaptor KINGPOST Approx 24
85. Rw2 Hook radius whip hoist min. Approx 12.35 Hook Block (multi fall) 0.35
86. S Pedestal centreline-boom test Hook Block (single fall) 1.00
87. T Rope (Main Hoist) TBC
88. Tm Highest hook to lowest hook position
(main)
LAT 101.698 Rope (Boom Hoist) TBC
89. Tw Highest hook to lowest hook position
(whip)
104.593 Luff rams (each) N/A
90. W Minimum boom width
91. 1 Boom angle minimum radius Approx 83.5
92. 2 Boom angle maximum radius Approx 0
93. Ram Luffing Crane NA
94. E Slew datum to top of boom - minimum NA
95. H Maximum height hook to ram foot-pin NA
96. K Ram foot-pin to LAT NA
97. R1 Hook radius max. NA
98. R2 Hook radius min. NA
99. U Pedestal centerline to ram foot-pin NA
100. Y Height pedestal datum to ram top pin NA
14,600
0.5m
14,100
2286
gear
47,200
50,000
2,979
53,733
0
4,169
2,325
3,400
11,000
12,500
103,933
106,733
1.3m
81
gear
1
1
1
1
1
1
1
1
1
1
1
1
1
3
IN MACH BED
3
INCLUDED IN
MACH BED
INCLUDED IN
KINGPOST
3
3
INCLUDED IN
MACH BED
INCLUDED IN
MACH BED
INCLUDED IN
MACH BED
3
3
3
INCLUDED IN
BOOM
INCLUDED IN
MACH BED
3
3
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms




101. Feature Required Offered Remarks
102. Construction Features
103. Boom
104. Construction Type Lattice Confirmed
105. Material As per MITS-31 As per API 2C
106. Overall Length/Weight (m, kg) 52 Approx 54 mtrs
107. Number of Sections By Vendor 6
108. Length/Weight per section (m, kg) By Vendor 2 x 6, 1 x 3 & 3 x 12
109. Walk Way By Vendor Yes
110. Walkway position relative to boom By Vendor Left Side of Boom
111.
112. A Frame
113. Construction Type As per API 2C Confirmed
114. Material As per MITS-31 API 2C
115. Lifting Aids required Yes Yes
116.
117. Base Frame
118. Construction Type As per API 2C Confirmed
119. Material As per MITS-31 API 2C
120. Tail Radius Limit (m) 4.868 Confirmed
121.
122. Drivers cabin
123. Position Relative to boom By Vendor Right Side
124. Mounting Requirement By Vendor Bolted
125. Air Condition System As per MITS-07, paragraph
3.1.16
Confirmed

126. Construction Type As per MITS-07, paragraphs
3.1.16
Confirmed

127.
128. Slew ring
NA
129. Maximum Load Axial/Radial (kN) By Vendor N/A
130. Maximum Overturning Moment
(kNm)
By Vendor N/A
131. Nominal Diameter (m) By Vendor N/A
132. Manufacturer/Model No. By Vendor N/A
133. Materials ring By Vendor N/A
134. Materials roller By Vendor N/A
135. Type By Vendor N/A
136. No. Gear Teeth By Vendor N/A
137. Bolting Outer Pitch
Circle (m)

138. Number of Bolts By Vendor N/A
139. Size of Bolts By Vendor N/A
140. Loading of bolts Outer Pitch Inner Pitch
1
3 4.826 4.826
4
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms



Circle (kN) Circle (kN)
141. Slew Movement Limits 2 Limit switches & 2 mechanical devices shall be provided
142. Maximum Wind Speed for Change
Out (m/s)
25

144.
145. Pedestal Adaptor By NPCC
146. Diameter Top (m) TBA
147. Diameter Bottom (m) TBA
148. Wall thickness (mm) TBA
149. Material As per MITS-31
150. Maximum Axial load (kN) TBA
151. Maximum load Oy (kN) TBA
152. Maximum Load on Ox (kN) TBA
153. Maximum overturning moment
(kNm)
TBA
154. Walkway Yes to cater for pin bolts inspection

155.
156. Sheaves
157. Number By Vendor 3 +1
158. Bearings Ball Roller Bearing
159. Material As per MITS-07 Para. 3.2
Confirmed

160.
161. Prime Mover
162. Type Diesel Engine As per MITS-
07paragraph 3.1.9
Confirmed

163. Power (kW) 366
164. Speed (rpm) 2100
165. Manufacturer Caterpillar
166. Refer Data Sheet No. Vendor to furnish data sheet
Later

167.

168. Gear Boxes Splitter Main Hoist Boom Hoist Slew Drive
169. Type Parallel Parallel Parallel
170. Power Normal/Max. (kW) TBA TBA TBA
171. Speed Input Normal/Max.
(rpm)
TBA TBA TBA
172. Speed
Output Normal/Max. (rpm)
TBA TBA TBA
173. Manufacturer Rexroth Rexroth Rexroth
174. Model Nos. TBA TBA TBA
175.

HH
SEE 4527L DRAWING
MOQ Doc No. ASEDA-10-70033-0019
NPCC Doc No. 6048-70033A-F007-001
EN 10225 S355 G8 + N
See Doc. 6048-70033A-G002-001 / ASEDA-10-70033-0027
N/A
1
2 3
(mm)
(mm)
2286mm
2286mm
60
PROVIDED IN OPERATIONS MANUAL
PROPRIETARY
N/A
N/A
20165L
N/A
N/A
N/A
20165B
N/A
N/A
N/A
20071
3
3
3
3
3
4
4
4
See Doc. 6048-70033A-G002-001 / ASEDA-10-70033-0027
See Doc. 6048-70033A-G002-001 / ASEDA-10-70033-0027
See Doc. 6048-70033A-G002-001 / ASEDA-10-70033-0027
PLANETARY
PROPRIETARY
PROPRIETARY
PROPRIETARY
COTTER
20259
PROPRIETARY
PROPRIETARY
FAIRFIELD FAIRFIELD FAIRFIELD
PROPRIETARY PROPRIETARY
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms



Hydraulic Power Suppl y System
176.
177. Hydraulic Pumps Main Hoist Boom Hoist Slew Drive
178. Type PISTON PISTON PISTON
179. Manufacturer REXROTH REXROTH COMMERCIAL
180. Displacement (cm
3
/rev) 160 160 TBA
181. Pressure Normal/max (barg) 354 NORMAL 354 NORMAL TBA
182. Flow Normal/max (l/min) 511 NORMAL 511 NORMAL TBA
183. Speed Normal/max (rpm)
184. Power Normal/max (kW)
185. Hydraulic Motors
186. Type PISTON PISTON PISTON
187. Manufacturer REXROTH REXROTH COMMERCIAL
188. Displacement (cm
3
/rev) 160 160 TBA
189. Pressure Normal/max (barg) 354 NORMAL 354 NORMAL TBA
190. Flow Normal/max (l/min) 511 NORMAL 511 NORMAL TBA
191. Speed Normal/max (rpm)
192. Power Normal/max (kW)
193. Hydraulic Rams
NA
194. Numbers Two (02) NA NA
195. Manufacturer By Vendor NA NA
196. Single/double acting Double Acting. NA NA
197. Push Load (tonnes) By Vendor NA NA
198. Pull Load (tonnes) By Vendor NA NA
199. Stroke (mm) By Vendor NA NA
200. Piston Area
Cyl/Rod side (mm
2
)
By Vendor NA NA
201. Speed max.
Push/Pull (m/s)
By Vendor NA NA
202. Seals Type/Material By Vendor NA NA
203. Cylinder Material By Vendor NA NA
204. Rod Material Rolled & Chrom/Nickel plated NA NA
205.
206. Power Demand Summary (Maximum Operating Conditions)
207. Main Hoist (kW) By Vendor TBA TBA TBA
208. Boom Hoist (kW) By Vendor TBA TBA TBA
209. Slew Drive (kW) By Vendor TBA TBA TBA
210. Auxiliaries (kW) By Vendor TBA
211. Total (kW) By Vendor TBA Corresponding to two
simultaneously
movements
212.
213. Hoist Data Main Hoist Boom Hoist Whip Hoist
214. Drum Diameter (mm)
As per API 2C 660 TBA 508
559
1
3
3
3
180
193 NORMAL
370 NORMAL
62
172
111
3
3
3
N/A
N/A
N/A
186
186
119
0
366
3
3
3
3
3
4
4
4
N/A
260 260
399 NORMAL 399 NORMAL
2100 2100 2100
186 186 119
VANE
VICKERS
GEAR
COMMERCIAL
1176
31 106 106
3057 3057
399 NORMAL 399 NORMAL
Refer to the comment
on the cover page
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms



215. Drum Flange Diameter (mm)
As per API 2C 1118 TBA 864
216. Drum width between flanges (mm)
By Vendor 1600 TBA 1600
217. Number of layers
As per API 2C TBA
218. Number of lead turns
As per API 2C 5 min 5 Min 5 Min
219. Rope speed at drum (m/s)
By Vendor 84 TBA 101 m/min
220. Rope load at drum (kN)
By Vendor TBA TBA
221. Luffing time max to min (s)
By Vendor Approx 100 Seconds
222. Grooving Type
By Vendor Lebus LEBUS LEBUS
223. Fleet angle maximum (
o
)
By Vendor API 2C API 2C API 2C
224. Primary brake type By Vendor as per API 2C
& MITS-07 para. 3.1.6
Dynamic Dynamic Dynamic
225. Primary brake location
By Vendor Shaft Shaft Shaft
226. Primary brake full load torque (kNm)
By Vendor TBA TBA TBA
227. Sprag clutch
By Vendor N/A N/A N/A
228. Secondary brake type By Vendor as per API 2C
& MITS-07
Band Band Band
229. Secondary brake location
By Vendor Drum Drum Drum
230. Secondary brake full load torque
(kNm)
By Vendor TBA TBA TBA
231. Spooling Device Required, Lebus as per
MITS-07 para. 3.1.5
Provided Provided Provided
232.

233. Wire Ropes
By Vendor as per API 9A & MITS-07

234. Manufacturer
By Vendor Teufelberger or Equiv. Teufelberger or Equivalent Teufelberger or Equivalent
235. Type
API 9 A Confirmed Confirmed Confirmed
236. Construction Non
twisting
Confirmed Confirmed Confirmed
237. Core material
By Vendor Carbon Steel Carbon Steel Carbon Steel
238. Wire material
By Vendor Confirmed Confirmed Confirmed
239. Galvanized
Yes Confirmed Confirmed Confirmed
240. Maximum operational load (tonnes)
By Vendor As per SWL Charts As per SWL Charts As per SWL Charts
241. Safe working load (tonnes) By Vendor as per
API 9A & MITS-07
As per SWL
Charts
As per SWL Charts As per SWL Charts
242. Min. breaking load (tonnes) By Vendor as per
API 9A & MITS-07
72 72 72
243. Diameter
By Vendor 28 28 28
244. Total length (m)
By Vendor 425 TBA 150
245. Weight/meter (kg/m)
By Vendor TBA TBA
246. Operating Temperature
(max/min)
By Vendor
<80 C <80 C <80 C
247.
248. Hooks
249. Type/standard C.S. Bronze Coated. Provided Provided
250. Number of sheaves By Vendor
3
5 1
251. Safety latch type By Vendor
Provided
Provided Provided
252.

Bearings and Lubrication
118
584
1
1
3
3
3
3
3
3
3
3
3
6
62
23,192kgs 14,988kgs 17,629kgs
(kgs)
(m/min)
806
59.56 66.80
903 806
39.43
699
3.72 3.9 3.9
PROVIDED
N/A
N/A
4
4
4
1 3
(Nm)
(KNm)
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms



253. Bearings and Lubrication
254. Manufacturer Type Material Lubrication
255. Boom hinge
Seatrax Bush Nylon GP Grease
256. Ram pin top
NA N/A
257. Ram pin bottom
NA N/A
258. Rope sheave
Torrington or Equal Roller Carbon Steel GP Grease
259. Drum bearing
(main hoist)
260. Drum bearing
(luffing)
261. Drum bearing
(whip hoist)

Instrumentation

263. Controls
264. Mipeg 2000 Required YES
265. Engine Start Yes, Mechanical YES
266. Engine Stop Yes as per MITS-07 YES
267. Engine Speed Control Yes YES
268. Main Hoist Control Yes YES
269. Boom Hoist Control Yes YES
270. Slew Control Yes YES
271. Windscreen wiper/washer Yes YES
272. Heating/Ventilation/demisting Yes YES
273. Lighting Yes YES
274. Emergency Stop Yes YES
275. Boom lower override required YES
276. Horn warning Yes YES
277. Emergency hoist brake release Yes YES
278. Emergency luff brake release Yes Manual YES
279. Wave following selector Yes as per MITS-07 Part of Emergency Load Release
280. Emergency load release Yes YES
281.
282. Indicators
283. Safe load Yes YES
284. Radius Yes YES
285. Wind speed Yes YES
286. Hydraulic Oil level Yes YES
287. Fuel level Yes YES
288. Engine oil temperature yes YES
289. Engine cooling water temperature Yes YES
290. Engine fuel pressure Yes YES YES
3
2000NR + OLM 2
4 SEE NOTE 1 BELOW
NOTE 1 : THE ENGINE IS FITTED AS A STANDARD WITH FUEL PRESSURE GAUGE. NO ALARM.
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms



291. Engine speed Yes YES
292. Air system temperature Yes YES
293. Air system reservoir pressure No YES
294. Hydraulic boost oil pressure No NO
295. Hydraulic control oil pressure Yes YES
296. Hydraulic luff pressure No YES
297. Hydraulic main hoist pressure No YES
298. Hydraulic whip hoist pressure No YES
299. Hydraulic slew pressure No YES
300. GOP healthy No Emergency Release Device
301. Hoist line motor No NO
302. Hydraulic oil filter condition Yes YES
303. Accumulator charge pressure No NO
304. Electrical power status Yes YES
305.
306. Warnings
307. Horn Yes YES
308. Engine over speed Yes YES
309. Boom out over moment Yes YES
310. Boom hoist limit min. radius Yes YES
311. Max. radius Yes YES
312. Load hoist limit over hoist Yes YES
313. Over lower Yes YES
314. Slew arc limits Yes YES
315. Engine cooling
Water temperature high
Yes YES
316. Oil temp. high Yes YES
317. Oil pressure low Yes YES
318. Hydraulic oil level low Yes YES
319. Boost pres. Low No NO
320. Oil temp. high Yes YES
321. Oil cavitation No NO
322. Fuel oil low No YES
323. Main hoist row slack No HOOK BLOCK DESIGN
324. Boom hoist rope slack No NO
325. Accumulator charge pressure low No NO
326. Hydraulic control pres. Low Yes YES
327. Rope vicinity temp. high No NO
328. GOP system activated No NO
329.
330.
NO
NO
1
1
OLM (MIPEG) 2
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms



331. Safety Features
332. Communication system Yes as per MITS-07 FREE ISSUE
333. Load / radius indicator Yes YES
334. Boom back stops Yes YES
335. Slack rope preventer main hoist Yes HOOK BLOCK DESIGN
336. Slack rope preventer luff hoist Yes NO
337. Drum rotation indicator No NO
338. Dry powder extinguisher Yes YES
339.
Construction Features Electrical
340. Supply Data
341. Voltage Cycles Phase
342. Main Supply 400 50 3PH+N+E
343. Auxiliary supply (zone 1 lighting) 230 50 1PH+N+E
344. UPS Supply 230 50 1PH+N+E
345. Control 24 DC Internally derived by
vendor as required.
346. Lighting As per MITS-07 & MITS-10 YES
347. Flood Lights Yes YES
348. Slewing
349. Boom tip Yes Yes
350. Aircraft warning Yes Yes
351. Drivers cabin/Machinery room Yes Yes
352. Access ways/rear dick/intermediate
platform
Yes Yes
353. Heating No

354. Collector Ring REQUIRED Number of Circuits Remarks Fully compliant with MITS-07
355. Details of the Collector Ring shall be provided by Vendor
356. Main power(3PH +N) 4rings Yes Separate 230v, 1 phase
for zone-1 lighting
357. UPS Power (1PH +N) 2 rings Yes For aircraft warning
lights
358. Auxiliary Supply (1PH+N) 2 rings Yes For Zone-1 lighting
359. Earth (IS, Main/Aux. power and
UPS)
4rings Yes
360.
361. Loudspeaker As per MITS-07 As required by MITS
362. Telephone As per MITS-07 As required by MITS
363. Fire & Gas Warning As per MITS-07 As required by MITS
364. Other spare rings As per MITS-07 As required by MITS
365.
Utilities
366. Normal Maximum
367. Service Air Crane engine and its utilities shall not be dependant of air supply from the module
2
2
2
NPCC No.: 6048-T-DS-301

DATA SHEET

Rev.: 2

PROJ ECT TITLE :
GB Platforms



368. Pressure (barg)
369. Temperature (
o
C)
370. Consumption (Nm
3
/hr)
371.
372. Diesel Fuel
373. Pressure (barg) CAT Standard CAT Standard
374. Temperature (
o
C) As required As required
375. Consumption (l/hr) 72 ltr/ hr 72 ltr/ hr
376. Tank Capacity (l) 1300 litres approx. 1300 litres approx.
Supplementary Requirements
378. Cross Roller Bearing Not required Not Provided
379. Rotabolt Type Bolts for swing circle NO Confirmed - NO
380. Swing Roller Bearing Re-Placement
Device
NA Confirmed N/A
381. Hydraulic Tank SS316 L with
painting as per MITS- 34
Optional External Coating
382. Anti Skip Painting on top of the
boom
Not required
383. Limit Switches Yes. Yes
384. Hoist Limit Switch at Bottom Required Confirmed Supplied
385. Fully Automatic Safe Working Load
Indicator
Required Confirmed - Supplied SWL shall be identified
for any working position;
Visual & Audible alarm
when load reach 95% of
SWL for corresponding
radius;
Audible alarm when
load has reached 100%
of SWl for
corresponding radius;
Stop the hoist and out-
luffing motions
automatically when load
has reached 110% of
SWL for a
corresponding radius

Notes
1) .

1) Free Issue items (to be installed by SEATRAX):
Auteldac telephone with integral speaker, Motorola Battery charger, Gooseneck microphone with 600mm length of M10 threaded connection
suitable for wall mounting, loudspeaker for PA/GA system-A& System -B, Interface J unction Box, foot activated switch.

2) VHF/FM Radio and Head set shall be provided and installed by NPCC.

N/A
1
1
1

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION H HYDRAULIC SCHEMATICS AND BILL OF MATERIALS (B003, J022)

Primary & Control Circuit Schematics
Hydraulic System Bill of Materials

Page 1 of 11

MAERSK OIL QATAR AS


HYDRAULIC SCHEMATIC DRAWING (4527)

MOQ DOC. No.: ASEDA-10-70033-0015
NPCC DOC. No.: 6048-70033A-B003-001
VENDOR DOC. No.: C003 4527H


SEATRAX UK LTD

3 08-Dec-08 Revised incorporating customer comments AS BUILT ISSUE (Drawing Rev 4)
2 27-Oct-08 Revised incorporating customer comments AS BUILT ISSUE (Drawing Rev 3)
1 06-Feb-08 Revised incorporating customer comments for review and approval
0 21-Dec-07 Issued for approval

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION I PNEUMATIC SCHEMATIC AND BILL OF MATERIALS (J015, J022)

Pneumatic System Schematics c/w Bill of Materials

Page 1 of 3

MAERSK OIL QATAR AS


PNUEMATIC SCHEMATIC

MOQ DOC. No.: ASYYY-10-70033-0036
NPCC DOC. No.: 6048-70033A-J022-001
VENDOR DOC. No. : C007 4527/28/29/30G


SEATRAX UK LTD

1 07-FEB-08 Revised incorporating customer comments for review and approval
0 11-DEC-07 Issued for approval

W
o
iL
z
a
<.>
I
I
- - - - - -OPERATOR'S CAB - - --

I
Lr-_J
@
AIR HORN
0"'
I
@-1
DIESEL ENGINEL
ALARf.4 VALVE
WITH LATCH .
------{}-----PLASTIC TUBING 6mm OD ..
FLAX HOSE (SAE 100R12)
-----cI>-- FLEX HOSE, GATES "LOL" - OR EQUIV.
VENT
J

6

.1) THROTTLE
12) IDLE I
13) WOT
20 UPPER WINDOW WIPER SYSTEM
'M
- -----'
WIPER SYSTEM
-'1 _________
'M

WASHER SYSTEM TOP WINDOW
VENT
CUENT: National Petroleum Construction Co.
End User: Moersk Oil Qatar AS
PROJECT: AI Shaheen Field Development
EQUIPMENT: Seatrax 59028 Cranes
Tag No,: ASEDA-A-6101
P.O. No.: 6048-07-70033-AC
Doc No.: 4527/28/29/30G
I
I
I
I
I
.,0STARTER SAFElY
-( VALVE
I
I ENGINE HOUSE-- -- --
UNLOADER .
1
. 14
VAlVE
24 SWIVEL JOINT ..
'"
.
L
AIR SUPPLY; .&.
7 BARG Nominal (100 PSI), 5 BARG Min (73 PSI).
10 BARG Mel( (145 psI).
,. MALE AUTOLOK/KAMLOCK 633F ADAPTER
------1
VENT
I
I
I

I
I
I
I
I
I
I
I
I
I
I
I
SET BY ENG. MFR.
2,300 RPM APPROX.
ENGINE .
15
./PRE5SURE
r-'- ..L'lSW'TCH .
VENT
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ENGINE SHUTDOWN
VALVE FUEL SHUTDOWN
ACTUATOR

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I

I"rpolS, IN, / AND COOLANT TEl.1P. TA
T/7 7 T T/7 7 ________ --=)-__ OjL ,=,REpSU.,RE

II/ARE AN INTEGRAL PART OF Tl1E ENGINE /.-/ L / J
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CL"/--'/' L L ,L.../--./..L L.L
-- -- -- -- -- --
&. TAG No's
Nore 4527 UK =
4528 UK =
4529 UK =
4530 UK
THIS DOCUf.1ENT AND THE CONTENTS HEREIN MAY NOT BE
EXPRESS WRITTEN CONSENT OF SEATRAX INC.
PATENT NO'S. US 4,280.628 US 5.310,067
US 5,328,040 GB 2253604 B GB 2254308 8
DRAWN
DB
ASED-A-6101
ASGD-A-6102
ASGA-A-6101
ASGD-A-6101
PO BOX 840687
Houston, Texas 77284
Phone: 713 896 6500
LPRESSURE SWITCH
&. ,---, A
EXHAUST ____ "'"
PROBE (AMOT)
@('L - . - - -.J
>< . VENT
\0.30-
RESTRICTOR

t1 MAERSK OIL OATAR
MAERSK
GA WELLHEAD MODULE, ED, GD AND GB PLATFORMS
<i.

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AS
Component ' em ty. Item Name
A B C D
Engine House 1 1 Actuator
2 1 Check Val'.!
3 1 Air Recei-..er

3 Ba1l Val'.!
5 1 Relief Val-..e
6 1 Filter Ass'y
7 1 Relay Val'.!
8 1 Starter Motor
9 1 Mechanical Val-..e
10 2 Shuttle Val'.!
Cab 11 1 Throttle Selector
12 1 Manifold
13 1 Pressure Gage
,. 1 D.CVal'.!
1 Val-..e
1 Button
15 1 D.CVal'.!
16 2 Mechanical Val-..e
17 1 Pressure Control Val'.!
18 1 Hom
19 1 D,C. Val'.!
20 1 Wiper System
21 1 Wiper System
22 2 Washer System
23 1 Shuttle Val-.e
Gantry 2. 1 Swi-.el Ass'y
Engine House 25 1 Probe
1 Control System
26 Probe
1 Control System
27 1 Regulator
28 2 Swi tch
Description/Notes
Oesel Engine Throttle Control
Ball-Cone, 1 112" f>I'T furts, 0.5 PSI CracKing Pressure
120 Gal. , 200 PSI I"oMOP, AStv'e, USCG, And ASS Certified
3/8"f>I'T furts, st. Steel Body
1" f>I'T Fbrt
16FPFbrts
2 Way, 2 Fbs. Pilot Operated Valve
For 3406 Cal. Engine Rand.
3 Way, 2 Fbs. Mxrentary Pushbutton Valve
Air Valve
Aleurrotioc Selector Valve, 3 R:ls . Parker
(10)6FPForts
0-200 Glycerfie filled, Stainless Case, 4M> Port
Engine Stop Valve
Aleurrotic Dir. Control Valve
"PLLL TO STOP I"oAarked Black Button
Engine Errergency Sto p Valve. I\brgen
3 Way, 2 Fbs. M:xrentary Pushbutton Valve
AxIal Type. Engine Accelerator
16 114" Air I-brn, Marine Rated
Hydraulic Pilot, Latched Override
\"pper VVindow VViper . 29" Arm, 40" Btade
Front VVindow VViper , 36" Arm, 40" Btade
Front & \..pper Windows
Air Valve
16M>and 16M) Fbrts
High Exhaust TelTperature Probe, Pyroban.
AMOT
Hgh Water TelTperature Probe.
AMOT
Air Line Regulator, l\brgren
Pressure Sw
CONFIDENTIAL ----------------------------------------...,
PIN
35073
40439 &,
35057
40393
&.
35078
35001
35036
150TMPF8T8R54-200 &.
35022
35083
B53004LW
&.
TC5014N
40177
TJ3OO5N-1
35087
20227
03042802

35022
35072
35006
35023
35016
35092
35058
35083
35011
480363/200
4075

2230C220F1 000/AA
4075

R72G-2GK-RMN
2
880300 ,
THIS OOCIJIllENT NlD 111: CCNTEIffli HEREIN IIIOoY NOT BE MONARC:H"
DISPlAYED, REPROOUCED OR OlliERIIISE USED wrTHOUT 111: SeaKlng
ElCPRES5 WRITTEN t)f SEATJW( INC. II A I I. A
'. ' ... ............,. "'" - 40-'0
Notionol Petroleum Construction Compony _11:11:
PO BOX .... ..
Houlton, T a. 77284 SEATRAX W MAERSK OIL QATAR All
7'J 895 5500 _ _ MAERiiK
PATENT NO'S. US 4,280,528 US
US 5,J28,040 GB 2253604 B GB 2254306 B
PNEUMATIC SCHEMATIC
AND MATERIAL LIST
AL SHAHEEN FIELD DEVELa'MENT 2005
GA 'M:LLHEAD MODULE, ED, GD NoID GEl PLATFORMS
604B-70033A-J022-001
08 11-29-07 ASYVY-l0-70033-0036

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

SECTION J ELECTRICAL SCHEMATICS AND BILL OF MATERIALS (J001, J021, J022)

Electrical Schematics (J020)
One Line Diagram (P009)
Wiring Diagram (P021)
Cable Schedule (J002, P002)
Bill of Materials and General Notes (J003, J005)
Electrical Load Calculations (P001)

Page 1 of 4

MAERSK OIL QATAR AS


ELECTRICAL SINGLE LINE DIAGRAM

MOQ DOC. No.: ASYYY-10-70033-0041
NPCC DOC. No.: 6048-70033A-P009-001
VENDOR DOC. No.: C001 4527/28/29/30E


SEATRAX UK LTD

3 13-May-08 Revised incorporating customer comments for review and approval
1 03-J AN-08 Revised incorporating customer comments for review and approval
DWG., SHT., DESCRIPTION DWG.' SHT., DESCRIPTION
4527/28/29/30E 1 ELECTRICAL SCHEMATIC DRAWING LIST 4527/28/29/30F 1 ELECTRICAL SCHEMATIC COLLECTOR RING
4527/28/29/30E 2 ELECTRICAL SCHEMATIC CABLE BLOCK DIAGRAM PART 1 4527/28/29/30F 2 ELECTRICAL SCHEMATIC 400vAC DISTRIBUTION PANEL PART 1
4527/28/29/30E 3 ELECTRICAL SCHEMATIC CABLE BLOCK DIAGRAM PART 2 4527/28/29/30F 3 ELECTRICAL SCHEMATIC 400vAC DISTRIBUTION PANEL PART 2
4527/28/29/30F 4 ELECTRICAL SCHEMATIC LIGHTS DETAIL
4527/28/29/30F 5 ELECTRICAL SCHEMATIC GAUGES & ALARM
4527/28/29/30F 6 ELECTRICAL SCHEMATIC LIMIT SWITCHES PART 1
4527/28/29/30F 7 ELECTRICAL SCHEMATIC LIMIT SWITCHES PART 2
4527/28/29/30F 8 ELECTRICAL SCHEMATIC WINDSPEED INDICATOR
4527/28/29/30F 9 ELECTRICAL SCHEMATIC MIPEG LOAD INDICATOR
4527/28/29/30F 10 ELECTRICAL SCHEMATIC FIRE & GAS SYSTEM
4527/28/29/30F 11 ELECTRICAL SCHEMATIC COMMUNICATIONS
I
Ii:
4527/28/29/30F 12 ELECTRICAL SCHEMATIC CABLE LIST
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4527/28/29/30F 13 ELECTRICAL SCHEMATIC PARTS LIST

"ftD':r.ft":1fta"'i .....
::::>
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ClIENT: National Petrol ..... Construction Co. THIS DDCI.IIENT NI) THE CONIENTS HEREIN !MY NCJI' IE PO BOX 840887 National Petroleum Construction Company
DISPI.A'tED. REPRODUCED OR cmtERWISE USED WITHDUI' THE Houston, Texas 77284
End LIller: MaenIk 011 Qatar AS EXPRESS WRITTEN CONEIfI' OF IE'A1IWC III Phone: 713 898 eeoo ..
PROJECT: Shaheen Field Develapment loll MAERSK OIL QATAR A.
EQUIPMENT: Soatrax S9028 .. S7226 Cra_a .. lENT NO'S. us .,2110.... US 5,310.007 ELECTRICAL SCHEMATIC .""RS'
Tag No.: us 5,328,040 .B 2253004 B GO 220430II B DRAWING US!
2005
PLATFORMS
P.O. No.: 8048-07-7OO33-H:
Doc No.: 4S27 /2B/2t/30E
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PROJECT: AI Shaheen Field Development
EQUIPMENT: Soatrax S9028 II S7228 era ...
Tag Mo.:
P.O. No.: 8048-07-70033-H:
Doc No.: 4S27 /2B/29ft
1, MAIN POWER & CONTROL CABINET IS EEx (de) TYPE SUITABLE FOR ZONE 1.
2, THE 'MAXIMUM LOAD HORN' IS INCORPERAlED INTOTHE MIPEG SYSTEM WITH
NO EXTERNAL LOUD SPEAKER.
3, THE CRANE ENGINE EMERGENCY STOP BUTTONS ARE PNEUMATIC AND NOT ELECTRIC,
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THIS DOCI.IIENT MD 1HE CONIENJS HEREIN IMY NCJI" lIE
PATENT NO'S. us 4,280,828 US 5,310,087
us 5.328.040 GB 22:i3604 B GB B
D.JD FULL
PO BOX 84OB87
Texas 77284
Phone: 713 888 8DOD
Ipl../ooJI .:.w..- &4-40
OIL QATAR A.
2005
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Page 1 of 14

MAERSK OIL QATAR AS


ELECTRICAL SCHEMATIC, WIRING DIAGRAM & CABLE SCHEDULE

MOQ DOC. No.: ASYYY-10-70033-0034
NPCC DOC. No.: 6048-70033A-J001-001
VENDOR DOC. No.: C002 4527/28/29/30F


SEATRAX UK LTD

3 17-J UNE-08 Revised incorporating customer comments for review and approval
1 03-J AN-08 Revised incorporating customer comments for review and approval
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CUENT: _ Petroleum eonotructlon Co.
End Usor: IIaorok 011 Qatar IS
PROJECT: AI Shaheen FIeld Development
EQUIPMENT: _ S9028 '" 57228 era_
Tag Mo.:
P.O. No.: 1I048-07-7OO33-AC
Doc No.: 4527/m/28/:wF
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PATENT NO'S. us 4,280,828 us 5,310,Q87
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PO BOX 84Q687
TItIC08 77284
Phone: 713 888 1500
OIL QATAR A. PROJECT: AI Shaheen FIeld Development
EQUIPMENT: s.atrax S9028 II 57228 Cru_
Tag No.:
PAlENT NO'S. us 4,280,828 US 5,310,087
us 5.328.040 GB B GB 2254J08 B
ELECTRICAL SCHEMATIC
LOAD INDICATOR
2005
PLATfORMS
P.O. No" 1I048-07-700J3-AC
Doc Mo.: 4S27/28/21ft/JF
D.JD FULL

Page 1 of 2

MAERSK OIL QATAR AS


ELECTRICAL LOAD CALCULATION

MOQ DOC. No.: ASYYY-10-70033-0035
NPCC DOC. No.: 6048-70033A-P001-001
VENDOR DOC. No. : D011 SXELC4527/4528/4529/4530


SEATRAX UK LTD

2 03-J an-08 Revised incorporating information has been changed in Electrical drawings
1 10-Dec-07 Revised incorporating customer comments for review and approval
A- ACCEPTED
B- COMMENTSASMARKED
C- NOT ACCEPTED
E
N
G
2
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0
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-
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D
.
A
BEFOREPROCEEDING.
B
C
VENDOR
DOCUMENT STATUS

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

Section K General Bills of Materials & Component Data
K1 General Bill of Materials
K2 Air Conditioner (Friedrich) Class 1 Div 2
K3 Air Starter (35038)
K4 Bearing Assembly Lower (TF8034)
K5 Bearing Assembly Upper (TF7049)
K6 Brake Actuator Assembly 500 Series For Load, Aux & Boom (TB4122)
K7 Brake Band Assembly For Main (TB4190)
K8 Brake Band Assembly 800 Series For Boom (TB4190)
K9 Brake Band Assembly For Aux (TB4071)
K10 Collector Ring TX4715BW
K11 Filter Assembly, Pilot Circuit (40587)
K12 Filter Assembly, Oil Conditioner (40585)
K13 High Pressure Filter (40577)
K14 Gearbox, Planetary 700 Series, Boom (20165)
K15 Gearbox, Parallel Shaft 700 Series, Main (20165L)
K16 Gearbox, Parallel Shaft 400 Series, Aux (20163L)
K17 Gearbox, 4 Pad, Transfer to Pumps (20259)
K18 Gearbox Slew (20071)
K19 Hoist Assembly Boom 800 Series (TB1075)
K20 Hoist Assembly Main 800 Series (TB1078)
K21 Hoist Assembly Aux 400 Series (TB1092)
K22 J oystick (40437)
K23 J oystick (TC3075)
K24 Motor, Gear Type (Slew) (40113)
K25 Motor, Piston Type c/w Motor Control Valve (40410) For Boom, Load & Aux
K26 Overhaul Ball Assembly (5370-005)
K27 Main Block Assembly (TA3135)
K28 Pump Variable Displacement Piston Type (40387) For Boom, Load & Aux
K29 Pump Pilot Pressure (40581)
K30 Pump Fixed Displacement Vane Type Slew & Oil Conditioning (40344)
K31 Hydraulic Starter System (50089)
K32 Sheave Assembly (TA1123)
K34 Mipeg 23 Sheave Assembly (TA1329)
K35 Valve Directional Control (40258)
K36 Valve Directional Control Boom (40371)
K37 Valve Directional Control Load (40372)
K38 Valve Directional Control Slew (40004)
K39 Valve, Brake Release (TC3060)
K40 Valve, Boom Limit Assembly (TC3142)
K41 Wind Monitor


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K1 General Bill of Materials

Bill of Material Job No.: 4527
Customer.... : NPCC
End User .: Maersk Oil Qatar AS
Project : Al Shaheen Block 5, ED Platform
Quote No....: 705104A-UK
Crane Series..: S90
Model......: S9028JU Boom Lg. : 170 Ft. R.H. Cab
The following drawings, in their latest, applicable revision, are an integral part of this document:
1 4527 F Electrical Schematics And Material List
2 4530 G Pneumatic Schematics And Material List
3 4527 H Hydraulic Schematics And Material List
Rev.

Phone: 713 896 6500 Fax: 713 896 6611
Page: 1 of: 12
Prepared Date Approval
Danny Be'er 12/10/07

0
1

Danny Be'er 12/10/07

M COOK 7/20/08

J ob No.: 4527 Page: 2 Rev.: 1
Page #
1 ALL
1 3 39
1 4 62
1 5 1
1 5 3
1 5 18
1 6 3
1 6 4
1 8 29
1 10 27
1 10 28
1 10 29
1 10 35
1 10 47
1 10 48
1 12 15
1 13 1
PART NO. CHANGE FROM TA3119N TO TA3138N
PART NO. CHANGE FROM 4499Y TO 4527Y
PART NO. CHANGE FROM TC6011N TO TC6048N
PART NO. CHANGE FROM TH1XXXN TO TH1012
QTY CHANGED TO 3
SeaTrax Inc. Houston TX, U.S.A.
Change Record
Change Description
PART NO. CHANGE FROM 60177 TO TD5012
PART NO. CHANGE FROM TL9035N TO TL9040N
PART NO. CHANGE FROM TB6050L TO TB6070L
US SUPPLY ITEMS INDICATED
PART NO. CHANGE FROM TD1023N TO TD1019
Bill Of Material
Rev.
PART NO. CHANGE FROM TB2090L TO TB2100
4527 Page: 3 Rev.: 1
A B C D (Dimensions are approx. - given for ease of identification)
1 1 KingPost weldment S9028 Crane TP2073N
2 1 Can weldment S9028 Series TP2XXXN
3 1 Hemisphere Machine Detail, S90 Series TP9008N US
4 1 Hemispheric Head Raw Hemisphere, 33" I.D, 1.75 Nom. Wall 70093 *US
5 1 Flange Kigpost Top Flange, S Series. TP9015N
6 1 Bull Gear Low Torque TP9011N US
Ad-Ons 7 1 Stab-In Guide S72/S90/S108 Series TP9021N
8 1 Gantry & Brackets Weldment S9028 Series TG9153R
9 1 Gantry Weldment S9028 Series TG2091N
10 1 Bearing Carrier S90 Upper Bearing Block TG9135N US
11 1 Dead End Sheave Plate For 1 1/8" (28mm) Rope Dia. TG9102N
12 1 1 Ton Maintenance J ib Connection TG9145N
13 1 J ib Crane Latch TG9137N
14 2 Boom Stop Ass'y External Spring Type, S72/S90 Series TG9141N
15 1 Boom Stop Outer Pipe Weldment TG9142N
16 1 Boom Stop Inner Pipe Weldment TG9143N
17 1 Boom Stop Spring Helical, Compression Spring TH6016N US
18 1 Grease Fitting Straight, 1/4" NPT 90003 STOCK
19 6 28" Nylon Sheave Ass'y Straight Roller Bearing TA1010N US
20 1 28" Nylon Sheave Grooved for 1 1/8" (28mm) Rope TA1010-9N *US
21 1 Bearing Straight Roller Bearing, 5.5" I.D., 7" O.D. 70017 *US
22 2 Retaining Ring For 7" Bore 80029 *US
23 18 Thrust Washer Nylon, 7 1/2" O.D. 3 9/16" I.D. 1/4" THk TA1010-2N STOCK
24 1 Sheave Shaft 5 1/2" Dia. 47" Lg. (6 Sheaves) TA1103N
25 2 Front Gantry Pin 6" Dia. 16 5/8" Lg. TA2138N
26 2 Rear Gantry Pin 6" Dia. 14 1/8" Lg. TA2139N
27 1 Gantry Sheave Guard 80 Series TA9006N
28 1 Rope Guard Gantry Rope Guard, S90 Series TG9107-2
29 1 Upper Bearing Ass'y S90 Series TF7049N
30 1 Upper Bearing S90 Series TF7044N US
31 1 Bearing Casting Nylatron Tapered Bushing Cast 70096 *US
32 2 Thrust Plate S90 Series Upper Bearing TF7048N US
34 1 Turntable & Boom Hoist Frame Wldmt. S90 Series Turntable with 1000 BoomHoist TU9513N
35 1 TurnTable Weldment S90 Series TU3064N
36 2 Boom Kickout Valve Mounting Plate TU9081N
37 4 Stand Off 1/4-20UNC, 1.5" High TD6017N
38 2 Stand Off 1/2-13UNC, 1.5" High TD6025N
39 1 Boom Hoist Frame Weldment 1000 Series, S90 Cranes Series TB2100
40 1 Brake Collar Brake Eccentric Lever Bearings Housing TB4169N
41 1 Pawl Housing Dog Pawl Lever Bearing Housing TB4051N
42 1 Shaft Bearing Housing 5/8-11UNC, 1.5" High TB6018N
43 1 Wing Deck ass'y S90 R.H. Series TU1001R
44 1 Main Wingdeck Weldment R.H. Cab Deck TU5062R
45 1 Rear Wing Deck Weldment S90 Series TU5063N
46 1 Right Wing Deck Attachment S90 Series TU5064N
47 1 Left Wing Deck Attachment S90 Series TU5065N
48 1 Wing Deck Support S90 Series TU5066N
49 1 Wingdeck Handrail Weldment S90 Series, R.H. TU9442R
50 1 Safety Gate R.H. Swing, Single Bar 20185 US
51 2 Grating 1 1/2" I-Bar, 3'-1" X 20' 95018 STOCK
52 4 Cab Mount 750 Kg. Load 20196 US
53 2 Boom Foot Pins 7" Dia. 15 5/8" Lg. 4130 Steel TA1099N
54 2 Slew Gearbox S-20 Type 20071 US
55 2 Input Gear Reduction G07 ("Pancake") Gear 20078 US
56 4 O-Ring AS-568A-158 (4 3/4" Dia.) 80030 US
57 2 Slew Pinion Gear Low Torque, 11 Teeth (40 Teeth Spline) TF2021N US
58 2 Pinion Gear Retainer For S-20 Gear TF3005N
59 1 Lub Oil Reservoir Slew Gear Oil "Day Tank" TC8003N
60 1 Breather 1/2" NPT 40119 US
61 1 Infill Grating S90 Upper Front TU9456N
62 0.5 Grating 1 1/2" I-Bar, 3'-1" X 20' 95018 STOCK
63 1 Central Greasing System For Lower Bearing Shoes TU9XXXN
Component #
Qty.
P/N Item Name
Bill Of Material
Description/Notes
Weldment
Pins
Guards
Upper Brg.
Boom Stops
Upper
Misc..
Slew Area
Decks
Turntable
KingPost
Weldment
Sheaves
Gantry
4527 Page: 4 Rev.: 1
1 1 Fuel Tank weldment 400 Gal., St.Steel, S90 Series, Cylindrical TU7115R
2 1 Fuel Tank Cover Gasket 1/8" Thk. Neoprene TU7062N
3 2 Fuel Tank Pad 6" Wide, 120" Lg, 3/8" Thk Plastic Strip 95038
4 1 Filler Cap 2 1/2" NPT 90067 US
5 2 Ball Valve 1/2" NPT Ports, St. Steel 40441 US
6 1 Boom Hoist Ass'y 800 Series TB1075L PART US
7 1 Drum Weldment 22" DrumDia. TB3163L
8 1 Shaft Drive Plate 12" Dia. (45 Teeth Splined I.D.) 20066 US
9 1 Lebus Grooving For 22" Dia.Core with 22 7/8" Between Flanges S.P.
10 1 Brake Band Ass'y 800 Series TB4190N US
11 1 Brake Band Weldment 800 Series TB4191N *US
12 1 Brake Band Anchor 1 1/2-6UNC, 20" Lg., 500/700 Hoist Series TB4152N *US
13 0.4 Brake Lining 5" Wide x 3/8" Thk.Woven Material Strip 20044 *US
14 1 Bearing 1 5/8" I.D., 1 3/4" O.D., 1" Lg. Plastic Bushing 70090 *US
15 102 Flat Head Rivet Semi Tubular, 1/4" x 3/4" Lg., Brass 60040 *US
16 1 Lock Nut Shaft End Lock Nut, 4 15/16" O.D. 70064 US
17 1 Oil Seal 4 3/4" O.D., 7/16" Wide (Brake Side Bearing, Outer) 80011 US
18 1 Bearing Cover Plate 400/700 Hoist Series TB6041N
19 2 Grease Vent 1/8" NPT 90013
20 4 Grease Fitting Straight, 1/8 NPT 90012
22 1 Oil Seal 5 3/16" O.D., 1/2" Wide (Brake Side Bearing, Inner) 80075 US
23 1 Bearing Housing 400/700 Hoist Series, 8.85 Bearing Bore TB6044N
24 2 Oil Seal 7" O.D., 7/16 Wide (Gearbox Side Bearing) 80124 US
25 2 Bearing Cover Plate 400/700 Hoist Series, 7.09 Bearing Bore TB6043N
27 2 Bushing 2 3/4" I.D., 3" O.D., 2" Lg. Plastic Bushing 70004 US
28 2 Thrust Washer 3 3/8" O.D., 2 7/8" I.D., 1/8" Thk.Nylon TB4005-9N
29 1 Eccentric Shaft 1 5/8" Eccentric Pin Dia. TB4186N US
30 1 Brake Lever 700 Series (45 Deg.12 1/2" Lg.) TB4117N
31 1 Retaining Cap 2 1/2" Dia. TB4004-2N
32 2 Cotter Pin 1/8" Dia. 1 1/4" Lg. 60021
33 1 Push Rod 23 1/4" Lg. (22" B.C.) TB4006-2N
34 2 Shoulder Pin 9/16" Dia. 1 1/2" Lg. 60063 US
35 2 Wire Rope Clip For 1" to 1 1/8" (26-28mm) Rope Dia. TB8007N
36 1 Hoist Shaft 700 Hoist Series,Long (54 1/2" Lg.) TB5016N US
37 1 Parallel Shaft Gearbox, 700 Series 78.65:1, "D" Flange with "D" Input Shaft For Piston Motor 20165B US
38 1 Label Personnel Lifting Approval Plackard TH5010N
39 1 Shaft Nut 700 Hoist Series, 5 1/4-8UN Thd. TB6039N US
40 1 Shaft End Cap 700 Series (5.6" Shaft end Dia.) TB6048N US
41 7 Male Cone Bushing Tie Down ArmPin Retainer TB6057N US
42 7 Female Cone Bushing Tie Down ArmPin Retainer TB6058N US
43 1 Long Pin Tie Down ArmPin Retainer (9 3/4" Lg.) TB6059N US
44 1 Short Pin Tie Down ArmPin Retainer (8 1/2" Lg.) TB6060N US
45 1 Tie Down Arm 400/700 Hoist Series, 13" B.C. TB6061N
46 1 Bearing Spherical, Roller Bearing, 6" I.D., 8 7/8" O.D. (Gear Side) 70052 US
47 1 Bearing Spherical, Roller Bearing, 3 3/4" I.D., 6 11/16" O.D. (Brake Side) 70029 US
48 1 Lock Washer For Shaft End Lock Nut 70066
49 1 Pawl and Shaft weldment TB4114L
50 2 Thrust Washer 2 1/2" O.D., 1 15/16" I.D., 1/8" Thk.Nylon TB4020N US
51 2 Bushing 1 3/4" I.D., 2" O.D., 2" Lg. Plastic Bushing 70013 US
52 1 Dog Latch Lever Ass'y BoomHoist Dog TB4089N
53 1 Pawl Lever Weldment BoomHoist Dog Latch TB4090N
54 1 Latch weldment BoomHoist Dog Latch TB4086N
55 1 Clevis Pin 9/16" Dia. 1 1/2" Lg. 60063 US
56 1 Washer 9/16" Flat Washer 60094 STOCK
57 1 Cotter Pin 1/8" x 1 1/2"Lg. 60021 STOCK
58 1 Knob Black, Oval Tapered, Plastic 20149 STOCK
59 1 Torsion Spring BoomDog Latch Lever, 4 7/16" I.D. (When Loose) TH6004N US
60 1 Cover Plate Gear Input Cover, SAE "D" Flange TB9017N
62 1 Boom Hoist Guard 400 Hoist series TB6070L
63 1 Manual Emergency Lowering device TB9027N
Fuel Tank
Upper (Cont.)
Boom Hoist
Bill Of Material
J ob No.:
Component #
Qty.
Item Name P/N
Description/Notes
4527 Page: 5 Rev.: 1
1 1 Cab Weldment "S" Series (29 1/4 x 84 1/4") Opening TD1019
2 175 Nail 12 Ga. 3" Lg. (Insulation Stud) 60181 STOCK
3 1 Door Ass'y Door With Window, L.H. Swing, Fits TD5075
4 1 Cab Panels Ass'y S Series, Universal Cab Panels TD9021N
5 1 Cab Floor Panel S Series TD9018N
6 1 Cab Seat Floor Panel Standard TD9019N
7 1 Light Diffuser Panel 2' x 3' Styrene Panel 95039
8 1 Light Diffuser Panel 2' x 7 1/2" Styrene Panel 95040
9 1 Front Console Cover TD9022N
10 1 Elect. Cables Bracket TD9023N
11 1 Cab Front Grating Ass'y Open loop Slew System TD2076N
12 2 Grating Weldment Side Segment TD2072N
13 1 Throttle mount Segment TD2073N
14 1 Grating Weldment Center Segment TD2079N
15 1 ESD & Slew Brake Valvs Mount TD2075N
16 1 ESD Valve Placard English Placard TH5049N
17 1 J oystick Panel - L.H. Slew & BoomJ oystick TH1009N
18 1 J oystick Panel - R.H. Main & Aux. Hoist, W/Selector Switch TH1012
19 1 Front Window Ass'y Fixed, Framed, 79" x 67" 20247 US
20 2 Side Window Center Pivoted, Framed, 56" x 28" 20068 US
21 1 Fixed Windows Set Upper, Lower, Front Sides, W/ Grommets 20045
22 1 Operator's Seat With a "Dead Man" Swich 20072
23 1 API 2C Monogram TH5011N
24 1 Floor Mat Sheet 1/2" Foam, 58"x46" 95024
25 1 Cab Guard Front Window Protector TD9015N
26 175 Washer Insulation Clip 60182 STOCK
27 175 Cap Insulation Dome 60183 STOCK
28 32' Insulation Material 1" Thk. 54" Wide 95021 STOCK
29 1 Tool Box 95003
30 1 Console Cover Plates 4530K
31 1 Rating Charts 4527RC
32 1 Engine Tachometer Digital Display 50052 US
33 1 Engine Oil Pressure Gage 2" Dial, Analog Display 50016 US
34 1 Engine Coolant Temp. Gage 2" Dial, Analog Display 50069 US
35 2 Gage Retainer 50076 US
36 1 Fire Extinguisher 20 Lbs. ABC 95008
37 1 Fire Extinguisher Bracket 95009
Description/Notes
Cab & Door
Safety
Gratings
Internal Panels
Misc.
Console
CAB
Bill Of Material
J ob No.:
Component #
Qty.
Item Name P/N
4527 Page: 6 Rev.: 1
1 1 Engine House Weldment S90 Series, R.H Cab With St.Steel Doors (29 1/4 x 84 1/4") Openings TU4094R
2 170 Nail 12 Ga. 3" Lg. 60181 STOCK
3 1 Door Ass'y Door, No Window, R.H. Swing, Fits 29 1/4 x 84 1/4" Opening TD5012
4 1 Door Ass'y Door, No Window, L.H. Swing, Fits 29 1/4 x 84 1/4" Opening TD5012
5 1 Engine 490 HP @ 2,100 RPM, IMO/Zone 2, W/Air Compressor CAT-3406
6 4 Vibration Mounts 2,860 Lbs. 20130 US
7 1 Exhaust J acket 3406 Cat. Engine 50096
8 1 Engine Start Button Bracket Ass'y Supporting Engine Starter Pushbutton Valve TE9058N
9 1 Engine Start Button Bracket TE9057N
10 1 "Start" Placard TH5053N
11 1 Pneumatic Throttle Actuator Bracket Cat 3406 Engine TE9055N
12 13 Insulation Material 2" Thk. 54" x 96" 95023 STOCK
13 170 Washer Insulation Clip, St. Steel 60182 STOCK
14 170 Cap Insulation Dome, Al. 60183 STOCK
15 12 Angle 1 1/2" x 1 1/2" x 10' Lg. St. Steel 60184
16 1 Rain Deflector S Series TU9460N
17 1 Cooling Air Louver Guard Rubber Guard, Louver to Oil Cooler J oint TU9457N
18 1 Louver Weldment Standard TU9455N
19 5 Hose Bracket Hydraulic Hoses Guide TD7011N
20 1 Quad Pump Drive 1,000 HP, 1:1 Ratio 20259 US
21 1 Pump Drive Flex Plate Block Coupling, Engine to Pump Drive 20260 US
22 1 Pump Drive Bracket (Right) TE3005N
23 1 Pump Drive Bracket (Left) TE3006N
24 1 Eng. House Ladder S90 RH Series TU9443R
25 1 Eng. House Hand Rails S90 RH Series TU9444R
26 1 Safety gate RH Swing, Single Bar 20185 US
27 1 Roof Vent Hood Weldment S90 Series TU9402N
28 4 Lifting Eye S-265 Type, Size 5 10001
29 1 Muffler Ass'y 8" Muffler TU9148N
30 1 Roof Vent Flange Clamped Style TE9026N
31 1 Exhaust Flange Weldment 3406 Engine Flange, Clamped Style TE9015N
32 1 Exahust Flange 6" , 4 Bolts Flange TE9001N
33 1 Flex Pipe 6" Corrogated St. Steel 50071 US
34 1 Exhaust Tail Pipe R.H. Carbon Steel TE9050R
35 1 Muffler Ass'y MSA1, Std. Grade 50008
36 2 Gasket 13 1/2" O.D., 8 1/2" I.D. - Muffler Flanges 50068
37 1 Gasket 8" x 8" Sq. 5 3/4" I.D. -Engine Flange 50067
38 2 Clamp Heavy Duty, for 6" Exhaust Pipe 50082 US
39 1 Muffler Support Adjustable, TU9512N
40 1 Fire Extinguisher 20 Lb. ABC 95008
41 1 Fire Extinguisher Bracket 95009
Safety
Misc.
Roof
Eng. House
Engine
Enclosure
Description/Notes
Bill Of Material
J ob No.:
Component #
Qty.
Item Name P/N
4527 Page: 7 Rev.: 1
1 1 Boom Butt Weldment S90, R.H. 800/400 Load Hoist Series TL3063R
2 4 Bracket Elect. Wires Tray and PlatformSupport TL9154N
3 4 Bracket Elect. Wires Tray Support TL9157N
4 2 Brake Eccentric Shaft Housing TB4113N
5 1 Main Hoist 800 Series TB1078N
8 1 Shaft End Cap 700 Series (5.6" Shaft end Dia.) TB6048N
17 1 Hoist Shaft 700 Hoist Series,Long (97" Lg.) TB5013N US
19 1 Brake Lever 700 Series (45 Deg.12 1/2" Lg.) TB4117N
20 1 Eccentric Shaft 1 5/8" Eccentric Pin Dia. TB4188N US
21 1 Brake Band Ass'y 800 Series (Use With 1 5/8" Eccentric Shaft Pin Dia.) TB4190N US
22 1 Brake Band Weldment 800 Series TB4191N *US
24 1 Brake Lining 5" Wide x 3/8" Thk.Woven Material Strip 20044 *US
25 1 Bearing 1 5/8" I.D., 1 3/4" O.D., 1" Lg. Plastic Bushing 70090 *US
26 90 Flat Head Rivet Semi Tubular, 1/4" x 3/4" Lg., Brass 60040 *US
27 1 Push Rod 800 Hoist Series, 25 5/16" Lg. (24 1/16" B.C.) TB4074N
28 2 Thrust Washer 3 3/8" O.D., 2 7/8" I.D., 1/8" Thk.Nylon TB4005-9N US
30 2 Grease Vent 1/8" NPT 90013 STOCK
31 2 Grease Fitting Straight, 1/8 NPT 90012 STOCK
32 2 Grease Fitting Straight, 1/4 NPT 90003 STOCK
36 2 Bushing 2 3/4" I.D., 3 1/4" O.D., 2" Lg. Plastic Bushing 70067 US
37 1 Lock Washer For Shaft End Lock Nut 70066 US
42 1 Parallel Shaft Gearbox, 700 Series 78.65:1 Ratio, For Piston Motor 20165L US
44 7 Female Cone Bushing Tie Down ArmPin Retainer TB6058N US
46 1 Drum Weldment 800 Series, 26" Core Dia. TB3177R
47 1 Shaft Drive Plate 12" Dia. (45 Teeth Splined I.D.) 20066 US
48 1 Lebus Grooving 26" Core Dia. 63.5" Lg. S.P.
49 1 Auxilliary Hoist Ass'y 400 Series TB1092R
52 1 Cap Plate 400 Hoist Shaft (4.5" Shaft End Dia.) TB6074N
61 1 Hoist Shaft 400 Hoist Series, Long (97" Lg.) TB5014N US
63 1 Brake Lever 400 Series (45 Deg. 9 1/2" Lg.) TB4118N
64 1 Brake Eccentric Shaft 1 3/8" Eccentric Pin Dia. TB4208N US
65 1 Brake Band Assy 400 Series Hoist (Use With 1 3/8" Eccentric Shaft Pin Dia.) TB4200N US
66 1 Brake Band Weldment 250/400 Series TB4071-1N *US
68 0.3 Brake Lining 7 1/2" Wide x 3/8" Thk.Woven Material Strip 20044 *US
69 1 Bearing
1 3/8" I.D., 1 1/2" O.D., 1" Lg. Plastic Bushing 70103 *US
70 78 Flat Head Rivet Semi Tubular, 1/4" x 9/16" Lg., 1/2" Head Brass 60039 *US
Bill Of Material
J ob No.:
Component #
Qty.
Item Name
Description/Notes
Weldment
Boom Butt
P/N
Load Hoist
4527 Page: 8 Rev.: 1
1 1 Brake Push Rod 400 Hoist Series, 9" Lg. (7 3/4" B.C.) TB4132N
2 2 Thrust Washer 3 3/8" O.D., 2 7/8" I.D., 1/8" Thk.Nylon TB4005-9N
4 2 Grease Vent 1/8" NPT 90013
10 2 Bushing 2 3/4" I.D., 3 1/4" O.D., 2" Lg. Plastic Bushing 70067 US
11 1 Lock Washer For Shaft End Lock Nut 70066 US
16 1 Parallel Shaft Gearbox, 400 Series 50.99:1, "D" Flange For Piston Motor 20163L US
17 1 Drum Weldment, 20" Core Dia. TB3100R
18 1 Shaft Drive Plate
12" Dia. (30 Teeth Splined I.D.)
20177 US
19 1 Lebus Grooving 20" Core Dia. 63.5" Lg. S.P.
22 7 Female Cone Tie Down ArmPin Retainer TB6058N
23 1 Radius indicator Assy TL5124N
24 1 Radius Indicator Placard S90, 52 meters (170 Ft.) Boom, Series TL5XXXR
25 1 Spacer 1/2" Dia, 5/8" Lg. St. Steel Tubing TL5125N
26 2 Bushing 1/2" I.D. Shoulder, Plastic Bushing 70010
27 1 Load Radius Indicator Pointer TL5016N
28 2 Boom butt bushing, S90 series 7" O.D., 6" I.D. Shoulder Plastic Bushing TL9038N
29 2 Spacer, Boom Butt 9" O.D. 7" I.D. 5/8" Thk. Plastic Spacer TL9040N
30 1 Rubbing Guard TL1033N
31 2 Motor Guard Wire Rope Deflector TL9206N
32 1 Boom Kickout Actuator Rod 1" All Thread TL9188N
Load Hoist
(Cont.)
Radius Ind.
Misc.
Boom Butt
(Cont.)
Bill Of Material
J ob No.:
Component #
Qty.
Item Name
Description/Notes
P/N
4527 Page: 9 Rev.: 1
1 1 Boom Point Weldment 80 Series, Sq. Tubing, 40' Lg. TL2046N
2 14 Bracket WalkWay/Electric Tray TL9154N
3 2 Bracket Walkway/Light BoomPoint End TL9155N
4 2 Bracket BoomPoint End TL9156N
5 6 28" Nylon Sheave Ass'y Straight Roller Bearing (Main Rope) TA1010 US
6 1 28" Nylon Sheave Grooved for 1 1/8" (26-28mm) Rope Dia. TA1010-9 *US
7 1 Roller Bearing 5 1/2" I.D. 70017 *US
8 2 Retaining Ring 7" Dia. Bore 80029 *US
9 18 Thrust Washer Nylon, 9" O.D., 5 9/16 I.D. 1/4" THk TA1010-2 US
10 1 Sheaves Shaft 5 1/2" Dia. 43" Lg. (6 Sheaves) TA1101
11 2 Bolt-On Shaft Retainer TL9043
12 6 Grease Fitting Straight, 1/4" NPT 90003
14 1 34" Nylon Sheave Grooved for 1 1/8" (28mm) Rope Dia. TA1110 *US
16 2 Sheave Hub Steel Hub TA1121 *US
17 2 Grooved Pin 3/8" Dia. 2 1/2" Lg. 60131 *US
18 8 Cap Screw 5/8-11 Hex. Socket Flat C'Sunk Head, 3 3/4" Lg. 60123 *US
20 1 34" Nylon Sheave Grooved for 1 1/8" (28mm) Rope Dia. TA1110 *US
22 2 Sheave Hub Steel Hub TA1121 *US
25 10 Thrust Washer Nylon, 9" O.D., 5 9/16 I.D. 1/4" THk TA1155 STOCK
26 8 Thrust Washer Nylon, 9" O.D., 5 9/16 I.D. 1/8" THk TA1154 STOCK
27 1 Sheaves Shaft 5 1/2" Dia. 35 9/16" Lg. - for 5 Sheaves TA1100
29 1 J ib Boom Extension Weldment 80 RH Series, TL2045R
30 1 Anti Two Blocking Frame 80 Series, Close Rad. Fitting TL8012N
31 2 Anti Two Blocking Frame Spacer Nylatron Spacer, Fits 5" & 6" Pipe TL9017N
32 1 28" Nylon Sheave Ass'y Straight Roller Bearing TA1010 US
33 1 28" Nylon Sheave Grooved for 1 1/8" (26-28mm) Rope Dia. TA1010-9 *US
35 2 Retaining Ring 7" Dia. Bore 80029 *US
36 2 Thrust Washer Nylon, 9" O.D., 5 9/16 I.D. 1/4" THk TA1010-2 US
37 1 Sheave Shaft 5 1/2" Dia. 16 3/4" Lg. - for 1 Sheave TA1026
39 1 Mipeg 23Sheave Assy Sheave and Mipeg Shaft Ass'y TA1329N PART US
40 1 Shaft 4" (Sheave) Dia. to 2 1/2" (Mipeg Sensor) Dia. 9" Lg. TA2051N
41 2 Thrust Washer Nylon,6" O.D. 4" I.D. 1/4" Thk. TA1041N STOCK
42 2 Thrust Washer Nylon, 8 1/2" O.D. 4" I.D. 1/8" Thk. TA1150N STOCK
43 2 Retaining Ring 4 1/4" Dia. 80048
44 1 23" Nylon Sheave Ass'y Straight Roller Bearing (Mipeg System) TA1003N US
45 1 23" Nylon Sheave Grooved for 1 1/8" (26-28mm) Rope Dia. TA1003-1N *US
46 1 Bearing 4" I.D. 70009 *US
47 2 Retaining Ring 4 13/16" Dia. Bore 80028 *US
Boom Tip
Boom Point
Jib
Mipeg
Description/Notes
Bill Of Material
J ob No.:
Component #
Qty.
Item Name P/N
4527 Page: 10 Rev.: 1
1 1 20' Boom Section S90 Series, 6 & 4 Bolts Pads TL4057N
4 2 40' Boom Section 80 Series TL4022N
7 1 10' Boom Section 80 Series TL4035N
10 1 17 Ton Overhaul Ball Assembly For 1 1/8" Wire Rope TA3027N
11 1 Headache Ball Weldment 16" Dia. 40" Lg. 640 Lbs. (1" to 1 1/8" Rope) TA3005-1N
12 1 Swivel Retainer Weldment For 17T Headach Ball TA3033N
13 1 Retaining Pin 2 1/2" Dia. 8 5/8" Grip (Stinger to Swivel) TA2061-12N US
14 2 Retaining Pin 2 1/2" Dia. 5" Grip (Stinger to Hook) TA2061-11N US
15 1 Swivel J oint 25 Metric Tons, Eye-to-Eye 10034
16 1 Stinger Cable 28mmTK16S Galvanized Rope, Open Spelters 10036
17 1 Wedge Socket 1 1/4", S421-T Style 10018
18 1 Bushing Nylon Sleeve, For 1" to 1 1/8" Rope TA9004N
19 1 Tag Nameplate, Rating and Capacity, St.Steel, B&W TH5020N
20 4 Drive Screw #8 x 3/8", St. Steel 60093
21 1 17 Ton Hook & Latch Ass'y SeaTrax safety hook TA3146N US
22 1 17T Seatrax Hook Machined Hook, BRONZE PLATED TA3094N *US
23 1 17T Seatrax Hook Casting TA3092N *US
24 1 Latch TA3095N *US
25 1 Quick Release Pin 1/4" x 1 1/4" With 6" Lg. Lanyard 60119 *US
26 1 Tension Spring Double Torsion TH6009N *US
27 1 75 ton Hook Block Ass'y Triple 34" Nylon Sheaves TA3135N
28 1 Load Block Weldment 75T, For Three 34" Sheaves TA3136N
29 3 34" Nylon Sheave Ass'y Straight Roller Bearing, 5 1/2" Dia. Shaft TA1123N US
30 1 34" Nylon Sheave Grooved for 1 1/8" (28mm) Rope Dia. TA1110N *US
32 2 Sheave Hub Steel Hub TA1121N *US
35 1 Shaft 501/2" Dia. (3 Sheaves) TA2101N
36 8 Thrust Washer 9" O.D., 5.9/16 I.D., 1/4" Thk. Nylon. TA1155N STOCK
37 1 75T Seatrax Hook 4"-8UN Threaded Shank, BRONZE PLATED TA3050N US
38 1 Hook Casting 75T Seatrax Hook Casting TA3036N *US
39 1 Hook Latch Weldment 75T Seatrax Hook TA3098N US
40 1 Hook Latch Spring Double Torsion TA3065N US
41 1 Quick Release Pin 5/8" Dia. x 2 1/2" Grip Lg. 10087 US
42 1 Lanyard Ass'y 6" Lg. 10067 US
43 1 Thrust Bearing 7" O.D. 4" I.D. 1 3/4" High, 70023 US
44 1 Oil Seal 8" O.D., 7" I.D. 5/8" Thk. 80115 US
45 1 Lock Pin Rolled, 3/8" Dia. 4 1/2" Lg. 60012 US
46 1 Stinger Nut 60-80 Ton (7" O.D. 4"-8UN Thread, 4" Lg.) TA1046N US
47 1 Cross Brace 8" x 8" x 1" Angle, TA3137N
48 1 Locking Bar Flat Bar. TA3138N
50 1 Tag Nameplate, Rating and Capacity TH5014N
Boom Sections
Overhaul Ball
Headache Ball
Hook
Bill Of Material
J ob No.:
P/N #
Qty.
Item Name
Description/Notes
Component
40'
10'
Block
20' " S" Series
Load Block
Hook
Nut & Bearing
Misc.
Sheaves
4527 Page: 11 Rev.: 1
1 1 Boom Butt Access Walkway S90 Series TL7170N
2 1 Deflector Plate Blocks Gap Betw'n BoomButt and BoomStraight Platforms, "Wings" Sty TL9187N
3 6 Toe Plate Brace 4" x 4" Angle, 2" Lg. TL9159N
4 15 J -Bolt For 2" Phenolic Grating, 5/16" Dia. 5 3/8" Lg. TL9153N
5 19 Grating Clip 1 3/4" x 2", 1/4" Thk. Washer TL9173N
6 23 Bolt-On Clip 2 Holes, 3 1/4" x 1 1/8", 1/2" Thk. Bracket TL9152N
7 1 Boom Access Ladder FromEngine House Platform TL7181N
8 1 Ladder Guard Blocks Gap Next To Ladder TL9185N
9 1 Front Platform Guard Blocks Gap to Eng. House Platform TL9172N
10 2 Access Ladder Upper Bracket BoomAccess Ladder TL9186N
11 1 8" Walkway Access Step BoomButt to BoomStraight Step-up TL9175N
12 1 Grating 2" I-Bar, 3'-1" x 20' Lg. 95020 STOCK
13 1 Installation Kit Bolted BoomWalkway TL9184N
Installation 14 2 Bolt-On Clip 2 Holes, 3 1/4" x 1 1/8", 1/2" Thk. Bracket TL9152N
Kit 15 4 J -Bolt For 2" Phenolic Grating, 5/16" Dia. 5 3/8" Lg. TL9153N
16 1 Toe Plate 4" x 4" Angle, 2" Lg. TL9159N
18 1 Magnetic Level 1 5/8"x5/8", 9" Lg. 20250
19 1 20' Boom Walkway Ass'y Bolted Style TL7163N
20 4 Support Rail Bolted BoomWalkway, "L" Shape TL9158N
21 2 Hand Rail Bolted BoomWalkway, 20' Segment TL9160N
22 1 Toe Plate Bolted BoomWalkway, 20' Segment TL9161N
27 1 Grating 2" I-Bar, 1'-7" x 20' Lg. 95019
28 2 End Walkway Ass'y, 40' Boom Point Bolted Style TL7161N
35 1 Grating 2" I-Bar, 1'-7" x 20' Lg. 95019
36 1 10' Boom Walkway Ass'y Bolted Style TL7177N
38 2 Hand Rail Bolted BoomWalkway, 10' Segment TL9179N
39 1 Toe Plate Bolted BoomWalkway, 10' Segment TL9161N
42 6 J -Bolt For 2" Grating, 5/16" Dia. 5 3/8" Lg. TL9153N
44 0.5 Grating 2" I-Bar, 3'-1" x 20' Lg. 95020
45 1 Bolted J ib Access Platform S90 BoomTip TL7173N
46 1 Boom Tip Walkaround Weldment S72 Series TL7176N
47 4 Handrail Mount Bolted Platform, 4" Sq. Tube J ib Walkaround TL9166N
48 2 Connection Plate 3 3/4"x9", 1/2" Thk. For 4" Sq. Tube J ib Walkaround TL9167N
49 2 Long Support Rail J ib Walkaround Walkway, "L" Shape TL9176N
50 4 Support Rail J ib Walkaround Walkway, "L" Shape TL9163N
51 2 Rail Brace J ib Walkaround Walkway TL9164N
52 2 Short Rail Brace J ib Walkaround Walkway TL9165N
57 24 Connection Clip 1 1/2" x 1 1/2" Angle, 1" Lg. TL9177N
58 2 Grating 2" I-Bar, 3'-1" x 20' Lg. 95020
59 1 Boom Tip Access Ladder 9'-7" Lg. TL7167N
60 2 Lanyard 6' Lg. Shock Absorbing, Personal Harness 95028
61 1 Label Kit Safety Glide Ass'y 95029
62 1 Tool Kit Safety Glide Ass'y 95030
63 1 Glide Cable Ass'y 180' Lg, Boom 95049
64 1 Termination Swegeless, Safety Glide Ass'y 95032
65 4 Bracket Intermediate, Safety Glide Ass'y 95033
66 2 Roller Detachable Link "D" Ring Type, Safety Glide Ass'y 95035
67 2 Harness Delta Type, Safety Glide Ass'y 95036
68 2 Swageless Terrmination Brackt TA9043N
69 1 Termination Toggle-Toggle Tensioner, Safety Glide Ass'y 95037
70 4 Walkway Support Bracket S72 series (6x6 Tubing BoomCord) TL9131N
Bill Of Material
J ob No.:
Component #
Qty.
Item Name P/N
Safety Harness
Boom Walkway
Description/Notes
20' Segment
40' Segment
Boom Tip
Boom Butt
10' Segment
4527 Page: 12 Rev.: 1
1 1 Lower Landing S90 R.H. TG4084R
3 1 Lower Landing Guard Ass'y S90 Series TG1028N
4 2 Ladder Guard Brace Flat Bracket TG9206N
5 1 Horizontal Connection Brace Angled Bracket TG9209N
6 2 Lower Platform Guard 3'-0", Three Bars ("W" shape) TG9199N
7 1 Lower Platform,Upper Vertical ladder Guard 1'-1", Two Bars ("U" shape) TG9200N
8 16 Spacer 3/8" Thk. TG9202N
10 1 Upper Landing S90 Series TG4083R
Main 13 1 Main Vertical Ladder S9028 Series TG5127R
Gantry 14 1 Gantry Ladder S90 Series TG5126N
Access 15 1 Access Ladder 4527Y
16 1 Main Hoist Wire Rope 1 1/8" (28mm)Dia. (See Rope Purchasing Spec.) CH1125
17 1 Aux. Hoist Wire Rope 1 1/8" (28mm)Dia. (See Rope Purchasing Spec.) CH1125
18 1 Boom Hoist Wire Rope 1 1/8" (28mm)Dia. (See Rope Purchasing Spec.) BL1125
19 2 Wedge Socket 1 1/8" Dia. Rope BoomHoist 10018
20 1 Retaining Pin BoomHoist Wedge Socket, 2 1/4" Dia. 8.4" Lg. TA2061N-11 US
21 1 Wedge Socket 1 1/8" Dia. Rope Main Hoist 10018
22 1 Lower Bearing Shoe Set S90 Series TF8034N
23 12 Lower Shoe Support S72/S90 Series TF8032N
24 12 Lower Bearing Shoe Nylon Shoe, 72/80 Series TF8027N
25 4 Spacer Rear Lower Shoe Support (1/4" Thk, 3" x 3" Angle) TF8033N
26 12 Retaining Pin Lower Shoe, 3/4" Dia. 2 3/4" Lg. TF1002-5N US
27 12 Hair Pin 1/8" Dia. 2 9/16" Lg. St. Steel 60038
29 48 Self Tapping Screw #14 x 1 1/4" Lg. 60009
30 4 Upper Bearing Retainer S90 Series TF7046N
31 1 Drain Pan Bolted On Kingpost, Below Bull Gear TP3036N
32 3 Pinion Gear Cover TF9007N
33 1 3 Ton Maintenance J ib S72 Series TG9130N
33 2 Bearing 2 1/2" O.D., 2" I.D., 1 1/2" Lg., Plastic 70003 US
34 1 1 Ton Maintenance J ib 7'-0" Arm, Gantry Top TG9133N
35 2 Link Plate For 1 1/8" (28mm) Rope TA5050N
36 1 Retaining Pin Dead End to Link Plates Pin, 2 3/8" Dia. 7.4" Lg. TA2061N-13 US
37 1 Retaining Pin Link Plates To Sensor Pin, 2 1/4" Dia. 7.4" Lg. TA2061N-10 US
38 1 Retaining Pin Sensor To Rope Socket Pin, 2 1/4" Dia. 8.4" Lg. TA2061N-11 US
Ladders
Rope Termination
Jibs
Mipeg Load Ind.
Wire Rope
Lower Bearing
Misc.
P/N
Lower
Landings
Upper
Loose Gear
Bill Of Material
J ob No.:
Component #
Qty.
Item Name
Description/Notes
A B C D
3.1 1 Hydraulic Oil Tank S72 Series, 300 Gal. TC6048N
4 Pad Eye #14, 1 1/4" I.D., 2 1/4" O.D. 316 Ss.Steel 10090
7 Half Coupling 2" SAE O-Ring Female Boss Port 40314 US
3.2 6 Diffuser 2" NPTF Port 40241 US
3.3 4 Check Valve In-Line, 2" NPTF, Ball Cone- 0.5 PSI Spring Loaded 40388 US
3.4 2 Check Valve In-Line, 2" NPTF, 65 PSI Cracking Pressure 40368 US
3.5 1 Suction Strainer 2" NPTF Port 40243 US
3.6 1 Clean Oil Chamber Cover TC6013N
3.7 1 Clean Oil Chamber Cover Gasket For Filtered Oil Chamber Cover TC9040N
3.8 1 Filler Cap With a Splash Guard TC9008N US
1 Pipe Cap 3", 150#, 316 St. Steel 90110
3.9 1 Oil Tank Lid TC6012N
3.10 1 Oil Tank Lid Gasket TU7034N
3.11 2 Suction Strainer 6" NPTF Port 40021 US
3.12 1 Ball Valve 1" NPTF Ports 40062 US
3.13 3 Butterfly Valve 4" Dia., Suction Shutoff 40180 US
3.14 1 Ball Valve 2" NPTF Ports, Suction Shutoff 40443 US
3.15 2 Modified Elbow 1 1/2" Elbow with 1/4" SAE Female O-Ring Boss Tapping Port TC5205N US
1 Elbow 1 1/2" SAE Male Boss-Female J IC 24FB-24MJ -90 *US
3.16 1 Suction Hose Ass'y Slew and Oil Conditioniong Pump Suction Hose TC6017N
1 Hose 4" Corrogated Hose, 52" Lg. 90135
1 Flange 4" 150# Lap J oint Flange 90136
1 Nipple 4" Floating Nipple 90137
1 Combination Nipple 4" Beveled End 90138
2 Ferrule 4" Crimp Ferrule 90139
1 Pipe Reducer 4" to 3" Sched. 40 Pipe Reducer 90048
1 Pipe Elbow 3" Sched. 40 Short 90 Deg. Elbow 90140
1 Flange 3" SAE 4 Bolts Code 61 Flat Socket Pipe Flange (With 80087 O-Ring) 90131
2 Half Coupling 1/2" SAE Female O-Ring Boss Port 40276
2 Plug 1/2" Male, Hex. Socket Head SAE O-Ring Boss Plug 8MB-H
3.17 1 Suction Hose Ass'y Load Hoist Pump Suction Hose TC6019N
1 Flange 4" 150# Floating Flange 90136
3.18 1 Suction Hose Ass'y Boom Hoist Pump Suction Hose TC6018N
1 Flange 4" 150# Floating Flange 90136
3.19 1 Check Valve In-Line, 1 1/2" SAE O-Ring Boss Port, 65 PSI Cracking Pressure 40097 US
3.20 1 Piston Pump Var. Disp. ADU Type, 62cc/Rev. Max. Disp. 40581 US
3.21 2 Piston Pump Var. Disp. Open loop, AA11VLO Type, 260cc, Boom and Load Hoists 40387 US
3.22 1 Pump, Vane Type Fixed Disp. VMQ145 Type, 180cc/Rev. 40344 US
3.23 1 Filter Ass'y 2" SAE Code 61 4 Bolts Flange Ports With 40133 Element 40585 US
3.24 1 Check Valve In-Line, 1 1/2" SAE Female O-Ring Boss Ports, 5 PSI Cracking Pressure 40207 US
3.25 3 Manifold (6) 16FB, (1) 32MBA Ports. TC5109N
6 Half Coupling 1" SAE Female O-Ring Boss Port 40280
1 O-Ring 2 1/2" O.D., 1/8" C.S. 80099
3.26 1 Oil Cooler Oil to Air Heat Exhanger, 62"x67" 40403 US
3.27 1 Test Port 1/2" SAE Male O-Ring Boss Port 40423 US
3.29 1 Flange 2" 4 Bolts SAE 518, Code 61 90053 US
3.30 1 Hyd. Starter Systyem Starter Motor, Hand Pump, Accumulators 50089 US
Component Item
Machinery
House
Qty.
Item Name P/N
Description/Notes
(Dimensions are approx. - Given for ease of identification)
A B C D
4.1 1 Pressure relief Valve Flange Mount, In-Line, 3/4" Ports. 40569 US
4.2 1 Manifold Pilot Pressure - Includes Motors Cooling Lines Orifices TC5191R US
4.3 6 Test Ports 3/8" SAE Male Boss Port 40425 *US
4.4 1 Manifold (7)12FB, 24FB Ports TC5139N US
7 Half Coupling 3/4" SAE Female O-Ring Boss Port 40278 *US
1 Half Coupling 1 1/2" SAE Female O-Ring Boss Port 40282 *US
4.5 4 Shuttle Valve Pump Command Signal valves 40094 US
4.6 1 D.C.Valve 4 Way, 3 Pos., Single Spool, 1MO32 Type 40371 US
4.7 2 Pressure Relief Valve "Pump in Neutral" Back Up Pressure Valve, DBD Type 40399 US
4.8 2 Adapter 1 1/4" SAE 518 4 Bolts, Code 62 to 1" SAE O-Ring Boss Port TC5140N US
1 Flange 1 1/4" SAE 518 4 Bolts, Code 62, Blanking Flange (With 80054 O-Ring) 90056 *US
4.9 3 Flange 1 1/2" SAE 518 4 Bolts, Code 61 (With 80085 O-Ring) 90068 US
4.11 3 Brake Release Valve TC3060N US
1 Spool TC3014-4N *US
1 Housing TC3059N *US
1 Spring Retainer TC3062N *US
1 Adapter TC3063N *US
1 Outer Sleeve TC3198N *US
1 Inner Sleeve TC3199N *US
1 Spring Helical Compression, 1 1/4" O.D., 3" Free Lg. 20257 *US
1 Screw 5/16-8UNC, 4" Lg. Socket Head Cap Screw 60075 *US
1 Washer 5/16" Type "A", Narrow Washer 60076 *US
1 O-Ring 1 3/4" O.D., 1/8" C.S. 80053 *US
1 Adapter 1" Male to 1/2" Female SAE O-Ring Boss Ports, 6KPSI Rated 40197 *US
1 Reducer 1 1/4" Male to 3/4" Female SAE O-Ring Boss Ports 12FBR-20MB *US
1 Plug 1/4" Male, Hex. Socket Head SAE O-Ring Boss Plug 4MB-H *US
4.13 1 D.C.Valve 4 Way, 3 Pos., Dual Spool, 2MO32 Type 40372 US
4.14 3 Adapter Elevetad Discharge Port TC5213N US
1 O-Ring 1 3/4" O.D., 1/8" C.S. 80054 *US
4.15 1 D.C.Valve 4 Way, 3 Pos., Single Spool, D85 Type 40004 US
4.16 2 Test Point 1/4" NPT Male Port 40422 US
4.17 2 Filter Ass'y High Pessure, 1 1/2" 4 Bolts SAE Code 62 Flange Ports, With 40309 Element 40577 US
4.19 1 Filter ass'y 1" SAE Female O-Ring Ports, With 40135 Element 40587 US
4.20 1 Solenoid Valve Block 2 Way 4 Pos. 24VDC, 3/8" Female SAE O-Ring Boss Ports TC3191N-7 US
1 Solenoid Valve Ass'y 8 Valves, 24VDC Coils TC3193N-7 *US
4 Dual Valve Housing TC3178N *US
5 O-Ring 80143 *US
8 Solenoid Valve 40565 *US
1 End Block TC3189N *US
2 End Plate and Bracket TC3190N *US
2 Threaded Rod 3/8-16 All-Thread, 16 5/8" Lg. ( - )
4.21 3 Ball Valve 3 Ways, Lockable Handle, 3/4" SAE Boss Ports, 6,000 PSI 40526 US
Valve Board
Component Item
Qty.
Item Name P/N
Description/Notes
A B C D
5.1 1 Motor, Piston Type Fix. Disp., AA2FM Type, 160cc/Rev. Built-In Motor Control Valve 40410 US
5.2 1 Brake Actuator Fail Safe, 500 Series TB4122N PART US
1 Spring Cylinder 8 1/4" O.D., 7 3/7" I.D., 15 1/8" Lg. TB4079N
1 Bottom Plate 10 1/2" Lg. 8 1/4" Wide, 1/2" Thk. TB4081N
1 Spring Retainer 7 5/8" Dia., 3" Tall TB4082N
1 Brake Rod 1" Dia. 27 1/2" Lg. TB4083N
1 Spring Retaining Ring ass'y 2 Halves, 1 1/8" O.D. TB4084N US
1 O-Ring 13/16" O.D., 1/16" C.S. 80072 *US
1 Cylinder 5 1/2" O.D., 3 1/2" I.D., 10 3/4" Lg. TB4123N
1 Piston 3 1/2" Dia. 3 3/8" Lg. TB4124N
1 Top Plate 10 1/2" Lg. 8 1/4" Wide, 1 3/4" Thk. TB4125N
1 Cylinder Cap 6 3/8" x 6 3/8", 1 1/2" Thk. TB4126N
1 Bearing Housing 5 1/4" Dia. 2" Tall , Bronze TB4127N
1 Spring Helical Compression, 5 1/2" O.D., 18 1/2" Free Lg. TH6001N US
2 Bolt 5/8-11NC, 22 1/2" Lg. Gr.5 Hex.Hd Cap Screw 60095 US
2 LockWasher 5/8" Lock Washer 60096 US
2 O-Ring 4" O.D., 1/8" C.S. 80052 US
1 Seal Polypack 3 1/2" O.D. 1/2" Deep 80126 US
4 Bolt 7/8-9NC, 13 1/2" Lg Gr.8. Hex.Hd Cap Screw 60121 US
1 Bearing 1 1/4" O.D. 1" I.D., 1/2" Lg. Plastic Bushing 70001 US
1 Rolled Pin 1/8" Dia. 2" Lg. 60004 US
1 Bearing 1 1/4" O.D. 1" I.D., 1" Lg. Plastic Bushing 70005 US
4 LockWasher 7/8" Lockwasher 60097 US
5.3 1 Orifice TC1014N US
1 Seal Eolastic Seal 80139 *US
6.1 1 D.C.Valve 3 Way, 2 Pos. Foot Operated, Manually Reset 40258 US
6.2 1 Ball Valve 3 Way, 2 Pos. Slew Parking Brake Valve 40034 US
6.3 1 J oystick Ass'y Dual Axis, Single Lever 40437 US
6.4 1 J oystick Ass'y Single Axis, Dual Lever TC3075N US
2 J oystick Ass'y Single Axis, Single Lever 40436 US
1 Adapter J oystick Ports Adapter TC3068N US
4 O-Ring Metric (11/16" O.D., 1/16" C.S.) 80066 US
6.5 2 Manifold (4)6FB, (8)8FB, (2)12FB Ports TC5095N US
6.6 2 Pressure gage 0-10,000 PSI, Glycerine filled, Stainless Case, 1/4" NPT Port 40158 US
6.9 1 D.C.Valve 3 Way, 2 Pos. Manual 40103 US
6.10 1 ERD Valve Box Ass'y TC3180N US
1 ERD Valve Box TC3179N US
1 SC Box 6 1/4" x 6 1/4" x 8 1/4" , Screw Cover Fiberglass Box 40539 US
1 Valve Assy TC3089N US
1 D.C.Valve 3 Way, 2 Pos. Manual 40248 US
1 Bracket 3"x3" Angle, 3" Lg. TC3091N US
1 Plackard ERD Placard, St. Steel, Colored TH5038N US
3 Connector 1/2" SAE Adjustable Male O-ring to J IC Male ports, 45 Deg. Elbow, 8MBA-8MJ -45 US
6.11 1 Pedal Valve Slew Brake Pedal 40015 US
7.1 2 Motor, Gear Type Fix. Disp., WM51 Type, 1 1/2" Gear 40113 US
7.2 2 CrossOver Relief Valve Ass'y TC3020N US
1 Valve Housing TC3019N US
2 Reliefe Valve Cartridge Type 40069 US
2 O-Ring 1 1/8" O.D. 1/8" C.S. 80060 US
2 Plug 3/4" SAE Male O-Ring Boss, Hex. Socket Head Plug 12MBH US
7.3 2 Brake Ass'y Fail Safe, Wet type, SAE "C" Mounts 40116 US
7.4 1 Manifold 16FB,(4)8FB TC5098N
1 Half Coupling 1" SAE Female O-Ring Boss Port 40280
7.5 1 Boom Limit Valve Ass'y TC3142N PART US
1 Boom Kickout Valve Ass'y TC3135N US
1 Housing TC3136N *US
2 Sleeve TC3131N *US
2 Plug TC3132N *US
2 Plunger TC3137N *US
2 Spring Helical Compression, 1 1/4" O.D., 3" Free Lg. 20180 *US
2 O-Ring 1 1/4" O.D., 1/8" C.S. 80095 *US
6 O-Ring 1 3/4" O.D., 0.1" C.S. 80122 *US
2 O-Ring 1" O.D., 0.1" C.S. 80123 *US
2 Plug 3/8" SAE Male O-Ring Boss, Hex. Socket Head Plug 6MB-H *US
Slew
Cab
Boom Hoist
Component Item
Qty.
Item Name P/N
Description/Notes
A B C D
1 Cover Weldment TC3141N
1 Cam "Down" Side Cam TC3127N
1 Cam "UP" Side Cam TC3128N
1 Pawl Boom Kickout Lever TF2020N
1 Radial Thrust Bearing TC9022N
1 Spacer TC9023N
1 Mounting Plate TF1026N
4 Elbow 3/8" SAE Male O-Ring Adjustable Boss to Male J IC Ports, 90 Deg. 6MBA-6MJ -90 US
1 Adapter 3/8" SAE Male O-Ring Boss to Male J IC Ports 6MB-6MJ US
1 Elbow 3/8" SAE Female J IC to Male J IC Ports, 90 Deg. 6FJ -6MJ -90 US
8.1 2 Motor, Piston Type Fix. Disp., AA2FM Type, 160cc/Rev. Built-In Motor Control Valve 40410 US
8.2 2 Orifice Ass'y Use with 80139 Eolastic Seal TC1014N US
1 Seal Eolastic Seal 80139 *US
8.3 2 ERD Valve Ass'y TC3184N US
1 ERD Valve Body TC3185N *US
1 Pressure Relief Valve Cartridge Valve 40073 *US
1 O-Ring 9/16" O.D., 1/8" C.S. 80138 *US
1 Diverter Valve Cartridge Valve 40530 *US
2 Plug TC5202N *US
2 O-Ring 1 3/4" O.D., 1/8" C.S. 80097 *US
2 O-Ring 1 3/4" O.D., 1/8" C.S. 80102 *US
2 Adapter 3/8" SAE Male O-Ring Boss to Male J IC Ports 6MB-6MJ *US
2 Adapter 3/4" SAE Male O-Ring Boss to Male J IC Ports 12MB-12MJ *US
4 Plug 3/8" SAE Male O-Ring Boss, Hex. Socket Head Plug 6MB-H *US
12 Screw M14, 8 3/8" (213mm) Lg. Gr. 5, Hex. Socket Head Cap Screw 60191 *US
4 Screw M6, 4" (100mm)Lg. Gr. 5, Hex. Socket Head Cap Screw 60192 *US
8.4 2 Brake Actuator Fail Safe, 500 Series TB4122N
1 Spring Cylinder 8 1/4" O.D., 7 3/7" I.D., 15 1/8" Lg. TB4079N
1 Bottom Plate 10 1/2" Lg. 8 1/4" Wide, 1/2" Thk. TB4081N
1 Spring Retainer 7 5/8" Dia., 3" Tall TB4082N
1 Brake Rod 1" Dia. 27 1/2" Lg. TB4083N
1 Spring Retaining Ring ass'y 2 Halves, 1 1/8" O.D. TB4084N US
1 O-Ring 13/16" O.D., 1/16" C.S. 80072 *US
1 Cylinder 5 1/2" O.D., 3 1/2" I.D., 10 3/4" Lg. TB4123N
1 Piston 3 1/2" Dia. 3 3/8" Lg. TB4124N
1 Top Plate 10 1/2" Lg. 8 1/4" Wide, 1 3/4" Thk. TB4125N
1 Cylinder Cap 6 3/8" x 6 3/8", 1 1/2" Thk. TB4126N
1 Bearing Housing 5 1/4" Dia. 2" Tall , Bronze TB4127N
2 Bolt 5/8-11NC, 22 1/2" Lg. Gr.5 Hex.Hd Cap Screw 60095 US
2 LockWasher 5/8" Lock Washer 60096 US
2 O-Ring 4" O.D., 1/8" C.S. 80052 US
4 Bolt 7/8-9NC, 13 1/2" Lg Gr.8. Hex.Hd Cap Screw 60121 US
1 Bearing 1 1/4" O.D. 1" I.D., 1/2" Lg. Plastic Bushing 70001 US
1 Rolled Pin 1/8" Dia. 2" Lg. 60004 US
1 Bearing 1 1/4" O.D. 1" I.D., 1" Lg. Plastic Bushing 70005 US
4 LockWasher 7/8" Lockwasher 60097 US
8.5 2 Manifold 16FB, (4)12FB Ports TC5138N US
4 Half Coupling 3/4" SAE Female O-Ring Boss Port 40278 *US
1 Half Coupling 1" SAE Female O-Ring Boss Port 40280 *US
Component Item
Qty. Description/Notes
Load Hoist
Item Name P/N
Slew (Cont.)

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K2 Air Conditioner (Friedrich) Class 1 Div 2

920-024-05 (12-04)
920-024-05 (12-04)
General Instructions ............................................................................................................................................................................ 3
Filter Information ................................................................................................................................................................................ 4
Maintenance Checklist. ....................................................................................................................................................................... 4
Special Features........................................................................................................................ .......................................................... 5
Control Panel ..................................................................................................................................... ............................................ .... 6
Underwriters Laboratories .................................................................................................................................................................. 6
Electrical Requirements.................................................................................................................. ................................................... 7
Unpacking the Unit ............................................................................................................................................................................. 9
Chassis Wiring and Preparation....................................................................................................................... ................................. 9
Shell Preparation .............................................................................................................................................................................. 10
Shell Installation................................................................................................................... ............................................................. 11
Sash Window...... ........ ................ ........ ........ ................ .......... ....... ....... ........ ........... ...................................................... ....... ...... 11
Through-the-Wall ........................................................................................................................................................................ 14
Chassis Installation ............................................................................................................................................................................ 17
WARRANTY ................................................................................................................................................................................... 19
2
920-024-05 (12-04)
Your new Friedrich has been carefully engineered and manufactured to give you many years of dependable, efficient operation, main-
taining a comfortable temperature and humidity level. Many extra features have been built into your unit to assure quiet operation, the
greatest circulation of cool, dry air, and the most economic operation.
Here are some to you use your new Friedrich most eUjicientl:y:
1. Carefully read and follow the installation instructions.
2. Your Friedrich Hazardgard room air conditioner is electri-
cally grounded for your safety. The power supply must
also be grounded and must be installed in accordance with
NEC Article 501. The branch circuit rating is shown on
the nameplate for each model.
3. Make sure the unit is the right capacity for the area to be
cooled. Too little capacity makes the unit work too hard,
using more electricity than needed and increasing wear.
Too much capacity is also hard on the unit as it will cycle on
and off too rapidly, and cannot control humidity as well.
4. When you first tum on your Friedrich, set the thermostat
to its coldest position to cool the room. When the desired
temperature is reached, tum the thermostat control to-
ward the "warmer" position until you hear a click and the
compressor goes off. The thermostat will then cycle the
compressor to maintain the selected temperature.
5. Clean the filter frequently (See General Maintenance).
6. Do not block the air flow to and from the unit. Make sure
the louvers are directed to give even distribution of air
throughout the room. Caution: If air is directed into a
restricted area such as behind a bed or into a comer, this
may cause the unit to cycle on and off rapidly, which could
damage your unit.
7. A dirty filter or improperly set controls can affect the cool-
ing ability of the unit.
8. If cooling is weak and you have verified that the filter is
clean and the controls are properly set, the unit may be low
on refrigerant, and you should call your Friedrich service
provider to check the unit.
9. Keep blinds, shades and drapes closed on the sunny side
of the room being cooled.
10. Proper insulation helps your unit maintain the desired inside
temperature.
11. Whenever possible, shade west-facing windows with aw-
nings.
12. Keep window coverings away from the unit to provide free
air flow.
3
920-024-05 (12-04)
The filter in your Friedrich removes dust, pollen and other
impurities from the air as they are drawn through the unit.
The filter is permanent and reusable, and has a germicidal
treatment which is not affected by washing.
A clogged, dirty filter reduces the air flow through the unit and
reduces its efficiency. You should check the filter every seven
to ten days, depending on the amount your unit is used. Clean
the filter regularly.
FilTER RETAINER CLIPS
The filter can be removed for cleaning by opening the front of
the unit and releasing the filter from its retaining clips.
If the unit operates, but doesn't cool, check to see that the con-
trols are properly set. Inspect the filter and clean it thoroughly, if
needed. Check to see if the chassis seal is installed
to installation instructions).
If the unit does not operate at all, check that the power supply
connections are tight. Check for blown fuses or tripped circuit
breakers. Replace blown fuses with the proper size time-delay
fuse. The nameplate on the unit shows the proper fuse size. After
restoring power, wait three minutes before restarting the unit.
Your Friedrich Hazardgard is designed not to freeze with outdoor
temperatures as low as 45F OC). Freezing should only occur
when the outside air is damp and below 45F OC). If the indoor
4
coil should ice over while cooling, set the thermostat to the warm-
est position until the ice on the coil is gone. Setting the thermostat
to a slightly warmer position will probably keep ice from forming
on the coil. A dirty filter will contribute to icing.
The front grille of your Friedrich, as well as the complete cabi-
net may be cleaned with warm water and a mild detergent. The
coils and base pan should be cleaned periodically for the most
efficient operation. We suggest you call your Friedrich dealer
for this service.
Fan motors are factory lubricated and sealed. No lubrication
is required.
920-024-05 (12-04)
Permanent Split-Capacitor, totally enclosed fan motor to
assure efficient operation even under adverse electrical
conditions. Motor has a special stainless steel shaft to resist
corrosion and a hermetically sealed overload for arc-free
operation.
capacity compressor with internal hermetically sealed
overload.
Solid-state printed circuit board insulated against corrosion
on conductor paths. Contains transient voltage suppressor
to protect controls against transient voltage spikes. Provides
solid state switches for arc-free operation.
Hot gas bypass low ambient control to permit operation
without freezing at outdoor ambient temperatures as low
as 45F (70C).
Environmentally sealed on-off switch and gold plated
contacts in thermostat for corrosion resistance.
Electrodeposited epoxy primer and alkyd enamel, both
oven-baked for an attractive, long-lasting finish.
o Copper tubing/aluminum fin coils.
o Galvanized steel cabinet and base pan, all bonderized.
Slide-out chassis for easy installation in window or
through-the-wall.
o Extra insulation inside, including completely insulated
plenum chamber for quieter, more efficient cooling.
Entire unit test run in environmental chamber before
crating.
Eight-way air flow control for uniform air circulation.
Patented electronic control circuit.
9 Condensate drain with exclusive mosquito trap.
15 amp circuit with time-delay fuse required. Accommodates
direct wiring.
Long lasting 3/8" (10 mm) thick air filter, )';"'UH'''''''''-U)'
treated, easily removed for cleaning.
Friedrich Air has been proven more than 25 years of successful V 1 ~ ' ; ' ' ' from the Gulf of Mexico to
the sands of the Arabian desert,
This switch is a double pole, single throw toggle switch.
ON - Turns everything on.
OFF - Turns everything off.
The knob at the bottom is the thermostat which is a cross ambient
type used to maintain the desired comfort level. The thermostat
reacts only to a change in temperature at the bulb location - turn
the knob clockwise to set counterclockwise for warmer.
Friedrich leads with the first UL Listed Room Air Conditioners
designed to cool living quarters and other enclosures situated in
hazardous locations where specific volatile flammable liquids or
gases are handled or used with enclosed containers or systems.
Friedrich Hazardgard room air conditioners are designed to
meet the National Electrical Code, Article 500 requirements
for Class I, Division 2, Groups B, C, D Hazardous locations,
and are the only air conditioners UL Listed for this application.
THIS UNIT IS LISTED BY UNDERWRITERS LABORA-
TORIES FOR USE IN CLASS I, DIVISION 2, GROUPS
B, C, D HAZARDOUS LOCATIONS. Operating Temperature
Code: T3B.
100M AIR COIIIOmOIi!EI
fOI 1IIIIIIAWt00US UlCATlOIiS
CUSS OMSIOIII 2, IIIfUIUPS A, I, 0
Wl'i"II\lli.illliIiIl; iEMPEUTlJRE CODE:
iMtll!lUli:
THIS EQUIPMEIT MIIST IISTAl.lED !'ER IIIATlIlIAl
EtECTlUC CODE (III",A 70, AImCtE 501
Off ON
5
920-024-05 (12-04)
NOTE: THIS MANUAL INCLUDES INSTALLATION INSTRUCTIONS FOR BOTH WINDOW MOUNT AND THROUGH-
THE-WALL INSTALLATIONS
ALL FIELD WIRING MUST MEET THE REQUIREMENTS OF THE NATIONAL ELECTRICAL CODE (ANSIINFPA 70)
ARTICLE 501.
THE FIELD-PROVIDED CIRCUIT PROTECTION DEVICE (HACR CIRCUIT BREAKER OR TIME DELAY FUSE) MUST
NOT EXCEED THE AMPACITY INDICATED ON THE PRODUCT NAMEPLATE.
IMPORTANT: Before you begin the actual installation of your air conditioner, check local electrical codes and the information
below.
Your air conditioner must be connected to a power supply with the same A.C voltage and frequency (hertz) as marked on the data
plate located on the chassis. Only alternating current CA.C), no direct current (nC), can be used.
An overloaded circuit will invariably cause malfunction or failure of the air conditioner; therefore, it is extremely important that the
electrical power is adequate. Consult your dealer or power company if in doubt.
The following instructions are for HAZARDGARD models and cabinet sizes listed below.
GROUPS CABINET SIZE (H x W x D)
SMALL CHASSIS SH15
15 15/
16
" x 25 15/
16
" x 27 3ia"
(405 mm x 660 mm x 695 mm)
MEDIUM CHASSIS SH20
17
15
/ 16" x 25
15
/ 16" x 27
3
/ 8"
(455 mm x 660 mm x 695 mm)
Model Number
Circuit
Time Delay Fuse
SH15 Junction Box 250V-15 Amp
SH20 Junction Box 250V-15 Amp
6
920-024-05 (12-04)
iTEM DESCRIPTION CTY.
No.
SHELL MOUNTING PARTS
1 SUPPORT BRACKET 2
2 SCREW, 10 - 24 x 1" HEX HEAD 4
3 10 - 24 FLAT WELDNUT 4
4 SCREW, SHEET METAL #12A x 2" 7
WINGBOARD ANGLE MOUNTING
5 WINGBOARD ANGLE, TOP 1
6 WINGBOARD ANGLE, SIDE 2
7 SCREW, SHEET METAL #8A x 3/8" 2
WINGBOARD MOUNTING PARTS
8 WINGBOARD (MASONITE) - (NOT SHOWN) 1
ITEM #2 ITEM #3
9 "J" TYPE SPEED NUT 4
10 WINGBOARD CLIP (SPRING STEEL) 4
11 SCREW. #8A x 1/2" PHILLIPS TRUSS HD. 4
WINDOW SEALING
12 SEALING GASKET (VINYL) 1
ITEM #4
13 WINDOW SEAL GASKET (DARK FOAM) 1
14 CHASSIS SEAL GASKET (LIGHT FOAM) 1
ITEM #7 ITEM#9 ITEM # 11
ITEM #10
ITEM # 13
ITEM # 14
---ITEM#12
ITEM # 1
NOT TO SCALE
7
8
1
2
920-024-05 (12-04)
Remove decorative retum air to a safe area away from the unit.
Remove the installation wlllgo
l
oalra and two light colored and one dark colored) gaskets from beneath the
unit, and place them in a safe area away from unit.
Remove the chassis retainer by rf'n,(1vtn
chassis retainer after installation
at the rear of the unit.
screw in the (see Figure A); save this screw to reattach the
Also. remove and discard the two retainer screws and plastic bushings located
4 While an assistant holds the cabinet use the hand at the front of the base pan (see Figure A) to pull the
chassis out of the cabinet. Remove white foam blocks used to restrain the compressor during shipment Inspect basepan
2
for dislodged white and remove. Do not remove any other foam.
HAND
Remove
black wires only, ap]:.rmam.ately
Insert all wires (2
clockwise until the mnr'nr" ..
sure that the shell can
0HLPP'HF, pm;mc.n undemeath the fan motor. Install one
11H,rtu-m box.
~ V U V H connector on the side of the control compmtment. Strip the
the box onto the conduit connector until tight. Back off counter
at the facing the box opening. Be
FRIEDRICH PN: 613-893-00
INC. PN: 5324-0
613-892-00
5173-0
920-024-05 (12-04)
It will be necessary to relocate the sill plate of the cabinet 2"
back from its shipping position, and the shell guides 4" forward,
to the forward-most hole in the shell raiL Discard the chassis
retainer wire disconnected in Section Step 3. The junction
box mounting leg from Section VI, Step 1, and the field-installed
conduit will retain the chassis in the shelL
IF THIS INSTALLATION IS FOR A SASH WINDOW - With
the wide flange and pilot holes of the sill plate forward, put the
screws/nuts in the rear holes of the sill plate and third shell hole
from the front (the center of three square holes). Anchor the
side angles (Item #6) by engaging the tabs at each end of the sill
plate with the bottom loops of the side angle. Engage the tabs at
CABINET
SILL PLATE
TURN SILL PLATE
END TO END
CABINET
SCREW
(2 REQUiRED)
NOTE: HOLES
MOVED TO
BACKSIDE
NUT
(2 REQUiRED)
each end of the top angle (Item #5) with the top loops of the side
angle. Install two (2) screws (Item #7) to secure the top angle
tabs and the side angle to the rear-most holes in the side of the
cabinet (See Figure B, below).
IF THIS INSTALLATION IS THROUGH A WALL - Turn
the sill plate end to end so that the wide flange with pilot holes
will be over the wall header (towards the rear) and two inches
from the front of the cabinet. Bend the tabs into the channel
of the sill plate, put the screws/nuts in the front holes of the sill
plate and into the second shell hole from the front. Use one bolt
on each side to secure the sill plate to the cabinet. (See Figure
C, below.)
SlDEANGLE
(ITEM #6) 2
REQUIRED
SA X 3/8" LONG SCREW (ITEM #7)
:2 REQUIRED
Detail B2
Position the sill
cabinet with the sill
to the back. the
inches from the front of the
cabinet and secure it with a nut
and bolt in each end.
9
920-024-05
1 Check the window sill and frame to be sure they are in good condition and firmly anchored to the wall. Repair if
necessary.
STEP2 CABINET MOUNTING: Raise the lower window sash 114" more than the height of the cabinet. Carefully slide the cabinet
through the open window until the sill plate channel rests behind the window sill and the top support angle rests against the
window (See Figure D). Center the cabinet side to side and drill three (3) 5/32" dia. pilot holes into the window sill using
the holes in the cabinet sill plate as a guide. Install three (3) #12A x 2" long screws (Item #4) (See Figure D).
CENTER CABINET SiDE TO SIDE iN WINDOW
DRiLL:3 5/32" PILOT HOLES AND INSTALL :3
#12A X 2" LONG SCREWS (ITEM #4)
E
WINDOWSILL
LOCATE THE SILL PLATE GUiDE CHANNEL
JUST BACK OF THE WINDOW SILL.
A 1" X 4" OR 2" X 4" SPACER SHOULD BE USED BE
TWEEN THE WALL AND BRACKET WHEN INSTALLED
ON ALUMiNUM, ASBESTOS OR ViNYL SIDING.
TOP SUPPORT ANGLE
PULL WiNDOW SASH DOWN BEHIND
THE TOP SUPPORT ANGLE
SIDE SUPPORT ANGLE
BRACKET (ITEM #1)
1024 X 1" HEX HEAD SCREW (ITEM #2)
3 OUTSIDE SUPPORT MOUNTING: Assemble the support brackets (Item #1) to the bottom rails of the cabinet with four
(4) 10-24 1" long screws (Item #2) and four (4) 10-24 flat nuts (Item #3). Adjust the support brackets to bring the bottom
pads in contact with the wall surface. (See Figure
A 1" x 4" or 2" x 4" SPACER SHOULD BE USED BETWEEN THE WALL AND THE SUPPORT BRACKETS WHEN
INSTALLED ON ALUMINUM OR VINYL SIDING). Drill 5/32" (4 mm) dia. pilot holes, and secure the brackets to the wall with
two (2) #12A x 2" long screws (Item #4). Adjust the support brackets to provide an approximate 3/8" (10 mm) down slope towards the
outside for drainage. Tighten all screws. (See Figure E).
10
920-024-05 (12-04)
The illustrations below show a standard frame construction installation as well as some suggested ways of adapting the support bracket
to thick walls and large stone ledges.
1
3
10 24SCREW
10 24 FLAT NUT
3/8" (10 MM)
SLOPE DOWN
#12A X 2" SHEET METAL SCREW
1" X 2" OR 2" X 4" SPACER BETWEEN WALL
AND BRACKET SHOULD BE USED ON ALU-
MINUM, ASBESTOS OR VINYL SIDING
r 3/8" (10 MM)

#12A X 2" SHEET METAL SCREW
4
FlF=;:::::,:====:::;:;=== 3/8" (10 MM)
SLOPE DOWN
STONE LEDGE
OUTSIDE WAll
CUT TO FIT DIMENSION "A"
AND BEND DOWN TO FOR A
VERTICAL LEG
;;;:;::::::::;:::::::;;::::::::t 3/8" (10 MM) SLOPE DOWN
t
STRAIGHTEN TAB TO LAY FLAT ALONG
THE BOTTOM RAIL OF THE SHELL.
SECURE THE LONGEST SIDE OF
THE BRACKET TO THE SHELl.
ADJUST IN OR OUT TO
REST ON THE LEDGE
4 CUT WINGBOARD PANELS: Measure and cut the wingboard panels from the supplied masonite (Item #8) to fit the
spaces between the side window channels and the sides of the cabinet (See Figure F).
NOTE: AFTER CUTTING PANELS, MAKE A TRIAL TEST TO SEE IF THEY FIT TIlE SPACE WITH ABOUT
1/8" CLEARANCE BEFORE GOING TO STEP 5.
F
MEASURE DISTANCE "13" TO THE INSIDE
OF THE CHANNEL ON EACH SIDE
CUT HERE AND DISCARD THE CENTER
WASTE MATERIAL
SUBTRACT 1/8" (3 MM) FROM
DIMENSION "13" AND MEASURE FROM
THE EDGE OF THE WINGBOARD (ITEM
# 8), MARK AND CUT WITH A SAW.
11
"J" TYPE SPEED NUT
G 2
CENTER THE HOLE IN THE SPEED NUT OVER
THE SLOT IN THE WING BOARD PANEL
920-024-05 (12-04)
SPRING STEEL CUP (ITEM #10)
2 REQUiRED
CUP OVER CUT EDGE OF WiNGBOARD PANEL
STEPS ASSEMBLE CLIPS TO WINGBOARD PANELS: Assemble "J" type speed nuts (Item #9) and spring steel clips (Item
#10) to the edges of the cut wingboard panels (See Figure G).
SECURE THE SiDE WINGBOARD PANELS TO
THE SIDE ANGLES WiTH FOUR (4) #8 )( 1/2"
LONG SCREWS (ITEM #11), TWO ON EACH SIDE.
PLACE WINGBOARD PANEL IN WINDOW JAM TO
COMPRESS THE SPRINGS INSIDE THE RUNNERS,
AND SWiNG THE PANEL iNTO PLACE iNDICATED
BY THE DOTTED LINE.
\"" VlrINIJIO'W JAM
STEP6 INSTALL SIDE WINGBOARD PANELS: Be sure that the cabinet has been secured to the window sill and the outside
support brackets have been installed as shown in Figures D and E on Page 11. Raise the window sash and install the right
and left side wingboard panels (See Figure H).
7 INSTALL WINDOW SEALING GASKETS: Measure and cut the vinyl window seal gasket (grey color, Item #12) to fit
the width of the window and install as shown in Figure I. Pull the window sash down behind the gasket. Measure and cut
the dark foam window seal gasket (Item #l3) and install it between the upper glass panel and the top part of the lower sash
(See Figure I).
I
VINYL WINDOW SEAL GASKET ITEM #12)
FOAM WiNDOW SEAL GASKET (iTEM '# 13)
LOWER WiNDOW SASH
VINYL WiNDOW SEAL GASKET
TOP WINGBOARD ANGLE
B
NOTE: FOR REASONS OF SECURITY AND SAFETY, THE CUSTOMER MUST PROVIDE A MEANS OF PREVENTING
THE WINDOW FROM OPENING.
8 When possible, caulk the outside of the installation with industrial type caulking to prevent air and water leaks.
12
920-024-05 (12-04)
The maximum wall thickness permissible without special construction is determined by the model size to be installed. THE OUT-
SIDE CABINET CONDENSER AIR INTAKE LOUVERS MUST NOT BE BLOCKED BY EXTENDING INSIDE THE WALL
AREA. Observe the maximum wall thickness shown as dimension ''A:.' in Figure J.
CONDENSER
AiR INTAKE
LOUVERS
TOP VIEW SHOWING BEVELED SIDES
FOR AIR INTAKE. WALL BELOW
UNIT MUST ALSO BE BEVELED TO
ASSURE PROPER TILT ANGLE.
the following suggested construction
r ~ ~ . . CONDENSER AIR
INTAKE LOUVERS
CHECKING WIRING AND PLUMBING: Check all wiring and plumbing inside and outside the wall to be sure none
will be broken where the hole is to be cut.
HOLE CONSTRUCTION: Depending on the size of the unit to be installed, layout the hole dimensions in accordance
with the chart below (See Figure K). Cut and frame in the hole to the finished dimensions. Use
2" x 4" material for framing and follow the suggested typical installations in Figure L, M or N on Page 15.
NOTE: IF THE WALL CONSTRUCTION IS TYPICAL FRAME OR 2 X 4 STUDDING WITH BRICK OR STONE VENEERS,
LOCATE THE HOLE NEXT TO ONE OF THE STUDS. FOR MASONRY, CONCRETE OR CINDER BLOCK WALLS,
LOCATE THE HOLE FOR CONVENIENCE.
FINISHED
DIMENSION
A
SMAll
CHASSIS
16-3/16"
MEDIUM
CHASSIS
18-3/16"
26-3/16"
NOTE: THESE DIMENSIONS ARE FOR FINISHED HOLE
13
FigureL
Figure
Figure
14
CAULK ALL SIDES "' __ _
WEATHER CABINET
CAULK ALL SIDES
CAULK ALL SIDES
CABINET ~
MORTAR
920-024-05
SHIM THE VOID SPACE AT THE TOP AND
SIDES WITH WOOD AS REQUIRED
SHIM VOID SPACES AT TOP AND
SIDES WITH WOOD AS REQUIRED
920-024-05 (12-04)
3 Slide the cabinet into the hole far enough to allow the guide-channel of the sill plate to contact the inside wall surface (See
Figure
4 Drill three (3) 5/32" dia. pilot holes through holes in sill-plate into the framing and install three (3) #12 x 2" long screws
(Item #4) (See Figure 0).
TRIM MoULDING
SCREW #12A )( 2" LoNG
USES
SILL PLATE GUIDE CHANNEL
INSIDE WALL SURFACE
3 8 ~ (10 MM) SLOPE DoWN
NoTE: SUPPORT BRACKETS MAY BE OMITTED FRoM
THROUGH-THE-WALL INSTALLATIONS IF THE CABINET IS
SECURED AS FOLLOWS. DRILL 2 HOLES IN EACH SIDE
.AND INSTALL 4 FASTENERS (2 EACH SIDE).
USE #12A X 2"
EXPANSiON AN\.nUII'(
SCREWS, TOGGLE BOLTS oR
AS SHoWN IN STEP 5.
SUPPORT BRACKETS (ITEM 1) (SEE NOTE ABOVE)
SCREW #12 X 2" LONG, USE ONE IN EACH
BRACKET. DRILL 5123 (4 MM) DIA. PiLOT HOLES.
NOTE: ALTERNATE FASTENERS WHICH MAY BE USED FOR SECURING THE SILL PLATE IN THE AND THE
SUPPORT BRACKETS TO THE OUTSIDE WALL ARE NOT FURNISHED, BUT ARE AVAILABLE AT A LOCAL
HARDWARE STORE.
MOllY TOGGLE EXPANSION ANCHOR BOLT
5 Drill two (2) 5/32" dia. holes in each side at the locations shown (Figure 0) and install four (4) # 12 x 2" screws
(Item #4). If the hole construction in Step 2 provides a sturdy mount with solid vertical studs, no support brackets are
required. The installation must support the weight of the unit plus an additional weight of 400 pounds (185 kg) on the rear
of the cabinet. The brackets may be used for through-the-wall installations as shown in Figure 0, for additional
support.
6 If desired, trim around the cabinet on the room side with a suitable frame molding furnished by the installer (See Figure
15
920-024-05
1 Slide the chassis into the cabinet stopping approximately 3" from full insertion. Stuff the chassis seal gasket (Item #14) one
inch deep between the chassis and the cabinet (See Figure P). Begin at either bottom corner and go up the side, across the
top, and down the opposite side. Make sure that the gasket is behind the conduit connector (furthest from you). Push the
chassis into the shell the remaining distance so that the plastic front shrouds the front edge of the shell. Fasten the junction
box mounting foot to the shell with the sheet metal screw.
If chassis seal gasket is not installed, the
outside noise will be amplified.
of the unit will be affected. Also, the operation noise and
NOTE: Field wiring must be provided to this junction box in accordance with NATIONAL ELECTRIC CODE ARTICLE 501.
Field and equipment grounds are to be terminated at the post in the junction box with the green screw provided. Equipment
power leads are to be connected with the field supply by means of wire nuts (not provided). Install the gasket and cover
plate onto the junction box.
Figure P
16
920-024-05 (12-04)
2 Be sure that the filter is in place then install the return air grille (See Figure Q). The top of the return air grille can be butted
against the bottom of the discharge plenum. Snap the grille into place by pushing the grille up and onto the unit's latches at
the bottom.
1
Return air
Side view
(Cutaway)
Latch
3 You have completed your installation. Conduct a review of your installation to insure that the unit is safely and securely
installed. Refer to the "OPERATING GUIDE" section of this manual to test the operation of your unit.
17
18
920-024-05 (12-04)
Friedrich Air Conditioning Company
P.O. Box 1540
San Antonio, TX 78295
210.357.4400
www.friedrich.com
1. limited warranty - One year. Friedrich warrants that it will provide a replacement for any part of this HazardGard Room Air
Conditioner found defective in material or workmanship for a period of one (1) year from the date of original purchase.
2. limited warranty - One year. The Friedrich warranty also covers the cost of labor for repairing any compressor, condenser,
evaporator or inter-connecting tubing found defective within the warranty period, providing the unit is returned to an authorized
Friedrich Repair Station located within the Continental United States.
The Friedrich warranty does not cover:
(1) Any charges for removal, transportation or reinstallation of the unit; (2) the cost of labor to replace parts other than those
described above; and (3) does not apply to any HazardGard Room Air Conditioner that has been subject to (a) accident, misuse,
flood, fire, or neglect; (b) repairs or alterations outside of the Friedrich Authorized Dealer or Service Center so as to affect adversely
its performance and reliability; or (c) any repairs or servicing as a result of using parts not sold or approved by Friedrich.
LIMITATIONS: This warranty is a LIMITED warranty. Anything in the warranty notwithstanding, IMPLIED WARRANTIES
FOR PARTICULAR PURPOSE AND MERCHANTABILITY SHALL BE LIMITED TO THE DURATION OF THE EXPRESS
WARRANTY. MANUFACTURER EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTiAL OR
INCIDENTAL DAMAGES FOR BREACH OF ANY EXPRESSED OR IMPLIED WARRANTY.
(10-04)
SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K3 Air Starter (35038)

35038.doc Page 1 of 5
Phone: 713 896 6500 Fax: 713 896 6611
35 October 1999
Air Starter for Caterpillar 3406 / 3408
Part No. 35038
Starter Basic Operation
Pressurized air is admitted to the starter by depressing the start button on the
engine, or in the cab, which opens the relay valve. Air expands through the
turbine, which provides shaft rotation and torque. The acceleration of the
drive assembly causes the pinion to advance and engage the ring gear of the
engine. The diesel fuel system now fires the engine to continue the rotation.
Releasing the start button now disengages the starter. This closes the relay
valve and the pinion retracts.
Preventative Maintenance
Maintenance is suggested on this starter every six months. All that is
necessary is to check the condition of the grease and bearings. If the
planetary gearbox requires fresh grease, approximately one pint of EP
grease will fill the case. While the starter is disassembled, inspect the
bearing and races for excess wear or discoloration. Replace as necessary.
Before reinstalling starter, put a small amount of grease on the starter=s
pinion teeth.
Troubleshooting
Trouble Probable Cause Remedy
Air always flows to starter Relay valve plumbed improperly Check air lines against drawing
Relay valve plumbed improperly Check air lines against drawing
Starter does not run (no air flow)
Bad relay valve Replace relay valve
Broken turbine rotor (either stage) Replace starter Starter does not run with air
flowing through starter Geartrain problem Replace starter or broken parts
Insufficient inlet pressure Check air pressure at relay(90 psi min)
Excessive back pressure Check air pressure and exhaust screen
Y strainer clogged Clean strainer
Damaged or clogged first stage nozzle Clean or replace nozzles
Worn starter drive Replace starter drive
Reduced starter output power;
engine fails to crank or cranks too
slowly.
Wrong rotation starter Replace with right hand (CW) rotation
Parts List
Item # Description Qty. Item # Description Qty.
1 Screw 8 22 Turbine shaft 1
2 Exhaust support 1 23 Ring gear 1
3 Exhaust screen 1 24 Carrier shaft weldment 1
4 Screw, rotator attachment 1 25 Planet shaft 3
5 Rotor washer 1 26 Planet shaft spacer 6
6 Stage 2 Rotor 1 27 Planet gear 3
7 Square key (1/8) 2 28 Planet bearing 3
8 Turbine bearing 2 29 Gearbox bearing 2
9 Bearing pre-load spring 1 30 Bearing pre-load spring 1
10 Bearing spacer 1 31 Bearing spacer (gearbox) 1
11 Hollow hex plug 1 32 Gearbox housing 1
12 1 NPT cap plug 1 33 Hex bolts (gearbox attachment) 4
13 Stage 2 Noz/Containment 1 34 Bearing lockwasher 1
14 Screw 5 35 Bearing retainer nut 1
15 Stage 1 Rotor 1 36 Bearing retainer 1
16 Lip seal 2 37 Screw 12
17 Spacer / Seal bearing 1 38 Drive spacer 1
18 O ring 1 39 Drive bendix, 6-8 pitch, 11 tooth 1
19 Turbine housing / Stage 1 1 40 Nose bearing 1
20 Bearing retainer 1 41 Drive housing 1
21 Screw 1 42 O ring 1
Exploded View
3
5
0
3
8
.
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e

4

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5
3
5
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3
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5

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K4 Bearing Assembly Lower (TF8034)

/
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c
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SECTION A-A
I
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IL_
I
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CONFIDENTIAL
/
CONFIDENTIAL
II
II
TOTAL WEIGHT = 3551/

/
I
/
SCALE: 4X

I
/
(TYP. 8 PLC'S.)
SECTION B-B
ASSEMBLY

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K5 Bearing Assembly Upper (TF7049)

r
CONFIDENTIAL
L -'
A
F=------
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CONFIDENTIAL
MATERIAL LIST
ITEM OTY. WEIGHT PART NUMBER DESCRIPTION
1 1 TF7044 UPPER BEARING
2 2 TF7048 THRUST PLATE
3 24 1 1!2-6UNC, 6 3!4" Lg HEX HEAD BOLT, ASTM A3S4 Gr BO FLOUROKOTE #1 BLUE,
4" MIN THREAD LENGTH
4 24 1 1 2" LOCK WASHER ASTM F436 FLOUROKOTE "1 BLUE
5 8 1 1 4-7UNC 6 1 4" L HEX HEAD CAP SCREW ASTM A354 Gr BO FLOUROKOTE "1 BLU
6 8 1 1 4 LOCK WASHER ASTM F436 FLOUROKOTE "1 BLUE
7 2 TF7046 BEARING RETAINER
8 2 7 8-9UNC 4 3 4" L .HEX. HEAD CAP SCREW CAO. PLATED Gr. 5
9 2 7 8" LOCK WASHER
10 2 90003 GREASE FiniNG
GANTRY
,1/
/1'
,1/
t6l
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KINGPOST -
,1/
/1'
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/1'
Q
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SECTION A-A
REV. DESCRIPTION DRN. DATE
ANGLE
THIRD -$-El
PROJECTIOtl -
.X .030 MACHINING Li s
THIS oot:uuwr ArlO THE comErns HEREUI I.1AY fjQT BE
DISPLAYED, REPRODUCED OR OTHERWISE USED WITHOuT THE
EXPRESS WRlnD/ CQrlSErH OF SEATRAX INC.
.XX .015 FABRICATION d 1' PATENT NO'S. US 4,280,628 US 5,310,057
.XXX .005 MACH. FINISH us 5,328,040 G8 8 GB 225430B 8
MONARCH
SeeKing
MAnlHE ChANE:;
PO BOX 8406B7
Phone; 713 896 6500
SEATRAX
-
UPPER BEARING ASS'Y
S90 SERIES (24 HOLE)
FRACTIONS TO':;' 1/16"
OVER 3' l/a" DRAWN SCALE -8- 12 DATE DWG/PART NO. SHEET 1 of REV.
.005 TIR RER 1 "=1 '-0" 07/18/05 TF7049 o

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K6 Brake Actuator Assembly 500 Series For Load, Aux & Boom (TB4122)


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K7 Brake Band Assembly For Main (TB4190)

3'-7"1/4"
CONFIDENTIAL
\
'\- - ):/,-
/ ~ ~
\0//
BETWEEN _/ -- --
OF RIVETS SCALE 4X
CONFIDENTIAL

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K8 Brake Band Assembly 800 Series For Boom (TB4190)

L
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UNING TO BE RIVETED
TO BRAKE BAND
150'
1/2"
3'-7"1/4"
1'-0 1/2"
1/4"
,
o
l/B"
SLOT CENTERED BETWEEN
EVERY 3RD PAIR OF RIVElS
CONFIDENTIAL
3/16"
SCALE 4X
CONFIDENTIAL
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
~ ~
TI-IIRD ~
ANGLE +-
PROJECTION
.X .030 MACHINING Li .S'
.XX .015 FABRICATION.::i 1'
.XXX .005 MACH. FINISH 1 ~
FRACTIONS TO 3' 1 / 1 6 ~
OVER 3' 1/8"
MACHINING CONCENTRICITY .005 TlR
ALL DIMENSIONS IN INCHES
MATERIAL LIST
ITEM QlY. WEIGHT PART NUMBER DESCRIPTION SIfT
1 1 TB4191 BRAKE BAND WELDMENT
2 1 20044 BRAKE UNING 1.19010 MATERIAL 3 B" X 5" X 113 1 2"L
3 2 1 1 2-6 UNC HEAVY HEX NUT GR 5
4 102 60040 RIVEl FLAT HEAD SEMI-TUBULAR 1 4 X 3 4 BRASS
5 1 70090 BEARING 1 5 B" 10 X 1 3 4" 00 X 1" L
--'
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'" G:
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0
<>
REV. DESCRIPTION DRN. DATE
THIS DOCUMENT AND THE CONTENTS HEREIN WlY NOT BE
DISPLAYED, REPRODUCED OR OTHERWISE USED WIll-IOUT THE
EXPRESS WRITTEN CONSENT OF SEATRAX INC.
MONARCH
SeeKIng
PO BOX 840687
Phone: 713 a96 6500
SEATRAX
PATENT NO'S. US 4,280,628 US 5,310,067
US 5,328,040 GB 2253604 B GB 2254308 B
MARINE I:RAIilES
BRAKE BAND ASSEMBLY
44" - 700 HOIST
DRAWN SCALE -8- 6 DATE OWG/PART NO. SHEET 1 of
MS 2"=1' 5/17/05 T84190
REV.
o

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K9 Brake Band Assembly For Aux (TB4071)

04'-3" ID
1/4"
CONFIDENTIAL
DETAIL B
CONFIDENTIAL
-' r 3/16"
d ~ ["I"
5 ~ ~ I J T
SECTION A-A
SCALE: 4X
1/8" SLOT POSITIONED ~ ~
EVERY 3RD ROW OF RIVETS
TO AVOID CENTER RIVET /
/'
DETAIL B
SCALE: 4X
3/16"
SHEET 1 of 1
T84171 0

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K10 Collector Ring TX4715BW

ENGINEERING
TQP9.14
INSTALLATION &
MAINTENANCE INSTRUCTIONS
FOR
TX4715 Exde
SLIP RING UNIT
TYPE TX4715
SERIAL NUMBER 47152722008
Drawing No: 1/466/1405 Issue A
W.O.11077/08
9. 14.IM
Page 1
Issue 06/07
TQP9.14
1.0
2.0
3.0
4.0
5.0
6.0
INDEX
GENERAL INFORMATION & STORAGE
SPECIFICATION
INSTALLATION
3.1 PRE-INSTALLATION INSPECTION
3 .. 2 MOUNTING
3.3 TORQUE ARM
3.4 CABLE ENTRIES
3.5 FASTENERS
3 .. 6 FLAMEPATHS
3.7 TERMINAL COVERS
3.8 SLEW LIMIT SWITCHES
3.9 CHECKLIST
MAINTENANCE
4.1 CARBON BRUSHES
4.2 BRUSH HOLDERS
4 .. 3 SLIP RINGS
44 HEATER
4.5 BEARINGS
PARTS REPLACEMENT
5.1 MAIN HOUSING TERMINAL COVER
5.2 MAIN HOUSING TERMINAL GLAND PLATE
5 .. 3 MAIN HOUSING TERMINAL BOX
5.4 MAIN HOUSING Exd COVER
5.5 ENDPLATE
5.6 SMALL BEARING
5.7 TERMINAL HOUSING COVER/GLAND PLATE - SMALL
5 .. 8 TERMINAL HOUSING COVER/GLAND PLATE - LARGE
5 .. 9 TERMINAL HOUSING
5.10 NOT USED
5 .. 11 SHAFT ASSEMBLY
5.12 SMALL BEARING 5.15 LARGE SHAFT SEAL
5.13 RING ASSEMBLY 5.16 BRUSH HOLDER
5 .. 14 LARGE BEARING 5 .. 17 BRUSH
CERTIFICATES OF CONFORMANCE
9. 14.IM
Page 2
Issue 06/07
TQP9.14
1.0 GENERAL INFORMATION
The TROLEX TX4715 series of Electrical Slip Ring Unit is designed primarily for use in
Hazardous Areas on Offshore Pedestal Cranes transferring power, signal and video circuits
across the rotational interface. It has been certified by Baseefa (2001) Ltd as conforming to
the requirements ofEN60079-0, EN60079-1, EN60079-7, IEC61241-0 and IEC61241-1,
@ II 2 GD (El180 code Exde IIB Ex tD A21 IP65 T100C (T amb = -20C to +40C) for
use in Zone 1, 2, 21 & 22 hazardous areas.
Design and manufacture has been in accordance with our approved and registered ISO 9001:
2000 Quality Management System and Baseefa Ltd licence.
Reference must be made to the enclosed EC type examination certificate section: Special
Conditions for Safe Use.
WARRANTY
TROLEX ENGINEERING warrants the TX4715 Series Electrical Slip Ring Unit to be free
from defects in materials and workmanship at the time of leaving our premises and for a
further period of 12 months from commissioning subject to a maximum of 18 months from
date of despatch from our premises. Our liability under this warranty is limited to repairing
or replacing the unit at our option.
The warranty on any replaced part is extended by 12 months from the date of
replacement.
Shipping and other incidental charges are not included in the warranty.
STORAGE
Short term: It is important to store the slip ring preferably in the original packing case or box
and in dry conditions preferably at a constant temperature between OC and + 30C.
Long term: For storage periods greater than 90 days it is recommended to contact T.E.L.
Engineering Limited.
Prior to installation it is important to check the condition of the slipring unit and where
possible carry out basic electrical checks such as continuity and insulation resistance and
optical values where applicable. If in doubt please contact T.E.L. Engineering Limited.
9. 14.IM
Page 3
Issue 06/07
TQP9.14
2.0 SPECIFICATION
Certified by Baseefa (2001) Ltd for use in Groups IIA & IIB II 2 GD (El180
Code Exde IIB Ex tD A21 IP65 TlOOC
Baseefa 2001 Certificate - Baseefa02ATEXO 180
Protection IP66
Ambient temperature range -20C to 40C
Max speed 20 rpm
Max voltage per circuit - See Outline G.A. Drawing, number shown on page 1 of manual
Max current per circuit - See Outline G .A. Drawing, number shown on page 1 of manual
The TX4715 consists of two housings mounted on a common shaft with each able to rotate
independently -
The small housing which is an Exe terminal box is fixed to and rotates with the shaft. The
larger housing is Exd and contains the slip rings and brush gear and an integral part of this
housing is an Exe terminal box. Large access covers give easy access to terminals and
brushgears.
Housing Material
Shaft
Bearings
Slip Rings (Power)
Slip Rings (Signal)
Brushes (Power)
Brushes (Signal)
Fasteners
Heater
Cable Gland
Outline G.A.
Approximate Weight
Mild steel grade 43A or 550
Carbon steel grade 080 M40
Sealed for life ball bearings (min. 1,000,000 rotations)
Phosphor bronze
Phosphor bronze Silver/gold plated
2 per ring copper graphite
2 per ring silver graphite
Stainless steel
20 Watt 240 V AC with separate thermostat
Use only glands approved for Exe equipment in-group
IIB orIIC gases
Enclosed with manual
250 kgs
9. 14.IM
Page 4
Issue 06/07
TQP9.14
3.0 INSTALLATION
Weather protection
The slipring unit may be supplied with cable pigtails.
Explosion protected slipring units with cable pigtails will normally be supplied with the
cables sealed inside a barrier gland. It is the installer's responsibility to ensure that adequate
cable protection is used, this is of particular importance where multiple single cores are
fitted and conduit will be required. The Ex barrier gland will be suitable for the attachment
of the installers' conduit fitting.
Weather protected slipring units are often despatched with cable pigtails through OPEN
flanges and a threaded gland or flanged adaptor is required to attach cable protection such as
conduit or hose to seal the enclosure. It is essential that no foreign o ~ j e t s or liquid/moisture
is allowed to enter the enclosure during storage and installation. Electrical sliprings and
fibre optic devices are particularly prone to damage - often irreparable - caused by o ~ j e t or
liquid ingress.
Ingress protection
The ingress protection rating is stated in the technical information. It is important that the IP
rating is maintained by the type of cable protection.
Explosion protection
Where fitted the sealing of multi-core cable will be afforded by an appropriate Ex cable
gland. Where multi-individual cable cores/multi-core cables are fitted these will normally
be sealed inside an appropriate Ex barrier gland. It is the installer's responsibility to protect
the cables adequately and in accordance with applicable Standards. If in doubt please
contact T.E.L. Engineering Limited.
If the equipment is likely to come in contact with aggressive substances then it is the
responsibility of the installer/user to prevent it from being adversely affected thus ensuring
that the type of protection is not compromised.
Further reference to Special Conditions of Safe Use is important.
3.1 PRE-INSTALLATION INSPECTION
The TX4715 will be despatched from the factory packed in a substantial wooden case, which
should ensure delivery without damage, however packing cases can be dropped whilst in
transit and on delivery the case should be inspected for signs of damage.
Any damage to the case and its contents must be reported to TROLEX no later than 3 days
after delivery.
9. 14.IM
Page 5
Issue 06/07
TQP9.14
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
*
MOUNTING The TX4715 is designed to allow it to be mounted either standing or hanging
from its flanged endplate. Eyebolts and/or lifting brackets are supplied these are only rated
to carry the weight of the TX4715.
TORQUE ARM (RESTRAINT) Depending on how the TX4715 has been mounted, one of
the housings u ~ t be prevented from rotating by an arm fixed to one of the bosses provided
for this purpose. The arm MUST NOT be rigidly held, it must allow radial and axial
movement to accommodate some misalignment.
CABLE ENTRIES The TX4715 will normally be delivered with all necessary holes
provided in the terminal boxes. Cable glands will not be supplied unless specifically
ordered. It is the Customer's responsibility to ensure that only the appropriate Certified
glands are used and fitted correctly. To maintain IP66 rating of the TX4715, cable glands
and blank plugs must be sealed by washers or PTFE tape.
Unused holes must be blanked using an approved Exe plug. The unit should be earthed.
FASTENERS All fasteners used on removable covers, endplates, bearing housings etc. are
Stainless Steel minimum grade A2-70 lower graded MUST NOT be used.
FLAMEP A THS If brushgear inspection covers have to be removed during installation, care
must be taken when re-fitting to ensure that the sealing gasket is fitted correctly and that the
machined facings on the housing and inspection cover are not marked or scratched, such
damage could invalidate the BASEEF A certificate. Always tighten fixing screws in
sequence, maximum gap at joint is 0.15mm (0.006").
TERMINAL COVERS To maintain the IP66 rating of the TX4715 please take care when re-
fitting terminal covers not to damage the sealing gasket. Tighten screws in sequence.
SLEW LIMIT SWITCHES Refer to enclosed drawings for details and instruction
CHECK LIST Before re-fitting terminal and inspection covers at installation please check:-
Terminal boxes cleaned out *
Main housing cleaned out *
All terminal screws tight
Gland fitted with sealing washers or tape
Inspection covers and housing facings undamaged
All gaskets in place
All cover screws in place and tight
Max gap at inspection cover joint 0.15mm
BY VACUUMING NOT AIR BLAST
9.14.IM
Page 6
Issue 06/07
TQP9.14
4.0 MAINTENANCE
The following should be incorporated in the planned maintenance schedules for the crane.
Intervals should be every 2000 running hours or 6 months.
4.1 CARBON BRUSHES Must be replaced when the minimum lengths shown below are
reached or could be before next inspection. Check that brushes are tracking in centre of ring.
Minimum lengths - Brush size 32 x 10 - 10mm
25 x 8 - 10mm
10 x 3 - 8mm
4.2 BRUSH HOLDERS Check that arms/brushes are free to swivel, clamp bolt and terminal
screws are tight. Check that there is sufficient tension in spring to maintain good contact of
brush onto ring. Check for signs of overheating.
4.3 RINGS
Power: Check for signs of local burning or discolouration, use a proprietary electrical
cleaner and if necessary very fine or worn emery cloth to clean rings. Remove all dust and
debris by vacuuming NOT air blast.
Signal: As for power ring but DO NOT use emery cloth on silver and gold plating, use
glass fibre brush.
4.4 HEATER Check function of heater and connections.
4.5 BEARINGS Lubricated for life and maintenance is not required.
5.0 PARTS REPLACEMENT - TX47153
An itemised parts list is shown on the enclosed As Built G.A. Drawing. When ordering spares
please quote the serial number of the unit and the description and number ofthe part required.
5.1 MAIN HOUSING TERMINAL COVER Remove M6 socket cap head screws, 5mm AlF Allen
key required.
5.2 MAIN HOUSING TERMINAL GLAND PLATE - As 5.1
9. 14.IM
Page 7
Issue 06107
TQP9.14
5.3 MAIN HOUSING TERMINAL BOX - As 5.1
5.4 MAIN HOUSING Exd COVER Remove M8 socket cap head screws, 6mm AlF Allen key
required.
5 . .5 ENDPLATE - As 5.4
5.6 SMALL BEARING - As 5.11 then remove circlip
5.7 TERMINAL HOUSING COVER/GLAND PLATE - SMALL - As 5.1
.5.8 TERMINAL HOUSING COVER/GLAND PLATE - LARGE - As 5.1
.5.9 TERMINAL HOUSING - As 5.4
5.1 0 Not Used
5.11 SHAFT ASSEMBLY Remove: Exd Covers
All brushes and holders
Endplate
Terminal Housing
Endplate
M8 x 16 screws securing bearing cap to main housing
Now withdraw shaft assembly from main housing taking care not to damage insulators in ring
assembly .
.5.12 SMALL BEARING As 5.11 then remove circlip and pull bearing from shaft.
5.13 RING ASSEMBLY Please contact TROLEX Technical Department for detailed instructions.
5.14 LARGE BEARING As .5.11 then remove circlip
5.15 LARGE SHAFT SEAL As 5.14 then remove bearing cap, then seal
9. 14.IM
Page 8
Issue 06107
TQP9.14
5.16 BRUSH HOLDER As 5.4 then remove M6 screws holding spindle clamps.
5.17 BRUSHES
Power - Remove screws/nuts securing brush to holder. DO NOT overtighten screws/nuts as
brushes are fragile.
Signal-Remove screw securing brush lead to holder, cut off crimp connector. Fit new brush,
fit sleeve over brush lead, fit new crimp connector (supplied with brush) reconnect lead to
holder.
NOTE! - Spare brushes will be supplied radiused to suit approximate ring profile but some
final bedding will be necessary to ensure 100% contact between brush and ring, use very
fine or worn emery cloth for this. Remove all brush dust by vacuum NOT air blast.
Repair of Explosion Protected Equipment.
As manufacturers of Explosion Protected Equipment we remind you that it is the
owners responsibility to ensure that wherever practical the manufacturer should carry
out any repairs that become necessary. Alternatively a company that has approval by
an appropriate authority may carry out the repairs and that all work done must be in
accordance with the appropriate Standards.
The standards that a repair company is deemed to comply with differ from those that
an original manufacturer uses. The manufacturer will ensure that when the equipment
is returned it is to the original standard.
In the event of a repair by a company other than the manufacturer, the nameplate
bearing the manufacturers Ex approval details must be removed and returned to the
manufacturer with details of all work done. This information is then archived for
future reference.
As required by the Rules and Regulations for the repair of such equipment the
repairers nameplate should be affixed to the unit in place of the manufacturers
nameplate.
Spare parts will only be supplied upon receipt of the serial number of the equipment.
9. 14.IM
Page 9
Issue 06107
TQP9.14
Health & Safety
Products: TEL Engineering Limited also trading as Trolex Engineering designs and manufactures
electrical slip ring units, gas and fluid swivels, cable reeling systems and special purpose electro-
mechanical machinery for offshore, mining, petro-chemical, nuclear and general industries.
Product information: Product design and manufacture in accordance with our Quality Assurance
and Management System and also approved by the Health & Safety Executive (BASEEF AlEECS)
for explosion-protected products, and using good engineering practice ensures as far as can be
reasonably practicable that products are fit for purpose and where used as intended will not cause
harm or inflict injury.
Product materials: There are no products that contain materials considered as harmful when used as
intended.
Self-powered products: Certain types of cable reeling products contain spring loaded items, labels
warning of potential danger if dismantled incorrectly are attached to the products where applicable.
Protective covers: Due care and attention should be made when removing access covers. Labels are
attached for electrical shock warnings and important information relating to explosion-protected
approval requirements of products used in potentially hazardous zones. Certain covers are heavy,
particularly those used on explosion-protected products, due care should be paid to the weight on
removal and refitting.
Removal of debris: Certain products such as slip ring units produce debris as the spring-loaded
sliding brush contacts wear. This material may be in the form of fine dust or small particles and
contain graphite, copper or silver alloys. Removal of the debris should be by vacuum or similar
method for disposal of dust and small particles and not by air blast.
Products used in potentially hazardous zones: Installation and Maintenance information is supplied
with these products. Due care must be taken in accordance with the requirements of the issuer of
the Certificate of Approval and local authorities.
The above information is issued for guidance only and should not be used in place of local Safety
Policies and/or other recognised health and safety practices.
9. 14.IM
Page 10
Issue 06107
Explosion Protected Group lIB Zone 1
Exd Ring Enclosure
I ~ ~
Exe Terminal Boxes
Hollow Shaft Option COMPLIANT
OPERATING SPECIFICATION
Ambient Temperature Range -20C to +40C
(higher available)
Maximum Speed
Maximum Voltage
Maximum Throughput
Curr'ent
Protection
Mounting
40rpm (higher on request)
770VAC
810 amps excluding
earths and neutrals
lP66
In any plane
TECHNICAL DETAILS
Housing Material
Shaft
Bearings
Slip Rings
Brushes
Fasteners
OPTIONS
Mild Steel grade 43A
Carbon Steel 080M40
Sealed for life ball journal
Phosphor bronze (precious
metal plated for signals)
Minimum of 2 per ring
(Copper Graphite for
power, Silver Gr'aphite for
signals)
Stainless Steel metric
.:. Mounting flange / brackets to Customer's
requirements
.:. Anti-condensation heater (self regulating)
.:. Hollow shaft
.:. Stainless Steel construction
.:. Internal or External slew limit switch
.:. Internal or External azimuth encoder'
.:. Factory fitted flying leads
.:. Special features to handle I..S. circuits
APPROVAL
Certification:
Baseefa02ATEX0180 @ II 2 GD (E1180
Code Exde lIB Ex tD A21 IP65 T1 Ooc
IT amb = -20C to +40C) Zones 1, 2, 21 & 22
To EN60079-0 EN600'79-1 EN60079-7
IEC61241-0 IEC61241-1
Trolex Engineering
T.E.L. Engineering Limited
Newby Road, Hazel Grove, Stockport SK7 5DA UK
Tel: +44 161 4566545 Fax: +44161 4563810
E-mail: mail@trolexengineering.co.uk
CERTIFICATE OF CONFORMANCE
Quantity One
Description TROLEX TX4715 EEx de Slip Ring Collector column
SeriallPart Number 4715272 2008
Customer Seatrax UK Limited
Work Order No. 11077/08
Purchase Order No. 217967
Drawing and/or specification and issue -
Drawing No. 1146611405 issue A
BASEEF A Certificate No. Baseefa02ATEX0180
Deviations (e.g. Major Concessions or Production Permits) -
None
Certified that the equipment described has been manufactured and tested in accordance
with our approved and registered BS EN ISO 9001: 2000 Quality Management System
and - unless otherwise stated above - conforms in all respects with the requirements of the
Contract or Purchase Order.
For and on behalf of Trolex Engineering
I E L ENGINEERING LIMITED
Date: September 1 st 2008
4.9.2.9
Issue 06/94
EC Declaration of Conformity
T.E.L. Engineering Limited (also trading as Trolex Engineering) declares, under our sole
responsibility, that the product(s) listed below conform with the relevant provisions of ATEX
Directive 94/9IEC of23 March 1994.
Product:
Manufacturer:
Notified Body:
Type TX4715 Slip Ring Units
T.E.L. Engineering Limited (also trading as Trolex Engineering)
Newby Road
Hazel Grove
Stockport
Cheshire
SK75DA
Baseefa (2001) Limited
Rockhead Business Park
Staden Lane
Buxton
SK179RZ
(Notified Body Number 1180)
Conformity has been demonstrated with reference to the following documentation:
EC-Type examination certificate Baseefa02A TEXO 180
Quality Assurance Notification Baseefa ATEX 1428
Compliance with the Essential Health & Safety Requirements has been assessed by reference
to the following standards:
EN60079-0: 2004
EN60079-1: 2004
EN60079-7: 2003
IEC61241-0
IEC61241-1
T.E.L. Engineering Limited hereby declares that the equipment referred to herein conforms to
the above directive.
Form TX4715EC-DofC (EN60079) GAS & DUST
Date: 27 February 2008
08 2008
L QUALITY ASSURANCE NOTIFICATION
2. t:qui!>ment or Prottttive Systems or Components Intended for use in Potentially AtmoSl)OCreS
Dire(;ti\'c !} .. /WEe
3, NotifitaflQl'I number: Basc.cfll ATKX 1428
5.
Manufilcturcr:
1 E

Hlllel Grove
Cbes.bire
MauufaClllre r
UNCONTROLLED DOCUMENT
THIS DOCUMENT IS NOT
SUBJECT TO AMENDMENTS
T.E.L. ENGINEERING LIMITED
Bllsccfa Ltd. Notified Bod) No I {80 for IV and \/11 in accordance wHh article 9 oralle Council
Directive 94/95':(' of tbe l\brell t.o the applicant tllat I.he at1ual t.CI$ qU,1!it\'
system which with Annexes rv and VII of Ihe Directive
I'll.ls can be withdrawn if tile ulWlufllctufcr no
Vii
satisfies the requirements of the Annexes
ate a part of this Nolificatiou
9. This Notification valid UlltU 1 ',,108120 11 ilnd c.an withdrawn If tbe manufaclurer does Oi/! the
assurance rC-asscssmcnl
to t\rticlc HI [I) of !lie Directive 9..J/9lEC t.il.: cr shall be followed by Ille idemifkatioll
nmnber 1180 identifying the notified ill\'ol\'ed in the pnxltu:::llon control stage.
This No!ificotiol1 mal

8wfu.-l'itn.. St;d .. lIl ..
Uln(oll, I) .. SK17 I'n!tt'd t.:lnaduM.
frl. +.oM {t}1298 I'lll., '44 (0)1298 766601
,,maiI w .. b!iil .. . "'f11
and \\ilhout au} change.
R SINCLAIR
DIRECTOR
Jssued: 8 July 2008
Page: 1 of 1
Schedule to AlEX Quality Assurance Notification J IECEx Quamy Assessment Report
Number: 1428
Issued to: T.l. Engineering Ltd
T/A Trolex Engineering
Products for which the Manufadurer controls the design and manufacture of the product
Product y ~ Designation CI1>1tifi<:",t .. Number
AlEX)
IECEr; Certlflc<lte of
Conformity Number
2
3
4
5
6
Certificate Number
Baseefa02ATEX0180
Issued 22 November 2002
Page 1 of2
EC - TYPE EXAMINATION CERTIFICATE
Equipme.nt or Protective System lntended for use in Potentially Explosive Atmospheres
Directive 94/9!EC
EC l'ype Examination Certificate Haseefa02ATEX0180
Number
Equipment or protective system, Type TX4715 Slip Ring Units
Manufacturer
Address
T.E.L Engineering Limited also trading as Trolex Engineering
Stockport, Cheshire, SK7 5DA
7 'f his equipment and any acceptable variation thereto is specified in the schedule to this certificate and the
documents therein referred to
8 Baseefa (2001) Ltd Notitled body numbel 1180, in accOldance with Article 9 of the Council Directive 94!9/EC of
23 MaIch 1994, cerlities that this equipment or protective system has been found to comply with the Essential
Health and Safely Requirements relating 10 the design and constlUction of equipment and protective systems
intended fbr use in potentially explosive atmospheres given in Annex II to the Directive
The examination and test results are recorded in confidential Report No 02(C)0180!2
9 Compliance with the Essential Health and Safety Requirements has been assured by compliance with:
EN 50014: 1997 t Amendments 1 & 2 EN 50018: 2000 EN 50019: 2000
except in respect of those requirements listed at item 18 ohlle Schedule
10 If the sign "X" is placed after the certifIcate number, it indicates that the equipment or protective system is subject
to special conditions of safe use specified in the schedule to this certificate
.11 This EC - TYPE EXAMINA nON CERTlFICA fE relates only to the design and constlUction of the specifIed
equipment or protective system If applicable, further requirements of this Directive apply to the manufacture and
supply ofthis equipment or pIOtective system
12 The marking of the equipment or protective system shaH include the fbllowing .
@ II 2 GO EEx de lID TlOO"C (Trunh See schedule)
This certitlcate may only be reproduced in its entirety, without any change, schedule included
Baseefa (200]) Ltd Customer Reference No. 1428
This certificate is granled subject 10 the geneml terms and conditions of
Baseefa (200 I) Ltd. It does not ncccssru:ily indicate Ihat the equipment
may bc used in particular industries or circumstances
1..--=---__ ....:-___________ . , . _,_ .. __ .
Baseefa (2001) Ltd.
Health and Safety Laboratory Site, Harpur Hill,
Buxton, Derbyshire SKi7 9JN
Telephone +44 (0) 129828255 Fax +44 (0) 129828216
e-mail info@b!fjseel2001.bizwebsiteWvIIW.baseefa2001.biz
Registered in England No. 4305578 at 13 OovedaJe Crescent, Buxton,
Derbyshire, SK17 9BJ
Project File No 0210180
DIRECTOR
On behalf of
Baseefa (200 I) Ltd
Re-issucd 26'" May 2004 t" dele'" draft issue
Certificate Number
Baseefa02ATEX0180
Schedule
Page 2 of2
15 Descri(>tion of Equipment or Protective System
The Type TX4715 Slip Ring Unit comprises a fabricated mild steel or stainless steel enclosure incorporating slip rings
and associated brush gear in a flameproof enclosure Increased safety terminals tor extemal conneciions are housed within
two increased safety junction boxes The flameproof enclosure has a flange OJ foot at one end and a rotating end cover with
lOlling element bearing at toe other One increased safety junction box is attached to the fixed flameproof enclosure the
other is attached to the revolving end cover. The slip rings are individually rated up to nov, 100A and may be used lor
power, signal and intrinsically safe circuits, with a maximum total throughput of 8 lOA
Options include an anti condensation heater, aitemative bearing arrangements (TX4 7151 Units), alternative larger increased
safety terminal enclosures (TX47152 Units), a combination of both the above (TX47153 Units), and a reduced maximum
total throughput rating of 420A with an illcreased ambient temperature to f55"C whilst retaining TI OOC marking
(TX47154 Units)
16 Report No.
02( C )0] 80/2
17 Special Conditions for Safe Use
None
18 Essential liealth and Safety Requirements
None additional to those covered by the standards listed at item 9
19 DI'awings and Oocuments
Number Sheet Issue I>ate Description
1/466/315 1 to 4 inc H 201102 General Assembly and Label Details - IX4715 Unit
1/466/412 1 to.3 inc C 20 11 02 General Assembly and Label Details - TX47151 to TX47153 Unhs
3/466/631 C 201102 Nameplate - TX47154 Unit
)/47151760 D 201102 Recove[y Techniques - All Units
11466/940 A 02 lO 02 Cables and Glands Details - All Units
Certificate Number
Baseefa02A TEX018011
Issued 21 May 2004
Page 1 of 2
SUPPLEMENTARY EC - TYPE EXAMINATION CERTIFICATE
2 Equipment or Protective System Intended for use in Potentially Explosive Atmospheres
Directi;;e 9419IEC 1
3 Supplementary EC - Baseefa02ATEX018011 THIS DOCUMENT IS NOT
Examination Certificate Number: SUBJECT TO AMENDMENTS
4 Equipment or Protective System: Type TX4715 Slil) Ring Units T.E.L. ENGINEERING LIMITED
5
6
Manufacturer:
Address;
Stockport, Cheshire, SK7 5DA
7 This supplementary certificate extcnds EC- T ypc Examination Certi.ficate No. Baseefa02A TEXO 180 [0 apply to
equipment or protective systems designed and constructed in accordance with the specification set out in tbe
Schedule of the said certificate but having any variations specified in the Schedule attachcd to this certificate and
the documents therein referred to
This supplementary certificate shall be held with the original certificate
This certificate may only be reproduced in its cntiret;y, without any change. schedule included
Baseefa (2001) Ltd Customer Reference No. 1428
celti/kate is granted to the general Icons and conditions of

Ba:;eefa (200l) Ltd It does not nt,'ccssarily indicate that the equipment
may be used in particular industries or circumstances
------ ---------'
Baseefa (2001) Ltd.
Health and Safety Laboratory Site, Harpur Hill,
Buxton, Derbyshire SK17 9JN
Telephone +44 (0)129828255 Fax +44 (0) 1298 28216
e-mail info@baseefa2001.biz web site www.baseefa2001.biz
Registered in England No. 4305578 at 13 Dovedale Crescent, Buxton,
Derbyshire, SK17 9BJ
Project File No. 04/0225
R S SINCLAIR
DIRECTOR
On bchalfof
Baseefa (2001) Ltd
13
14
15
Certificate Number
Baseefa02A TEX0180/1
Schedule
Certificate Number Baseefa01A TEX018011
Description of the variation to the Equipment or Protectiw System
Variation 1.1
Issued 21 May 2004
Page 2 of 2
Additional. compression type. cable glands. as certificate SiraOIATEXI272X These glands are for use ",ilh single core
cables as shown on the drawing below.
Variation 1.2
Additional. barrier compression type. cable glands. as certificates BASO.IATEX2079X BASOIATEX2080X
BASOIATEX2082X BASOIATEX2077X, SiraOOATEXlO7.JU, SiraOlATEXi285X and Sira03ATEXl479X These
glands are for usc \vith mulli core cables as shown on the drawing below,
Val"iati.,n 1.3
Additional cables for usc with tbe appropriate glands, electrical ratings and ambient temperatures as shown on the drawing
belo\\
16 RCJ}ort Number
Basecfa Certification Report 04(CI)o226 (held with certificate Baseefa02ATEX0060/l)
17 Special Conditions fOI" Safe Use
NOlle additional to those listed previously
18 Essential Health and Safety Requirements
Compliance with the Essential Health and Safety Requilements is not affected by this variation
19 Drawings and Documents
Number Sheet Issue Date Description
1/4661940 C 26 APR 04 Cables and Glands Details- All Units
2
3
..
5
Certificate Number
Baseefa02ATEX0180/2
Page 1 of 2
SUPPLEMENTARY EC TYPE EXAl\lINATION CERTIFICATE
Equil)mellt or Protectil'C System Intended for use in Potentially Ex.plosive Atmospheres
Directive 94/9/EC
Supplementary EC - Tvpe
Examination Certificate Number:
Equipment or ProtectIve
Manufacturer

Baseefa02ATEX{H80/2
T}'J,e TX4715 Slip Ring Units
T.E.L Engineering Limited also trading as Tl'Olex Engineering
Ha71 Grove, Stockl)ort. Cheshire, SK7 5DA
7 This certificate extends EC - Type Examination Certificate No. Baseeficl02ATEX02.5.1X 10 applY to
equipment or protective systems designed and constrtlcted in accordance with the specification set out in the
Schedule oflile said certificate but baying any yariations specified in the Schedule attached 10 this certjficate and
the documents therein referred to.
This supplementary certificate shall be held with the original certificate
This certificate m;n onl" be reproduced in its enlilely. withont anv change. schedule included.
Basecfa Customer Reference No 1428
1111$ rrrlili<.:utc j" granted to the general {cm1, and conditions 01
Raseda (20GI) Ltv II vncs not neces,aril\ indicate lhat the equipment
nla\ he in jJ1lftiwlar mdUSlIi,;., Df
Baseefa
Rockhead Business Park, Staden Lane,
Buxton, Derbyshire SK17 9RZ
Telephone +44 (0) 1298766600 Fax +44 (0) 1298766601
e-mail info@.Q.(jeefa.cofnwebsite\Wv.\.baseefa.com
Baseefa is a trading name of Baseefa (2001) Ltd
Registered in England No 4305578 at the above address
File No OS/07S0
R S SINCLAIR
DIRECTOR
On behalf of
Basccfa (200 I) Ltd
13
Certificate Number
Schedule
Page 2 of 2
14 Certificate Number Baseefa02ATEX0180/2
15 Description of the \'al'iation to the Equipment 01' ProtectiYe System
Variation 2.1 T.E.L. ENGINEERING LIMITED
To permit recovery ofthc cylindrical flamcpath at {he f l n g e ~ cndplatc end, via It press fitted sleeve
The sealing clement is fitted cxtcmally 10 tIle flamepalh
Variation 2.2
Clarification of df'dwing detail
16 RCllOrt Numbcr
None
J 7 SI)ccial Conditions for Safe Usc
None
18 Essential Health and Safet) Requirements
Compliance wilh the Essential Health and Safety Requirements is not affected by this \ariation
19 Drawings and Docnmcnts
Number'
11.+ 7151760
1l466f412
Sheet Issue
E
D
Date
IHl7 05
7 NOV 05
Description
Approval GA - Type TX4715 Slip Ring Units
Certification GA - TX4 715 Types Ex de Slip Ring
2
J
Certificate Number
Baseefa02ATEX01BOf3
Issued 5 February 2007
Page 1 of 2
SUPPLEMENTARY EC - TYPE EXAl\UNATION CERTIFICATE
Equil}ment or System Intended for use in Potentially Explosive Atmospheres
Directive 94191EC
Examination
Equipment or Protective
MmmfaeturCi:
Address:
Ba:,'t'tfa02A TEXOJ80/J
TX4715 Slip Ring Units
T.E.L
as Trolex EUjgjll1i.'crin
l:hlesh:me. SK7 SDA
7 This certificate extends EC Examination No. Baseefa02ATEXO 180 to to
efllupl:nellt or systems and constructed in accordance with the set out the
Schedule of the said certificate but any variations III the Schedule attached to this certificme and
the documents therein referred 10
This sUj:lplemental:y certificate sbalJ be held with tbe certificale
This ccnificatc ma" without any
Basecfa Customer Reference No. 1428
tenus and of
n<"""",.,.;I,, iudiCille Ihat the eq!lliplllent
Baseefa
schedule included.
File No. 0610959
Certificate Number
Baseefa02ATEX0180/3
Schedule
Certificate Number Baseefa02ATEXOl
15 of the variation to tbe
Vari'ltion 3.1
Revised ammgenlcnls
Bascefa06ATEX0057X
Page 2 012
Revised use of increased teonirmls those certificates KEMA 97 ATEXl KEMA
<J8A1EX KEMA and KEMA 98ATEX16861J
"'1 ..1j..I"n .....'''' covered Ihis certificate.as arncnded thc above bas becn reviewed lhe
of EN60079-0; 2004. 6{)079-7: 2003. IEC61241-O and fEC61241-1 in respect of the
differences from ,lle standards to tms cerlific<ltc was issued: none of l!lese differences alIcct this ""'I'UI""''''''
uni!.s so formed arc coded:
n 2 GD Exde fIB Ex tD A2l rp65 T100"C ""sce
V;,uh.tion 3.2
Revised arrangements HIC usc
STRAOIATEX1272X and barrier cOlnpI'cssion Iype
as SIRAOIATEXl270X and
Rc\!scd usc of im::rcased lerminals those cc!1ificalcs KEMA 97 A TEX! 798U, KEI\iv\
KEMA 98ATX1684U and KEMA 98ATEX1686U
""I'"'P'''''''''' CQn::rcd Ibis cerlificate as amended the above emmgles has been reviewed the
EN600791- 2004 and EN 60()71)7: 2003 in of the differences from the
s!,mdmds to whicb I.his certificate was I10Ile oftbese differences affect !.his
units so [oollcd arc coded:
n 2 G Exde lIB T5
Numbe.'
see
17 Conditioll!> for Safe Use
None additionall!) those lisled
18 Essential Health and
with tbe Essential Heal!.h and
19
Number
1/+66/1219
3/466/1217
1146611218
and Docoments
Sbeet issue
A
A
A
is not affected this variation.
Date Description
18 D.C06 TX4715 ENilEC Sl1llidanls Glands & Tennjuais
9 NOV 06 TX47 I 5 Series Slip ENIIEC Standards
1 DEC 06 TX4715 Altem<ltive Cude Labels
Certificate Number
Baseefa02ATEX0180/4
Page 1 of 2
1 SUPPLEMENTARY EC - TYPE EXAMINATION CERTIFICATE
2 Equipment or Protective System Intended for use in Potentially Explosive Atmospberes
3
4
5
6
SupplementaIy EC -1)'pe
Examination Certificate Number:
Equipment or Protective System:
Manufacturer:
Address:
Directive 9419IEC
B aseefa02ATEXO 180/4
Type TX4715 Slip Ring Units
Newby Road, Hazel Grove, Stockport, Cbesbire, SK7 5DA
7 This supplementaIy certificate extends EC - Type Examination Certificate No" Baseefa02ATEXOl80 to apply to
equipment or protective systems designed and constructed in accordance with the specification set out in the
Schedule of the said certificate but having any variations specified in the Schedule attached to this certificate and
the documents therein referred to"
This supplementaIy certificate shall be held with the original certificate"
This certificate may only be reproduced in its entirety, without any change, schedule included"
Baseefa Customer Reference No, 1428
This certificate is granted subject to the general tenus and conditions of
Baseefil (2001) Ltd It does not necessarily indicate that the equipment
may be used in partiCUlar industries or circwnstances ..
Baseefa
Rockhead Business Park, staden L.ane,
Buxton, Derbyshire SK17 9RZ
Telephone +44 (0) 1298766600 Fax +44 (0) 1298766601
e-mail info@baseefa.com web site www.baseefa.com
Baseefa is a trading name of Baseefa (2001) Ltd
Registered in England No" 4305578 at the above address
Project File No 07/0931
~ ~ ~ ~
DIRECTOR
On behalf of
Baseefa (2001) Ltd,
13
Number
Schedule
Page 2 of 2
14 Certificate Number Baseefa02AtEX0180/4 ,...----------...,
15 Description of the variation to the Equipment 01" Protective System
Variation 4.1
Increase in the number of slip rings with an increase in the overall length of the flameproof enclosure. The side covers are
increased in length accordingly, with a proportionate increase in the number of fixing screws. The overall electrical rating
remains unchanged.
Variation 4.2
Increase in diameter of the main bearing assembly (left hand side) with a corresponding increase in that of the diametral
flamepath.
Variation 4.3
Increase in thickness of the side flanges on the flameproof enclosure.
Variation 4.4
Change in type of the anti-condensation heater.
Variation 4.5
Minor design changes.
The unit so formed by the above variations is designated as the:-
Type TX4716 Slip Ring Unit
This unit has a minimum ambient temperature in service of -3QoC and the coding is to be amended to:-
II 2 GD Exde lIB Ex to A2l IP65 TlOOoC (-30:sTamb$+40C)
or
II 2 G Exde lIB T5 (-30:sT
am
b$+40C)
16 Report Number
Baseefa Certification Report 07 (C)0931
17 Special Conditions for Safe Use
None additional to those listed previously
18 Essential Heal.tb and Safety Requirements
Compliance with the Essential Health and Safety requirements is not affected by this variation.
19 Drawings and Documents
l/4715/1280 C 21 FEB 08 TX4716 Slip Ring Unit
2
.3
5
Certificate Number
Baseefa02ATEX0180J5X
Issued 26 August 2008
Page 1 of 2
SUPPLEMENTARY EC - TYPE EXAMINATION CERTIFICATE
Equipment 01' Protective S,}'stem Intended for use in Potentially Ex"losive Atmospheres
Supplementary EC - Type
E:-;(lmination Certificate Number:
Equipment or Protective System:
lVillnufacturcr:
Address:
Directive 9419/EC ...------------,
Baseef'a02A TEXO 180/.5X
TYlle TX4715 SUI} Ring Units
T.E.L Engineering Limited also trading as Trolex EnginL'Cring
Newby Road, Hazcl Grove. Stockllort, Cheshirc, SK7 5DA
7 This supplementary certificate extends EC Type Examination Certificate No. Basccfa02ATEX0180 to apply to
equipment Of protective systems designed and constructed in accordance with the specification set OUI in the
Schedule of the said certificate but having any variations specified in the Schedule attached to this certificate and
Ihe documentS' therein referred to
TIllS supplementary certificate shill I be held with the origimll ccrtific.:1te ..
This ccrtifjc<uc may ouly be reproduced in its entirely. without any change, schedule included
Baseefa Customer Reference No. 1428
Jhix ccllilicilte is granted stlQject to the general wnns and
Basedo II docs not llccessillilv imlicat<: Hlllt the cquipmcnt may
used III industries or cin:umstmces
Baseefa
Rockhead Business Park, Staden Lane,
Buxton, Derbyshire SKi7 9RZ
1 stephana +44 (0) 1298766600 Fax +44 (D) 1298766601
a-rnail info@baseefa.cam web site www.baseefa.cam
Saseefa is a trading name of Baseefa ltd
Registered in England No, 4305578 Registered address as above
PrQ.iect File No. 08/0532
R S SINCLAIR
DIRECTOR
On behalfof
Baseefa
u
Certificate Number
Baseefa02ATEX0180/5X
Schedule
Issued 26 August 2008
Page 2 of 2
14 Certificate Number Baseefa02A TEX0180/5X
~ ~
15 Description of the variation to the Equipment or Protective System
V.lriation 5.1 T.E.L. ENGINEERING LIMITED
Io penni! 1l1e replacement of cable glands by Type RGB, RGG or RGS Multi cable transits to Baseefa08ATEX0016X.
illlm::hed to the increased safety terminal enclosures ifrcquired.
16 Report Number
None
17 Speci<1I Conditions for Safe Use
Ancmion is drawn 10 the Special Conditions for Safe Use associated with Baseefil08A TEXOOl6X
The blocks must be assembled using the manUfac{llIer'S supplied tallow lubricant wltich must be applied to all
faces ofthe sealing bloeks prior to assembly.
2 The assembled frame and c.lbles shaH be left for a period of 48 hours prior 10 the installation being energised.
"\ The 1113Xi1UtHll current and cuubient tClllpcrature is litllited to 7 0 0 A ~ and 40(: respectively" \vhen the cable transits
arc used
18 Essential Healtb and Safety Requirements
Compliance with tbe Esscnti.al Health and Safety Requirements is not affected by this variatlon,
i ) Drawings and Documents
1/.\.66/1190 c 21.08.08 General Arrangemcnt- Multi Transit Option
ON

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K11 Filter Assembly, Pilot Circuit (40587)

Phone: 713 896 6500 Fax: 713 896 6611
STDFM-43 Rev. 1 01/31/01

STDFM-43 Portrait Header.doc Page 1 of 1

Control Circuit Filter Unit
Part No. 40587

Replace filter element when the visual indicator is red
instead of green. When servicing the filter, use the
following procedure:

1. Stop the cranes power unit.

2. Relieve pressure in the filter line and drain
bowl by carefully removing the drain plug.

3. Rotate bowl counter-clockwise and remove.

4. Remove filter element from bowl and
DISCARD. These elements are not re-
useable.

5. Inspect bowl seal and replace if necessary.
Grease and install seal.

6. Insert new element in housing.

7. Replace bowl and hand tighten.

8. Replace and tighten drain plug.

9. Start motor and check for leaks.


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K12 Filter Assembly, Oil Conditioner (40585)

Phone: 713 896 6500 Fax: 713 896 6611
STDFM-43 Rev. 1 01/31/01

STDFM-43 Portrait Header.doc Page 1 of 1
Main Return Filter Unit
Part No. 40585
Maintenance

This filter unit is equipped with a visual
filter condition indicator that turns from
green to red as the filter becomes clogged.
The operator should check the filter
condition on a daily basis and schedule
replacement once the indicator begins to
change from green to red. NOTE: the
filter indicator should be checked with the
engine running.

Service
1. When servicing a filter, use the following
procedure Stop the cranes power unit.
2. Relieve pressure in the filter and line and drain the
filter by cautiously removing the drain port.
3. Rotate cover counter-clockwise. Carefully lifr and
remove the cover.
4. Remove and DISCARD filter element. These
elements are NOT re-useable.
5. Center new element in filter housing.
6. Inspect cover O-ring and replace if necessary.
Apply a light coat of grease on O-ring and install.
7. Replace cover and torque hand tight.
8. Start prime mover and check for leaks.


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K13 High Pressure Filter (40577)

Phone: 713 896 6500 Fax: 713 896 6611

High Pressure Filter Unit
Part No. 40577

MAINTENANCE
The filter unit is equipped with visual filter condition indicator
that turns red when filter becomes clogged. The housing is
equipped with a manual reset monitor that will stay red until reset
by hand. The indicator should be checked daily.

If the element becomes clogged the flow diverts over a bypass
valve around the element.

Once the indicator to changes to red, replace the filter
immediately, check the tank for contamination, and check the
pressure from the corresponding pump.

40577 Page 2 of 2
FILTER REPLACEMENT
1. Stop the cranes power unit.

2. Relieve pressure in the system.

3. Use a wrench on the hexagon-fitting cast into the bottom
of the filter bowl to loosen the bowl. Unscrew the filter
bowl from the filter head.

4. Remove and discard filter element. These elements are
NOT re-useable.

5. Center new element in filter bowl.

6. Inspect cover O ring and back-up ring; replace if
necessary. Apply a light coat of grease on seals and
install.

7. Replace bowl and tighten with a wrench.

8. Start prime mover. Maximize the pressure the system to
check for leaks.

PARTS LIST

PART # DESCRIPTION
1 Contamination Indicator
2 Filter Head
3 By-pass Valve
4 Filter Element
Part No. 40309 for 10 Micron Element (Option)
Part No. 40582 for 5 Micron Element (Standard)
5 Seal Kit (2 part)
6 Filter Bowl


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K14 Gearbox, Planetary 700 Series, Boom (20165)


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K15 Gearbox, Parallel Shaft 700 Series, Main (20165L)


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K16 Gearbox, Parallel Shaft 400 Series, Aux (20163L)


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K17 Gearbox, 4 Pad, Transfer to Pumps (20259)

SHEET OF
DIMENSIONS ARE IN INCHES
COTTA
TRANSMISSION COMPANY, LLC
1301 PRINCE HALL DRIVE BELOIT, WI 53511
REVISION DATE
CHECKED
DATE
DATE
PART NAME
PART NUMBER SCALE
DRAWN
MODEL
APPROVED DATE
PROPRIETARY NOTICE: THIS DRAWING AND ALL INFORMATION THERON IS THE PROPERTY OF COTTA TRANSMISSION COMPANY.
THIS DRAWING IS NOT TO BE COPIED OR USED FOR THE PURPOSE OF MANUFACTURING EXCEPT BY WRITTEN
CONSENT OF COTTA TRANSMISSION COMPANY.
LTR DESCRIPTION ECN DATE BY
ENGINEERING CHANGE NOTICES
C
C
1.00
4.53 4.00 17.00
34.00
17.00
34.00 TYP
8.000
TYP
8.000
TYP
8.000
TYP
8.000
4.00
8.00
TO SURFACE OF SAE "D", "E", & "F" PADS
11.57 TO SURFACE OF SAE "B" & "C" PADS
12.62 TO SURFACE OF "M" PADS
11.72
REF 5.91
.32 DEEP
TYP (4) PLACES
7.753
+.002
-.000
REF
OIL
LEVEL
8.0
REF
OIL
LEVEL
9.0
37 43
57
RATIO: 1 TO 1.015 OVERSPEED
MAX INPUT SPEED: 2200 RPM
MAX INPUT POWER: 1000 HP
MAX OUTPUT POWER PER PAD: 950 HP
MAX INPUT TORQUE: 2500 FT.LB.
APPX WEIGHT: 1400 LBS
APPX 2 GALLON OIL CAPACITY
NOTE:
PUMP PADS WITH O-RINGS MUST BE INSTALLED PRIOR TO OPERATION

COTTA PUMP PAD KIT NUMBERS
PADKIT-1B: SAE "B", 2 AND 4 BOLT PATTERNS
PADKIT-1C: SAE "C", 2 AND 4 BOLT PATTERNS
PADKIT-1D: SAE "D", 4 BOLT PATTERN
PADKIT-1E: SAE "E", 4 BOLT PATTERN
PADKIT-1F: SAE "F", 4 BOLT PATTERN
PADKIT-1M: METRIC (250mm PILOT), 4 BOLT PATTERN (13.00" BOLT CENTER)

COTTA SPLINE ADAPTER KIT NUMBERS
SPLINEKIT-1D2BB: SAE "B-B", 15 TOOTH SPLINE
SPLINEKIT-1D2C: SAE "C", 14 TOOTH SPLINE
34 38
31/64 THRU
TYP (24) PLACES
EVENLY SPACED
ON 20.875 BC
62
82
MAGNETIC DRAIN PLUG
61
SECTION C-C
03
04
11
12
13 23 32 42
47
48
49
65
49
69
02
81
79
80 2-ROW 14"
RUBBER BLOCK DRIVE
13
14 15
21
78
3/4-10 THREAD
1.25 DEEP
TYP (4) PLACES
BOTH SIDES
SAE #1
BELL HOUSING
83
55
36 40
10
59
22
33 42
51
51 61
74
63
24
BREATHER & FILLER
NAMEPLATE
62 MAGNETIC
DRAIN
PLUG
52 53 76
DIPSTICK MAY BE MOUNTED
ON EITHER SIDE
54 3/8 NPT PUMP OUTLET TO COOLER
(APPROX 1.7 GPM @ 2100 RPM)
1-11
1
/
2
NPT
RETURN FROM
COOLER
30 INVOLUTE SPLINE
13 TEETH
8/16 PITCH
TYP (4) PLACES
1/2-13 UNC TAP
.86 DEEP
TYP (32) PLACES
09-MAR-07
PUMP DRIVE, GENERIC
PD2255-0
PD2255
1 1 0.250
JPH 09-MAR-07
NOTE: INSTALL LOCTITE #17430 OR EQUIVALENT
AT ALL MACHINED SPLITLINES UNLESS A
GASKET IS FURNISHED. SEAL ALL NON-MACHINED
INTERFACES WITH SILICONE SEALANT.
NOTE:
TIGHTEN LOCKNUT SCREWS IN LOCKNUT 7 FOOT POUNDS MINIMUM
TIGHTEN SCREWS EVENLY AND OPPOSITE TO ONE
ANOTHER (180 ), GRADUALLY INCREASING THE TORQUE.
AT NO TIME SHOULD THE LOCKING SCREWS BE TIGHTENED
WITHOUT BEING ASSEMBLED ON THE MATING SHAFT, AS THIS
MAY CAUSE AN OVER-DEFLECTION IN THE LOCK SCREW AREA.
QUAD PUMP DRIVE CONFIGURATIONS
PIN
Q)
Durst Fairfield Cotta A a B b C c 0 d Ratio NOTES
(!)
20135 20200 20258 C C B BB E D E D 1 :1

20248 C C B BB E D E D 1:1 TH7001 Input Shaft & TH7002 Mounting Flange
20249 C C B BB E D E D 1 :1.19 TH7001 Inpul Shaft & TH7002 Mounting Flange
20138 C C B BB E D E D 1 : 1 "0" Flywheel Pilot
C!)
20153 E D B BB C C E M 1:1

20156 C C B BB E D E D 1:1.19 Increased output - For electric crane
' /.:7 " .&"/.,
/././ "h"
20173 E F B BB E D E F 1.19:1 Decreased Output
''l'./. // / ;.(/
20195 20255 20261 E D B BB E D E D 1:1 180 CI.Loop Slew Pump on C

20199 E M B BB E D E M 1.19:1 Decreased Output (Two Dual 260 with Big Momma DCV's)
20201 20265 E M B BB E D E M 1.15:1 Decreased Output (Two Dual 260 with Big Momma DeVs)
20213 20224 20259 E D B BB D D E D 1 :1 125 CI.Loop Slew Pump on C
20232 E D C C D D E D 1 :1
20214 E D B BB E D F M 1:1 500cc HydroKraft pump on D
20216 D D C C E D E D 1 :1 W/20215 Clutch Housing & long shaft
20217 B BB E D E D D D 1:1
20219 E M C C E D E M 1.15:1 Decreased Output
20262 C C B BB D D E D 1 :1 TH7001 Inpul Shaft & TH7002 Mounting Flange
FLYWHEEL SAE SIZES
SIZE A B BOLTS
SAE SPLINED SHAFT
L I
0
S K d
SAE
J744 Nom. Dia. No.ofTeeth DP (+0.000.-0.002) J744
0 26.750 25.500 1/2-13 (16) A-A 0.500 9 20/40 1.062 2.00 3.250 0.406 A-A
1 20.875 20.125 7/16-14 (12) A 0.625 9 16/32 1.250 3.25 4.187 0.437 A
2 18.375 17.625 A-H 0.750 11 16/32 1.250 A-H
3 16.875 16.125 3/8-16 (12) B 0.875 13 16/32 1.625 0.375 4.00 5.000 5.750 0.562 B
4 15.000 14.250 B-B 1.000 15 16/32 1.81 2 B-B
5 13.125 12.375 3/8-16 (8) C 1.250 14 12/24 2.187 0.500 5.00 6.375 7.125 0.687 C
CLUTCH PLATE CS 1.375 21 13/32 2.187 CS
Nom. Size C D HOLES CC 1.500 17 12124 2.437 CC
7.5
11
9.5 8.75 11/32" (8) 0 1.750 13 8/16 2.937 0.500 6.00 9.000 9.000 0.812 0
8" 10.375 9.625 13/32" (6) E 1.750 13 8/16 2.937 0.625 6.50 12.500 12.500 0.812 E
10
11
12.375 11.625
13/32" (8)
11 .5" 13.375 13.125
F 2.000 15 8/16 3.435 0.625 7.00 13.781 13.781 1.062 F
M* 2.250 17 8/16
1411 18.375 17.250 17/32" (8)
I
I
f"-"'t:
I
I
"An
"B
II
h
"e"
r-'
" 0"
- Not SAE Standard

-f

I "5"
C "" I iiif 0 $

;-"d"j K 7
LJ
''L''
"I<"
-
!
,
!

,
''--n'
REF # COTTA # DESCRIPTION QTY.
PD2255-0 PUMP DRIVE BASE UNIT
2 02TR8906A KEY 5/8 X 5/8 1
3 0620679A KEY 3/4 X 3/4 1
4 0621072B SPACER 1
10 0628352B BRACKET 1
11 0629854D SHAFT 1
12 0629855D GEAR 68T 1
13 0629856D GEAR 67T 4
14 0630003F COVER 1
15 0630002F CASE 1
21 0629871F BELLHSG #1 1
22 0629874D PUMPHSG 1
23 0629875D SEALHSG 1
24 0629881D DIPSTICK 1
32 80AX109 HHCS 1/2-13X1-1/2 P 6
33 80AX133 HHCS 1/2-13X1-3/4 PLN 4
34 80AX155 HHCS 1/2-13X2-1/4 PLN 28
36 80AX204 HHCS 5/16-18X3-3/4 PLN 4
37 80AX214 HHCS 3/4-10X2 PLN G5 4
38 80BX161 NUT 28
40 80DX103 LOCK WASHER 4
47 80GX334 BRG-BALL 1
51 80IX144 DOWEL PIN 2
52 80J X10 ELBOW 90DEG 1
53 80J X203 BUSHING TAPER-LOCK 1
54 80J X337 PLUG 1
55 80J X1094 CONNECTOR 1
57 80VX2265 TUBE SS 26
59 80J X1095 ELBOW 45DEG 1
61 80J X776 PLUG 1" 2
62 80J X897 PLUG MAGNETIC 2
63 80J X1096 ELBOW 90DEG 1
65 80SX150 SNAPRING 1
69 80TX935 SEAL 1
74 80VX1210 PLUG-9/16-18 O-RING 1
76 80VX1481 BREATHER 1
77 80VX1692 TAG-OIL EMPTY 1
78 80VX1755 PUMP 1
79 80VX1820 BUSHING TAPER-LOCK 1
80 80VX1821 RUBBER BLOCK DRIVE 2-14" 1
81 80VX1839 LOCKNUT 1
82 80VX2195 NAMEPLATE 1
83 80VX1766 TUBE SS 11.5

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K18 Gearbox Slew (20071)

20071 Page 1 of 29
Phone: 713 896 6500 Fax: 713 896 6611
20 March 2000
Slew Gearbox and Shaft
Disassembly and Re-Assembly Instructions
Part No. 20071
INTRODUCTION
This manual is a step-by-step guide to assembly and disassembly of hub drive units. It is
designed for the customer or shop mechanic who is repairing a particular model hub drive.
Manual users should note that each part mentioned is followed by an identification number
enclosed in parentheses. These part numbers may be referred to in the Parts List section of this
manual and on the cross-sectional view of this unit. A print of each tool discussed in this
manual is shown in the tooling section. Users should familiarize themselves with the
procedures for roll and leak testing and bolt tightening and torquing found on the following
two pages before getting started.
20071 Page 2 of 29
SAFETY
Standard safety practices should be followed during the disassembly and assembly procedures
described. Safety glasses and safety shoes should be worn. Heavy, heat resistant gloves should
be used when heated components are handled. Be especially alert when you see the word
CAUTION: This indicates that a particular operation could cause personal injury if not
performed properly or if certain safety procedures are not followed.
ROLL AND LEAK TESTING
These drive units should always be roll and leak tested before disassembly and after
assembly to make sure that the unit's gears and seals are working properly. The
following information briefly outlines what to look for when performing these tests.
ROLL TEST
The purpose of a roll test is to determine if the unit's gears are rotating freely and properly.
You should be able to rotate the gears in your unit by applying a constant force to the roll
checker. If you feel more drag in the gears only at certain points, then the gears are not rolling
freely and should be examined for proper installation of defects. Some gear packages roll with
more difficulty than other. Do not be concerned if the gears in your unit seem to roll hard as
long as they roll with consistency.
The 500 Series Gearbox is a 116:1 ratio, therefore, rotate the input splines 116 times in each
direction to complete the roll test.
LEAK TEST
The purpose of a leak test is to make sure that the unit is air tight. You can tell if your unit has
a leak if the pressure gauge reading on your air checker starts to fall once the unit has been
pressurized. Leaks will most likely occur at the main seal or wherever "O" ring or gaskets are
located. The exact location of a leak can usually be detected by brushing a soap and water
solution around the main seal and where "O" rings or gaskets meet the exterior of the unit then
checking for air bubbles. If a leak is detected in a seal, "O" ring, or gasket, the part must be
replaced.
OIL INFORMATION
See Operation and Maintenance Manual Section D, Lubrication.
NOTES:
Higher temperatures require more frequent oil changes.
These units run cooler and last longer if filled with synthetic lubricant.
Change the oil after the first 50 hours of operation and every 1000 hours thereafter.
Never exceed one year between oil changes.
20071 Page 3 of 29
REFILLING GEARBOX LUBRICANT
1. Drain the old oil (approx. 3 gal.) by removing the plug on the bottom on the gearbox, then
removing the one at the highest point.
NOTE: Drain oil when hot to help remove any sludge buildup.
2. Inspect the old oil for sand size or larger particles. If
these are present, the unit may require repair or
replacement in the near future.
3. After draining, replace the lower plug and remove the
plug located 90 to the left of the upper plug.
4. Slowly fill the unit through the top plug until oil runs out
the side plug.
5. Install the side and top plug. Test for leaks.
6. Recheck fluid level after one day of operation.
TIGHTENING AND TORQUING BOLTS
NOTE: DO NOT use impact wrenches to tighten bolts. All bolts, especially the shoulder bolts,
must be tightened by hand.
The following steps describe the proper procedure for tightening and torquing bolts or socket head cap
screws (shoulder bolts) in a bolt circle.
1. Tighten (but do not torque) bolt A until snug.
2. Go to the opposite side of the bolt circle and
tighten bolt B until equally snug.
3. Continue around bolt circle and tighten the
remaining bolts.
4. Now use torque wrench to apply the specified
torque to bolt A.
5. Continue around the bolt circle and apply an
equal torque to the remaining bolts.
NOTE: Shoulder bolts should be tightened and
torqued last.
20071 Page 4 of 29
MAIN DISASSEMBLY
1. Remove the two magnetic pipe plugs (7)
from cover (6) and drain the oil from the
unit.
2. Remove the 16 bolts (17) and four
shoulder bolts (18) that hold cover (6) in
place.
3. Remove lockwashers (22) from cover (6).
4. Lift cover (6) off the hub (1G), and set it,
small end down, on table.
5. Remove "O" ring (5) from the counter-
bore around rim of cover (6).
6. Remove thrust washer (8) from the
counterbore in the center of cover (6).
7. Remove thrust washer (15), thrust bearing
(16), and the other thrust washer (15)
from the counterbore in the center of
carrier (3).
8. Lift ring gear (4) off of hub (1G).
9. Lift carrier sub-assembly (3) out of hub
(1G).
10. Lift input gear (13) out of carrier sub-
assembly (3). Now do step 14.
11. Remove "O" ring (5) from the
counterbore around the rim of hub (1G).
12. Remove thrust washer (15), thrust bearing
(16), and the other thrust washer (15)
from bearing plate (1K).
13. At this point the main disassembly is
complete.
HUB-SHAFT DISASSEMBLY
1. Set hub (1G) on its large end. Remove
bolts (1R) from seal carrier (1Q).
2. Lift seal carrier (1Q) off of seal
3. Remove "O" ring (1S) from seal carrier
(1Q).
4. Remove seal (1B) from the small end of
hub (1G).
5. Remove the three magnetic pipe plugs
(1P) from the underside of hub (1G).
6. Remove pipe plug (1T) from its hole near
seal carrier in hub (1G).
7. Turn hub (1G) over onto its output shaft,
and cut the safety wires connecting bolts
(1N) to the bearing plate (1K). Remove
bolts (1N) from bearing plate (1K).
8. Remove bearing plate (1K) from output
shaft (1A).
9. Remove shims (1L) from output shaft
(1A).
10. Lift internal gear (1J) out of hub (1G).
11. Lift hub (1G) off of output shaft (1A).
12. Using a punch and hammer, remove
bearing cone (1D) from output shaft (1A).
13. Using a punch and hammer, carefully
hammer bearing cup (1C) out through the
small end of hub (1G).
NOTE: Be very careful not to strike the
counterbore (where the cup is located)
with the punch.
20071 Page 5 of 29
14. Turn hub (1G) over onto its large end.
Using a punch and hammer, carefully
hammer bearing cup (1E) out through the
large end of the hub.
NOTE: Be very careful not to strike the
counterbore (where the cup is located)
with the punch.
15. At this point the hub-shaft disassembly is
complete.
INTERNAL GEAR DISASSEMBLY
1. Using a punch and hammer, carefully
hammer bearing cone (1F) off of internal
gear hub (1H).
2. Remove bolts (1M) from plates (11).
3. Remove plates (11) from internal gear
(1J).
4. Lift internal gear hub (1H) out of internal
gear (1J).
5. At this point the internal gear disassembly
is complete.
CARRIER DISASSEMBLY
CAUTION: Safety glasses should be during
this step
1. Using retaining ring pliers, remove
retaining ring (3H) from the groove in
planet shaft (3E).
2. Remove spacer (3G) from planet shaft
(3E).
3. Remove planet shaft (3E) from carrier
housing (3A).
4. Remove cluster gear (31T), with bearing
cones, from carrier housing (3A).
5. Using an alignment punch and hammer,
drive roll pin (313) out of carrier housing
(3A).
6. Remove bearing cones (31)) from cluster
gear (3F).
7. Set cluster gear (317) onto any base that
is deep enough and wide enough to allow
bearing cups (3C) to drop out of the gear.
Using a punch and hammer, carefully
hammer bearing cups (3C) out through
each side of cluster gear (31T).
8. Repeat steps 1-7 to remove the two
remaining cluster gears.
9. At this point, the carrier disassembly is
complete.
20071 Page 6 of 29
CARRIER SUB-ASSEMBLY
1. Using bearing cup pressing tool to press
one bearing cup (3C) into each side of
cluster gear (3F).
2. Place one bearing cone (3D) into each
bearing cup (3C) in cluster gear (3F).
3. Set carrier (3A) on table with one set of
planet shaft holes over the edge of table.
Insert assembled cluster gear (3F) into
carrier (3A).
4. Insert a planet shaft (3E) through one set of
planet shaft holes. The end of the planet
shaft with the retaining ring groove should
be inserted first.
20071 Page 7 of 29
5. Place spacer (3G) onto the end of planet
shaft (3E).
CAUTION: Safety glasses should be worn
during this step:
6. Insert retaining ring (3H) into the groove on
the end of planet shaft (3E).
7. Using an alignment punch, align the roll pin
holes in planet shaft (3E) and carrier (3A),
then hammer roll pin (3B) into the aligned
roll pin holes.
8. Check endplay by attaching an endplay
indicator on the top of cluster gear (3F) and
using screwdriver to push up on cluster
gear. A reading of .001, .002, or .003 is
normal. If the reading is not one of these
three, change spacer.
9. Stamp 1 (for .001), 2 (for .002), or 3 (for
.003) on carrier housing (3A) next to cluster
gear (317).
20071 Page 8 of 29
10. Repeat steps 1-7 to install the two
remaining planet gears.
11. At this point the carrier sub-assembly is
complete.
20071 Page 9 of 29
HUB-SHAFT SUB-ASSEMBLY
1. Using bearing cup pressing tool to press
bearing cup (1E) into the counterbore in the
deep end of hub (1G). Make sure the cup
sits square with the counterbore before
pressing.
2. Turn hub (1G) over. Using bearing cup
pressing tool to press bearing cup (1C) into
the counterbore in the shallow end of hub
(1G). Make sure the cup sits square with
the counterbore before pressing.
3. Set output shaft (1A) down on your work
surface so that the end with the eight bolt
holes faces up. Using bearing cone
pressing tool to press bearing cone (1D)
onto output shaft (1A).
4. With small end down, lower hub (1G) onto
output shaft (1A). Bearing cone (1D)
should fit into bearing cup (1C).
20071 Page 10 of 29
5. Set internal gear hub (1H) onto your work
surface so that the hub's small end faces up.
Using bearing cone pressing to press
bearing cone (1F) onto the raised edge of
internal gear hub (1H).
6. Lower internal gear hub (1H), small end
down, into internal gear (1J).
7. Place the four plates (1I) over the bolt holes
in internal gear (1J).
8. Apply Loctite 271 to the threads of the
eight bolts (1M).
NOTE: Loctite is an anaerobic adhesive. Once
out of contact with the air, it sets.
Therefore, once the bolts have been placed
into the bolt holes they must be tightened
and torqued immediately or they will be
impossible to turn.
9. Insert bolts (1M) into the bolt holes in
internal gear (1J) and tighten. Then apply a
torque of 20-25 ft- lbs to each bolt (1M).
20071 Page 11 of 29
10. Lower internal gear (1J), with internal gear
hub (1H) down, into hub (1G). Bearing
cone (1F) should fit into bearing cup (1E).
11. Using a micrometer, measure the width of
bearing plate (1K) at several points next to
each of the plate's two small measurement
holes. Find the average of all these
measurements and record this value as the
"average plate width."
12. Place bearing plate (1K) on top of output
shaft (1A). Align the bolt holes in the
bearing plate and output shaft.
13. Tighten one bearing plate bolt (1N) into the
bolt hole next to one of the two small
measurement holes in bearing plate (1K).
Tighten a second bearing plate bolt (1N)
into a bolt hole directly opposite from the
first bolt.
14. Apply a total torque of 200 in-lbs. in 40-50
in-lb. increments to each bearing plate bolt
(1N). Rotate the hub several times in both
clockwise and counter clockwise directions
after each increment.
20071 Page 12 of 29
15. Using a depth micrometer, measure the
depth of each of the two small measurement
holes in bearing plate (1K). Find the
average of the two measurements to three
decimal places (0.???) and record this value
as "average hole depth." Now subtract the
"average plate width" (found in step 11)
from "average hole depth" and record this
value as the gap measurement."
16. Refer to the shim chart on page 22 of this
manual to determine the proper shim width
to be used for your calculated "gap
measurement."
17. Remove the two bolts (1N) from the
bearing plate (1K).
18. Lift the bearing plate (1K) off the output
shaft (1A).
19. Measure the shims (1L) and select the
correct number of them.
20071 Page 13 of 29
20. Place the correct amount of shims (1L) onto
the top of output shaft (1A). Align the bolt
holes in the shims and the output shaft.
21. Place bearing plate (1K) on shims (1L).
22. Apply Loctite 277 to the threads of all
bearing plate bolts (1N).
NOTE: Loctite is an anaerobic adhesive. Once it
is out of contact with the air, it sets.
Therefore, once the bolts have been placed
into the bolt holes they must be tightened
and torqued immediately, or they will be
impossible to turn.
23. Tighten bolts (1N) into the bolt holes in
bearing plate (1K). Torque the bolts to 30-
35 ft.-lbs.
24. Safety wire the bolts together in groups of
two. To do this follow steps A through I:
20071 Page 14 of 29
A. Choose two bolts to be safety wired
together and position yourself so you can
locate one bolt to your right and one bolt to
your left.
B. Align the safety wire holes in the top of
each bolt so they are roughly horizontal.
C. Starting with the bolt on your left, draw a
length of wire through the bolt's safety wire
hole from right to left so that the end of the
wire that went through the hole ends up
pointing away from the other bolt.
D. Take the end of the wire that has gone
through the wire hole and wind it clockwise
around one half of the bolt until it meets the
other end of the wire.
E. Twist the two ends of the wire together and
wind the twisted length counterclockwise
around half of the other bolt until it reaches
the safety wire hole on the right side of the
bolt.
20071 Page 15 of 29
F. Pull one of the loose ends of the wire from
right to left through the safety wire hole of
the right-hand bolt so that the end of the
wire that went through the hole ends up
pointing toward the first bolt.
G. Take the end of the wire that has gone
through the hole and wind it clockwise
around half of the bolt until it meets the
other end of the wire.
H. Twist the two ends of the wire together a
few times and then cut away any remaining
loose ends.
I. Repeat steps A to H to wire the remaining
bolts together.
25. Turn hub (1G) over. Wipe seal (1B) clean
with a soft cloth. Make absolutely sure that
there is no dirt or oil on the seal. Insert seal
(1B) into the small end of hub (1G). The
side of the seal with the small lip around
one edge should be inserted first.
26. Set seal carrier (1Q) on table, small end
down. Grease "O" ring (1S) and place it
into the counterbore of seal carrier (1Q).
Then wipe seal carrier (1Q) clean with a
cleaning solvent.
20071 Page 16 of 29
27. Place seal carrier (1Q) over seal (1B).
Align bolt holes in seat carrier and output
shaft.
28. Tighten bolts (1R) into the bolt holes in seal
carrier (1Q), and apply a torque of 23-27 ft-
lbs to each bolt (1R).
29. Apply a light coat of "Never-Seize" to
magnetic pipe plugs (1P), and tighten the
three magnetic plugs (1P) into the pipe plug
holes on the underside of hub (1G).
30. Apply a light coat of "Never-Seize" to pipe
plug (1T) and install it in the hub near the
seal carrier.
31. At this point the hub-shaft sub-assembly is
complete.
20071 Page 17 of 29
MAIN ASSEMBLY
1. Set hub (1G) on its output shaft (1A). Place
one thrust washer (15), one thrust bearing
(16), and another thrust washer (15), in that
order, on bearing plate (1K).
2. Grease one "O" ring (5) and place it into the
counterbore around the edge of hub (1G).
3. Set input gear (13) onto end of output shaft
(1A).
4. Look at carrier sub-assembly (3). Locate
the punch mark on each cluster gear (3F).
Align all punch marks at 12 o'clock. See
Figure 1.
Figure 1
20071 Page 18 of 29
7. Using a timing fixture or timing gear to
keep the cluster gear punch marks in their
correct position, lower carrier sub-assembly
(3) into hub (1G), into mash with input gear
(13). The smaller side of each cluster gear
(3F) should mesh with internal gear (1J).
Make sure the punch marks remain in their
correct positions. Go on to step 8.
8. Find the shoulder bolt hole on hub (1G)
marked with an "X". Note the location of
the other three shoulder bolt holes in Figure
2. Mark the location of each shoulder bolt
on the side of the hub with chalk.
Figure 2
20071 Page 19 of 29
9. With squared shoulder side down, place
ring gear (4) onto hub (1G). The ring
gear should mesh with the larger side of
each cluster gear. Align the shoulder bolt
hole marked with an "X" on the ring gear
over any one of the marked shoulder bolt
holes in the hub.
NOTE: "A" drives have a coupling. "B" drives
do not. If you have a "B" drive, go to
step 11.
10. Place coupling (19) onto input shaft (11).
End of coupling with groove around it
goes down into input shaft. NOTE: Not
used on 20071 Gearbox.
11. Spray a light coat of oil inside hub (1G).
12. Set cover down on its closed face. Grease
one side each of one thrust washer (15),
the remaining thrust bearing (16) and the
other thrust washer (15). Place them
greased side down, in that order, over the
raised edge in the center of cover (6).
13. Grease remaining "O" ring (5) and place
it in the counterbore in the front of cover
(6).
20071 Page 20 of 29
14. Grease thrust washer (8) and place it into
the counterbore in the center of cover (6).
15. Note the location of shoulder bolt holes
on cover. Place cover (6) on ring gear
(4). Align the pipe plug holes in the
cover with the pipe plugs in the hub
according to Figure 3. Once the pipe plug
holes have been aligned, check to see that
the cover shoulder bolt hole marked with
an "X" is aligned over one of the marked
shoulder bolt holes in the hub.
Figure 3
16. Place lockwashers (22) over the bolt holes
in cover (6).
20071 Page 21 of 29
17. Insert the four shoulder bolts (18) into the
marked shoulder bolt holes and tighten by
hand.
18. Insert the 18 bolts (17) into the remaining
holes in cover (6) and tighten.
19. Apply a torque of 175 ft- lbs to each
shoulder bolt (18). Apply a torque of 300
ft- lbs to each grade 8 bolt (17).
20. Roll test the unit in both clockwise and
counterclockwise directions. Perform the
same number of turns in each direction as
the ratio of the unit. The 20071 slew
gearbox is a 116:1 ratio.
21. Leak test the unit at a press psi for 2-3
minutes.
20071 Page 22 of 29
22. Apply a light coat of "Never-Seize" to the
two magnetic pipe plugs (7), and tighten
magnetic plugs (7) into the pipe plug
holes in cover (6).
23. At this point the main assembly is
complete.
20071 Page 23 of 29
SHIM CHART
GAP (in.)
SHIM WIDTH
(in.)
GAP (in.)
SHIM WIDTH
(in.)
000 to .002 006 .030 to .032 036
.002 to .004 008 .032 to .034 038
.004 to .006 010 .034 to .036 040
.006 to .008 012 .036 to .038 042
.008 to .010 014 .038 to .040 044
.010 to .012 016 .040 to .042 046
.012 to .014 018 .042 to .044 048
.014 to .016 020 .044 to .046 050
.016 to .018 022 .046 to .048 052
.018 to .020 024 .048 to .050 054
.020 to .022 026 .050 to .052 056
.022 to .024 028 .052 to .054 058
.024 to .026 030 .054 to .056 060
.026 to .028 032 .056 to .058 062
.028 to .030 034
PARTS LIST
ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION
1 1 Hub Shaft Sub-Assy. 3 1 Carrier Sub-Assy.
1A 1 Output Shaft 3A 1 Carrier
1B 1 Seal (Face) 3B 3 Roll Pin
1C 1 Bearing Cup 3C 6 Bearing Cup
1D 1 Bearing Cone 3D 6 Bearing Cone
1E 1 Bearing Cup 3E 3 Planet Shaft
1F 1 Bearing Cone 3F 3 Cluster Gear
1G 1 Hub 3G 3 Spacer
1H 1 Internal Gear Hub 3H 3 Retaining Ring
1I 4 Plate 4 1 Ring Gear
1J 1 Internal Gear 5 2 O Ring
1K 1 Bearing Plate 6 1 Cover
1L 1 Shim Set 7 1 Magnetic Pipe Plug
1M 8 Bolt 8 1 Thrust Washer
1N 8 Bolt 13 1 Input Gear
1P 3 Magnetic Pipe Plug 15 4 Thrust Washer
1Q 1 Seal Carrier 16 2 Thrust Bearing
1R 6 Bolt 17 16 Bolt
1S 1 O Ring 18 4 Shoulder Bolt
1T 1 Pipe Plug 22 20 Lockwasher
24 1 I.D. Plate
25 4 Drivescrew
20071 Page 24 of 29
Phone: 713 896 6500 Fax: 713 896 6611
CUTAWAY VIEW OF 20071
SEATRAX '
-=- APPLY A LIGHT COAT
OF GREASE
APPLY A LIGHT COAT
I' OF OIL
APPLY A LIGHT COAT
OF NEVER-SEIZE
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20071 Page 25 of 29
Phone: 713 896 6500 Fax: 713 896 6611
Pressing Tool for Bearing Cup 3C
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20071 Page 26 of 29
Phone: 713 896 6500 Fax: 713 896 6611
Pressing Tool for Bearing Cup 1E
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15'

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20071 Page 27 of 29
Phone: 713 896 6500 Fax: 713 896 6611
Pressing Tool for Bearing Cup 1C
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20071 Page 28 of 29
Phone: 713 896 6500 Fax: 713 896 6611
Pressing Tool for Bearing Cone 1D
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20071 Page 29 of 29
Phone: 713 896 6500 Fax: 713 896 6611
Pressing Tool for Bearing Cone 1F
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TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K19 Hoist Assembly Boom 800 Series (TB1075)

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REV. DESCRIPTION
THIS DOCUI.4ENT AND THE CONTENTS HEREIN MAY NOT BE
EXPRESS WRITTEN CONSENT OF SEAlRA)( INC.
MONARCtf
seeKIng
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61
PO BOX 840687
Phone: 713 896 6500
DRN. DATE
SEATRAX
.X .030 MACHINING LS. .S"
.XX .015 FABRICATION Ll. H PATENT NO'S. US 4,280,628 US 5,310,067 BOOM HOIST EXPLODED VIEW ASSEMBLY
.xxx .005 MACH. FINISH US 5,328,040 GB 2253604 B GB 2254308 8 700 SERIES S90
FRACTIONS TO 3' 1!16"
OVER 3' DRAWN SCALE-B- DATE DWG/PART NO. SHEET 1 of 2 REV.
.005 TIR MS N.T.S. 5/17/05 TB 1 075 a

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K20 Hoist Assembly Main 800 Series (TB1078)


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K21 Hoist Assembly Aux 400 Series (TB1092)

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MACHINING ..:::i ,' PATENT N . G8 225360
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.XXX .005TQ 3' 1/1f
FRACTIONSOVER 3' l/B 005 TIR DRAWN
NCENTRICITY .
MACHINING IN INCHES
ALL DIMENS MDS NTS
DRN. DATE
MONARCH. Houston, 6500
Ph,,, 713 1ST ASSEMBLY
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FOR SHEET 1 of 2
DWG/p"'T NO. TB 1 092N 0

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K22 J oystick (40437)

Phone: 713 896 6500 Fax: 713 896 6611

Boom / Slew Joystick
Part No. 40437 (Replaced 40160)

Operation

This unit offers pressure-related fine adjustment of valves, and pump and motor control. In
neutral, the operating element is held in zero position by return spring (4). When lever (1) is
operated, plunger (5) is pushed against the return spring (4) by the switching plate (7). At the
same time, the regulating spool (2) is pushed through the regulating spring (3). When the
regulating stroke begins, there is a connection from port B via bore (8) and ports 1,2,3, or 4 to
the unit to be adjusted. The outlet pressure is related to the lever position, determined by the
operator, and the regulating spring characteristic. Rubber boot (9) protects the mechanical
components from contamination.

Hydraulic Operated Joystick
Single Lever - Dual Axis

This hydraulic pilot unit operates on the basis of direct operating pressure reducing valves.

Parts List

Item Description Item Description
1 Grip-Handle 31 Kit-Plunger & Guide Ports
1,2,3,4

2 Kit-Straight Lever 32a Kit-Regulating Unit curve
162 ports 1& 3

3 Boot-Rudder Straight 32b Kit-Regulating Unit curve 39
ports 2 & 4

4 Kit-Cardan Straight Lever 33 Spring- Return
5 Plate-Rretaining
9 Upper Body
10 Kit-Seal
11 Lower Body


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K23 J oystick (TC3075)

Phone: 713 896 6500 Fax: 713 896 6611

TC3075 Joystick.doc Page 1 of 3
Joystick Control Unit
Part No. TC3075
(Modified 40162)
(Includes 40436 Single Lever Joystick)

Operation

This unit offers pressure-related fine adjustment of valves, and pump and motor control. In
neutral position, the operating element is held in zero position by return spring (4). When
lever (1) is operated, the plunger (5) is pushed against the return spring (4) by the rocker plate
(7). At the same time, the control spool (2) is moved by the regulating spring (3). At the start
of control, a flow is created from the P port via passage (8) (shown in the neutral position)
and to the selected outlet port. Lever movement and the type of control spring being used
determine outlet pressure. When used with a pilot supply system, remote pressure control is
possible without the need for a separate pilot pump. Rubber boot (9) protects the mechanical
components from contamination.

Hydraulic Operated Joystick
Dual Lever - Single Axis

ITEM DESCRIPTION
1 Operating Control
2 Control Spool
3 Control Spring
4 Return Spring
5 Plunger
6 Housing
7 Operating Plate
8 N/A
9 Rubber Boot

This hydraulic pilot unit operates on the basis of direct operating pressure reducing valves.


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TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K24 Motor, Gear Type (Slew) (40113)

40113 Page 1 of 2
Phone: 713 896 6500 Fax: 713 896 6611
Slew Motor
Part No. 40113
1.5 Gears
General Instructions
NOTICE:
These services instruction are generic and applicable to all gear motors and pumps used on the
SeaTrax Cranes. The instructions will familiarize you with the single and multiple pumps and
motors, their component parts, and the relative position of each part. Proper methods for assembly,
or disassembly, of these units are necessary to insure best performance and longer working life.
Use Specific Assembly Drawings and their item numbers when ordering parts.
Dirt is the enemy of any hydraulic system. The first requirement of good maintenance of hydraulic
equipment is cleanliness. Make sure you disassemble and assemble your hydraulic equipment
in a clean area.
It is a good idea to check all replacement part closely before installing to insure that no damage
occurred during shipment. Use caution in gripping all parts in the vise to avoid damaging
machined surfaces.
A pump must be driven in the direction of rotation for which it was built: otherwise, pressure will
blow the shaft seal. Check the exploded view below for proper direction of rotation.
40113 Page 2 of 2
Part No. 40113
Order Parts by using motor part number and required item numbers with descriptions listed below.
Order Parts for a 40113 Motor with 1.5 Gears
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
1 Snap Ring 1 12 Drive Shaft and Gear Set, 1.5 1
2 Spacer or Outboard Bearing 1 13 Gasket Seals 2
3 Seal Retainer 1 14 Gear Housing 1
4 O Ring 1 14A Dowel Pins 4
5 Seal 1 20 Port End Cover 1
6 Shaft End Cover 1 21 Name Plate 1
7 Check Assemblies or Plug 2 22 Drive Screws 2
8 Ring Seal 4 23 Washers 8
9 Roller Bearing 4 24 Studs or Cap Screws 8
10 Pocket Seals 12 25 Nuts (N/A with Cap Screws) 8
11 Thrust Plates 2
NOTE: This motor is ported
through the rear cover (20),
not the Gear Housing (14),
but the parts are similar.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K25 Motor, Piston Type c/w Motor Control Valve (40410) For Boom, Load & Aux

HP Hoist Motor40410,18,19.doc Page 1 of 2

Phone: 713 896 6500 Fax: 713 896 6611

Hoist Motor

Part Nos.
40410, 40418 & 40419

All piston motors have a micro-finished interior surface. Any damage to this surface will affect
motor performance.

This motor is suggested as part of the two year spares listing. If it is not performing properly, it
should be replaces with a new unit. Repair in the field is not feasible.
HP Hoist Motor40410,18,19.doc Page 2 of 2
Functional Description

This Fixed Displacement Bent Axis Piston Motor is designed to produce torque at the shaft in
open or closed hydraulic circuits. The motor basically consists of the housing (1), the port
plate (2), and the rotary group (3-8).

The cylinder barrel (6) rotates on the control plate (7) which has two kidney shaped slots, one
inlet and outlet. The motor is rotated with a fluid flow to the inlet port A or B. This fluid via
the inlet kidney in control plate (7) extends the piston. In the bent axis principle, at any given
instant three pistons are open to the inlet kidney, three to the outlet kidney and one in the cross
over position. As the pistons (5) move in and out of their bore, the cylinder barrel (6) rotates
producing output torque to the PTO shaft (3) which is supported by the heavy duty tapered
roller bearings (4). The shaft speed is directly proportional to the input flow and inversely
proportional to the displacement (size). The output torque is dependent on the maximum
operating pressure. The center pin (8) keeps the barrel aligned and the forces balanced. The
upper most of the two ports, which varies depends on the particular installation, (9) is used as a
case drain port (T) and the lowest port accepts low-pressure hydraulic oil which acts as a motor
coolant.

When installing a new unit, replace the O-ring (80031) and lubricate the splines with anti-seize.
HP Hoist Motor.doc

Phone: 713 896 6500 Fax: 713 896 6611

Major Subassemblies
Parts List

.
Part No. Description Quanity
1 Housing 1
2 Port Plate 1
3 PTO Shaft 1
4 PTO Shaft Bearings 2
5 Pistons 7
6 Cylinder Barrel 1
7 Valve Plate 1
8 Center Pins 1
9 Threaded Plug 1

SE.ATRAX
-----------
Rotary Group
2
Phone: 713 896 6500 Fax: 713 896 6611
Rotary Group
Parts List
8 3 6 7
11
MONARCH
SecKing
M /I. R I NEe R /I. N E S<I')
Spllr'1ed
1 Drive Shaft w/Bearings 1
2 Hydraulic Section 1
3 Front Cover 1
4 Disc 1
5 Retaining Plate 1
6 Retaining Ring 1
7 Shaft Seal Ring 1
8 O-Ring 1
9 Shim 2
10 Shim 1
11 Slot Head Screw 7
SE.ATRAX
Detail X
M 5:1
2
--
Phone: 713 896 6500 Fax: 713 896 6611
Rotary Group
Hydraulic Section
Parts List
5 6
Installation as
per markings
on the piston ring
7 7
1 Cylinder Barrels 1
2 Control Plate 1
3 Control Pin 1
4 Piston 7
5 Spring Collar 1
6 Cup Spring 4
7 Priston Ring 14
MONARCH
SeeKing
MAR I NEe RAN E ~
3
4

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K26 Overhaul Ball Assembly (5370-005)


TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K27 Main Block Assembly (TA3135)

L
(")
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o

A
8'-3"
A
SECTlON A-A
SCALE: 2X
CONFIDENTIAL
(j
I I
LJ
6
lui
I I
L
SEE NOTE 1
co
\
'0 2
l:IQIES;
1. DRILL & INSERT ITEM #18 1l1RU ITEM #7 AT FINAL ASSEMBLY.
2. ADDED DATA AS SHOWN ON ITEM #21.
(a.c. TO ASSIGN SERIAL NUMBER.)
3. WORKMANSHIP IS TO BE OF PROFESSIONAL aUALITY.
CONFIDENTIAL
co
\
.X .030
TOTAL WEIGHT = 4824.5#
/'
BLOCK
/ CRANE SERIAL NO. \
f
ASSEMBLY PART NO TA3135 \
STATIC LOAD CAP. 75 TONS
\
PERSONNEL CAP 19 TONS
MIN. SERVICE TEMP 15 'F
9
BLOCK ASS'Y WT 4825 LBS
g
THIS DOCUMENT AND THE CONTENTS HEREIN MAY NOT BE
EXPRESS WRITIEN CONSENT OF SEATRAX INC.
/
)
'j!
...
SEATRAX
.xx .D15 FABRICATION PATENT NO'S.
.XXX .005 MACH. FINISH
FRACTIONS TO 3' 1!16- REV.
OVER 3' 1/8"
MACHINING CONCENTRICITY .005 TlR
DIMENSIONS IN INCHES GAM o

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K28 Pump Variable Displacement Piston Type (40387) For Boom, Load & Aux

Phone: 713 896 6500 Fax: 713 896 6611
1 July 2000
High Pressure Variable Volume Pump
Part Nos. 40387(260cc)
NOTE: Because of the close tolerances of this pump, rebuilding in the field is NOT recommended.
The pump should be replaced. The following instructions are for reference only.
Phone: 713 896 6500 Fax: 713 896 6611
Contents
Pressure Setting Procedure 3
Sectional View 4
General Repair Instructions 5
Seal Kits and Sub-assemblies 6-7
Sealing of the Drive Shaft 8
Sealing the Regulator Housing 8
Sealing the Pump Support 10
Checking the Directional Valve 10
Removing the Impeller 11-12
Disassembly of the Regulator 13
Removing the Port Plate 14
Removing the Rotary Group 15
Disassembly of the Rotary Group 16
Disassembly of the Hydraulic Control 17
Inspection Notes 18-36
Assembly of the Pump 37-38
Tightening Torques 39-40
Assembly of the Pump 41-46
Tightening Torques 47
Safety Regulations 48-49
Phone: 713 896 6500 Fax: 713 896 6611
29 June 1999
Setting Pressure
Locate the pump, corresponding control valve, and brake actuator. On the brake actuator, disconnect
and plug the line running from the brake release valve to the brake release actuator.
Figure 1 shows the pressure regulator assembly which includes the pressure compensator. Locate the
compensator on the pump (there may be a cone shaped cover over it that must be removed). Loosen
the jam nut and screw this all the way in.
On the control valve, locate the pressure relief valve cartridge (this may be covered by a disposable
cap). Loosen the jam nut and back out the adjustment screw one full turn.
Start the engine and let it run for five minutes. Have the operator drive the corresponding hoist in the
full down position at full throttle (the pressure should read about 2,000 psi). This should be held
during the complete adjustment process. Since the brake release line has been disconnected the hoist
should not move.
On the control valve, slowly turn the screw in until the pressure reaches 5,800 psi. Lock the jam nut at
this pressure.
Return to the pump and back out the adjustment screw until the pressure drops to 5,400 psi. Lock
down the jam nut. NOTE: 60 Series boom hoist pumps are set to 5,000 psi.
Reconnect the brake release line. Recheck pressures. Pressure adjustment on the pump and valve is
now complete.
Pressure Compensator
Figure 1
Regulator Assembly
Repair Instructions Sectional view
Setting
Impeller (play)
Setting
Hydraulic stop
Setting measure "D"
Cylinder preload
Repair Instructions
Attention!
Observe the following notices when carrying out repair
work at hydraulic aggregates!
Close all ports of the hydraulic aggregates.
Replace all seals.
Use only original HYDROMATIK spare parts!
Check all seal and sliding surfaces for wear.
Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.
Fill up hydraulic aggregates with hydraulic oil
before start- up.
General repair instructions
Repair Instructions
1
Seal kit for drive shaft.
2
External seal kit.
3
Housing
4
Complete rotary group.
5
1. Hydraulic control small size
2. Hydraulic control big size
Seal kits and sub-assemblies
6 Brueninghaus Hydromatik
Repair Instructions
8
Pump support
9
Locking plate
10
Impeller
Sub-assemblies
6
Valve plate
7
Complete regulator
Repair Instructions
11
12
Protect drive shaft.
13
Loosen retaining ring and remove it,
press away front cover.
14

1. Press in a new drive shaft seal with bush, make sure
correct position.
2. Deep running groove! Insert shim before the shaft seal.
Shim NG 250 I 9831587 75 x 90 x 1
Sealing of the drive shaft
Repair Instructions Sealing of the regulator housing
Remove screws and press off regulator,
thereby make sure that sealing surface is
not damaged.
1. Power control
2. Cross-Sensing-valve
3. Load-Sensing-valve
Note:
Do not change position of adjustment
screws. Remove complete set of threaded
bush with adjustment screws.
15
Assembly position!
Repair Instructions
16
Pump support for auxiliary through drive
Remove locking srews and press off support, make sure
sealing surface is not damaged.
17
Locking plate without auxiliary through drive.
18
Directional valve
19
1. Connection piece, 2.O-ring, 3.Bush, 4.Valve poppet
Part 3 can only be removed by extraction device
(threaded spindle).
20
* Press-in bush
Projection of pump support / Checking of the directional valve
1
2
3
4
*
Repair Instructions
22
Remove pump support with coupling hub or cover.
23
Remove retaining ring and sealing disc.
24
Remove retaining ring and shim(s).
Removing of the impeller
21
Repair Instructions
25
Remove impeller.
26
Press off key.
Remove shim(s) and retaining ring
27
Reassembly in reverse order.
Note: Make sure that distance between impeller and housing is
correct, compensate with shims!
Reference dimension size 200/ 250 - 22,5 mm
28
Control:
Assembly position:
1. Press down manually the shaft.
2. * Play 0,2
+0,1
mm
Removing of the impeller
0,2
+0,1
mm
spielfrei
....
*
Repair Instructions Disassembly of the regulator
Remove metering piston with bush from control piston.
30
Remove regulator housing.
Note: Do not change position of adjustment screws.
29
Repair Instructions Removing of the port plate
32
Mark position of valve plate, remove locking screws.
Screw in ring screws and lift off valve plate with the aid of
a crane.
33
Note: Control plate, parts of the control might fall out!
31
Repair Instructions Removing of the rotary group
35
Remove control plate and regulation parts.
36
Remove Qmax and Qmin screws after noting down
adjustment dimension.
37
Mount extraction device on drive shaft with the aid of a key
groove and a screw, than extract by crane.
34
Repair Instructions Disassembly of the rotary group
39
Loosen screws for fixing segments and remove them.
Remove cylinder with pistons and retaining device.
40
Remove swash plate with bearing.
41
Press out drive shaft from bearing flange.
38
Repair Instructions Disassembly of the hydraulic control
Hydraulic control rod - small size
42
Hydraulic control rod - big size
43
Repair Instructions Inspection notes
Note
Product knowledge and practical experience are pre-
requisites for the quality of the repair performed.
Guide lines for parts inspection cannot replace either but
can be of assistance in making a damage analysis when
the decision must be made as to which parts must
be replaced or eventually reworked.
Wear can be seen on polished upper surfaces, running
surfaces, running paths in the form of scratches,
grooves, seizure, marks, breakouts, deposits, shape
deviation etc.
Wear can be optically/mechanically judged. Inspection
using pencil lead is a practical aid. Scratches, grooves,
shape deviations that can be filled-out makes it
necessary that the part be replaced. Parts with wear
dimensions must be measured.
Discoloration can occur due to heat influence or
chemical reactions. Providing the outer surface is not
noticeably effected, this can be removed by reworking
using a fine grain sand paper or by lapping. With
appearances of overheating, local deformation can
be expected which will make it necessary to replace
the effected part.
Each part has definite check points which are covered
in detail on the following pages and must be observed
during inspection.
Standard replacement parts at every repair are roller
bearings, sealing and holding elements.
* Blind Threaded Hole in Drive Shaft
Thread undamaged. Thread is needed in order to
pull the rotary group back against the retaining ring
after being assembled in housing (and/or drawing
the drive elements (gear) into the shaft).
1. Splines
Damaged teeth profiles with feelable indentations
require that the drive shaft be replaced.
2. Running Surface of the Shaft Seal
Run-in grooves from the sealing lip is normally
cause to replace the drive shaft because the width
of the run-in shaft is usually larger than the
technically possible offset of the shaft seal in the
front cover using shims (max. 1,0 mm). Due to
solidity reasons, it is not permissable to rework the
supporting shoulder of the front cover.
Note
Run-in grooves will be accelerated by fine dirt
particles which are deposited on the seal lip or
through excessive case pressure and through
hardening of the shaft seal as a result of excessive
operating temperatures.
3. Bearing Seats
Worn bearing seats on the drive shaft caused by the
turning of the inner ring of the tapered roller bearing
(e.g. bearing damage) necessitates replacing of the
drive shaft when the minimum diameter falls below
that needed for a proper press fit.
1
3
1
*
2
3
4
1
Inspection:
Gears (1 ); Contact area shaft seal (2);
Bearing seat (3); Key (4).
NG 250 = 58
+0,024
+0,011
NG 250 = 42,01
+0,006
-0,005
Shaft
with wear on the splines.
Wear steps can be seen but can be felt -
Do not use again.
Shaft
with wear in the seal surface.
Can be felt with lead pencil > 0,8 mm -
Do not use again.
Inspection!
Cylinder boring (1),
Gears (2).
1. Setting rin)
2. Plug gauge
3. Holde
4. Fine dial indicator
Cylinder Bores
The cylinder bores cannot be reworked. If there are
scratches, grooves, local identations or break-out, in
the piston stroking area, then all further inspection
is of no need. The cylinder must be replaced.
Control:
Cylinder boring groove-free.
Test:
Close cylinder and piston boring with finger.
Move the piston - "Noise.
Measurement of the cylinder boring
NG 200 = 29,55 + 0,005 mm
NG 250 = 31,8 + 0,030 mm
Range of tolerance
Control Surface - Cylinder
Breakouts in the area of the cylinder bores on the
spherical control surface side of the cylinder is
contributable to cavitation. Cylinder must be replaced.
Sickle-shaped glossy marks on the edge of the cylinder
bores are edge wash-outs with resulting smoothing
(polishing) effect. This is the first stage of cavitation
breakout (inadequate supply).
Dark discoloration alone is of no importance, however,
in conjunction with pittings (lead washouts), is an
indication of overheating. Single pittings are of no
importance (lapping), inter-linked pittings or breakouts,
cracks along the core borders, necessitates
replacement of the cylinder.
Scratches and small ridges on the cylinder control
surface can be removed through lapping together with
the control plate. Lapping results in removal of material
from the hardness layer of the control plate. Minimum
hardness of the control plate is 62 HRc (file test). The
visual inspection of the cylinder control surface is
supported by the practical experience of the lapping
procedure.
Inspection!
Cylinder contact area (1),
RDE 92500-04-R/01.97
Reparaturanleitung A11VLO
Repair Instructions A11VLO
berprfungshinweise
Inspection notes
Control Surface - Control plate
Scratches, small grooves can be removed through
reworking (lapping together with the cylinder barrel). In
lapping material is removed from the hardness layer.
Lapping is only possible down to the minimum hard-
ness of 62 HRc. Check with file.
If there is wave-shaped wear on the control surface of
the control plate, then it must be replaced. This wear
can be felt with a pencil between the kidney slots.
Note
Wave-shaped run-in is a result of fine dirt particles in
the pressure fluid whith a high density of solid matter
particles smaller than 10-5 micron that have the effect
of lapping paste.
Contact Surface to the Port Plate
Flat and level. If fretting corrosion has occured, remove
it on the lapping plate. Inspect the levelness with a hair-
line ruler.
Note
If both the control plate and cylinder are to be replaced,
then no lapping is necessary. Factory new spare parts
are ground to dimension and interchangeable.
When used and new parts are paired, the control
surfaces must be lapped together.
By lapping with circular, excentric movements of the
cylinder on the control plate, at the same time pressing
the cylinder against the control plate, material from the
hard control plate will be lapped off quicker than from
the "soft" surface of the cylinder. The degree of lapping
is limited by the minimum hardness of the control plate.
Lapping Paste
For pre-lapping, a standard lapping paste with 25
micron coarseness should be used, for final lapping 10
micron coarseness. After lapping, brush the cylinder
control surface in order to remove all lapping residue.
Afterwards, clean in wash solvtion before the contact
inspection with soft pencil or lightly applied touch up -
paste.
Note
If cylinder and control plate are exchanged at the same
time, then lapping is not necessary. Factory new spare
parts are ground to dimension and are interchangeable.
When matching used parts with new parts, lapping is
required.
Inspection!
Contact area control plate (2),
RDE 92500-04-R/01.97
Brueninghaus Hydromatik 23
berprfungshinweise
Inspection notes
Cylinder Barrel
Scratches in the cylinder bores that can be
seen but can not be felt with a Lead pencil.
Use again!
Cylinder barrel with wear (small grooves) in
the control surface may be used again if
grooves can be removed through lapping
together with the control plate.
Use again!
Breakouts in the area of the cylinder bores
on the spherical control surface are
contributable to cavitation.
Do not use again!
Control plate:
Breakouts in the spherical control surface.
Do not use again!
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
Inspection!
Retaining ball (2)
Retaining plate (1).
1
2
1. Contact Surface
Flat, without deformation. Rework not possible.
2. Sockets
Without grooves, without scratches. Rework not
possible.
Surface that can be seen but can not be felt with a
lead pencil
Use again!
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
Inspection:
Contact area (1)
1
Small grooves in the contact area can be
removed through lapping.
Use again!
Slipper pad in contact with contact area.
(Heat cracks)
Do not use again!
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
Inspection :
Seat (1); Contact area (2);
1 2
2
1. Bearing Fit
Seat undamaged. No turning or run-in traces.
Reworking not possible.
2. Contact area
Dull contact points are of no consequence.
Use again!
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
Inspection:
Contact area of bearing (1)
Dull contact points are of no consequence.
Use again!
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
Inspection:
Socket for regulator (2)
2
2. Sockets
No grooves, no traces of seizure.
Use again!
Reworking is not possible.
RDE 92500-04-R/01.97
Inspection!
Boring (*), 21 / 23
+0
+0,025
Range of tolerance
Scratches in the bores that can be seen
but can not be felt with a lead pencil.
Use again!
berprfungshinweise
Inspection notes
10
H7
+0

+15
1. Setting ring
2. Plug gauge
3. Holder
Inspection!
Positioning piston (1),
Boring - control bush (2).
NG 200 = 21
-0,008
mm
-0,020
NG 250 = 23
-0,008
mm
-0,020
Range of tolerance
RDE 92500-04-R/01.97
Inspection!
Boring (*), 35 / 38
+0
+0,030
..........
Scratches in the bores that can be seen
but can not be felt with a lead pencil.
Use again!
berprfungshinweise
Inspection notes
Inspection!
Pistons(*)

1. Setting ring
2. Plug gauge
3. Holder
NG 200 = 35
-0,009
mm
-0,030
NG 250 = 38
-0,009
mm
-0,030
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
Inspection!
Contact area control plate (1).
1. Contact Surface of the control plate
Smooth and level. Removal of fretting corrosion by
lapping on the lap plate.
Port Plate
Contact surface for the control plate with no scratches
or grooves, smooth and level. Removal of fretting
corrosion by lapping on the lap plate.
Use again!
RDE 92500-04-R/01.97
Measurement of the piston diameter
NG 200 = 29,55
- 0,05
mm
NG 250 = 31,8
- 0,055
mm
Range of tolerance
berprfungshinweise
Inspection notes
2
3
1
2 Inspection!
Slipperpads (1),
Axial backslash (2)
Piston shaft (3).

max. 0,1 mm
Axial backslash (2)
3. Piston Shaft
No grooves, no seizure marks. Rework not possible.
Note
Seizure marks on the piston ball are indications of dirt.
Seizure marks on the piston shaft are indications of
over-speeding (exeeding the permissible maximum
speed). If grooves can be felt, this is an indication
of contaminatcd pressure fluid.
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
- 0,01 mm
All 9 pistons same height - play - 0,01 mm
- 0,01 mm
- 0,01 mm
Slipperpads
Scratches and small grooves can be remove
by rework.
Instruction
Remove with grinding paper (grain 1000)
Small grooves - rework
Use again
Inspection!
Slipperpads
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
Inspection!
Fixing segments
*
*
+ 0,06 mm
+ 0,02 mm
=
=
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
45
Inspection: see notes page 18.
Impeller (1)
Boring (2)
Key groove (3)
44
Inspection! see notes page 18.
Fixing segments (*)
RDE 92500-04-R/01.97
48
Complete bearing with retaining ring.
49
Insert drive shaft with bearing into flange.
50
Mount O- ring, front cover and retaining ring.
Pumpe montieren
Pump assembly
46
Drive shaft
47
Mount internal bearing ring non reversed and in warmed
condition (max. 90
o
C).
RDE 92500-04-R/01.97
53
Fit bearing in swivel track and bearing guide in cage guide.
54
Fit swivel cradle
Note: Fit bearing guide * into guide roll,a correct mounting
permits easy swivel movements and automatic return into
horizontal position.
55
Mount shims, springs and retaining ball.
Note: Observe correct mounting position*.
Pumpe montieren
Pump assembly
51
Insert O- ring
52
New assembly position:
Fit bearing guide
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
Feder
(4 springs) Shim
Pos. A
Simulator ring
Shim
Pos. D
Note:
No combination of shims! The tolerance position
is so that one shim is sufficient. Only one shim must be
mounted.
Adjustment of the hydraulic part of
the rotary group
Adjustment of Pos. D is effected with one shim of
different thickness and a simulator ring Pos. A.
Size 200 250
Piston diameter ( mm) 29,55 31,8
Pos.D (mm) 149,50
-0,2
160,95
-0,2
Pos.A (mm) 7,26
+0,01
7,82
+0,01
-0,03 -0,03
RDE 92500-04-R/01.97
berprfungshinweise
Inspection notes
B A
Size 250
Simulat. ring
(mm) A 73
(mm) B 53
Size 250
1 Measuring bell 452 869
2 Simulating ring 452 765
3 Centering piece 452 865
A
B
C
Size 250
Center. piece
(mm) A 59,5
(mm) B 72,0
(mm) C 3,2
1. The measuring bell shall press on the retaining
plate in the center.
2. Measure dimension D with depth gauge and
compensate with a shim*.
Attention!
Use only one shim!
Note
It is recommended to repeat the measurement on
the opposite side and/or at adjacent spots. Even
out the dimensions if need be.
1
2
3
*
D
RDE 92500-04-R/01.97
58
Assembly hint:
Fix pistons with the aid of a string or an O-ring.
59
Mount cylinder with pistons.
60
Insert fixing segments.
Pumpe montieren
Pump assembly
56
Put on retaining plate.
Note: Cover retaining ball with special grease.
57
Insert piston slipper pads
Note: Slightly cover with oil
RDE 92500-04-R/01.97
63
Assembly position:
Note: Screw off Qmax - Qmin screws.
64
Insert fixing pin for zero position.
65
Insert rotary group into housing with the aid of a crane.
Note: Zero position to be fixed
Pumpe montieren
Pump assembly
61
Insert new screws with Precote
Note: Thread to be free of grease
62
Assembly hint:
Mount assembly device
RDE 92500-04-R/01.97
68
Screw in threaded pin with point and put craddle horizontal.
Measure with dial gauge.
69
Pumpe montieren
Pump assembly
66
Inspection for correct mounting of the rotary group:
* Size 200 = approx. 167 mm
* Size 250 = approx. 176 mm
67
Take note of the dimension x Q-min / Q-max.
Loose nut and screw out the stop screw.
Do not change setting dimension x
X
X
RDE 92500-04-R/01.97
72
Control plate mounted correctly! E.g. "clockwise rotation"
Note: Stick control plate by using a little grease.
73
Insert O- ring.
Pumpe montieren
Pump assembly
70
Insert regulator parts (1 )
Insert pins (2)
Measure hole in the piston (3). Take note of dimension
71
Control plate for clockwise (1) and anti-clockwise rotation (2).
3
2
1
RDE 92500-04-R/01.97
76
Place four distance holders ( ~ 10 mm thick) and
put on port plate.
77
250 0,5
+0,1
mm
Inspection:Setting of hydraulic Q-min.
78
Inspection, for instance with steel needle or the shaft of a
spiral drill.
Example: Hole 3 mm - 0,5
+0,1
mm = Drill 2,4 - 2,5 mm
Play out of tolerance means exchange of the positioning bar -
longer or shorter.
Pumpe montieren
Pump assembly
74
New assembly position:
Attention: Control plate is only fastened with grease
75
Mounting of valve plate.
Note: Place rcgulator parts in position and fit in the plate.
1
0,5
+0,1
mm
RDE 92500-04-R/01.97
Pumpe montieren
Pump assembly
79
1. Mount locking screws.
2. Remove threaded pin.
3. Screw in fixing screws.
80
Screw in Qmax- and Qmin screws according to noted
adjustment dimensions.
Assembly position!
81
RDE 92500-04-R/01.97
Strength Classes
Thread 8.8 10.9 12.9
size Tightening Torque (lb.ft)
M 3 0,8 1,2 1,4
M 4 2,1 3,0 3,6
M 5 4,4 6,3 7,4
M 6 7,4 10,3 12,5
M 8 18,4 25,8 30,2
M10 36,1 50,9 61,2
M12 63,4 88,4 106,9
M14 99,5 140,0 169,5
M16 154,8 217,4 261,6
M18 213,7 298,5 357,4
M 20 302,2 427,5 508,5
M 22 405,4 574,9 685,4
M 24 523,5 737,0 884,4
M 27 773,9 1105,5 1326,6
M 30 1068,7 1474,0 1768,8
Tightening torques for shaft bolts
(Metric ISO Standard Thread)
The values for tightening torques
shown in the table are valid only for
shaft bolts with metric ISO- standard
threads and head support surface
dimensions in accordance with DIN
912, DIN 931 and DIN 933. These
values are also valid only for light or
unoiled, untreated surface as well as
for use only with torque-indicating
wrenches and force limiting tools.
Tightening torques for locking screws VSTI
(Metric ISO fine thread)
Thread size Designation Tightening torques (lb.ft)
M 8 x 1 VSTI 8 x 1 -ED/SA = 4
M 10 x 1 VSTI 10 x1 -ED = 7
M 12 x 1,5 VSTI 12 x 1,5 -ED = 15
M 14 x 1,5 VSTI 14 x 1,5 -ED = 22
M 16 x 1,5 VSTI 16 x 1,5 -ED/SA = 22
M 18 x 1,5 VSTI 18 x 1,5 -ED/SA = 29
M 20 x 1,5 VSTI 20 x 1,5 -ED/SA = 37
M 22 x 1,5 VSTI 22 x 1,5 -ED = 44
M 26 x 1,5 VSTI 16 x 1,5 -ED/SA = 51
M 27 x 2 VSTI 27 x 2 -ED = 66
M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 74
M 33 x 2 VSTI 33 x 2 -ED/SA = 88
M 42 x 2 VSTI 42 x 2 -ED/SA = 147
M 48 x 2 VSTI 48 x 2 -ED = 220
seal-lock nuts of the strength class 8.8
and with metric ISO-standard thread.
Strength classes
Thread 8.8 10.9 12.9
size Tightening torque (lb.ft)
M 6 7,4
M 8 16,2
M 10 29,5
M 12 50,9
M 14 81,1
M 16 125,3
Tightening torques for seal-lock nuts
(Metric ISO-Standard Thread)
Strength classes
Thread 8.8 10.9 12.9
size Tightening torques (lb.ft)
M 3 0,8
M 4 2,1
M 5 4,4
M 6 7,4
M 8 18,4
M10 36,1
cross-slotted lens head screws DIN
7985 of the strength class 8.8 and with
metric ISO-standard thread.
Tightening torques for cross-slotted lens head screws
DIN 7985
(Metric ISO- Standard Thread)
RDE 92500-04-R/01.97
Sicherheitsbestimmungen
Safety regulations
General advice
Make yourself familiar with the equipment of the
machine.
Only operate the machine if your are completely
familiar with the operating and control elements as
well as the functioning of the machine.
Use your safety equipment like helmet, safety shoes
and hearing protection.
Make yourself familiar with your working field.
Only operate the machine for its intended purpose.
Please observe the guidelines of the Professional
Association and the machine manufacturer.
Before starting
Observe the operating instructions before starting.
Check the machine for remarkable faults.
Do not operate the machine with defective
instruments, warning lights or control elements.
All safety devices must be in a secure position.
Do not carry with you movable objects or secure
them to the machine.
Keep oily and inflammable material away from the
machine.
Before entering thc drivers cabin, check if persons
or obstacles are beside or beneath the machine.
Be careful when entering the drivers cabin, use
stairs and handles.
Adjust your seat before starting.
RDE 92500-04-R/01.97
Start
When starting all operating levers must be in
neutral position.
Only start the machine from the drivers seat
Check the indicating instruments after start to
assure that all functions are in order.
Do not leave the machine unobserved when the
motor is running.
When starting with battery connection cables
connect plus with plus and minus with minus.
Always connect mass cable (minus) at last and cut
off at first.
Attention
Exhaust gas is dangerous. Assure sufficient fresh
air when starting in closed rooms!
Hydraulic equipment
1. Hydraulic equipment is standing under high
pressure.
High pressure fluids (fuel, hydraulic oil) which
escape under high pressure can penetrate the
skin and cause heavy injuries.
Therefore immediately consult a doctor as
otherwise heavy infections can be caused.
2. When searching leakages use appropriate auxiliary
devices because of the danger of accidents.
3. Before working at the hydraulic equipment, lower
pressure to zero and lower working arms of the
rnachine.
4. When working at the hydraulic equipment, absolutely
stop motor and secure tractor against rolling away
(parking brake, shim)!
5. When connecting hydraulic cylinders and motor pay
attention to correct connection of hydraulic flexible
hoses.
6. In case of exchanging the ports, the tunctions are
vice versa (f. ex. lift-up/lower) - danger of accidents!
7. Check hydraulic flexible hoses regularly and replace
them in case of dammage or wear! The new hose
pipes must comply with the technical requirements
of the machine manufacturer!
Orderly disposal or recycling of oil, fuel and
filters!
Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustrae 2, D-89275 Elchingen, Tel. (07308) 820, Telex 712538, Fax (07308) 7274
Phone: 713 896 6500 Fax: 713 896 6611
Connections
A Pump Discharge Port - 1 1/2"
G Control Pressure Port - 9/16"
LG1 Load Limiting Control, Negative
M High Pressure Gauge Port - 9/16"
R Case Vent Port - 9/16"
S Suction Port - 4"
T1 Case Drain Port - 1 5/16"
T2 Case Drain Port - 1 5/16"
Y Pilot Pressure Port - 9/16"
Z Power Setting Control Port
Pump Parts List
Item No. Description
1 Rotary Group
2 Port Plate with Adapter
3 Regulator
4 Hydraulic Control
5 Hydraulic Control
7 Cover with Accessories
40 Shuttle Valve
10 Housing
12 Impeller, Left Hand Rotation
13 Seal Disk
30 Shaft Key
20 Threaded Pin
21 Threaded Pin
22 Seal Lock Num
23 Cylinder Pin
24 Locking Screw
28 Retaining Ring
29 Retaining Ring
31 Shim, 42 X52 X0,1
31 Shim, 42 X52 X0,2
31 Shim, 42 X52 X1
Rotary Group
Item No. Description Item No. Description
1 Cylinder with Control Plate 24 Retaining Plate
2 Piston-Slipper Pad 25 Retaining Ball
11 Cup-Spring Stack 30 Retaining Segment
12 Cradle 31 Plain Roller Bearing
14 Drive Shaft 32 Cradle Bearing Assembly (Set)
15 Bearing Flange 36 Retaining Ring
16 Cover 37 Retaining Ring
17 Wire 38 Shaft Seal Ring
18 Joint Pin 39 O-Ring
20 1.2 Shim 40 O-Ring
20 1.0 Shim 46 Clamping Pin
20 0.8 Shim 47 Socket-Head Screw
20 0.6 Shim
Port Plate w/Accessories
5 Port Plate, Left-Hand Rotation
6 Valve Bushing
10 Plain Roller Bearing
11 O-Ring
12 Cylinder Pin
13 Cylinder Pin
14 Socket-Head Screw
15 Double Break-Off Pin
16 Locking Screw
17 Locking Screw
18 Orifice
Regulator
1 Control Element 50 Socket-Head Screw
2 Control Element 51 Clamping Pin
4 Measuring Piston 52 Double Break-Off Pin
5 Control Element 53 O-Ring
10 Control Housing 54 O-Ring
20 Angle Lever 60 Retaining Ring
21 Bearing Bolt 61 O-Ring
22 Bearing Bushing 66 Orifice
Control Element No. 1
1 Control Bush
2 Control Piston
4 Spring Collar
5 Pressure Spring
6 Pressure Spring
7 Connecting Piece
8 Threaded Pin
9 Control Piston
11 Seal Lock Nut
12 O-Ring
13 O-Ring
15 Socket-Head Screw
Control Element No. 2 Control Element No. 3
1 Locking Screw 1 Locking Screw
2 Control Piston 2 Control Piston
3 Spring Bolt 3 Spring Bolt
5 Pressure Spring 5 Pressure Spring
6 Pressure Spring 10 Threaded Pin
10 Threaded Pin 11 Seal Lock Nut
11 Seal Lock Nut 12 O-Ring
12 0-Ring
Measuring Piston Shuttle Valve
1 Measuring Piston 1 Connecting Piece
2 Setting Bush 2 Bush
3 Bolt 3 Valve Poppet
10 Roller 5 O-Ring
11 Retaining Disk
Hydraulic Control No. 1
Hydraulic Control No. 2
Hydraulic Control No. 1 Hydraulic Control No. 2
1 Positioning Piston
1 Return Piston
2 Rod 161,80
2 Return Rod
2 Rod 162,00
2 Return Rod
2 Rod 161,60
2 Return Rod, 184,60
2 Rod 161,20
2 Return Rod, 184,80
2 Rod 161,00
2 Return Rod,
2 Rod 160,80
3 Pressure Spring
3 Pressure Spring
Cover Plate w/Accessories
1 Cover
3 Socket-Head Screw
5 O-Ring

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K29 Pump Pilot Pressure (40581)

Phone: 713 896 6500 Fax: 713 896 6611
STDFM-43 Rev. 1 01/31/01

40581control System.doc Page 1 of 1
9February 2006
Control Circuit
Open Loop Pump
Part No. 40581 (62cc)

This pump is mot serviceable by field personnel; therefore, no repair information is given.
Pressure id factory set by qualified SeaTrax Personnel. No adjustment is necessary. If problems
occur, customer is advised, to contact SeaTrax service department.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K30 Pump Fixed Displacement Vane Type Slew & Oil Conditioning (40344)

40344 Page 1 of 8
Phone: 713 896 6500 Fax: 713 896 6611
Slew Pump
Part No. 40344
To order parts use the Illustration Number and Description.
NOTE: This pump is suggested as part of the spares listing for this crane. One should be kept on
hand in case of failure, or normal wear replacement. These pumps should be replaced and not
repaired. They are fairly simple and if it is necessary, the disassembly and re-assembly is
rudimentary requiring no specialized tools.
This pump can be rebuilt by replacing the removing the rear housing and replacing the cartridge.
The cartridge is composed of: Cam Ring, Rotor, Vanes, Pins, and Port Plates.
It may be necessary to clock a new pump so the suction and discharge sides positioned differently
than shipped. To do this, remove the 4 bolts from the back of the housing. DO NOT pull the
sections apart. Gently rotate the sections to the correct positions and reinstall the bolts. Torque the
bolts to 187 Newton meters.
40344 Page 2 of 8
Before disassembly, mark the relationship of
one section to the other.
Remove the four Bolts at the rear of the pump.
Remove the Rear Housing to expose the
Cartridge.
Slide the Cartridge off and inspect the Bearing
and Seal. If one or both require replacement,
remove these two Snap Rings and replace the
worn parts.
40344 Page 3 of 8
At this point, it is strongly recommended
that the cartridge be replaced instead of
rebuilding the unit with individual parts.
Mark the position of the two Machine Screws
before removing them from the Cartridge.
Remove the Rear Port Plate and Thrust Plate.
Inspect them for excessive wear. (The parts
shown in these diagrams are new so you can
judge the extent of wear on your parts).
Remove the Cam Ring from around the Rotor
Insert Assembly. Inspect the Cam Ring for
wear or gouges.
Light scratches can be honed out, deeper
scratches require replacement of the Cam Ring
and Vanes.
40344 Page 4 of 8
Carefully remove all Vanes and Pins.
Inspect the vanes and Rotor Insert Assembly
for scratches or gouges. Light scratches can be
sanded out with very fine paper, deeper
scratches require replacement the part.
(Always replace Vanes as a set).
Inspect the Pressure Port Plate and Thrust
Plate.
Thoroughly inspect all parts of the Cartridge
When disassembling, re-stack the
parts in reverse order
40344 Page 5 of 8
Align the dowel pin hole on the Pressure Port
Plate and Thrust Plate.
Set the Rotor Insert Assembly on the Pressure
Port Plate and Thrust Plate assembly. Grease
and insert the pins into the Rotor Insert
Assembly.
Grease and install the Vanes. The convex edge
go to the outside (towards the Cam Ring).
Out
40344 Page 6 of 8
Align the dowel pin and install the Cam Ring.
Align the dowel pin and install the Thrust Plate
and Rear Port Plate.
Install the Machine Screws and tighten by
hand.
40344 Page 7 of 8
Replace the Seals and Back-up Rings as
necessary. Be careful that you dont stretch the
back-up rings.
Lubricate the Cartridge and test fit it in the
Front Housing.
Lubricate and install a new Case Seal.
Note the position of the Dowel Pin and
Dowel Pin Hole.
Black
Seals
White Back-up Ring
White Back-
up Ring
40344 Page 8 of 8
Lubricate the cartridge and install into the Rear
Housing. Ensure the Dowel Pin is in the
Dowel Pin Hole.
Install the Front Housing. Torque Bolts to 187
Newton meters.
Install new O-ring or gasket before installation
on pump drive.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K31 Hydraulic Starter System (50089)

50078 Hyd Starter.doc Page 1 of 18

Phone: 713 896 6500 Fax: 713 896 6611


Part No. 50089

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STARTER MOTOR

DISASSEMBLY

1. Clamp the motor assembly in a vise. Remove the pinion housing and the mounting flange which
are fastened to the motor housing by four screws. Knock out the housing welsh plug, loosen the
set screw and slide the drive assembly off the shaft. Remove the two Woodruff keys from the
shaft.

2. Before removing the port plate put an indexing mark on the port plate and the motor assembly to
enable proper position of the port plate at re-assembly.

3. Remove the port plate fastening screws and lock washers that hold the port plate to each
assembly. There is a slight spring load on this plate and upon loosening the screws, any fluid left
in the housing will drain out. Remove the port plate.

4. Remove the barrel assembly by turning the housing upside down and allowing the barrel and
pistons to slide off the spline of the shaft. Remove the pistons from the barrel.

5. Remove the retaining ring. Press the shaft out of the housing from port plate end. The seals, seal
holder and ball bearing will come out with shaft.

CAUTION
DO NOT APPLY EXCESSIVE HEAT
Do not remove thrust bearing unless it is to be replaced.

6. To remove the thrust bearing, press against thrust bearing housing with a little pressure and the
bearing housing with thrust bearing assembly will come out of the port plate end as an assembly.
Remove the thrust bearing plate. To remove the thrust bearing from the thrust bearing housing,
apply heat to the housing and press out the thrust bearing.


All parts should be cleaned and free of fluid or grease before attempting inspection. Care should be
taken to assure that machined surfaces of parts are not nicked or scratched by careless handling.

Pinion Housing: Visually check the housing for cracks or other damage. Examine the bearing for
damage or wear. Replace if necessary.

Drive Assembly: Examine the pinion gear to be sure that the teeth are not worn excessively or
chipped from interference with the ring gear. Check to insure that the compressing
springs are not damaged or broken.

Port Plate: The port plate face, where the barrel rides, must be smooth and free of scoring. Slight
scuff marks can be removed by lapping on surface plate. (See Note C). Check the
needle bearing for wear or damage. Replace if necessary. To remove the bearing,
apply even heat to the port plate.

CAUTION
DO NOT APPLY EXCESSIVE HEAT.
Do not remove bearing unless it is to be replaced.

Bearing will fall out when port plate is tapped against wooden block or bench.
Caution must be used when tapping the plate, so as not to damage the lapped surface.
Check threads on inlet and outlet ports.

Barrel and Pistons: Examine the ported face of the barrel for scratching or scoring. Slight scuff marks
can be removed by lapping on a surface plate. The bores of the barrel should be
smooth and free of scoring.

The diameter of the pistons should be smooth and free of scoring. The closed end of
the pistons may show brinnelling where they contact the thrust bearing plate, but no
burrs or flat spots are permissible.

Drive Shaft: Check the ends of the shaft for wear or scoring. The splines should be smooth and
free of nicks. Check the ball bearing and replace if necessary.

Check Bearing: Replace if necessary.

Motor Housing: Visually check housing for cracks or other damage. Be sure that the thrust bearing
rolls free and smooth. Inspect tapped holes for thread damage.

Seal Holder (O Rings & Slipper Seal): Replace the "O" rings with new "O" rings. Replace the
slipper seal. If the seal holder did not contain a slipper seal, replace the seal holder.
(See Note A and B.)
RE-ASSEMBLY

1. Be sure all parts are clean and free of burrs before starting re-assembly.

2. Install the thrust bearing housing with bearing and plate assembly into motor assembly with slight
pressure. Press in until it has bottomed against motor assembly. Be sure dowel pin is in place.
Install thrust bearing plate into thrust bearing.

3. Install the bail bearing on the drive shaft. Install the retaining ring. Press the drive shaft with ball
bearing and retaining ring into motor assembly. Install seat assembly on the drive shaft. (See Note
C.)

4. Install the barrel with pistons on the drive shaft. Be sure that the barrel spring in the barrel in
place. Assemble the port plate to the motor assembly. Torque the screws to 300 in./lbs. There
should be a slight pre-compression of the barrel with the port plate. If not, replace the barrel
spring in the barrel.

TEST PROCEDURE

1. Mount the hydrotor in a suitable fixture and connect all hoses to appropriate fittings as illustrated
in the System Schematic Section.

2. Open the external control valve, start the engine pump to circulate fluid through the complete
system with the control valve remaining open, thus purging the system of air. Examine the
hydrotor and all fittings for possible leaks before releasing the control valve.

3. Allow system pressure to build up to 3000 psi (207 bars), at which pressure the unloading valve
by-passes fluid to the reservoir. Again examine for leaks in the system. Should pressure fail to
rise rapidly to accumulator pre-charge pressure and then build up gradually to 3000 psi (207
bars), it indicates system was not purged completely. Purge again if necessary.

NOTE: If at anytime, leaks occur externally, the unit must be disassembled to correct leakage before
proceeding with test.

CAUTION
ALWAYS RELEASE ALL HYDRAULIC PRESSURE
BEFORE DISCONNECTING ANY LINES

4. After it has been determined that the unit is not leaking, open the control valve, permit the unit to
operate until the accumulator fluid volume has been exhausted. Release the control valve. The
system will now recharge to 3000 psi (207 bars). Repeat charge and discharge cycle several
times to determine that the hydrotor functions properly.

5. Attach TSE 8603 Lock Testing Tool to the motor assembly. This can be accomplished by
inserting two pinion gear housing fastening screws finger tight 180 apart. The lock test tool can
now be slipped over these fastening screws and spline in tool engaged with spline on drive shaft.

6. Open the control valve slowly to the full open
position. Hold it open for 3 seconds before
closing. While control valve is in open position,
a pressure drop to 500 psi (35 bars) maximum is
permissible.

7. Proceed to test each of the pistons in the matter
described above by rotating the lock test tool in
increments as provided until all pistons have
been tested. Should the pressure drop faster than specified when testing at one particular
position, it indicates internal leakage. This could be a piston requiring replacement.

NOTE: Turn lock test tool and shaft one full turn and retest before replacing any one particular piston.
A pressure drop at all pistons indicates that the port plate fastening screws are not properly torqued or
that there is insufficient spring tension to keep motor barrel against the port plate. It may be necessary
to lap the port plate and barrel on a lapping plate or replace the barrel spring to eliminate leakage. (See
Note C).

8. After the preceding test is complete, remove the lock testing tool and install the drive assembly
on the drive shaft.

9. Install the pinion housing and mounting flange and tighten the four fastening screws with lock
washers.

10. Open the control valve to the full open position, allowing the accumulator to discharge
completely. Hydraulic pressure gage should now read 0 psi (0 bars).

CAUTION
DO NOT DISCONNECT ANY LINES UNTIL HYDRAULIC PRESSURE IS
COMPLETELY EXHAUSTED. REMOVE THE HYDROTOR FROM THE TEST
CIRCUIT. DRAIN REMAINING QUANTITY OF FLUID FROM THE HYDROTOR
AND CLOSE ALL, OPENINGS WITH SUITABLE PLUGS TO PREVENT
ENTRANCE OF FOREIGN MATTER DURING STORAGE OR SHIPMENT.

NOTES

NOTE A: On newer models the outer and O ring seals, slipper shaft seal, and the seal holder have
been replaced by a one piece seal. Replace that seal.

NOTE B: INSTRUCTIONS FOR INSTALLATION OF SLIPPER SHAFT SEALS

1. Install the inner O ring seal in the seal holder. Deform the slipper seal and install it
on top of inner O ring seal. Push the tool EHS 41-2858 through the holder once in
each direction to smooth out the deformed slipper seal.

2. Place the tool EHS 41-2858 over the drive shaft and against the installed ball bearing.
Slide the holder containing the O rings and slipper seal over the tool until holder is in
place against the bearing. Hold the seat holder in position and remove tool.

EHS 41-2858

NOTE C: Port plates are lapped at the factory with the straight fittings installed in both ports. Fittings
are torqued to 25 lb.ft. Leave these fittings in the port plate when testing or lapping. If they have been
removed, replace with new fittings when testing or lapping.

HAND PUMP SERVICE

Service Kit

QTY DESCRIPTION
1 Bleed screw O" ring
1 Inlet fitting O" ring (outer)
1 Inlet fitting back-up ring
1 Inlet fitting O" ring (inner)
1 Check valve seat O" ring
1 Plunger back-up ring

1 Plunger O" ring
1 Check valve spring
1 Plunger gland O" ring (inner)
1 Plunger gland O" ring (outer)


DISASSEMBLY

1. Disconnect the lever from the housing and the plunger. Remove the retaining ring and the clevis
pin before removing the link assembly.

2. Remove the plunger gland retaining ring from the housing. The plunger gland will come out oil
the plunger when the plunger is pulled from the housing. Remove the plunger gland from the
plunger.

3. Remove the discharge check valve seat from end of the plunger. Discharge check ball valve and
discharge check valve spring will drop out of the plunger.

4. Remove the inlet fitting from the end of the housing. Inlet check ball valve and the inlet check
valve spring will drop out of the housing.

5. Back out the bleeder screw and remove the ball.


Housing: Check for cracks and other visible damage. Bore of cylinder must be smooth with no
pitting or scoring. All threads should be checked. (It is not necessary to remove the
pipe plug unless there has been leakage at threads). Bleed ball valve and its seat in
housing must be checked. Replace ball valve if damaged. Replace the bleed screw
"O" ring with a new one.

Inlet Fitting: Examine internal and external threads. Inspect inlet check valve seat for nicks or
scratches. Replace the inner and outer inlet fitting "O" rings and back up rings with
new ones. Examine inlet check ball valve and spring. Replace if damaged.

Plunger: Check plunger for scoring on large diameter and on plunger shank where it rides in
plunger gland. A wear pattern may be evident but no scores or scratches should be
present. Replace the plunger "O" ring and back-up ring and the discharge check valve
seat "O" ring with new ones. Examine discharge check ball valve and spring and
discharge check valve seat. Replace any damaged parts.

Lever: Check link assembly for wear or damage. Replace if necessary.

Plunger Gland: With the inner plunger gland "O" ring and back-up ring removed, check gland on
plunger shank to be sure it does not bind. Inner and outer plunger gland "O" rings and
back-up rings should be replaced with new ones.

ASSEMBLY

NOTE: Make sure that all parts are clean before assembling. To facilitate assembly, use light oil or
grease on O rings and back-up rings.

1. Install inlet check valve spring and ball into housing. With the inner and outer inlet fitting "O"
rings and back-up ring oil the inlet fitting, install the fitting into the housing. Tighten the inlet
fitting securely being sure that the inlet check ball valve seats property in end of the inlet fitting.

2. Install discharge check valve spring and ball into plunger. With discharge check valve "O" ring
in place, thread discharge check valve seat into plunger and tighten securely.

3. Insert the plunger into the housing, bottoming plunger in pump bore. Install the plunger gland
being sure that the inner "O" ring is closest to the leading edge (see illustration). Press the
plunger gland in until groove for the retaining ring is uncovered, then insert the retaining ring.

4. Drop bleed ball valve into place and with bleed screw "O" ring in position insert bleed screw.
Tighten the bleed screw securely.

5. Install the link assembly to the plunger and the lever. Place the lever into position and insert the
clevis pin and the retaining ring. Put other side of link on and secure with clip.

TEST PROCEDURE

1. Mount hand pump in suitable holding fixture and connect all hoses to appropriate fittings as
illustrated in Hydraylic Schematic (see page 2) leaving the discharge connection loose. Slowly
operate the hand pump until all the air is expelled. Re-tighten connection. This operation will
also assure that the plunger is free in the housing. With high-pressure valve open, operate the
hand pump long enough to sufficiently purge the system.

2. Close the high-pressure valve. Operate the hand pump until the system pressure is approximately
1800 psi (124 bars). Check for external leakage.

3. Operate the hand pump until system pressure is 3000 psi (207 bars). Observe the pressure gage
closely to determine if the unit is pumping on each stroke. (Pump is double acting.)

4. Locate the pump plunger is mid-position and release the operating handle. Any movement of
handle indicates leakage past inlet check ball valve or "O" rings on inlet fitting. (There should not
be any perceptible drop in pressure gage reading.)

5. Move the plunger in the full extent of its travel until the plunger bottoms in housing. Disconnect
inlet line from pump. A steady pressure reading of 3000 psi (207 bars) indicates that the
discharge check valve plunger "O" rings and bleed valve are sealing properly. If leakage occurs
at this point it will be necessary to correct and retest as required.

6. Slowly open high-pressure valve and release pressure to 0 psi.

CAUTION
DO NOT DISCONNECT ANY HIGH PRESSURE LINES
UNTIL HYDRAULIC PRESSURE IS COMPLETELY EXHAUSTED.

7. Remove the hand pump from the test circuit. Drain the remaining quantity of oil from the hand
pump and close all openings with a suitable plug to prevent entrance of foreign matter during
shipment or storage.

HYDRAULIC CRANKING SYSTEM TEST CIRCUIT

TheTest Circuit Schematic for Hydraulic Cranking System Components illustrated in this section
shows the approximate position of the equipment required for testing purposes. This may be altered to
meet the individual requirements of shop lay-out and components to be tested.

Reservoir: The reservoir should be mounted high enough so that the outlet at the bottom of
the reservoir is above the oil inlet to the engine pump. The reservoir should be
filled to approximately 3/4 of its maximum oil volume. (This pertains to a test
circuit only and does not refer to actual application specifications.) This will
provide sufficient space above the oil level for the return oil to surge back into
the reservoir when components are being tested without the hydrotor in the
circuit.

Accumulator: The capacity of the accumulator should be 230 cu. in. (1 gal.) for the time factor
used when testing the engine pump. It also provides a sufficient volume of oil
for testing other components.

Electric Motor: The electric motor should be at least 1 HP and have a speed of 1750 RPM. This
speed and HP are required when testing and operating the engine pump at the
high pressures attained.

Hand Pump: The hand pump is not required in the circuit unless it is one of the components
to be tested.

High Pressure Valve: [3000 psi (207 bars)] The high pressure valve is used in the circuit when
components other than hydrotors are being tested. It is to be inserted between
the accumulator and reservoir to provide a means of returning the high pressure
oil to the reservoir. A Crane #222 H, Steel, 1/2" valve, or equal should be used.

Fittings and Hoses: All return hoses from components to the reservoir should be larger (#10 or
larger recommended) than the inlet hoses (#8 recommended). This will
eliminate back pressure within the unit. Hose should be as shown as possible to
prevent surging. All fittings and hoses should be inspected periodically to
insure that they are in good condition. If there is any doubt about a fitting or
hose it should be replaced.

CAUTION
ALWAYS RELEASE ALL HYDRAULIC PRESSURE IN THE SYSTEM
BEFORE DISCONNECTING ANY HOSES.

Clean all hose assemblies before installing. Do not use sealing compound when installing fittings.

Unloading Valve: Most engine pumps include an integral unloading valve. When testing such pumps,
set the system unloading valve at approximately 3500 psi (241 bars) so as not to
interfere with the integral unloading valve in the pump under test.

Hydraulic Oil Recommendation: Clean, high quality hydraulic oil, appropriate for all seals should be
used in the test circuit. Test oil temperature should be maintained at 75 to 80F
(24 to 27C), during testing.

High Pressure Filter: Follow instructions as outlined in components catalog HF- 1.

ALWAYS PURGE THE SYSTEM BEFORE ATTEMPTING ANY TEST

Purging:
A. Open valve at reservoir outlet.

B. To purge the hand pump (if used), loosen the discharge connection and slowly operate the hand
pump until all the air is expelled. Retighten connection.

C. To purge the complete system open the control valve if a hydrotor is installed or the high
pressure valve if this is being used. Start the engine pump to circulate the oil through the system.
Allow the pump to operate for a period sufficient to completely purge the system of air, After
purging, close the appropriate valve and proceed with the test.

TROUBLESHOOTING

CAUTION
Before servicing any part of the hydraulic cranking system, the accumulator pressure
must be released to prevent possible injury to personnel.

A. NO SYSTEM PRESSURE

1. Air in engine driven pump.
All pumps are self-bleeding. Check for dirt in the pump piston bleed hole. See that the bleed
hole is facing the inlet port. To assist the pump in, expelling air, fill the pump with fluid
through the return port.

2. Hand pump bleed valve open.
Check to insure that the hand pump bleed screw (located above the inlet port) is tight. (See
Low System Pressure Item 2)

3. Drive belt slipping (belt driven pump)
Adjust belt for proper tension.

4. Drive gear loose (direct drive pump)
Secure gear to drive shaft.

5. Unloading valve by-passing fluid to the reservoir.
Fluid will be passing through the return port indicating the unloading valve spindle in the
RPA model pumps is stuck in the open position or the pressure adjusting screw is backed off.
Check to insure the unloading valve spindle is free. Turn the adjusting screw CW to move
the spindle into the closed position.

Remove and clean. Make sure the swivel ends are correctly attached.

B. LOW SYSTEM PRESSURE

1. Unloading valve set too low.
Turn adjusting screw on 0 RPA model pumps CW to increase system pressure to desired
level.

2. Hand pump bleed valve leaking.
Remove the bleed screw and ball. Use ball to re-coin seat.

3. Engine pump valve(s) leaking
Replace inlet valve or re-coin seats of the three ball checks.

4. Low fluid level
Add fluid to the reservoir.
C. CRANKING SPEED TOO LOW

1. System fluid too heavy.
Check fluid in the system. Use MIL-H-5606 hydraulic fluid or equivalent. Fluid must be
compatible with Buna-N seals.

2. Engine fluid too heavy.
Replace fluid with proper viscosity grade. Refer to the engine lubrication fluid specifications.

3. Control valve not fully open.
Types VCA. Valve body sticking in valve housing. Replace valve cage and valve assembly.

4. Inlet line restricted.
Check plumbing from accumulator to hydrotor to insure hoses are riot collapsed and are free
of obstructions.

5. Excessive internal leakage in hydrotor.
Examine hydrotor internally for broken thrust bearing plate, scored port, plate, frozen piston
or broken barrel spring.

6. Line size too long and/or too small.
Discharge line from the hydrotor to the reservoir causing high back pressure. Discharge hose
should be at least one size larger than inlet hose. Eliminate elbows and reducers where
possible. Insert a tee containing a gage in the hydrotor discharge port. Attach the discharge
hose and measure back pressure which should not exceed 75 psi (5 bars).

D. LOSS OF FLUID FROM RESERVOIR

1. External leaks.
With pressure in system, check all hoses and fittings for leaks. Tighten or replace fittings and
any defective parts.

2. Hydrotor shaft seal leaking.
Remove the hydrotor inspection cover or welsh plug and look for signs of hydraulic fluid on
the drive shaft, the hydrotor shaft and inside the pinion housing. Replace the shaft seal
assembly.

3. Engine pump shaft seat leaking.
Replace shaft seal using proper tool to prevent seal damage.

4. Hand pump seal leaking.
Remove plunger gland and replace inner and outer "O" rings.

E. LOSS OF PRESSURE WHEN ENGINE IS NOT RUNNING

1. Ambient temperature decrease.
A small decrease in pressure is normal due to decrease in temperature. Pressure will decrease
approximately 3 psi (0.2 bars) per degree F. temperature change.

2. Engine pump check valve leaking
Examine unloading valve spool for damaged "O" rings. Re-coin ball check seats in
unloading valve portion of the engine drive pump.

3. Hand pump leaking
Disconnect inlet fine from reservoir. Leakage from inlet fitting means that either the relief
valve alone or both the inlet and outlet check valves are defective. Clean ball seats in pump
body and replace balls and springs if necessary. (See Low System Pressure, Item 2 and Loss
of Fluid from Reservoir, Item 4.)

4. Control valve leaking
To test for leakage, disconnect plumbing at inlet to hydrotor. If seepage is present replace
"O" rings in type VA 202180 valves or replace valve assembly in type, VCA valves.

5. External leakage in system
Visually locate source of fluid leakage and tighten applicable connection. Use of liquid
teflon on pipe threads is permissible if properly applied.

6. Loss of accumulator pre-charge (nitrogen)
Test for pre-charge after opening bleed screw on hand pump. Install a gage assembly on the
accumulator gas valve. Open valve and read nitrogen pressure. Correct nitrogen pressure
appears on the accumulator name plate, usually one half the system working pressure.

F. HAND PUMP FAILS TO RAISE SYSTEM PRESSURE

1. Bleed valve open or leaking
(See No System Pressure, Item 2 and Low System Pressure, Item 2)

2. Check valves leaking
Hand pump handle will not stay in neutral position but will move to one end of the stroke.
Examine for broken ball check springs or damaged check valve seats. Re-coin seats using the
ball checks. Make sure there are no foreign particles in the pump.

Remove and clean.

4. Fluid level low
Add fluid to reservoir.

5. Piston seal damaged
(See Loss of Fluid from Reservoir, Item 4)

G. HYDROTOR TURNS BUT ENGINE DOES NOT

1. Pinion not, engaging flywheel ring gear.
Incorrect flange to ring gear dimension. Change pinion gear housing and flange assembly.

2. Drive broken.
Replace drive. Operator should disengage hydrotor as soon as engine starts. Prolonging the
period during which clutch overruns will reduce clutch life.

3. Incorrect drive.
Hydrotor may be assembled for LH rotation but with a RH drive. Change to correct hydrotor
drive.

H. LOSS OF ACCUMULATOR PRECHARGE (NITROGEN)

1. Damaged seat on piston.
Overhaul the accumulator

CAUTION
Release all hydraulic pressure before removing the accumulator from the system
and release all nitrogen pressure before disassembling the accumulator.

2. Defective gas valve
Release pressure in system by opening bypass valve on hand pump. Then open gas valve to
release remaining pre-charge before attempting to remove valve from the accumulator.
Replace gas valve.

3. Damaged seal on end cap.
Apply liquid soap on accumulator end cap. Bubbling of soap indicates a leak past the end
cap seal. Release nitrogen pre-charge; before removing cap to replace seals.

4.Defective safety fuse.
Replace safety fuse assembly after releasing all nitrogen pressure.

I. HIGH PRESSURE IN SYSTEM

1. Defective gage.
Replace gage.

2. Unloading valve not operating properly.
Clean and adjust to specified working pressure. Check that the plunger is not binding or
sticking. There is a 500 lb. differential between cutout and cut-in.

J. FLUID EMERGES FROM RESERVOIR FILLER CAP WHEN ENGINE IS CRANKED.

1. Filter element in filler cap loaded with dirt.
Replace filler cap

2. Excess fluid in reservoir.
Check fluid level when the accumulator is empty. The fluid level should be approximately 2-
1/2" from the top of the tank.

K. FLUID EMERGES AROUND PISTON ON HAND PUMP

1. Damaged piston seal
(See Loss of Fluid from Reservoir, Item 4.)

L. CRANKING CYCLE TOQ SHORT

1.Insufficient accumulator capacity.
Add more and/or larger accumulator(s).

2.Faulty pressure gage.
If gage is reading higher than actual system pressure, fluid volume in the accumulator will be
less. Replace gage.

3.Excessive internal leakage in hydrotor.
(See Cranking Speed too Low, Item 5)

4.Hydrotor too small.
Check engine cubic inch displacement to determine that the hydraulic cranking motor is the
correct size.

5. Accumulator pre-charge too high.
With the fuel shut off to prevent engine from starting, crank the engine until all fluid is used.
If the gage then registers zero pressure, install a gage assembly on the gas valve and drop the
pre-charge to 1250 psi (86 bars). Repeat cranking cycle. If gage will still drop to zero at end
of cranking cycle, reduce pre-charge to 1000 psi (69 bars).

6. Accumulator pre-charge too low.
Open the bypass valve on the hand pump to discharge fluid from the accumulator. Install a
gage assembly on the accumulator gas valve. If pre-charge is less than 1500 psi (103) bars,
add nitrogen. Make sure pre-charge holds by testing for nitrogen leakage per Loss of
Accumulator Pre-charge (Nitrogen).

M. IMPROPER DRIVE ENGAGEMENT

1. Insufficient depth of tooth engagement.
Standard dimension from flange to ring gear is 2.00" (50.8mm). Measure with depth gage. If
greater than 2.00" (50.8mm), depth of engagement will not be adequate.

2. Tooth engagement too deep.
The collar behind the teeth will be marked by the ring gear. Insert spacer between the
hydrotor flange and the ring gear housing.

3. Improper drive and ring gear mesh.
Use bluing or other marking fluid on the pinion. Install the hydrotor and crank the engine
one or two turns. Remove the hydrotor and check contact areas for proper mesh.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900



TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900


CONFIDENTIAl
TOTAL WEIGHT - 79.51
~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - O - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~
+

CONFIDENTIAL
PO BOX 84OI!B7
Hou8lon. Te.... 77284
Pnona: 713 !1115 Il5OO

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K34 Mipeg 23 Sheave Assembly (TA1329)

CONFIDENTIAl
-"""",
1. ALL wn.os ARE TO BE PER SATRAX WELD PROCEDURES.
2. ALL wn.os TO BE CONTINUOUS.
3. UNLESS OTHERWISE SPECIFIED. AI...l. MATERIAL WILL BE
ASTM A-36 OR EQUIVALENT.
4. WElD CLEANING TO BE IN ACCORDANCE WITH AWS D1.1.
5. WORKMANSHIP IS TO BE Of PROFESSIONAl... QUAUTY.
CONFIDENTIAl
TOTAl... WEIGHT - 871
I

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K35 Valve Directional Control (40258)

Phone: 713 896 6500 Fax: 713 896 6611

40258 - Directional Control Valve Page 1 of 1

13 September 2007

Valve Directional Control

Part No. 40258

There are no replacement parts in this valve. The replacement of the complete assembly is required if faulty.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K36 Valve Directional Control Boom (40371)

Phone: 713 896 6500 Fax: 713 896 6611
12 March 2001
Control Valve
Part No. 40371
Function:
This valve has a spring that centers the spool when the controls are returned to neutral. Pressure from
the pump enters through port P. When the spool is centered, any remaining pressure will be vented
through the tank port T.
As the joystick is moved from neutral to pay out rope, pilot pressure will flow from the joystick to the
b port on the control valve. As pressure is applied through port b, the spool will shift from the neutral
position (upper view) toward the other side of the valve (lower view). This allows pressurized fluid to
flow from port P through the spool and out through port B.
Since SeaTrax uses an open loop system, the fluid flows from port B through the motor and
counterbalance valve and returns through port A. From here it runs through the spool and out of the
valve through port T. The fluid then returns to the hydraulic oil tank.
When the joystick is released, pressure no longer flows to port b, and the control valve internal spring
will automatically center the spool.
A. Up Port Output to Motor
B. Down Port Output to Motor
P. Pressure Input from Pump
T. Output to Tank
a. Up Signal Input from J oystick
b. Down Signal Input from J oystick
Parts List
ITEM # DESCRIPTION
1 Housing
2 Control Spool
3 Seal
4 Spring
5 Spring Cover
6 Pressure Relief Valve
1
2
3
4
5
6
Service:
This valve requires no periodic preventative service.
If the valve requires service, this is easily accomplished by removing the Spring Cover and sliding out
the spool assembly and relief valve. Thoroughly clean the spool assembly, relief valve, and housing
(after removing the hoses) and reinstall. The spool can be lightly polished but do not round the edges
of the valve, these should stay sharp. If the spool has lengthwise groves, it may need replacement.
Since the spool is matched to the housing, if the spool requires replacement, the whole valve must be
replaced.
Adjustment:
The only adjustment is the relief valve pressure. To set the pressure, disconnect the brake release
hoses on the hoist controlled by this valve. Pressure this hoist by operating its joystick in the down
position. Read the gauge in the cab. It should read between 5,300 and 5,500 PSI. If adjustment is
necessary, remove the cap covering the pressure relief valve (if fitted). Loosen the jam nut. Insert an
Allen wrench and screw in to increase pressure or back out to lower pressure. Once the pressure is set
at 5,400 PSI, tighten the jam nut and reconnect the brake hoses. Pressure will vary with fluid
temperature.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K37 Valve Directional Control Load (40372)

Phone: 713 896 6500 Fax: 713 896 6611
Hoist Control Valve
Part No. 40372
Function:
This valve has a spring that centers the spool when the controls are returned to neutral. Pressure from
the pump enters through port P. When the spool is centered, any remaining pressure will be vented
through the tank port T.
As the joystick is moved from neutral to pay out rope, pilot pressure will flow from the joystick to the
b port on the control valve. As pressure is applied through port b, the spool will shift from the neutral
position (upper view) toward the other side of the valve (lower view). This allows pressurized fluid to
flow from port P through the spool and out through port B.
Since SeaTrax uses an open loop system, the fluid flows from port B through the motor and
counterbalance valve and returns through port A. From here it runs through the spool and out of the
valve through port T. The fluid then returns to the hydraulic oil tank.
When the joystick is released, pressure no longer flows to port b, and the control valve internal spring
will automatically center the spool.
A. Up Port Output to Motor
B. Down Port Output to Motor
P. Pressure Input from Pump
T. Output to Tank
a. Up Signal Input from J oystick
b. Down Signal Input from J oystick
Parts List
ITEM # DESCRIPTION
1 Housing
2 Control Spool
3 Seal
4 Spring
5 Spring Cover
6 Pressure Relief Valve
Service:
This valve requires no periodic preventative service.
If the valve requires service, this is easily accomplished by removing the Spring Cover and sliding out
the spool assembly and relief valve. Thoroughly clean the spool assembly, relief valve, and housing
(after removing the hoses) and reinstall. The spool can be lightly polished but do not round the edges
of the valve, these should stay sharp. If the spool has lengthwise groves, it may need replacement.
Since the spool is matched to the housing, if the spool requires replacement, the whole valve must be
replaced.
Adjustment:
The only adjustment is the relief valve pressure. To set the pressure, disconnect the brake release
hoses on the hoist controlled by this valve. Pressure this hoist by operating its joystick in the down
position. Read the gauge in the cab. It should read between 5300 and 5500 PSI. If adjustment is
necessary, remove the cap covering the pressure relief valve (if fitted). Loosen the jam nut. Insert an
Allen wrench and screw in to increase pressure, or back out to lower pressure. Once the pressure is set
at 5400 PSI, tighten the jam nut and reconnect the brake hoses. Pressure will vary with fluid
temperature.

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K38 Valve Directional Control Slew (40004)

40003-4 Page 1 of 8
Phone: 713 896 6500 Fax: 713 896 6611
Hoist Control Valves
Part No. 40003 (Dual Spool)
Part No. 40004 (Single Spool)
This manual has been prepared to assist you in the proper maintenance of SeaTrax directional
control valves. To facilitate repairs and before any work is done, we suggest that you read these
disassembly and assembly instructions completely.
General Information
All valve components, except spools and housings, are available as replacement parts or
subassemblies. Spools are hone-fitted to their individual housings. Therefore, damage to either
component means the entire section must be replaced.
Dirt is the natural enemy of any hydraulic system. The first rule of good maintenance is
cleanliness, including the work environment. Make sure you disassemble and re-assemble
your hydraulic equipment in a clean area.
40003-4 Page 2 of 8
1. Square Section Seal
2. Square Section Seal
3. Lockwasher
4. Cap Screw
5. Stripper Bolt
6. Retainer Plate
7. Back-up Ring
8. O Ring
9. Spring Guide
10. Spring
11. O Ring
12. Back-up Ring
13. Endcap
14. Check Spring
15. Check Poppet
16. Spool Clevis Lug
17. Ball
18. Spring
19. Ball Retainer
20. Spacer
Sleeve
General
Remove the valve from the equipment and
thoroughly clean its exterior surfaces before
beginning disassembly. All work should be
performed in a clean area. Carefully examine
the spools to ensure they are free of paint,
nicks or burrs that could damage the bore of
the housing as the spool is removed. Mark
each section in sequential order from inlet to
outlet to ensure that they will be properly
reassembled, If individual sections are to be
disassembled, tag each spool with the number
of the section from which it was taken. -Line
spools are not symmetrical. Mark one end of
each spool with dye so that it can be identified
for proper reinstallation. Spools are hone-
fitted to their housings and are not
interchangeable.
Figure 1 illustrates the proper relationship of
parts in a typical valve bank, and should be
used as a guide to identifying parts and for re-
assembly.
Figure 1
40003-4 Page 3 of 8
Disassembly
1. Tie Bolts - Remove the three tie bolts,
which hold the bank together and separate
the sections. Discard the section seals
(items 1 and 2).
2. Valve Endcap - Remove the four cap
screws and lock washers (items 3 and 4)
which fasten the endcap to the housing and
remove the endcap (item 13).
3. Seal Retainer Plates - Remove the four
cap screws and lock washers (items 3 and
4) which fasten the seal retainer plates to
the clevis end of the housing and remove
the retainer plates (item 6).
4. Valve Spool - Grasp the spring end of the
spool with a clean rag and pull the spool
from the housing with a steady twisting
motion.
The retainer plate, backup ring and spool
seal (items 6, 7 and 8) will generally come
out with the spool. CAUTION: For
valves with detented spools, be careful not
to remove the detent poppet sleeve unless
it is to be serviced. Without the sleeve, the
spring-loaded steel balls can pop free and
be lost.
5. Spool Seals - Remove the spool seals and
backup rings and discard (items 7 and 8).
6. Centering spring and Spring Guides
These parts should not be removed from
the spool unless they are to be replaced.
Once the spool is free of the housing, it
must be handled carefully to avoid
damage.
If it is necessary to remove the spring, the
spool in a soft-jawed vise and remove the
stripper bolt (item 5) with a wrench. The
centering spring is preloaded. Exercise
caution when removing the stripper bolt so
that the spring compression is released
slowly.
Once the stripper bolt is free the spring
and spring guides can be removed (items 9
and 10). Remove and discard the stripper
bolt O-ring and backup ring (items 11 and
12). CAUTION: The spool must be
gripped by the solid, center land only. The
spool can be damaged if gripped on the
hollow portion. DO NOT attempt to put a
screwdriver or drift pin through the holes
in the spool for wrenching purposes. This
can cause spool damage which will result
in a sticking spool and scored housing
bore.
Cautious application of heat may be
required to free the stripper bolt as an
anaerobic thread adhesive is used in its
assembly. Remove and discard the
stripper bolt O-ring and backup ring (items
11 and 12).
Remove the spool from the vise and
remove the transition check poppet and
spring from the spool (items 14 and 15),
Handle the check (item 15) carefully to
avoid damaging the sealing face. (NOTE:
Motor spools will not be equipped with
transition checks).
7. Detent Sleeve, Spring, and Steel Balls -
Remove items 17,18, and 21 by placing a
rag around the sleeve to keep the parts
from springing loose, and pulling firmly to
free the poppet retainer.
8. Spool Clevis Lug - This part should not be
removed from the spool unless it is to be
replaced. To remove the lug (item 16) grip
the spool by its center land in a soft-jawed
vise. Grip the lug flats with a wrench.
Give the wrench a sharp, jerking pull to
loosen the lug. If the staking cannot be
overcome with a sharp pull, it may be
necessary to tap the deformed metal out of
the notch with a punch. Exercise extreme
care to avoid damaging the spool. (See
figure 2 illustration of staking)
40003-4 Page 4 of 8
When the lug is free of the spool, remove
and discard the lug C-ring and backup ring
(items 11 and 12).
Carefully remove the transition check
poppet and spring from the spool (items
14and 15). NOTE: Motor spools will not
be equipped with transition checks.
Cleaning, Inspection and Repair
1. Inspect the spool bores and spools for deep
scratches, gouges or excessive wear. If
any of these conditions exist, replace the
section. Minor surface damage on the
spool may be polished away with crocus
cloth.
2. Examine the machined surfaces of the
valve housings for nicks or burrs that
could cause leakage between Sections.
3. Lightly stone these surfaces to remove
sure the spring guide is not pinched any
rough spots.
CAUTION: A shallow, machined relief
band extends across the O-ring face of the
valve housing and should not be stoned or
ground off.
4. Discard all used seals and backup rings.
5. Thoroughly wash all parts in clean solvent
and blow them dry before re-assembly
Assembly
Spool Lug and Transition Check
1. Carefully insert check poppet and spring
(items 14 and 15) into the spool. Install
the backup ring and 0-ring (items 12 and I
1) on the lug (item 16). Give the 0-ring a
light coat of grease to ease its entry into
the spool (apply 'Loctite" to lug threads).
Thread the lug into the spool.
2. Centering Spring and Spring Guide Grip
the spool in a vise by the flats on the lug.
Install the spool seal, backup ring and
retainer plate (items 6, 7 and 8) on the
spool about 1/2" from the end. Carefully
insert the transition check poppet and
spring (items 14 and 15) into the spool.
Install the 0-ring and backup ring (items
11 and 12) on the stripper bolt (item 5).
Place the spring guides and spring (items 9
and 10) on the end of the spool. Apply a
small amount of 'Loctite" to the stripper
bolt threads before assembly. (NOTE:
Follow the adhesive manufacturer's
instructions for proper curing). Insert the
stripper bolt through the spring guides and
spring and thread it into the spool while
compressing the spring. Be sure the spring
guide is not pinched between the spool and
stripper bolt. Tighten the stripper bolt and
lug while the spool is still in the vise.
Remove the spool from the vise and stake
the lug flange into the notch in the spool as
illustrated in Figure 2. If necessary, de-
burr the stake to prevent damaging the
housing when the spool is installed.
3. Valve Section Assembly - Apply a light
coat of clean hydraulic oil to the valve
spool. Carefully insert the spool into-the
housing. The spring and spring guides
should be lightly coated with high
temperature grease to prevent rusting.
Line up the holes in the retainer plate with
the four threaded holes in the valve
housing. Install the endcap (item 13)using
the cap screws and lock washers (items 3
and 4). Make sure the seal retainer plate is
properly aligned and is not rubbing the
spool. Torque the cap screws to 125 in.
lbs.
40003-4 Page 5 of 8
Lightly grease the spool seal and backup
ring (items 7 and 8) for the lug end of the
spool and slip them over the spool. Install
the seal retainer plates (item 6) to the lug
end of the valve housing using cap screws
and lock washers (items 3 and 4). As the
cap screws are tightened the spool seal and
backup ring will be gently forced into their
recess. Make sure the retainer plates are
aligned so that there is no contact with the
spool and torque the cap screws to 125 in.
lbs.
4. Valve Bank Assembly - Coat the section
seals (items 1 and 2) with grease to help
keep them in place during assembly.
Place the valve sections on the tie bolts in
their proper sequence. Assemble item 1
cap screws with 125 in.-lbs. torque.
Figure 2
40003-4 Page 6 of 8
Remote Operated Endcaps
Remote Operated Valve Sections
Remote operated valve sections are available
in both Group I and Group 11 configurations.
These sections are shifted by the application of
hydraulic pressure to either end of the spool.
The valve spool is spring centered to neutral.
The pressure to the endcap is modulated by a
hydraulic remote control valve, which varies
the pressure as a function of its operating
handle position. The springs in the endcap are
tuned to the remote control valve to provide
proportional spool movement.
Figure 3 illustrates the arrangement of parts in
the remote operated endcaps. These endcaps
may be serviced by first removing the four (4)
cap screws and lock washers on each cap
(items1and 12) which hold them to the valve
housing. Exercise caution when removing the
endcaps. The centering springs in these
sections are under considerable pre-load.
Figure 3
ITEM DESCRIPTION QTY
1 Cap Screw 8
2 Stripper Bolt 2
3 Stripper Bolt Back-up Ring 2
4 Stripper Bolt O-ring 2
5 Seal Retainer O-ring 2
6 Seal Retainer 2
7 Back-up Ring 4
8 Spring Retainer Plate 2
9 Stroke Limiting Sleeve 2
10 Heavy Spring 2
11 Light Spring 2
12 Lock Washer 8
40003-4 Page 7 of 8
System Overload Relief Valve (Pilot Operated)
Pilot Operated Main Relief Valve
The main relief valve protects the hydraulic
system against pressure extremes. The pilot
operated design of this valve combines
smooth accurate operation and excellent
pressure vs. flow characteristics.
Figure 4 illustrates the arrangement of the
parts and serviceable seals. This is a
cartridge-type relief valve and can be
removed from the control valve as an
assembly for replacement or service.
The screens in the main poppet protect the
pilot orifice from contamination. These
screens can usually be cleaned by flushing in
solvent and drying with air. The screens can
be removed for more thorough cleaning if
conditions warrant. CAUTION: The main
poppet is hone-fitted into the cartridge body.
Be careful not to nick or score the poppet or
its bore when servicing. It these parts
become badly scored the cartridge must be
replaced.
To service the screens, remove the setscrews
which hold the seat retainer in place- the seat
retainer, main seat and main poppet can be
removed by carefully rapping the open end
of the cartridge on the workbench. Remove
the snap ring in the main poppet to remove
the screens. Coat all parts with a light coat
of clean hydraulic oil to facilitate re-
assembly.
NOTE: When these at retainer set screws
are re-installed, they should only be finger
tight . Over tightening will distort the
cartridge and cause the relief valve to stick
open.
Figure 4
ITEM DESCRIPTION QTY
1 Metallic Gasket 2
2 O-ring 1
3 Copper Gasket 1
4 O-ring 1
5 Back-up Ring 1
6 O-ring 1
7 Back-up Ring 1
8 O-ring 1
9 Back-up Ring 1
10 O-ring 1
40003-4 Page 8 of 8
Troubleshooting
TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
Pinched or blown section seal Replace seal
Stud fasteners not correctly
torqued
Replace seals and re-torque
Oil leaks between sections.
Mounting plate not level
Loosen mounting bolts and
shim as required
Oil leaks at either end of
spool.
Worn or damaged spool seals Replace seals.
Broken centering spring Replace.
Spring centered spools do not
return to neutral
Foreign particles in system Clean valve and system
Cylinder leaking or worn Check cylinder-repair
Port relief valve not holding. Remove and clean or replace.
Load will not hold
Spool or housing scored or
worn excessively.
Replace section
Dirt or foreign particles lodged
between transition check
poppet and seat.
Disassemble, clean and
reassemble.
Load drops when spool moved
from neutral
Scored or sticking check valve
poppet
Replace poppet
Worn detent poppet sleeve Replace sleeve
Detent spools wont stay in
detent position
Weak or broken poppet sleeve. Replace Spring
Worm pump Check flow and pressure
Defective cylinder or motor Repair or replace
Low reservoir oil level Add oil to specs
Clogged suction strainer. Clean or replace
Suction line restricted Check lines
Relief valve not properly set. Check pressure setting
Relief valve poppet or seat
scored and sticking
Replace relief valve
No motion, slow or erratic
system operation
Valve spool not shifted to full
stroke
Check spool and linkage travel

TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K39 Valve, Brake Release (TC3060)

r -, CONF1DENTIAL
L ..J
CONF1DENTIAL
TOTAL WEIGHT .lO.2 Lb
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TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K40 Valve, Boom Limit Assembly (TC3142)

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0
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TOTAl WElGHT - 50#
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AI() 'f11UHM. 11m!. D8/1I/07/0I
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TEL:+44 (0) 1493 651311 FAX: +44 (0) 1493 604900

K41 Wind Monitor
~
Wind Monitors
(05103105103LM,05305
& 05106)
(including optional Wind Tracker)
Campbell ~
Scientific
-
Wind Monitors
(05103105103LM,05305
& 05106)
(including optional Wind Tracker)
User Guide
Copyrighl 1984-2006 C a m p ~ I Stlcnllfic In<
Prinre<! under liceoce by Campt..11 Scienliflc Ltd
c,..,,,
Guarantee
This equipment is against dd""iS in materials and
workmanship. This guarant"" applies for twel' -e months from date of
We will repa ir or replace products " hich pro, e \[) be defc><:tive
during the guarantee period pro, iMd the)' are returned to us prepaid. The
guara ntee ,,i l l not apply 10:
EquIpme nt which ha. t;.e.,n modified or altered in any way ",ithout the
wrinen permission of Campbell Scknt if,c
Raueries
Any product which has been SUbjc<:fcd to misuse. neglect. acts of God
or damage in Iran,;\.
Campt.ell Scientific "ill return guarantccd equipment by carrier
prepaid. Campbell Scientific wil l nOl reimburse the claimant for costs
incurred in remming and/or reinstalling equipment. Thi, guarantee and
the Company', obligation there under is in of all other guarantees.
expressed or implied. '1'fCIuding those of suitability and nine,., for a
panjcular purpose. Campbo"li Scientific is nOlliah1e for consequenti.,1
damage.
Please infom' us before returning equipment and obtain a Refer-
ence Number whether the repair is under guarantee or no\. Please Slate the
fault s as clearly as possible. and if the product is out of the guarantee
period it should be accompanied by a purchase order. Quotation, for re-
pairs can be given on reques\.
When returning equipment, the Repair Reference Number must be clearly
marked on the Qu!Sidc of the package,
Note that goods sent air freight are suhjcct 10 Customs fccs
which Campbell Scientific will charge to customers. In many cases, these
charges arc greater Ihan the cost of the repair.

SCientiV
CaoTeI ScIerlk lKL
GaIreI Port. 00 Ilathern RoacL
SIIep$I>ed, LE129GX,
1e1: {OJ 1509 f>J11(1
Fax: {o1 15tl9 6(l1091
f mal. "W"'I-.-.aro,1Jl
....... c.m{Deltsci.rn.1Jl
Contents
1. Description ................................................................... 1
I.l Speci fIcations. .......... , ... ________________________________ I
1 1. 1 Wind Speod. _____ ._ ... _ .............. ....... ..... , ......... , ...... ... " ................ , I
I L2 Wind Di,<:<; tion (Azimuth) , .................................... ,_ ............ .... .... ,2
2. Installation .................................................................... 2
2. 1 Initiall nspe<tion , ......... ........... ........... " .. _____________________________ 2
2.2 Siling ........ , ,........ . ........ , ________________________________________ 2
2.3 Moonting ________________________________ ._ ......... ................................... ... .3
2,4 S= , to Wiring ................. .............. . ............... .4
2.4. 1 Grounding. ................. .. .... _ .. __________________________________ 4
2.5 Win<h'ane Alignme"!.. ....................... " ________________________________________________
3. Programming ............................................................... 5
3.1 Wind Spe<:d ................................ ,," _____________________________ ... ... 5
3.2 Wind Direction Instruction Codc _____________ "... .. .. .. ................ 6
4. Calibration .............. ............. ............... .......................... 8
5. Maintenance ................................................................. 9
5.1 Potentiome1er Repla<emenl .. __________________________ 9
5. 1.1 Remo"e Mai n liousing ...... ______________________________________ __ ______ 9
5. 1.2 ___ ....... .......... . ..9
5. 1.3 Remoye Pot.nhm""t., . __..................................... . ... 9
5_1 .4 In, tall New Potentiometer. .. ............................. 10
5_1.5 . .. ___ 10
5. 1.6 Replace Ma in Housing ........... ______________________________________ I 0
5. 1.7 Align Vane ............... . .. .. .. " ______________________________________ 10
5. 1.8 Replace Nose Cone _________ """... .. ......................... .11
5.2 Flange Beanng Repla<ement ................. "" ........................ 11
5_2. I Rem.",. DId Bearings ................ .. ...... ,,"" _ -' ___________ II
5.2.2 Install Ne,.. Bearings .......................... _______________________________ II
5.} Venical Shaft Beanng Replacement.. ___________________ .. _ ....... . ................... 11
6. Troubleshooting ........................................................ 12
6. 1 Wind dIrect ion ........................... _12
0.2 Wind .,.ed ............ . .. .. _13
7. References ................................................................. 13
Appendix A. Diagrams Provided by R M Young ....... A-1
Appendix B. Using the Wind Tracker Display Unit... B-1
B. I Description ._ _ __ ., .. _ ........... ,.,.,.,.,.,., .................. B- 1
B_2 Connecling t ~ Wmd Tracker Directly 10 !he Wind Monitor ............. B-1
B.2. 1 Remo"ing \he IMQ Re, istor from t ~ Wind MonItor CII'cuit __ B2
8.2.2 Connections .. , ____ ................... B]
B.3 Connecting the W,nd Trackor to tbe Wind Monitor a"d a Dot,loggerB}
B.3_ 1 Connections.... ...................................... . .. 8-4
8.3_2 Wind Trocker _ EAarnple I'rogram, ........... .......................... " _B-.4
Appendix C. Wind Direction Measurement Theory .. C-1
Figures
I. Wind MonItor Mmmtro to a Vertical Pi!", .................. .............. .. .. , }
2. Wind Mo"ilOr mouot<Xl to Campbell Scientific's
018 Mounting Ann ............................................................. ,," ____________ 3
3. Wind MOIlitor ConnectIOns to Campbell s.:,c"lIflc Dataloggers _ ...... .4
Wind Monitor _ Section Viow ____________________________________ .................. AI
General A,sembly and Replacc"""'t Par1ll ................. '" ,.,."A-2
E- I Locati"" of I Mfl Re,i",,. on Circuit Board .................. , , , , , "B-2
B2 Dis<onnccting t ~ R .. istor from the Circuit....... """ " .......... 8 -2
B 3 Wind Monitor to Wind Tracker Cable Connections ................ B3
B-4 Connecting the Wind Tracker to a Datalogger using
Single-Ended Inputs ..................... ,," _ -'-' _______________________________ . B-4
8 -5 Connecting the Wind Tracker to a Datal"gger ""ing
DlfT<tcntial lnru'" _______________ """".............. . ............... " .. 8-4
C_I 05103 Potcnli""",tor in a Half Bridge Circuit ..... ,'c- I
Tables
31 Wind S!",od Multipli er .................... , , ... ..... .... ..... .. ........ 6
32, Parameters for Wind Di'e<;tion ..................... ,,"" __________________________ 6
Wind Monitors (051 031051 03LMI051 06)
These Wind Monilars m .... s",.../tori:oma/ .. 'ind SfJff" ond direction. Originally d<'l'eloped/or
UCClm <1"/(1 bljQ,,' ",e, Ilwy Of'(' n'gged 000 corrosi"" resisum/ yet aurmc "lid lighl>wighl
The mom housing. nose cone, prol"ller, and alher imuno/ parts oU Injection mOl./ded
UV- "abi/ised plastic. Both the pro{H'lIer and ,wlical s/tajis use s/ainless sleel precision grl1<it
hall Marmg.<. The "",,orillKS ha ... : /iglll (onla('/ing Teflon .<eo/s and ore filled ",jlit a
low-torque ... ide lemperal",e range g""".!" 10 help exclude cQniamin<J/ion and "'oW",'". TIrI'
"marill" . >"ersion, mockl 05 /06, is _'JX'Ciul/y m"de [or use j,. mari"... "nd other harsh
en, ,rutlmten/s. Model Q5103LM has a buill.in 4.}OmA lin .. d'i.'('r. Additional m"'JUji.IC'"rer:,
m"",,,,!.," (Ire pro,'ided ... ilh or<krs for Ihe 05103LM and 05106 models.
Wind ,llonilOrs C<1n be "sed direCI/" "'ilk lhe Wi"d Trocker display ,mil 10 gil." a con,.""icm
,mmediale ''''pia), of ""ind spHd and direclian. Appendu B gi"'" f"""'" ,ktails "f ha", la
co"ncct ami use Ihe lI'iml Trader.
1. Description
Rotation of the Wioo MOlIn"" p<opeller f"OO""'" an AC .i .... ,,'0'0 ,isnal ""h.
frequency proportional 10 lhe" ind speed. Thi' AC signal is indUoCed in a .utlo"ary
coil by a mounlrd on !be prorcll"" shafL Th,'" cornrlele .",.
waH ,yd ar. pmdUoCed for e""h propeller ,nolutiQ .
TIle posil>on ofllte " ind 'a .... is tran.mined by. IOIJ) precision rondUoCli'e
plaslic pol<1lliomeler "hieh require,. regulated exeilalion . Wnh.
conslanl ,ohag. applied 1o the poIentio",.t .. , lb. uutputSlgnal i, an .nalogue
"ohage d"",,'I) prop<)n'onlll,o ""imoth angl.
The instrumenl mounlS on 'tanda,d I nominal bore pipe. ol",ide diameter l4mm
(1.34"). An on.nlalion ring IS f"o, i<ltd 50 !be inslrumonl n be 'em", ed for
""'on,cnaoc. at><! re",'I3I1.d ",,!.ou, loss of" ,nd d".<:I"'n referenc . Both the
"""'"ling poS' O>SWlbly at><! ,he orienta,iOll ring'r<: secured to ,he mounting pipe b)
Stainless ... d band clamp', [I",,'rical ron""",io ...... mad<: in a jUr>:;'iOll box at ,It<:
"'"
1.1 Specifi cations
1.1 .1 Wind Speed
A""uraey
RInge
P,l<b,
Dl>tance Con'lant:
Threshold S.nsil"'i'Y
Transd""CI'
Outpul Fr"luency:
,,0.3,..,1. I 10 6Orn, .1, ,,1.00m .1. 60 to 100000"
I to 6Oms.
1
(130mph) for ",",-,mum accuracy. S .... ,
(nOmplo)
180mm di.mel.r 4-blade helicoid p"'peller """,Ided
from polypmp)I<nc:
294mm .ir passage ]><'r ",'ol,,"on
2.7m for reco' ory
I.Oms' (m ... ). O.5m.' 'ypical
Ce-n'TIlII) mOl!O,ed .,.IIonary coil, 2kQ nom;nal
DC
AC w .... s;g",,1 'nduced by >""n& mag .... ' on
I'wpellCl ,hafl; 125m V p-p al lOOrpm. I B V p-p at
IO,OOOrpm
J cycles per 1""I"'1l'" ,",olutlO/1 (0.098,..1 per ilL)
,
05103 WindMonlIol
1.1.2 Wind Dir&etion (Azimuth)
2. Installation
AccUlllC)': ;, j "
RanKe; 360' """MIlIo.l, 355 electrICal op<n:
parall el ,,"Si.IO' p ... signal in
deadballd)
Scmor: Ilalanc<'d ''OM, lSOmm Cum.ng
D&mpiol Rotio: 0.13
O" .. y Dtstantt: 13m for SO". =<I'n)'
Thre:!;hold Sensilmly: I.Oms" at 10" d,;placm><1l1 1.3ms-
1
at 5
d'-'l'''''''' ..... nl
D.mpNNatullIl W.'ei<1!lIlh: 7Am
Undamped Naturol W."el<1!1I1h: 7.2m
Tr.nsduc",", Precision cooduct,,-., pl:SSlic poIenliomet ....
lOU} resislance linearity,
upcda"<"Y $(I m,lIion "" .. <>IulJOnS. "",ed
IW ... 4O"C. OW ,I 125"C
Tnon<ducer Excitation: RegUlated DC " .. "oded b)i daialogg ..
(poI<fItiom<1<"f ralln, I SV DC IIW<.)
Output: Analogue DC 'oila8" plt>J>O"ion.l to azimuth
.ngle ""jth regulated ".citatlon volt.ge
acros.
2.1 Initial Inspection
NOTE
2.2 Siting
,
Wbetl the Wind Mooi,or Ii unpacked il.oould be cardully for any signs
of .hipplng damage Re"""',, tile plastic nut Of) the propell ... ,haft .0<1 imull {he
propeller on the .haft so the I.\\.r markings on lh. prOflClier forward (into tht
wind). The and .hould easily throop 360" "" thou{ fnCllun.
Chk {i>< "aJ>< balance by hold,ng ti>< ,"'!rument base w the ,'a"" .una". i,
boruonllol. It .hoold h .. e ""ar ""utn.1 Lorque w;thoolany parncular l<1><kncy 10
rotAte A 'lighl imbolanc ... 011 OO! degrade perfOl'1l"lall
If tho: W""I Mon,"" is to be used In remote Of i....:<:eU.bl. Iou-
non. )'OU may .. -j.b 10 lCS1 ,{ electrically before fi ... 1 i"""llItlOll. n".
can be done by fi .. t roll"'" ,ni tho: proccdu= for conr>c<:nnK ,t to {be
<L1lai<>uer (Soc{ion 2,4) and pro]ll'allll1ling (SocII"" 3). Fotlo" tbe
calibra{ion proeo<lu= for w,nd d"",{ion and w,nd speed dell<.'nbed
,n &til"" 4.
Proper placement of lhe ,nstrIUnent '..,ry i"""'"""t &l.hes from lIftS. bu.ildinp
or om.. .lruC1ures can 'nl1uence " 'in<! spd and ,,"00 dnCC11Of1
oo..."'alions. Tn get mean,n,rul daIlI for IlIOOI appbcallOflS lht il1lfUm<1lt
".11 abo". Ofupwind from obsuucIlO"'. As.. J!:OI'I'IllI AM. ,he .If no...' around
'!rue!u,"" IS di.turbed 10 {"ICe (he he'ght of the .1"",{ur. Up" ,nd. II> !"nes tbe
httpldo"'""ind,and "p 10 twic. height of the .truet"", abo". around. For
",me application, ,I m.oy I'IOt be p,,",,{ical or n", ... ,>'Y to meet th."" roqlliremcnt .
-
2.3 Mounting
NOTE
Use, Guide
Wind MonilQr moont. to any ,'.nical piece of I" nominal bore (34mm/ I .34"
0.0.) pire (..,. Figure 1). A band clamp at the b .... of the sensor i, tightentd to
secure the sensor to the plre.
A special fitting ,upplitd with the 017 and 018E mountmg ann, enable, the
"",,sor to be mounted on 25mm 0.0, pire ("'" Figure 2). This pan replaces the
normal orienla1ion ring. To mouJl1 lhe Wind Monilor 10 the 0 17 or 0 18 arm,
I. Fit lhe mounling post into lbe Nu-Rail conneclor. leaving about 20mrn
protruding from 1M bonom. Tighlen the two grub .Crew' 10 SeCure lhe I"',t In
lbe connector.
2. Slide the Nu-Rail COIlJlector onto the...,d oftbe arm and CTL.Urc th,t ,he
mounting post i, verlical , tho grub screw, lQ secure the connector
onto the arm.
3. Plate the orirnla,ion fItting (supplied wilh the arm) on lhe mounting I"'st. (Do
not tighten the band damp ye1.)
4. the Wind Monnor onto ,he ooentat iOD fining. ensuring that lhe notch on
lhe ori entation jining rngages ""ilb lhe slot in the base of the sensor. (Do nol
'ighten lb. band damp yet.)
The 0171018E arm i, not supphtd with the Wind Moni'or.
1
-
Figure 1 Wind Monitor Mounted to iI Verticat Pipe
---
Figure 2 Wind Monilor Moun/ed 10 Campbell Scientific's 0)8 Mounti ng Arm
,
05103 WindMonilor

2.4. Sensor to Datalogger Wiring
NOTE
Signal
the Wmd Monitor lead, to the datalogger (see Figure 3).
Tbe black out" J""' et of the cable is rubber. Thi,
compound wa, cho n for its resislaoe<: to temperature eur<mes.
moislure. aoo UV degradation. Howe"",". this jadet wI ll <upp"n
combustion in air. 11 is rated as slow burnmg whon to"ed ""cording
10 U. L. 94 H.B. 3JId will I"'SS FMVSS302. Local fire codes may
p=lud. its inside buildings.
CRto(X), CRSHl
Wind Monitor " 'ilh
Siork ( P/l' 9721)
Figure 3. Wind Monitor Connections 10 Campbell ScienNfic Dala/oggers
2.4.1 Grounding
CAUTION Fai lure to ground the wind monitor may resul1 in
erroneous signals or 1ransducer damage
Grouoding the Wind Monitor is vitally imponanl , WIthout propcr grounding. , tatic
electric.l charge can build up during cMain atmosphrnc condni"n, and discharge
through the transdueers, This dISCharge Can potontially cau,. orroneous signals or
transducer failure. To direct the di,charsc away from the transducers. the
mounting p<.><t osscmbly in which the transducers are mounted is made" Ith a
.pial onti . latic pla";c, It;s very imponantthat tbe mounting p<.><t be connectod
to a good eanh groond. 11Iere are two ways th" may he accompli,lled. Fir.;" the
Wind Monnor may be mounted 00 a metal plpc which," coooected 10 eanh
ground, The mounting pipe shoold n"'- be painted whore lhe Wind Monitor is
mountod. TIlwers or """Is t in coocret. shoold be connected to one or more
grounding rock If it is difficult to ground the mounting p<.><t in this mann.r, an
altemalive method may he used. Inside the junction 00, the tcrmi""l labellod
SPARE is imemallyconnectedtoth.anh . taticmQuntmg[>O". . U ... awire to
connttt this t.lminal to a good .anh ground as dose to the insll\lment as possible .
User Guide
2.5 Windvane Alignment
3. Programming
ThIS is most done ""th two pwple; to .dj ust the position
.nd other '0 ob,orn 'he Qutpu, from the datalol\l!or. A fl or miti al in,tallallon. the
iDslrument can be removed and returned to its mounting ",itMt r.-aligning the YaM
since the orienlation ftlling preser'''es the wind direction .. f""""e.
I . Program the for "md dirtttlOn a, dtscn l>cJ m Srtllon 3.
2. Cboos<: a knowD wind dirtttioD reference poi nt on the hori,on.
3 Sightmg down the m;!rument cC1ltT<ii nc. porn! n"", cono at the refero""e
point on horimn.
4. While holdmg vane in position, ,lowly tum lh< base and On ontatlOn f, tti ng
dataloggcr ,howo the proper value
S. Tighten the orientation fi ning band damp. This f,xes the" md dirttllOn
reference
6. Tighte n (he seDsor band clamp.
Thi, ,",,!ion i, for use", who write thei' own datalol\l!eI programs. A datalogger
program (0 measure (hi, sensor can be create<! using Campbell Seientiftc's
ShotlCu( Program Builder soO,,are. You do not to read thIS secl,oo 10 use
ShonCut
3. 1 Wind Speed
W,nd spttJ i. meas ured ",j,h pulsc count ins truction Tho Wind vector
in'!ruotion is w;cd to calculate wind'rd and direction. With the pulse
count instruction, specify a low level AC config""' t ioo. discarding counts from
exc<:ssive intervals. and the result in H,. With this configuration. the pulse count
instruct ion divides the nwnber of counts during the e'rtullon int"""al by (he
inter"al m ,""ooda before applying the multipli er and off",!.
The expression for "ind spttJ (U) is:
U - MX+B
where
M mulliplio'
X - numberofpuls ..
B - offset
T.ble 41 lists the multipl iers to oblain mileslhoU! or metresisecond when (he
pulse count instruction is configured 10 pro, ide its result in liz. helicoid
propcll<r has a calibration that passcs through zo,o: usc an Qff'ot of '0,0 (Gill.
1973: B.ynton. 1976).
,
05103 Wind Monitor
TABLE 3 1. Wind Sp""d Multipli.c
(With Configut"ation 21')
Mod,1 Milnill nuc Output MctcHlSond Output
051030r 05106 0,2192 O.t19S0
05305 0,2290 0.1024
Wh..., configurat IOn cooe I I IS used. the multiplier abo". is
dIvided by the .,,ution interv.l in se<onds.
3.2 Wind Direction Instruction Code
,
The wind direction sensor is potentiometer that ;s measUrM as a "half bridgc",
The ""tput ranges from 0 mV at 0 Jcgr' 10 th. excitation voltage .1355 degre<:s,
In dat.logge", progmmmed with dlog (CR l OX, CRBX, etc.). measure the "ind
dIrcction with Instruction 4 (hcite. Delay. and Measure), CR200 series
datalogge" use the ExDelSE instruclion and other CRBasic datalogg...-s tho
BRHalf instruClion, In general, a delay of I (0.01 seconds) is ,ufficlCTlt when Icad
lengths are less than 30 metres. If the cable i, 30 1<> 300 metTes. use a del.y of5
(O.OS se<oods). The wind dire<tlon h.,. a Ii," degree deadband
between 355 and 360 degree.; lherefore. lhe maximum signal;s.t 3SS degrees.
Th. r.,ult of lhe BRHaif inSiruction prior 10 .pplying lhe multiplier is "",asured
mV/ heit.tion mY; therefore. the multiplier is 3S5. Tho other mea'urc"",nt re.ult
is lhe measured mY; \he multiplier Wilh these InstructIOn,,, 35SIExcilation
Volt.ge, The offset is zero, The par.unctorS 10 be uS<;<! with each datalogger are
listed in Table 3-2.
TABLEJ-.2. Par a melers for Wind 1>1 ... lIon
CRI(I{X),
CRSI(I, CR7, liX. CR80(1 CKSOOO.
CR200 CRl3X CKIOOO

Measurement 2500 mY, 5000 mY. 2500mV, SOOOmV.
Range slow slow/ 50 50 11:<. r<YCT>< SO 117, reve""
<xcil.lion .xcitalion
EXCItation 2S00mV SOOO mV 2500mV 5000mV
Voltage
Multiplier 0.142 0,07 1 355 <leg 355 dog
<leg/mV exc\tat\on <, citalion
(mVlmV) (mV/ mV)
Offsel
" " "
"
CR10X EumpJe Prog,.m
;{CR/()X}
1 Prugmm
01: 5.0000
I: Pulse (P3)
I : I
2: I
3: 21
4: 3
5: 0.098
6: 0
Execution Imerv.l (=000')
Rep'
Pulse
Low Le,..1 AC. Output Hz
L<>e [WS IllS J
Mulliplie,
Off .. l
2: (SE) (P4)
1: I Rep'
User Guide
2: 5 2500 mV Slow Range .- jooo .. /6i) h=) Rangejor CRUX. 21X. CR7
3: I SE Channel
,
5: 2
6: 2500
, ,
8: 0,142
9: 0
Excito all rep. wlhohan I
lklay (0.01 = unit')
mV Excitation : 5000 mVjo, eRnx, 21x' CRJ
Loc [WindOi'
.- 0.071 jar CRnx, 21 X. CR7
Off>ot
3. If(X<_>F) (P89)
I: 4 X Loc [WindO"
2: 3 >-
J : 360 F
4: 30 1l>cn Do
4: Z- F x llYn (P30)
I: 0 F
2: 0 n. of 10
3: 4 Z Lo< [WmdD" J
s: End (P9S)
6: If ti"", i, (P92)
I: 0
2: 60
; '"
Minutes (Seconds _ ) into a
Interval (""me uni .. as abo"e)
Set Output Flag High (Flag 0)
7: SetAct;\ eStorageArea(P80)
I: I Final Storage Area I
2' 101 ArraylD
8: Re.l Time (pn)
I : 1220 Year,Oay,Hour Minute (midnoght - 2400)
9 Wind Voctor (P69)
I: I Reps
2: 0 Sample, per
3: 0 S, thcta(I). , igma('heta(1)) "'itb pola, senso,
4: 3 WindSpeedlEast L<>e [WS_m' J
S: 4 Wind Direct;ol1l'Nonh Lo< [WindO" J
,
05103 Wind Monitor
'CR I{)()(J
'Crealed hy SCWIN
'Declate "nd Units
Public WS ms
Public WindOir
UnitS WS _ ms- mcltt$i 'c<:ond
Unl!> WmdOir-Deg=,
'Define Dala Table.
Oal.Table (Table I.True,_I)
Datalnle,.".l (O,60,Mm,O)
WindV""lor (1 ,WS _IllS. WindDir.FP2.False.O.O.O)
F ieldNames("WS _ m. _ S _ WVT. WindD" _ D 1_ WVT. WindDir _SO 1_ WVT')
EndTable
'M"in Progmm
IkglOProg
Scan
'05/OJ W,nd Speed & Diredion &,lSor mMsuremen/s WS _ 1m j and WindDir 1.
PulseCount (WS _ ms, I.2, I.l ,O,098,O)
llrHalf (WindDir.1 ,mV2S00.2.1 .1.2S00.T rue.O. 6(lH,.JSS.O)
IfWindDir_ 360 Then WindDir-Q
'Call Dala Tables and Siore Dala
CaliTable (Table 1)
NextSc.n
EndProg
4. Calibration
8
The Wind MonilOf is fully cahbral.d kfott shiplIlCtll and ,bould require no
adjustments , Rc<ali brallon may 1>< .fler some mai ntenance operalions.
Periodic c.li brallon chock> arc desirable and may be n"",,"sary where lhe in>!",-
ment is used in applications which require auditing of sensor perfomlance
A "cry acCurato wmd dire<;tion calibration requires an R M Young Model ISI12
Vane Angle Bench Stand (a,'ailable from R M YOUl1g Co.). Without thi' de-ice
lhe folio'" ing melhod can yield vane calibralion of Or If
corefully done.
Wilh tbe datalogger programmed as describe<! in 5.e<tion 3. hold or
instrument so its cenlre of rotation is over the centre ofo of ra[><r which h""
30" or 45' crossmarkins" a n enl th. bas< so the junction bo' faces due south,
Vi,ually align WIth tho orossrnarkmp and obsc"'e lhe output, If lhe vane
po>itlon and 1n,1Ioalor do nol withm 5' . it may be neee,,,,ry to adju,t the
potent iometer <oupling in,ide the main housing. Detail, for making this ad-
jUSlment appear in Section 5. 1. 7.
Wind sr<! calibration is determined by propeller pilch.nd the outpul character
i"i<s of the transdllCer, The propeller is accurate to """hm For greater acCu_
racy, the propeller must Ix indIvidually calibmted in comparison ",ith a ,",'ind
speed .tandard_ To ched lhe wind .peed, tempor.rily rem,we the propeller and
eonnecl the shall to an R M Young Model IS801 Anemomeler Dri,,< (a,'ailablo
from R M Youns Co.)
5. Maintenance
User Guide
Delails on checking the be.ring which affects wind speed and dirtion
thresholds, appear in the folio,,-.ng
G,ven proper car., th. \Virod MOnitor provide yea" of .0" '''''. The onl)'
components likely to nee<! replacement due to normal wear are the pre<:ision ball
bearings and the wind dirtion potentiometer.
Only a qu.lified instrument technician ,h""ld perfonn the ...-placement, If ,;en-ice
facilitie, are not return the instrument to Campbell Sc .. ntiflc The
aster; , k ( 0) which appe." in the fol lowi ng outli ne, i, a rommd"" that lhe maxi-
mum torque on all sel screW'S i. O,OO6N"m (80 Ol-in,).
5.1 Potentiometer Replacement
The polentiometer has a li fe expectancy of fifty million re,'ol ulions. Ai; it become.
wom. the may begin 10 prodLlCe noi,y , ignals or become non hnear. When
signal noi"" or non linearity become. unac...,plablc. rcplace the potentiometer,
Refer to tho dn>wings;n Appendix A and prOCffd as fol lows:
5.1.1 Remove Main Housing
l , Unscrew lhe nose cone from lhe ma in housing, Set the o-ring as ide for later
""
2 Gently pusb th. mam housmg Ia!ch.
3. While pushing tbe latch. liflthe main housing up and remo'. it from the
voMical shaft bearing rolor,
5.1.2 Unsolder Transducer Wire
1, Slide the jUlI<lion bo;" cover up. exposing the cil'<"it board.
2 Removo 'he ><re"-. holding the circuit boord.
3, Unsolder the lhree poIemiom"ter wire, (,,'hite. gre<:n. black), lbe two wind
speed coil wires (red, black) and ground ,,' Ire (grey) from the board.
5.1.3 Remove Potentiometer
Loosen the set SCrew On the potenllomet.r coupling and re","",e it from lhe
potentiometer adjust thumbwhe<' l.
2, Loosen the set serew on the polenlio""'ter adjust thwnbwhe<'1 and remove it
from lh. pol<nllOmcl. r ,haft exl.n,ion.
3. Loosen the lwo sel serew. al the base of lhe transducer assembly and remov.
assembly from the vertical shaft
4. Unserew the potemiomeler housing from lhe potemiomeler mounling & coil
assembly.
5. r",h lh. potentiometer out of the potentiometer mount ing & coil assembly by
applying finn bUl gemle pressu,e on the polemiomeler shaft eXlension. Set the
o-ring aside for later use.
6. Loosen the sel serew on the pole n1 iomeler shaft ."ension and rerr.",. il from
the potenlio""' ter shaft.
,
05103 W'nd Monilor
5.1.4 Install New Potentiometer
I. Place the poIemiomeler shaft extension and onng On new potentiometer
(gap 0,04(1") and (igh'.n tb <1 "",cw . Re-grease the o-r;ng if necessary.
2. Push lhe new potentiometer into the polen,inmeltr mounting & coil .s.s<:mbly,
3. Food lh. potentiometer and coil wires through the hole in tb. boltom of the
potentiometer housing.
4. Scr.w lb. potentiometer h"",;ng onlO the potentiometer moonllng & coil
" .. <embry_
5. Gent ly ""lilhe transdue., WIT.' 'he bottom of the potentiometer
housing 10 lale up any slack. Apply. ,mall amount of silicone sealant around
lhcl!ol<
6. In,ull Ihe transducer as .. mbly On the' onical ,haft allowing O.Smm (0.020")
dearance frum the ,'.nical bearing, TigJHen lhe set ""'''',s' at Ihe boltom of
lhe transducer ","",mbly,
7, Place the potentiometer adJUSllhumbwhcd On the potontiometer shaft
eXlension and tighltn the ""t
K Place the polenliometer coupling on the polentiometer adJU>I the Ihumbwh",,1.
Do notlig,hten lhe sel serew yet
5.1.5 Reconnect Transducer Wires
I . Using pli." or paper clip bent to form a small hook, gently pull
lhe wi"", throug,h tbe hole ;n the jU!lClion box
2. Solder lhe w;,es 10 the cireoit board a<>rdmg 10 Figur< 1,
3 Secure the cir<uit board in thejull<tion OOX using the tw<> "'''-.'w' Do nol
mertighten.
5.1.6 Replace Main Housing
5.1.7 Align Vane
I. Place the main h<>using over the \enical shaft bearing rolor Be careful to
align lhe indexing key and channel in these two assemblies
2. lhe main hou,ing over th. \enical shaft bearing rot<>, until tM polen,,_
ometer <""piing is near ll1e top <>f1he main housing.
3. Turn the adJusl lhumbwhed until the pole"liomele, coupling is
",;ented 10 engage ridge in the lop ofth. main hous;t!3. Ensure th.t the set
serew On the potentiomeler coupling faces lhe fronl <>pening.
4. With lhe potentiome1er c<>uphng proper ly conlmue I'll,hing the main
housing <>nt<> the 'han bearing rolor unlillhe main housing latch locks
into pos;lI<>n wi"'. dick,
Connt and program the dalal<>uer.
2. Will1 the mounl mg posl held m po,ilion so lhe jUll<tion box is facing
due ""uh, orien! the \'ane to a known angola! (see Sec",,,, 4).
}. Reach in through fronl of main hou>ing ond the polenliomeler adjust
"'umbwh",,1 unlil the dalal<>uer irKI icates the P"'l"" value
4. Tighten lite se! sere,,' on the polen"umel ooupling.
-
Uwr Guide
5.1.8 Replace Nose Cone
Screw Ihe no .. cooe into Ihe main bousing umil Ihe o-ring seal is ..,.Ied, Be
certain Ihal!he threads are properly engaged 10 a .. uid
5.2 Flange Bearing Replacement
If Ihe anemometer bearings become noisy or the "ind speed threshold incre...."
abo'"e an acceptable le,'ei. the bearing' may noed replacemenL The cond,tion of
the ...,mometer bearing cao be chtth d using an R M Y""ng Moool 18310
Propell<T Turque Dis< ( . ... ilable from R M YOUIIi Co,), Wilhout it, a rough chock
can be j>Crformed by adding an ordinary paj>Cr clip (O.Sg) 10 the lip ofa propeller
blade, Tum lhe blade" ilh rhe paper di p to Ihe '!Iutt 0 'dock' or 'ntne 0 'clod'
posilion and gently rd.o,.. iL Failure '" rotate due 10 the weighl of the paper cl ip
indicates that lhe anemomet.r beari ng> need replacemem. Repeat Ihis test at
diff.rent pos;!ion. to check the full bearing rot.t ion. If replacemenl is needed,
pr<>cccd as ,hown below,
5.2,1 Remove Old Bearings
I. Unscrew rhe nose cone, Do nol 10.., Ihe o-nng ,eal
2. Loosen the set ""rew on the m.gnet 'haft coll ar and remove Ihe magnet ,
3. Slide the propeller shaft out of rhe no.., cone assembly,
4. Remo,'e the fronl beanng cap which COVOT'S lhe front bearing,
5. R.mo,e both fronl and rear bearing> from !he nose cone assembly. Inse" Ih.
e<lge ofa pocket knife under lhe beanng flange and lift It oul
5.2.2 Install New Bearings
I. Inse" rhe new fronl and rear bearings tnlo rhe nose <one.
2. R.place Ihe front bearing cap,
3. Carefully slide rhe prope ll er shaft through Ihe bearings
4. Plate tho magnet on the propell er shaft allowing O,Smm (0.020") cI""""",e
from the rear bearing.
S. Tighlen the set se.-cw On the magnet , haft collar.
6. Screw lhe nose cone inlC II><: main hou,ing umilthe o-ring seal is sealed. Be
...,rtain lhal lhe threads are properly engaged to a,'old cros'.lhreadlllg.
5.3 Vertical Shaft Bearing Replacement
The ,er1leal ,haft beari ngs much larger lhan tbe anemometer bearings.
Ordinorily. these bearing' will not require replacement al lhe s.ame
inter",1 as \he anemometer bearing>. 'The condilion of Ih. vert;cal bea.,ng can be
checked u,ing an R M Young Modcll8]31 Vane Torque Gauge (."ailable from R
M Young Co.). Wilhout it. a rough ehe<:k can be performed by holding Ihe
;nstrumenl with the "ane horizontal and pl.cing a 3g weighl (e.g. a ,mall com)
near rhe aft edge oflh. fin. Failure 10 rolal. downward Indicate' that tho .-erti,.1
bearings need replacement Rej>Cot this teslat differenl po,ilions 10 check Ihe full
beari ng rotation.
"
O5IOJ Wind Monitor
(h" protcdun:" , imllar to [hal for replacing the potentiometer,
only major step> are li,ted here,
L Remov. [he main housing (S""lion 5 l.l).
2. Unsold .... the tran'duc .... "'!res (Sttlion 5.1 2) and rcmo,'. the transducer
a,sembly. loosen the set screws .t Ibe base of the transducer assembly and
remove the emire .ssembly from (he ,-ertie.1 shaft,
3. Rorno,-. [he , . rtical ,haft beari ng rolOr by sliding it upward off lhe vertical
,hail
4 Remove the old ,'crt;ool bc'n"lIS and ;n,(all new hearings. When i"","ing the
new hearIngs. be ,..-ofol nol to arply pre"U," ", the beanng .hields.
S. Replacelhe '-enical shaft bearing rotor.
6. R<pl.cc the [raMdu" .. & re<onnec\ II", wires.
7. Replace the ma," housing (Section S. 1.6).
8 Align the ,'ane (Section S. 1.7),
9. Replace {he nose cone (See!iOll 5. 1.8)
6. Troubleshooting
6.1 Wind Direction
Symptom:.9999 or no change in direction
1. Check that the sensor is wired to the EXCItatIon ""d Slngle.Ended channel
specified by the measu",r .. nt instruction
2. Verify that the "'lIage ""d Rang. cod. arc Cont for the
datalogger type,
J Disronnectthe sensor from the datalogger and use an ohm meter to check ,h.
potentiometer. Resistance should be about 10K ohm' betw.en Ihe Blue and
White wires. The resistance between elth.r the BluciGI1l or
wires should ViIl)" be'ween about IK to II K depending on 'ane position.
R .. i,tance wben the vane is in Ille S dog,"" dead band should be .bout 1M
ohm.
Symptom: locolToet wi nd direction
I, Verify that the Excitat,on voltago. Range ,odo. muhipli er and offset
parameters Of" CQlTe<t for the datalogger type.
2. Check orient.tion of .. nSOl' as dos<ribed in Section 3.
-
User Guide
6.2 Wind Speed
7. References
Symptom: No
I. Ch.d lhallhe .en",r is wired to lhe Pulse channel specified by lhe Pulse
count inslruCtlOn.
2. Dis<onnecl lhe sensor from lhe dalalogger and uSe an ohm meIer 10 the
coi!. The reslStan bctwcrn lhe red.nd black wire, should be aOOul2075
ohms. Infimle .-..i,lon,e indicales an open coil ; low resislance indicates a
.hort.d coil .
3. V<rify lMllh. Conflgura1ion Code. and Multiplier and OfTset p.rame!<rs for
lhe Pulse Count instruclion are correct for th. datalogger lyl"'.
Symptom: Wind does not change
I. For llle dataloggcrs that are programmed with dlog. the mput locallon for
wind 'rd is not updated if the datalogger is goning "Program Tab1.
0, emlns" Increase the execut ion mt<r".l (scan rat.) 10 prewnl o"erT1.ln .
Gill. GC .. 197 J; The Helicoid Anemometer Almosph.re. II. 145 155
Baynl"". H.W., 1976: Erum; in Wind RUD E.:i1irnales from Rotational
Anempmeters flul. Am. Mel. Soc .. "o!. 57. No. 9. 11271 130
Th. foll owing ,of ere",., gi'" detailed information on sitmg wind speed and wind
direction ><n",,,
EPA. 1989: Quality A.< .. urance Handbocl</or Air
Offi". of Research and [)e, .. lopmem. Research Triangle Park. :-':C. 277 11.
P A. 1987, 0,,_5il. Program Guitkmce lor Regululory Modelling
Applications. EP,\-4501487-O 13. Office of Air Quality Planning and Standards.
Research Triangle Patk. NC 277 11.
Th. SIal. Chmatologi". 1985: Publication 0/ thR Association o/SIa"
Ci;malologis/$: Height and Exposure SWirdard:i. for S<nSorS on AUlomated
Weather Stations. "01. 9. No.4.
WMO. 1983: Guide 10 Melmrologjcul Inslroments ami MethodJo/Obsen"'tion.
World Meteorological Organualion. No. S. 51h edition. Geoev . Swit:l.erland.
"
Appendix A. Diagrams for model 05103
Provided by R M Young Co.
,"
NOT,
$(Mw (",CUlt" ''''' ""l
po'"n"",,". COO"'-'""
"" .... " ""'"""Hll
('Q" C)
.",." '" PCl.[ , .. elm (""'1 B)
CON( f>O't(.o.O
0"'00
G .... C'''-
:r-
... TO .. OVE .. "," HWSlNG - <)N1Wl(Al) NOSE CCt<[ P\JSM
HW$II.e lATCH, un
e. 10 RCPVCI.: \!I<THREo.il NOS[ C')'ir. Rr .. OIlE SIX
pOlE ",mC 'i,e sutlE PROPHlR ""'>1"' 1i1J1j
rC'''''ARU. "'reR O(M1NG GAP TO
o ""en (0020") ",HH B[.R1..c GAP Rl-1IGHTIN SO SCf[w
C 10 AO.oJsr P01.NTlOWE 1(R W TP<.J! SlCNN.. - NOS! CO<;" lOOSE:N
'/'6 SO SCR(w 'N 1fR cooptltJc. 'DJ<)" OUTPuT uy
0<' "O.oJSn.otNl n" .. .""",-", .. RC_lIC><lcN "'-1 ,Ol'-"
"'leT 10 manuiflc/u,e,', manual /0' """'d..) lor
05l0JLM and 05106,
A'
-
05103 Wind MonItor

I.lOOFL 0:'10.5 \\01:.0 I.IONITOR
0111 .. """"",r. Ie JO eM ... ,'"
1'0. ..... """
1Il" .... C (1 Arm)
. Mt CONI: ASSY
8-)1 J/< , ... '< >CI SOl' ...
O'11B ........-:'.,.. BOX 0._ (1 0'[(0)
c-wr 1><'''''''
"1" 10 Ih. UJHlNlt. ""m"ial:/"'" 's Ih.u ""Hld.) fi" J.'QII_,
Qjrk, 051O}!.1f and 05106 .
-
Appendix B. Using the Wind Tracker
Display Unit
The Wi"d Tracker i:; a compact .... ind speed and direction display 'mil. This mode' has
udn1l1ccd feamres. ;nc/uding 4lQrnA inpms. serial input/oil/put and alann fime/ions. This
Appendix describe" how 10 conneel the Wind Tracker direclly 10 Ihe model 05W] and ()5106
series of Wind MonilOrs /Q provide an immediate. direci display and also how 10 II,'" il in
('onjomer;on .... ilh" dala/agger.
NOTE
B.l Description
CAUT10N
Th" mQdcl of Wind Trader has beon .pecioll y modified for use
with Campbell Scientific datalogg ....
The Wind Tracker is an .,lr<mcly vcr>atik inSlTllITl<'nl, allowing a conlinu"",,,
display of <um:ol and maximum wind 'reed in a "ariety of uni ... and the se1!ing
up oh'arious alarm Coooilions. Cb.nges can be easily made using {he readily
.ccessible bUllan on {he fronl of the unit. Full detail, of using the unil sbo",n
in the R. M. Young manual provided ""th the Wind Track.,..
The Wind Tracker is designed for indoor use only. For
outdoor use it must be mounted in a suitable weatherproof
enclosure. A special waterprool marine version 01 tha Wind
Tracker is available for use in harsh environments. Please
request detaits.
B.2 Connecting the Wind Tracker Directly to the Wind
Monitor
When the Wind T",der i, prmidcd ",nh an Inder<ndent t230V OC po"'.r
suppty. the Wind Monnor can be dire<tly COllJlected to il lO provide. stand-alone
unit to measure aJld display'" iod speed and directi on. If using the Wind MonItor
in this way you will need to (or di,able) the 1 MO resistor (I.bened R3)
which" on the prin tt:d circuit board Inside the junoti on box. os de1ailt:d below.
,.,
Appendix B. Using the Wind Tracker Display Unit
B'
B.2.1 Removing the 1Mfl Resistor from the Wind Monitor Circuit
NOTE
11>< I Mfl resistor (labelled 10) is incl uded within tho Wind Monitor oircuil for
use with Campbell When Ihe Wind Monil0r is direclly
connected to Wind Tr.lder. Ihi, ""i,tor is not req uired and must be removed
(or di,abled).
Irlontify the correct resi .. or by referring 10 figure U-1. below II i, recommcrnkd
that the resislOr wire is sn,pped at tho lop edge and bent away from the resistor
itself. as sIlo"in in Figure B 2. dfect;,-ely remo"ing lh. re,istor from the circuit.
In lhi. way ' l IS a fairly .impl. job 10 reconnect the resistor. ,hould thIS be
required at a futu", dato (w thal yoo cOIIld use the Wind Mon"", dlroctly
connecled \0 a datalogger. for example). by repositlonmg lbe bent wire and
wlJering the connection.
Location of I Mfl ",,,,tor -
cut ,,"f< and bend to
diseonnect resistor from circuil
in Figure B-2
Figure BI Location of t Mn Resisloron Circuit Board
Cut the I Mfl res istor wi.e in th ..
vicinity and bend away.
L. ___ .. Board
Figure B-2 Disconnecting Ih6 Resistor from the Circuit
If you ha,'e any problem, location or remo"al of the
I Mfl res;sto . please eonlad Campbell Scientific for a,h'i<e.
Wind Monitor User Gu'de
8.2.2 Connections
Wind I\hm,lor
-->
,
EARTH GND
2, WS REF
,
WDREF
,
WD SIG
,
WDEXC
,
WSSIG
J,
Wind Monitor
123456
W,,,, Colour
SCREL'J
BLACK
WHITE
GREEN
BLUE
""
--+ Wind Tracker Sensor Terminals
5. SEto-SORGND
5. SEI'OSOR G:-':D
4. SEI'SOR REF
3, SENSOR WD
I. SEKSOR EXC
2. SENSOR WS
Wind Tracker

I- --I
Figure 8 -3 Wind Monitor to Wind Tracker Cable Connections
Wi", Ibe Wind Monitor to the Wind Tracker using the spe<:ial cable available
from Campbell Sciemiflc, The cabl. will be supplied to the length requtt'ed for
your install.tion. and muS! be ordered separately. When Ofdonng. be" In m,nd
that th. standard Wind Tracker unit is nol ,u,table for ""tdoor uS<' (unl ... fltted in
an appropriate enc1osUl'"C) and '" ,umeirnt cable ,t-.oold be oroe",d 10 easil y reach
the ,ite oflhe instrumrnl, Wire up the units as shown in figure fl -3. abo,'e ,
B.3 Connecting the Wind Tracker to the Wind Monitor
and a Datalogger
NOTE
When Y"" use Ibe Wind Monitor " 'ith a <iatalogger. os pan of a wealher station
installation for example. you will be able to slore and protess lhe wlOd data
according to the specific dataJogger program. Th" ",ill allow Y"" to access hoth
currenl,nd historical reCQrds as ",quired.
However. Y"" may 'till wish 10 add Ibe Wmd TrachT to your in,tallation,
po,,,bly 10 pro, ,de an i"'t"ntan<,,", display of current wind data al panictil ..
location. This section d.""ri bes the wiri ng ",quired "hen us ing a Wind Monilor
wilh both a dat,logger and Ibe Wind Trader,
When the Win<! Monitor is used in this way y"" "iii still {o
rem,,,,e til<: l Mfl resistor from 1he circuit as in Section
B.2,1. above,
'3
Appendix B. Using too Wind Tracl<er Display Unit
.. ,
8.3.1 Connections
Wind Monitor
When connectmg the Wind Monnor to both th. Wind Track.r and. datalogg",..
/irsl mnect.he Wind Monitor to 'he Tracker as shown in Figure B 3. abo,e.
r-;orrnally you <an use singl .... nded inpulS on the data logger. pro, ,dmg that 'he
Wind Tracker is powered from a sep.rate supply and thnc arc no ground loop
problems in your .ystcm. The "onnocti oos from 'he Wind Tracker 10 ,he
datal"ucc are shown in Figure 8-4. below.
WS REF W;;;;E"
(_toWO!<!
r ntd<.ef ... >hown ..
- - - II 1
A" "
A" 'H
I- - - - -n- - -I
F"q,q 6-3)
Wind Monitor
("""""""od to WInd
Tr_or o. """"" In

Wind Tracker
Datalogger
Figure B4 Connecting the Wind Tracker to a Datalogger using Single
Ended Inputs
If yoo suspect ,here may be ground loop problems you 'hould use differen,ial
inpulS to the dalalogger. as ,hown in Figure B5. below. Thi' method is also
advisable if lhe W",d Trachr " powOTod from the same supply as ,be dat.logger.
Datalogger
Figure 85 Connecting the Wind Tracker to a Data/ogger U$lng Differenhal
Inpurs
If there are nol enough frec differential chan ... l , on ,he datalogger. and the Wind
Trachr h"" 10 .hare the datalogger po"'er supply. measuremtnlS can
be mado bycon ... cti ng tbe REF conne<:tion to G (powered groundj on lhe
datalogger. However. ,mall errors may OCCur on the readings especially if the
cable run between lhe datalogger and the Wind Tracker i.long (more 'han a few
tens of m<lre.j.
8.3.2 Wind Tracker - Example Programs
The ,'oltage outputs on the Campbell Seien"r,< ,.e",on of lhe Wmd T rac' " are
scaled to ()'540' for O2.5V output for wind direc,ion. The ,,ind spee<! <alibrat;on
depends on the wind speed measureme nt units set yi. the fronl panel swil<hes
Tit< examples programs assume ,hat metres per second are sel. "ht<h scales ().
50m!. to 2.5V .
Wind Monitor User Guide
EX9mpie Progr9m usi ng Wi nd Tracker 0-2.5V Outputs and CRIOX Single-Ended Inputs
"
Volt (SK) ( Pl)
, ,
IIOp o
, ,
2300 ... v
Slow ""''1'0
"
,
SE Channd
"
,
~ o
,
" _Speed
,
:output in IlillivolU
, ,
0
~
"
0 0 OU .. t
"
z_x' r (P31)
, ,

W _Speec:\
,
0
., ,
"
, ,
W_Spe..:l.
:Conv.rt Ili l livolt ""'ading
"
Mgr ...
W Dir
2 , 0.216 r
3: 2 W Dir
:Ao tho output trom the Wind Tr.cke r gi ve. on output
:of 0 - 2.5V _ 0-540 c:\oagre for vind dir. ction
:pertora 0 modulo divide by 360 on tho input locotion
:to give the true r eodinq in doqr ...
"
,-.
,
(PH)
, , ,

o
,
W Dir
,
'"
,
"
, ,
o W Di r
Example Program usi ng Wi nd Tr9ckero-2.5V Oulputs and CRI OX Differentia/Inputs
,
voH (DiH) (P2 )
, ,
....
"
,
2500 .V 510 .. Ranqe
"
,
DIIT Ch",nel
"
,
~ o
,
If_ Speed
, ,
0
~
"
0 , 0 Ofl oot
;Con ...... rt &l.llivoH r eadinq to _tn. per con<l
"
z_x' r IP37)
, ,

If_Speed
, ,
0
., ,
"
, ,
" _Spee<l
;Convoort Ilillivolt r oodinq
"
de<Jr ...
,
Z""' P (P31 )
, ,

II air
"
0 . 216
,
, , ,
.. air
B,'
Appendix B. Using the Wind Tracker Display Unit

;A. the oueput fra. th. Vinci Tucku qi .... a n output
;f 0-2.3V _ 0-540 <leOlr ... for .. inc! C:\ir."ti.on
a ...c.fulo dividoo by on the input location
ito 'it".. th. trua readin.,. i.n
"
,.,

j
"
, ,

,
If Dlr
" '"

, , ,
VOir
-
Appendix C. Wind Direction
Measurement Theory
II j s nol nee",,,,,!), 10 undstand 1he "onctp" In thIS sctllon fm the gener.l
operallon of 1"" 05103 wllh C.m(>bcll Scientific' , dalalol:.l:er.
r------------------,
----- ' ,
r ... I ( WH>SPUDSI3NN.
FIGURE C_I. 05103 Potentiometer jn a Ha" Bridge Circuir
C.l BRHalf Instruction
The BRflalf in.truction outputs. pre<ise voltage (V,). and measures lbe
yoltage bctWtt1l thc wipcr and ground (V,) . Th. ,"i,tance botween lhe wiper and
ground, R" and V, ,'ants w,th wioo dircdion. Tho mea,urement ",ult ;.Iho ratio
of lh. measurN vollog< 10 Iho c,",I.tion vollag< (V,IV ,) Th;, ra,io i, rdated to
Ih. reSlstane" as 'hown below:
V,/V, =R,/(R, + R,)
llle maximum value Ina, R. will reach is R" JUS( ""fo,,", ,I <",sse; uYer frum tho
we,( 'ide of DOnh lO Ihe ea,t s;M of fIOnh (al thIS point R. - 0). V ,I V , re.ches ,t,
maximum "Olue of 1.0 mVirnY at 355 degrees. The multiplier > com eft V,IV, to
deg,.." is 355 degrees 1 1,0 V,fV, K lS5, Sirn;e the <!ala!ogg .... outputs Ihe ratio
V ,I V" the multiplier is ille same for both !he CR I O(X) and CR3000. even though
they use a different excitalion voltage, See Sectioo 13,5 in the d.lalogger manual
from more informat ioo on lhe bridge measurements,
C.2 EXDELSE (P4) Instruction
Instruction 4 outpulS a prtti .. exCilallOn vollage (V,) and meaSu,,,, the vollage
between !he wiper and analogue ground, V,_ The res"tanCe hetwn the wiper
and analogue groond, R" and V, ,'a.,<, with wind dlrection_ Instruction 4 ou'puts
the measured voltage, V.' This measu,..,d "oltage is ",Iated to resistance as ,hown
below;
V, =V, 'R, /(R, +R, )
The maXImum ,'al ue that R, will reach i. R, jw;t before it crosses o"er from llJe
we" . id. ofnorth to lhe east side ofnonh (allhis point It, 5 0), V, reaches its
maximum of V" This ma;o;imum '-ollage equals 2500 mV for an ",cjlalion
,-ollage of25 00 mV recommended for the CRIO(X) and 5000 mV for an
<xcilallon ,-ollage of 5000 mV r.c'ommended fur the CR23X "' 355 degrees, The
Appendix C. Wind Oirooion Measuremem Theory
muillplier l<> ,onv.n V, 10 deg,.." is 355 degre<:' / 2500 mV 0.142 f01" the
CRIOX, or, 355 Mgrees I 5000 mV _ 0.Q7 1 for the CR23X. See &eli"" 13.5 in
the dOI"logger manual from more inf<}fTTIation on the bridge measurements
-
CAMPBELL SCIENTIFI C CO:'l IPANIF; S
Compbd l Scientifoc. Inc. (CSII
815 West 1800 Nonh
log. n. U"h 84321
UNITED STATES
w"'"W.".mpbellsd.rom
tnt"',, ,"mrNlI", .. ,um
C.mpb.1I Sci.n,m, Md," I'ty, Ud, (CSAI)
1'0 IloA 2450
Somerset We>! 7129
SOUTH AFRICA
www.c .. frica.co.za
"k<!'" q.!!friCHO L'
Sc ien'ln< Au"rolla Pt)'. Ud. (CSA)
f'O EJ.ox 444
Thun ngo"" Crntral
QLD 4811 AUSTRALIA
www.c.mj>bcll><i.com . u
inC.,.-" e,nmbdl",i. ""u.'u
C.mpb.U Scion,ifi, do R,.,,,1t Ud (CSIJ)
Ru. Lui .. Crapsi Drsi. IS Il"tanll
CEP: OOSS43000 Slo Po"lo SP IlRAZIL
"'",,"W, campbell sci ,com, br
'''''''"!flo:- '' campbeltsi com br
C. mpb.1I S<;'ntili< Cand. Corp. (CSC(
11564 - 149th Strrn NW
Edroon' on.AlbcruTSM IW7
CANADA
wv."W _c.mph< II><i_c.
datologgm'a g.mpl!<:llr.ci q
C.mpb<1I Sc I. nUIl< Ud. (CSL)
Campbell Park
80 (I .. ,,"m Road
Shepshod, Loughboroogh LE12 9GX
UNITED K1NGDO."l
www,<omj>bcll>ci .co_u\;
>akpI<.mpbdli <0 yl;
Campbell Scientific Ltd. Wno n .. )
Mlni pa", du - Ilot, H
1, rue de Torre No",'o - Los Uli.
9t967 CEDEX
FRANCE
"',,"'W _c.mj>bc II >c i_ f r
,"mrNlI .",imtifLv ""naJoo_fr
Campbell Sclentillc Spoln. S. l.
F""t 14. locl t 8
08013 lla",.I"".
SPAIN
,,',,w., ampbd Isci_<">
int", <am[)bcll",i . <s
Conl,be" Scle"tWo ltd. (G ..
Fah",n,," i(,(nmc l. D-283S9 llromen
GERMANY
",.." ,,,mpbell,, j. d,
info'" c.mp):ell",i doe
YOUNG
METEOROLOGICAL
INSTRUMENTS
MODEL 04106
WIND MONITOR JR-MA
( E REV: 0101205
INSTRUCTIONS
-
MODEL 04106
WIND MONITOR JR-MA
( E REV: D101205
MANUAL PN: 04106-90
R. M. YOUNG COMPANY
2801 AERO PARK DRIVE, TRAVERSE CITY, MICHIGAN 49686, USA
TEl: (231) 946-3980 FAX: (231) 946-4772
-
MODEL 04106
WIND MONITOR-JR MA
0(0100 "'"
'3<mdiomtoof . __
_ofpOlj .. ""' .....
n.<moir_pet_
20m (11 811..)101' U'II._ry
'0_12-' ...... )
c.e.ty _ -.,. .... l'K Ohm
_oc_
At _ WJ"" ... "., 0Iduced '" I1U1ing
I'N9"01 on ..... 11. 000 tnV " II '00
tpft . 0 V H .. '0,000 flI'I\-
l cydH pet _lit! _""
10.,.7 ..... pet Hz)
W1NO (AZlMUlH) VEClFICAnoN SUM ...... RY
T,""",_, h" .. tlot>

Stir """' .... 2, em (II r.) l.mniI ,..,...
" o. '" (2 8 II) .... '-""'Y
17 ..... 1'8 ...... )11'0' ,
"'"' ,on,," J,c:ti pIuIoc poIIi'''''''''''''
,OIl 0IwI'I ........ """ (t2O'II.). ,'II. ...... oiIy
IiIo l . po<tInOy 100 million _I. ,Olea
, ... .n II 00' C. O .... on. 01 12S' C
R_ ......
r...-.... 0uipuI ""'""'" OC ...... _.0110 __
ongIo ..." reg ...... .., 0'-

INTRODUCTION
Tho WioJ LlOMO. ", .. IY' ...... I.ont.1 "".nJ ,p.d 'loG
Ji,.ctlon Ori9in,lI, d lOpeG 10. oce,n dOl, bYo, YOO .
I, 0 cOttOIIO' , .. I"ont ,., occ,.oto lOG 11lI"'
..... lgM Th. m', 0,,,nD. 100.1 co.. p,op.II ... 'nJ
ot/ iM.,ul port ... 0 1'locliO. moldoo U V "'bll,nJ
ol""c Bot" tho o,ooollor oM 00 Ie.1 ohofto ,n
,,"Inlo .. "e.1 p,""lllo' grodo b, 11 b .. "ng_ 80.,I.g.
h ... IigM con,.c,lng tollon ... 1. ono or, ',II.d ... ,," 10"
to'qUI "id, "mp ... IU" rang. g, .... to 1i0lp .. <I
""o" mlnot.on 1M "'0101,,,
P'Op.IIo, '010110. P'OJYc .... AC ",., ..... lig.11 .... ,.
tr ... uoocy P.oootl,onol to ... "" ...... Tn" AC '''11"" "
I"dl>td in 0 .. 'toon .., ... by , .1. pole "'.g ........ '10'
on 110. ",,,,,,II,, ,hI! Tn", co"'pl., ... no ..... c,cJoo
'" p'od,"'d 1o ... ch O'opoll., ".oIUiloo
Von. po, it i I, "'nomltt by , , OK .hm 9fO<lolo.
conduetl ,. 911111c po".lIom".. whleli 'OQUlfOl ,
fOgu loted . vcllOllon .011Ogo W.lh cOn,lo.' .01IOg.
oooll.d 10 ,h. pol.nllo", ..... '100 ou,put ,ignol io on ""OIl
.oll,g. direell'; O,oportlonll to ... Ind ""ootoon "g'-
Th. inottu",.nt mo.o" o. 'ilnJIfO 0"' 100:11 pip,. o.to.d.
d ..... ' .. ].I. mm (I )0-) A. ",10.'011010 nng io p,o ., 00
Iho In,' .umon' con bl ,omo.od fo. m .. n .... n'" ond
,,,n, .. U.d w1Ihou' 10 .. of ",.nd " ... ct.on "f.,on", kin
lh. moU"tong pO", .... mbly ,nd ,h. o,lent.,.on nng Ifl
IOCUfOd 10 ,h. mo,.tong Pil>. by .... nl ... 11 1 UnJ
cl.mpo AI"' .... (33 11) plgllil cOblt .... "'Diy I,
topoll.d f., .I.el "col coo.oello.o F., IO'go, c.bl.
leng'h. 0 ,ouOOI .. " 1,.,,1010 boo 0' conooo'o, m" bt
u .. d
INITIAL CHECKOUT
_on t.o WI.J MOMO' I. '.Plck.J ould bo .... CkoJ
clfol.11y tOt on, ''80, 01 pp.ng do",ogl Th,
,.ot .. ", , io OI'gn," bllo.tlel 'n" fully c.lib.".d .... 10 ..
'hipm t. how .. " " ,hould b. ....cI<.d both
m.ch.nic,11y o.d .loc'nc,'I, .... , ... i.",II"io. Tho ,,10,
,od pfopol'" Iho,ld 11,01, '01110 360- " .'hout IrictlO"
Ch.ek , bll,."" by 'oldl'g ,ho Inot,umo.' b ... '0 '.0
,..no _uo1oeo i, ho,l.oo .. 1 It ,hould h '"' ultl l
10'Qu. ""thoUl 'ny ".J c, '0 '0111, A ,lig"'
Imb,I,nc. ",III no' ... gro ... p"lo.m,nc.
Thl po"nll..",.,,, "Qultol I lI.bll DC Cllolion
Do no' .. e .. d 15 .do WM" .... po, toomOl" ... ' ... ' 10
in th. J .. db ...... g.on. tn. OUIII'" o'gn.1 10 ftO.Mg' InJ
m'J .how .. ..,Ing o. , ...... IOIIbI. vol , To P"v,.,
'it .... odingo. lign.1 <on ... ,lo.l.g .1.CUon,c, ""o.ld
cl.",p"" 'ign'l '0 O<C'llhon 0' .. f" .. ", 1 ... , "h.n ,h
oce." NOli: YOUNG .lg 1 condition In, d."I< ..
cl .mp Ih. ,IDnol to ... 11011010 1 ... 1 ...... id ,
cl fc, l' b.' .... . n Ih. wl nJ Jlrocllo. ,ig 1 lin. ,'J .It""
Ih. ..<ltOl.on 0. fll."nOl I,n.. D.",.go to 1 __
oo"n'lomot" moy o u. III 'hort '''CUit eo.d,lio ... I,,,
8010fO ,.".hllo . connoct I., '.Wumon' to 'n ItIdic .. o.
.. ,100"'10 in lh ... ,I.g "1Igfl'" o.d ch.ck I", P'O,",'
w,." .po.d ,nd ..... "h .. I", P"'.loon I nl 0'"
Ih ... Of p .... ' ...... 30' or OS ",o, ... o""ngo 10 .......
10 I'gnman, .
.....
INSTALLATION
Propor plocemonl of 'ho inOlfUmont i ery Eddio,
from , ...... bull<l lng,. 0' o'h., .Welu .... can gr lly
Inftuonce wind . peod and wind diroctiM oe'O'VOlion,. To
get mOlnlngful diiO fo' moot .ppliC01ion, 10011. Iho
Inotrumont woll above or upwind from ob,"Uellono. As a
gen .. ,,1 ,ule. t,e Ilr flow lIound I "'"elu'o i. di,turt>ed to
twice tho ,oillM of tho .tructuro upwind i. 11m .. tho hoig",
downwind. Ind up to 'wice 'ho hoight of tho , truetu," Ibo-e
IIlOuna Fa, t ome oppliootlont It moy no, bo procliOOI 0'
noce .. lry to moot tho. o reQu iromont .
F .... LURE TO PROPERLY GROUND THE
WI NO MONITOR
.. AY RESULT IN ERRONEOUS SIGN ... LS
OR TRANSDUCER D ..... AGE.
G,ounding th o Wind Mon itor io vitolly Import.n,. Without
pro""r g,ounaing .,otie , Ioetricol e'OIg, con build up during
certol. Ilmo,ph,rlo condillon, Ina di, ef1l1ge th,oug' tho
tr. nl duOl'" Th" dl,ef1"g" oon OIUle orronOOUI lignol. 0'
,,"nodueer f. ilu,.. To diroct the di l ohl<IIO oWl y Hom the
'"noduurs. th o mounting post numb ly it mldo wi1l1 a
I POoll1 on'''totio pln 'ie. Th' Wind Monilo' "ould bo
mounled on. mo,,1 pi"" w,lef1 It connOelod '0 eorlll ground
Tho mounting pipe 'hOuld nol be p"nle' whoro Ih o Wind
Monno, il mounted Towe", or mn tl .. 1 In concro'o .houla
bo connoclod to ono 0' moro IIrounding ,odo, II it i,
10 ground tho moun' ing po", in 1I\i l monnor. Iho lollowing
melhod Ihould bO u ... d. T" IOnlOr coblo Ihiold wltO II
intornoll y connoct.d IO! !he onlitl.,lo moun'ing po, l Thi'
. ,iold wire o'ould eonnoctod to on u", ground. (Roler
to wiring di l gram. )
in"oll ation il moot ... ily dono ... rth two people. ono to
odl"l tho In. trumon, .na tho other 10 .. "', ,ho
indicating dovioo. MOl 1011;. 1 Inlloll lllon, tho in l t,umonl oon
b, ,..mo d ond rolurnod 10 i1> mou'tlng wi,hout rooligning
tl10 , ano l in"" tho ononl,tion ring p ... I .. ' .. Iho wind
dlroOO1ion ",f,,,,nco In"oll th, Wind Monil0r following th, ..
atePI
1, MOUNT WINO MONITOR
0) Ploce ori on" lion ring on POOl, Do Not tig,,"n
CALIBRATION
Tho Wind Monito r i. fu lly colib"lOd bolore "Ipmonl ond
ohoul' "Quire no oOj. , lmenl . ReOllib .. tion moy b,
noco .. ,1)' .fte, lome moin"n, nce op .. "ion, PoriO<! ie
colib r"lon c,oclo: , oro d .. irabl. on. mo, noce.lO..-y
w'o", tho in",rumeol 10 UlOd in progrom. wh ie' roqu iro
of , on,or porlormance.
To coli b,.,.lo, wind dl .. etlon, lho foll owing mothod con yiold
vono Cll ibral ion o""urlol .. of oS' or bene, If o"ofully dono.
Begin by connettinll th, in. lrumonl 10 0 lignol conditioning
eiroui' whief1 hOI tome melhO<! 01 IndiOOling wind direction
.olu, Thlo m.y bo 0 di, ploy wIIlef1 ohow, wind dlreetlon
yo luOl in ongulor dog"" or limply' vohmow moniloring
'h' output. On' lorg. ,heel 01 PIper 0' Cl.oboord. o"olully
d ..... IInOl, pie ! .. ,ion, 01 45' incremenlO, Morl< the.e poin"
wllh deg .. e vo lUOl, 0', 45'. 90 Conter tho in , lrumonl
mounting boo. ,1 Ih o OInWpoln, of 1" m.,k,ng' ... i,h tho
junOlion bo, focinll South (180'1, "'Ioulily .lIgn Iho v e wllh
uo, o'o"mlrl<lng ond ob .. ",o tho ind icolor oulput If Iho
.. ne ond IndIOlI", do not .greo within 5 , ft mly b.
no"" .. ol)' to odi.ll Iho potonflometor coupling Inl"o tllo
m.ln '""" ng D .... il. for moking 1I1i, adlu,lm. nt oPP'" in t'o
M .... NTEN.t.NCE. POTENTIOMETtR REPLACEMENT oullin. ,
atep ] , 11 10 ImoMont '0 no," !hot whilo full 1001, wind
dirodion on " gnol conditlon;"g oloel'onloo m.y be 350., full
.c. lo wino di,0001ion l ignol tram In, In.l,umonl I. 352', Tho
I lgool conditlonlnll .loOlroni"" mUl l b. ,diu, led occordingly
fo, ,,"mplo, In. ol'euot w'ero 0 10 1.000 VDC ropro. ontl 0'
10 3e0' , tho oulPut mu", oaju"od for 0.978 VDC when Ihe
in l lrumonl i ., 352' . (352'/360 X 1.000 vol" 0.\1 7& voh.)
Wind , pud colibrotion il del"minod by propelle, pilen .nd
Iho OUlPut en"OOleri"ic, of the lranoducor Coli bra tion
10rmul .. ohowlng propollor rpm and oulpul
... Ind 'peOd oro Inol\Oded In thi. monu,l. Stondard o""uracy iI
_I 0 For g .. ol .. ,""",.CV. 'ho d.vice muot b,
individuolly ",Iibraled I. comp"l,on with ... Ind .poea
",ndara Contoe! tho foctory or your l upplior 10 ooho'ulo I
NIST (No"onol ln, h'u," of Siondordl 5
wind tuoool col, oraUon in our faci lity
Dotoil. on enocklng 'O'quo, ... hlch 0110001' wind
.peod I nd di",ction th .. thold. oppo" In Iho
.. tt ion
bond clomp yot. _"',U,',"',,,','O,',,',O, .. "","""''-_________ _
b) Pllce Wind Monitor on mounting POl l. Do Not ,' ghton -
cl.mp yel,
2. CONNECT SENSOR CASLE
I) Rou," COble co'efully to 1'010 , " . in.
b) U .. of I WII"proof ooonoelo' or junction box It
,"commonded
', ... LIGN V.t.NE
oj Conneot lo,,,umonl 10 On indlealor
b) Choo .. 0 .nown wind direction ,ef .. ence point on I',
'ori zon
c) SigMlng do"'n in"rume'l ""nlorlln, . poonl no.o COne 01
rof,ronco poinl on honzon
d) Wh il e 'olding yon, In oo, i'ion, . Iowly luIn bote u.'11
indOC010' o'ow. prop .. yOlue
0) Tiglrton mounting pO", b. nd ctomp
1) Eng.ge o,;' ntOlio. nng Induing pin in notef1 01
in, ltum,n' boo .
g) figh,"n orlon"'lo. "ng bano cllmp.
WIND SPEED v,
.
knol,
... .
- .
PROPELLER RPM
0.000190' rpm
0.00952. rpm
0. 01096. rpm
0,01764, rpm
WIND SPEED", OOTPUT fREQUENCY
mI, 0,0;&0 ,Hz
0.1904 ,Hz
mpf1 0,2192. Hz
I<m.t\ 0.3528 , Hz
MAINTENANCE
G/Won_ ........ __ -.JR ...... __ ,....d
..,..;00. n.....,_' ....... IMIy .. _, ..... , _ .. _
__ '''_i00i-._ ... __
Cb,_ 000Ir. quoWiod _*"._, ........ portoom
"', ' ,.O. M ___ """" _l1li
..... _ ..... "'-.. --
_porI ___ Tbo_' __
-... ......... 10._ ... __ ...... _
11100_,
n.pd Cb,_ ....
_ -.., ... -.. ....., t:>ovwo .. poW.ooo rooit)' .-or
- ................. tignaI ..... or "",...-.y _
............ _, ""'*'" ... , , Cb, __ .. _
......
,
I ) u..:.ww _ CEIno """'..- ""'- ,
b) ....... _"",--. ___ ...,....
<) - ........... -. ..... ""'-"" __ " .....
......
2.1..tfSOlr:ER TRN..,... l'HIv.E
. j __ ........... _____ iD
_ ...
b) $IoMIypul ___ .....
....... -...,_ ........ _ ...
<j ,.,..oIia' __ (WtoIIo,-.
_j, __ opeood "'" wio .. (re:!, bIId<) ...... ...".
fIIO\IIId ...... (11'0')') frI;m __
,
.J '--"_"p' Cb,_""""*'11 _
_ I ..... , , .. ,_"'*"' __ .... _
b) LocMn .. oaww .... , ... ,_...-_
_ ...... ,.,.. ... ,_ _ ..... c
<) LocMn ....... _ .. _"' '_ ,""_
_" ,"" ..... _--
d) VO-, .. .......... ,_ .........
col ,""
1) _, .. '_ .... d ....... '_ ........ ,. .... ;; .. _
,"" by""""" limo bo.lgwao _ "" ... ,_
..-rt " oobc Soot o."ii'iG _ ... __
I) LocMn .. _ ........... ' _______ _
............... ,---

) _ ....... , ___ lion..., <><'"II "".-
".,.._ (G.p MolD") _ ... ..,......
... *_
b)_.-......... ' _.., ......... ....
'DIj
oJ F"",,,,,oIia' __ .... _ .........
" Cb,_ ............
d) _,' ... ,_Ioouo01g""" ....... ,_ ...............
,""
__ ......... _d ....... '_
.. _ "" _.-0:. """"'. __ d .......
---
,) .. _ ..... --.D.5 .....
(G,020'1_ .... """'_-"'I ... _.
.. -..01_
QI -; ... ,- ......... ,_ ........... ,--
.. ..,...... .ri_.
'1_, , .. ,_""""*'11"" ...... ,_ .....
.... ,_ Do "'" tog/'oIIn "'_)WI.
"M .. III _ \OtCIu. 110 -In
l'HIVftS
I I Uoing _pIon .... _dp .... ID ...... _
..... __ ........
b) __ ID_ 'OIj,..,..._ ..... di"' .. ..mo
IiIIJwn. a-.o_-.".._ ...... 01_
........ _-, , .
<) Sean_& ____ .. _2:1,
ao,iEI
.) _..-............ ___ -..0_ Boonll.l
.. _1roo:Io>7>g "-Y -.,..... _ ..... ,---
bJ _ onoin """'"" ,..., _ o&IIIIt -... _ .....
......... ,_ .-"",oIonoin 1oouo01g.
0) TonpMoollo'_"'*"' __ ............... ,_
"""*'II ioo _ID _ ...... "'" d onoin""""'-'; SOC
_ on ......... ,_ """'*'II_1ioo 1Dog'" loon!
. .
d)WIIo, , ..
_ ........... _ -.... "*" ...... onoin """'*'lII
___ ................. 'cId<'
7 AU:;NVNff.
.) Comw:I.-. ......... _ ..... _ i .. _ .......
_... oio"' .......... 1iIIJwn.
b) __ .. ,...,...._ioo-..._
___ ID._ ...... ' ...... DMoIo_

<) _ ........... _d ...... -..._ ..... ,' .. ,_
"'*"'_ ..................... "'.,-..--
... -
.. , .....
3.REFVCE
.) _.-. aono riO ...... 1ioI.otOog . ....... only ""'"
......... Bo ___ .. _
- ...
.... , .. ,_ -.go - noioy .. -...0.1 -' _
;..,., IM_ ........ -.-.,""'_ ...... , ...
A oo.ogIo _ 01 , .. ,_ -..0 """""""' ... 100 ,..,," .. '" by
ICIdOog .. oo:IOoooy _ ... (0.5 9") ......... d 0 ___ _
T ...... __ ... _ ....... _ddocK ... _o_
...-._""",_ .. F ..... __ ID ......... d ...
-dp'-."''"'--''-'' , ...
.. _ .. _ ......... __ .-.
IooOto'iga .,. IOI>IIcood __
I . REloO.UDBENlt<GS
O)l.Inoin'w '- aono .
b) .. _ .. mognot .. ",, ___ mog_
0) Slide _ "'" 01 '-CEIno
0) Rormw -. _ ...... '.or -'1I<im_ CEIno
nl ,l:>!i."-Iodgod.I>Od<* ___ ."'"" .......
..
tNSflUtEWlIE-.GS
. ) InoerttwW __
b) c..uy _ ptOIIoIoi" _ .... -.
cj ....... "",iO'I ____ 05 inn
(O.(S2D") _ .... """'.--.
dI TV- .. _ ......... __
0) _'-CEIno __ toco.wou __ 110_._ ..
......... --.. -.
-
VERTICAl SHAFT BEARING REPl..ACEMENT
V.<Ik:01 "'an lHI.mg. or. m,,,,I, Ia'ge, Ihon tM 'n_III,
""oringl. O,dln,ray. 111.... ""Omgl -..II11 .. t .bou' twice II long
.. ,ho 1IHIITlOII"oe!0' """'"'V . CheOo: b .. mg """".;on 111,
instrument with tho v.n. Mtlzonllli -"" pjo<;ing l gm ... Ight
"" ... tho rft *<>\to ot til, fin. A U.S. penny o!tlh.lboul 3 gm 0""
is con".."n, !", th" ehtei<.. Fillure 10 rotlt. dow ..... ,'"
ind>cahl. 111 .... <Ik:ol "".ring. need ,.pIO.,."""". R.pe", tllia t.st
II dill.,.n, pooilion. '0 el"4d< !ul be'rir>g mtllion.
Sin"" 1M. plOO6du,. 10 similor 10 POTENTIOMETER
only ..... major _ .re listed """'.
1 REMCM hW'-I HCIJSING
2. WIRES ... ND
TAANSDUCER .o.sSEMBlY loo ....... t ""ow> st be ... 01
t"nodu"", 1 ... rnt>Iy """ remove .nure ..... mIIly /rom
on.ft.
3. REMOVE VERTiCAl SH.t.FT BEARING ROTOR by
upw.rd oft ...
REMOVE OLD VERTIC ..... BO.RINGS AND INST ..... l NEW
BEAAINGS. WI10n i."'ninIt n_ ""oring'. "" .ot to
'ppIy "' ..... ,. 10 ohleld .
REPVoCI: SIW'T eeAAlNG ROTOR.
6 REPlACETRANSOlICER&RECOI*ECTWRES
7.
$. .....IGN VANE
9. REfV,CE CONE
WARRANTY
Thil ",odu" wu,nled 10 "" t_ 01 dole"" in motori.", .""
construct ... 10, pe,'" 0/ !2 morM. /rom d.to of inilial
PIl""' . li.bility i. limited to ,opalr or IOplo<:e<neM 01 dol. ....
A _1 01 'ho .... """'Y "'"Y \H! <>blain,d /rom R. M.
YOUIl\i C<impony
CE COMPLIANCE
Th;. product hOI been ",,,.d .nd .hown '0 comply with
Eu,ope.n CE ..,quiromonlo kit: II'Ie EMC Oi/ective. _ note thll
'hielded cobie mul' "" uoed
Decllratlon of Conformity
AppllcaUon 01 CounCil DllOtll ... o:

St.nd.",. to ... hlth I. o.tlalOd:
EN WO!21 (IEC 80' 2. 3.0)
NI"" and Add" .. :
R. M. YOU"9C<impony
T",,,,,, .. City. 1011, '96M. USA
Importer'. Nom nd AddlO .. :
See SIMppor or In.<>ice
Typo of EqulpmOflI:
Metoorologicalln. trumenlo
Modol Numbor ,Yo .. of M.nuf.clure:
(joO'W'996
I, .... und."'iglHld. IIe,.by dedi,. tnot the equipment
opocIfIeod conformo '0 ,ho .-0 DndiYo nd SlOnd.orOo.
o.t.' Pia",:
TIO"","" City, MichIg.n, USA Fobruo", 1996
.;cf2. 7U(
DovidPoin_
R&D Mon,ge" R. M. YOU"9 Cornpony
MOOEl 04106
/

PERNANEIIT
"'''GNET
",CUNTEO ON

WIND MONITOR J" MA
......0 SPED lR .... SOOCER C'*-=
ROTATOlG ", .. GNET ON PROPEI.ID! SHAFT .. oua:S AC S>QoI ..... ",II<
Il!EQUENCV OIIttCn.v PRCo>ORnoo ..... TO .....0 SPED. l)IR[[
CYClS OUTf'UT RPASHT'S ONE f'Ra'EU.ER REVOlUTION
.. NO ClREcnON POIDfTlc..ETER,
10K c><"'s. '" lIIEAAlIY. 352' fUfCTION ANaL,
..... TT 0 4O"C, OR .. TED TO 0 WATT'S 0 C
''''PORTA''T - THE 'MND "'ONITOR
"'OUNTI NG "'lJST BE EARTH GROUNDED.
--
--
-
-
-'
'!';ef,;:' :..... --:J;. - - - - - - - - - - ...,
, -,-f,'-.. - --------- - - ---"",\--- 10 . __
_ _ <Tn< ( """ e __ < .... Da1,"'" q,_ -- --. , --,'i--j'r----
,.
"" .... ""n'" (,OV " .u) I \
,
,
_+-"'---";';"_1'_+_--"'_1- -- -'''''' -'" --------- --+--t: ----
I 1> " ,
: I
1Y- -"',.."-----1- "-----+' '+, - - --- - - - ---
_ ..... OOL I I'" 1 :
:i -_ -_ -_-----"i-- 'i -/'----
L...______ _ ...J 'v'
II AND Z2 AAE TRANSZORB TRANSIENT
PROrrCTlON
04106-90
WlND MONITOR JR SECTION VIEW
BEARING REPLACEMENT/POTENllOMETER ADJUSTMENT
COUPUNG
ADJJST TfjUt.lBIIHEEL
3-32 SET SCREW TYP. (NOTE C)
POI..[ IoIAGNO '" SH1<Fr COllAR (NOTE B)

IoIOUNll NG '"
C04L ASSY
CONE a-RING
PROPEU.ER '"
SHAFT ASSY.
CONE "'SSEIoiBLY
POTENTIOMETER

BEARING GAP
0.5 mm (0.020")
\/ERllCAL SHAn
BEARING ROTOR
"'-""
BEARING GW 0.5 mm
(0.020 ) (NOTE B)
MAIN HOUSING LATCH
SHAfT BEARING. 2 PLCS
051g0 BEARING
GAP GAGE
A TO REt.lOIo( ..... IN HOUSING - UNTHRE ... O NOSE CONE "'SSEMBlY. PUSH
"' .... N HOUSING LATCH. un UPWARD.
B. TO REPlACE ANEIo!OUETtR f1.ANGE BEARINGS - UNTHREAO NOSE CONE.
REWOIIE SIX POU: ..... GNET USING 1/15 HEX 'M!NCH. SUOE ?l!OPEL.lR
'" SHAfT ASSEuBLY rClRWARO. Rr.!OIlE f1.ANGE BEARINGS .... FTER
BEARING REPLACE .. ENT. SET BEARING 0"" TO O. :>mm (0.020") \11TH
BEARING 0"" GAGE. RE-TIGHTEN SET SCREW.
C. TO AO..I.JST POlENllOUETtR OUTPUT SIGN ..... - REWOIo( NOSE CONE.
LOOSEN SET SCIIEW IN POTENTlOUETtR COOf'l.iNG. AO..o.JST OOTPIJT
SIGN ..... BY .. E.t.NS OF POTENTlOIIE1"ER ... O..I.JSTUENT THUuSVlHEE\..
RE - TIGHTEN SET SCFlF; W.

04106
WIND MQNITOR JR- MA
P'fIOP!:LlR &: SH.<fT ASSY
-
1 F\.ANGE BEARING (2 REQO)
NOSE CONE
r'''''''-"' NOSE COOt
POTENTlOI.IfTER COUPUl<G
"='I-----t- POTENTIOMETER I
r &: 1
r--1-04127 POTENTIOMETIR SHAfT
6-32 1/6 SET SCREW
(6 REQO) 0032.-0002
_
_ EXTENSION (VilTli O-RING)
POTINTIOMETIR CEll
------
I
I
I
I
.J
LA TCtt ,2 1/4 PAN HO SS SCREW
1)0320-0200PP
0.123 VERTICAL SHAFT
BEARING ROTOR ASSY
04122 VERTICAL SH.<fT
&AAINO (2 REOO)
BANO QA1.IP

O!!IENTATlOO RING
()410fl-90
-------------------------------------------------------------------------------
R. M. YOUNG COMPANY WIND SENSOR CALIBRATION CERTIFICATE
-------------------------------------------------------------------------------
SENSOR:
SENSOR SERIAL NUMBER:
BEARINGS:
DATE:
WIND SPEED THRESHOLD TEST:
LOW WIND SPEED AMPLITUDE/FREQUENCY TEST:
HIGH WIND SPEED AMPLITUDE/FREQUENCY TEST:
VANE TORQUE TEST:
SPECIAL NOTES:
SPECIAL NOTES:
04106 WIND HONITOR JR-MA
WJ13492
SEALED/WATERPROOF GREASE
SEP 26 2007
PASS
PASS
'ASS
PASS
Insp. By
______ ------_____ ________________ ---_
i
0.:

_c

-5.,'
cO 100 1:0 ltD loS0 180 ::NO 220 2-50 :80 300 220 HO 6-
mN, -2.0<5 r.I'IX: 1.61 rGPEES
AZIMUTH POSITION us ACCURACV
050 3rol }'O3 3M 356 357 358 3'09 0
1.00 otGPEE O[fi[tSfillO

NOH, >,i..,t" 'os; t;on " >00"0<1 .. 'Q wi"," a,s de<lr .... , The . "'"'Y """'" ;n t'"
PO''''' ; -''' ,...";",, be,,,. .... 352 and 0 de\I'- ;. ,h. ," ... 1, 01 .., .. , ;" ..... '''-''Jot ""H.
PO"''''" ,MI>g< . Tho '.," ...," the "" .. I (op<n c;,eu; ')
-
MODEL 19120
SIGNAL LINE SURGE PROTECT10N

Tho 19120 pro>id ".n. iont ,,>1'000 . uppre .. ion for
up '0 . 1x .on"", . Ignol lin . HormM I ron ... n" oro t o
nh grooM in.I 01 d''''o.giog voltogo n.ili oQuip"'.nt
Norm. lI , oft. , Iho 10' 01 on tho .. """i.t.d lino """n,
to oormol 10'01. lho " .",Ionl deviU ,. \u<no to
high impOdonUl . t.to. In ca 01 Ou".nI ."...rlGad.
boYQOd '''. mo,;mum ,.Ung, tho '"'go ptOloO'ion do"' ''''' .... 111
foil p,OIOC1ong th o circuit.
INSTAlLATION
The unil i. oouo&<l in 0 wo.ther proof ooc".ure arid i. ouF'PIHK!
SPECIFICATIONS
p"""" Roling;
R05pOOSO Tme;
""h . t><.ck.t ond Ut,,,U .. hich .. ill
(0 1 OJ.2.0) pii><' - FOt m.,lmum pro .. ct>on il i. _""''''00(100 'not
II>t "011 bo moo",.d cIos. '0 "'" m"'''''''''''II1co1 .. n.on. AI..,
'ho grou"" wire .h<>ukll><l confI&C,.d '0 0 ooIki groooo,

Tho Sign.roIlino S ..... Protoctlon .. dHIg_ "'"' ooMao
with minimal main1onence. Tho Sign.roIlirHI Pn>lOCIion requi r ...
_......,..,,,.,,,..,.. ",", OioI.".dusI .,,,,,,,,,,,,,.,., on
"'" 00. ond brod< .. con !HI do_ "'"'..,.., ond ... ,""
OONOTUSE SOLVENTS.
TN, pmdUCI I ..... rronl.d ro 1><I1r 01 1""", ., ",",.rIaI, on<!
coootruction !Of perK>d of ,2 """""'" lrom d . .. 01 initial p<JfC!Io .. ,
.. _ '0 ,,,,, ... '" ,opt __ 01 ""_iva Mm, " ""pY
01 "'" ",..,..,ty poOey may !HI ""'oin.<l rrom R. M. Y"'-'"'\I eompony,
CE COMPlIAHCE
'"'"' _ hoi --. _ ond ..."." '" """"'Y ...... ..--on CE
r..,.,...,.... for tho EMC DinIct ... _ .. nolo ItIat _
" ..... , be......,;l
0

S

0
TI
),l-
INSTRUCTION SHEeT 19120-90
REYOl-Gl
33.3-36.8 Volts
500 W.1Is pdk pOWer d .. ..".bon
a25' Clot'"'" .,.;0;_
WIo+WC

75trvn(2,9;")H .
5&Twn(2,2 ;,,)D
'0&0
, & '
, & '
, & '
, & '
. & .
,.
-
TT
TO
JJ-
SCHEMATIC
0
[Q]
i9l
0
, .

SlGN"-LS
, ,

,

OUTGOING
SlGN"-LS
EARTH GROUND
R. M. YOUNG COMPANY 2801 .... ro-P .... 001 , T, ... , .. City, Mlch'Von U.S .... ,
TEL (23'1_3910 FAX
-

U-!lCU (NUrs;WA$HERS
/" STAINUSS
V II!.OCI(
-aPl 051151 WOUNnHG PlAT[
05653 CASE ASSY
SURGE PROTECntlN
QRCUlT CAR(l

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