Operation and Maintenance Manual

AmClyde Unit Model 10000XHD

Crane

Serial Number 2703100

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Orion Drilling—MIS Hull 108 Jackup Drilling Rig AmClyde Unit Model 10000XHD Crane
ADDITIONAL CODE SDRL CODE TOTAL PGS This document contains proprietary and confidential information National Oilwell Varco, L.L.P
which belongs to National Oilwell Varco, L.L.P.; it is loaned for
limited purposes only and remains the property of National Oilwell
73765 Penn Mill Road
REMARKS Varco, L.L.P. Reproduction, in whole or in part; or use of this design Covington, Louisiana 70435
National Oilwell Varco SO16153 or distribution of this information to others is not permitted without USA
the express written consent of National Oilwell Varco, L.L.P. This
MAIN TAG NUMBER DISCIPLINE
document is to be returned to National Oilwell Varco, L.L.P. upon
Phone 985-892-8216
request and in any event upon completion of the use for which it Fax 985-871-8630
was loaned.
CLIENT PO NUMBER
© National Oilwell Varco, L.L.P.

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

2703100-MAN-001 2703100-MAN-001 01

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Operation and Maintenance Manual
AmClyde Unit Model 10000XHD Crane
Serial Number 2703100
Operation and Maintenance Manual
AmClyde Unit Model 10000XHD Crane
Serial Number 2703100
Operation and Maintenance Manual
AmClyde Unit Model 10000XHD Crane
Serial Number 2703100
Operation and Maintenance Manual
AmClyde Unit Model 10000XHD Crane
Serial Number 2703100
 Document number 2703100-MAN-001
Revision 01
Page ii

REVISION HISTORY

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

CHANGE DESCRIPTION

Revision Change Description

01 First Issue

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TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
WARRANTY
1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.1 General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.2 Operating Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.3 Maintenance Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Operator Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5 Inclement Weather Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Crane Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Crane Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Control Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 General Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.1 Horn Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.2 Boom Angle Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.3 Load and Radius Indicator System . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.4 Window Wiper Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.5 Operator’s Cab Air Conditioning Controls . . . . . . . . . . . . . . . . . . 2-7
2.5.6 Area Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.7 Obstruction Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.8 PANEL LIGHTS Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.9 Boom Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.6 Power Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6.1 Diesel Engine Throttle Controls. . . . . . . . . . . . . . . . . . . . . . . . 2-8

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2.6.2 ENGINE KILL Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.6.3 EMERGENCY ENGINE KILL Control. . . . . . . . . . . . . . . . . . . . . 2-8
2.6.4 Diesel Engine Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.5 Diesel Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.6 AIR STARTER Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.7 Hydraulic Oil Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.8 Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . 2-10
2.6.9 Hydraulic Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.6.10 AIR PRESSURE Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.7 Crane Function Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7.1 Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7.2 SWING BRAKE OFF/ON Control . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7.3 SWING LOCK OFF/ON Control . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7.4 BOOM/SWING Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.7.4.1 Boom Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.7.4.2 Swing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.7.5 MAIN and AUXILIARY Hoist Controls . . . . . . . . . . . . . . . . . . . . 2-13
2.7.6 Swing and Hoist Speed Control . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.7.7 MAIN and AUXILIARY HOIST RELEASE Controls . . . . . . . . . . . . . 2-15
2.8 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.8.1 Pre-Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.8.1.1 Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.8.1.2 Before Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.8.2 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.8.3 Pre-Operating Checks (After Engine Start-Up) . . . . . . . . . . . . . . . 2-19
2.8.3.1 Anti–Two-Block System . . . . . . . . . . . . . . . . . . . . . . 2-19
2.8.3.2 Boom Angle Limit System . . . . . . . . . . . . . . . . . . . . . 2-20
2.8.4 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.8.5 Emergency Stop Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.8.6 Main and Auxiliary Hoist Emergency Load Release. . . . . . . . . . . . . 2-22
2.8.7 Emergency Load Lowering . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

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3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Introduction and General Instructions . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.1 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.2 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.2.1 Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2.2 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2.3 Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.4 Swing Gear and Pinions. . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.5 Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.6 Boom Hoist Pawl . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.7 Hoist Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.8 Swing Drive Gearboxes . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.1 As Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Before Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.3 After Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.4 Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.5 Every 8 Hours of Operation or Every Day . . . . . . . . . . . . . . . . . . 3-7
3.3.6 Every 40 Hours of Operation or Every Week . . . . . . . . . . . . . . . . . 3-8
3.3.7 First 100 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.8 Every 250 Hours of Operation or Every Three Months . . . . . . . . . . . . 3-8
3.3.9 Every 500 Hours of Operation or Every 6 Months . . . . . . . . . . . . . . 3-9
3.3.10 Every 12 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.4.1 Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.1 Air System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.2 Releasing Pressure from Air System . . . . . . . . . . . . . . . . . . . . 3-10
3.6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6.1 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-11

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3.6.1.1 Hydraulic Oil Sampling (National Oilwell Varco Drawing 604289) . 3-12
3.6.1.2 Hydraulic System Contamination Levels
(National Oilwell Varco Drawing 604289) . . . . . . . . . . . . . 3-15
3.6.2 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.3 Hydraulic Piping and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.4 O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.4.1 O-Ring Sizes for Bosses and Tube Fittings . . . . . . . . . . . . 3-18
3.6.4.2 Four-Bolt O-Ring Flange . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.5 Releasing Pressure from Hydraulic System . . . . . . . . . . . . . . . . . 3-20
3.6.6 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.6.1 Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . 3-20
3.6.6.2 Adding Hydraulic Oil to the Reservoir . . . . . . . . . . . . . . . 3-21
3.6.7 Draining and Filling Hydraulic System. . . . . . . . . . . . . . . . . . . . 3-21
3.6.7.1 Draining Hydraulic System . . . . . . . . . . . . . . . . . . . . . 3-22
3.6.7.2 Filling Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 3-23
3.6.8 Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.7 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.8 Non-Operational Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.8.1 Short-Term Storage—7 Days Up to 30 Days . . . . . . . . . . . . . . . . 3-24
3.8.2 Long-Term Storage—30 Days or More . . . . . . . . . . . . . . . . . . . 3-24
3.8.3 Removal from Long-Term Storage . . . . . . . . . . . . . . . . . . . . . 3-25
3.9 Welding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Emergency Load Lowering Procedure . . . . . . . . . . . . . . . . . . . . 603511 Rev. 3
Emergency Hoist Load Lowering Kit . . . . . . . . . . . . . . . . . . . 603457-L01 Rev. 9

4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Crane Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Hoist and Wire Rope Information . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Power Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.3 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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4.2 Tightening Values for SAE Coarse Thread Bolts

(National Oilwell Varco Drawing 1525177). . . . . . . . . . . . . . . . . . . . . . 4-4
Load Rating Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 831564
Load Rating Chart, Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 831563
5 API RECOMMENDED PRACTICE 2D SIXTH EDITION, MAY 2007 (API RP 2D)
INSERT FOR API RP 2D SIXTH EDITION (APPENDIX I)

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FOREWORD

This technical manual gives information for the recommended operation and maintenance of the equip -
ment. This technical manual is written for the original design application of the equipment. If the appli -
cation of the equipment changes, the operation and maintenance information and procedures could
change. This technical manual is not a substitute for comprehensive operator and maintenance train -
ing. Read and completely understand this technical manual, equipment functions, and equipment
safety features before operating or doing maintenance to the equipment.

If additional technical manuals are needed, they are available for an added cost.

The serial number of the equipment must be given with all communication for correct identifica-
tion of the equipment.

National Oilwell Varco

P.O. Box 4720 Covington, Louisiana 70434
73765 Penn Mill Road Covington, Louisiana 70435
Phone: (985) 892-8216
Fax: (985) 871-8630

Accessory Sales For replacement parts, retrofits, upgrades, spares, and accessories.
Field Service For service-specific questions and inquiries, including inspections, test-certificates,
service work, repair supervision, and operator/maintenance training.
Sales For new equipment.

This publication is one document of the technical manual for the Unit model 10000XHD crane, serial
number 2703100. The complete technical manual consists of the following volumes:

• Operation and Maintenance Manual, document number 2703100-MAN-001

• Parts and Vendor Data Manual, document number 2703100-MAN-002

T2008-02.04

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 WARRANTY

Products covered hereby are subject to the following warranty and no other: "The Manufacturer
warrants each new Product made by the Manufacturer to be free from defects in material and
workmanship, its obligation and liability under this Warranty being expressly limited to repairing
or, at the Manufacturer's option, replacing free of charge at its factory any part proving defective
under normal use and service within - twelve (12) - months or one thousand (1000) hours,
whichever comes first, after date the Product is first delivered to a user, provided written claim
hereunder is received by the Manufacturer within 15 days after expiration of said period. Parts
claimed to be defective and for which repair or replacement is desired shall, if requested by the
Manufacturer, be returned transportation prepaid to the Manufacturer's factory for inspection.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY
PARTICULAR PURPOSE, AND THE OBLIGATION AND LIABILITY OF THE MANUFACTURER
UNDER THIS WARRANTY SHALL NOT INCLUDE ANY TRANSPORTATION OR OTHER CHARGES
OR THE COST OF INSTALLATION OR ANY LIABILITY FOR LOSS OF PRODUCT TIME OR ANY
OTHER DIRECT, INDIRECT, OR CONSEQUENTIAL DAMAGES OR DELAY RESULTING FROM THE
DEFECT. Any operation beyond rated capacity or the improper use or application of the Product
or the substitution upon it of parts not approved by the Manufacturer or any alteration or repair by
others in such manner as, in the Manufacturer's judgement, to affect the Product materially and
adversely shall void this Warranty. No representative of the Manufacturer is authorized to change
this Warranty in any way, and no attempt, effort, or promise to repair Products of the Manufacturer
either by the Manufacturer or by any representative of Manufacturer at any time shall change or
extend this Warranty in any way. This Warranty covers only new and unused Products
manufactured by the Manufacturer. Products manufactured by others are covered only by such
warranties as are extended to the Manufacturer by its suppliers."

2/2003

1 SAFETY
1.1 Safety Warning
It is the responsibility of the owner and user of
this equipment to know the safety codes; insur-
ance requirements; and national, federal,
provincial, state, and local laws and regulations
affecting all uses of the equipment. This techni-
cal manual does not provide regulatory informa-
tion, because regulations are subject to change
and different from location to location.
It is the responsibility of the owner and user of
the equipment to obtain, read, and understand
the current edition of API Recommended Prac-
tice 2D, Recommended Practice for Operation
and Maintenance of Offshore Cranes (API RP
2D), a document from the American Petroleum
Institute (API). The document is published by
API Publishing Services, 1220 L Street, N.W.,
Washington, D.C. 20005. For more information
call 202-862-8375 (phone) or 202-962-4776
(fax), or visit the API website
(www.api.org/publications/).
Not using the equipment according to these
regulations can result in damage to the equip-
ment and death or injury to personnel.
National Oilwell Varco provides technical manu-
als for the different types of equipment that it
manufactures and sells. The owner and user
must use these technical manuals to give the
correct information and training to the people
who will operate, maintain, or supervise the use
of the equipment.
This equipment is designed to do heavy-duty
work and will wear during normal use. There-
fore, the owner and user must establish a regu-
larly scheduled inspection and maintenance
program based on the information in the
National Oilwell Varco technical manual.
Inspection and maintenance programs help
prevent accidents and keep the equipment
operating efficiently.
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Document number 2703100-MAN-001
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Correct training, inspection, and maintenance
programs are important to avoid personal injury,
damage to equipment, high maintenance costs,
and lost production.
Any performance ratings and specifications for
this equipment are valid only when the
equipment is used according to the manufac-
turer’s operating and maintenance procedures.
Read and understand the technical manuals
provided with this equipment before operating
or doing maintenance to the equipment. Assis-
tance is available from the National Oilwell
Varco Service Department.
The operator must know all the main parts,
controls, and safety features of the equipment
before operating it. The operator must know the
correct operation and inspection procedures of
the equipment before operating it.
The operator is responsible for the safe opera-
tion of the equipment, including the safety of
others in the work area.
1.2 Safety Signal Words
Throughout this technical manual are steps and
procedures that, if not followed, can result in a
hazard. The following signal words are used to
identify the level of a hazard.
!DANGER
• Danger is used to show a hazard that
WILL RESULT in death or serious
injury if not avoided.
!WARNING
• Warning is used to show a hazard or
unsafe practice that CAN RESULT in
death or serious injury if not avoided.

!CAUTION
• Caution is used to show a hazard that
WILL or CAN RESULT in minor or
moderate injury if not avoided.
CAUTION
• Caution used without the safety alert
symbol ! is used to show a hazard
that WILL or CAN RESULT in
equipment or property damage if not
avoided.
NOTICE
• Notice is used to call attention to
operation and maintenance
information that is important but not
hazard-related.
1.3 Safety Rules
National Oilwell Varco equipment, as designed,
can be used safely; however, no equipment,
regardless of design, can prevent injury or
damage because of operator error or careless-
ness.
This safety section includes information from
many sources. It gives examples of basic safety
rules. Additional safety rules can be necessary
for safe operation of the equipment. The infor-
mation in this section is not meant to replace
safety codes; insurance requirements; or
national, federal, provincial, state, and local
laws and regulations.
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1.3.1 General Safety Rules
1. Wear protective clothing and safety equip-
ment as required by job conditions when
operating the equipment or working in the
area of the equipment. Do not wear loose
clothing that could catch on controls or
moving equipment parts.
2. Keep the operator’s area and the work area
clean and free of debris.
3. Keep the equipment clean and free of dirt
and debris, to permit a good inspection of
the equipment.
4. Check the rigging before a lift. Rigging that
is damaged must be repaired or replaced
before it can be used.
5. Do not weld on hooks or shackles. Welding
on these items can weaken the material,
causing failure.
6. Do not use torches or open flame on or
near fuel system, hydraulic, and control
equipment.
7. Adequate fire protection equipment must be
available and in satisfactory operating
condition. Operating and maintenance
personnel must be familiar with the use and
care of the fire protection equipment.
1.3.2 Operating Safety Rules
1. Do not operate this equipment under any
conditions or in any manner other than
those for which the equipment has been
specified, sold, and described in this techni-
cal manual.
2. This equipment must be operated only by
personnel who are trained and authorized
for its operation.

3. Do not operate this equipment if you are ill
or physically or mentally not fit to operate it
correctly and safely.
4. Do not exceed the rated load capacity of
the equipment (see Section 4, Load Rating
Chart, drawings 831564 and 831563). Lift-
ing loads greater than those shown on the
load rating chart or operation at positions
not shown, or lifting when the boom is solid
against the boom stops, can cause struc-
tural failure or collapse of the boom or
crane and death or injury to personnel.
5. Do not rely on the load monitoring system
when common sense judgment indicates
an error. Do not use the load monitoring
system as a weighing device after lifting the
load.
6. Operate the equipment with no load at the
start of each workday to make sure all func-
tions work correctly.
7. Test the brakes for correct operation when-
ever a load at or near the load rating for the
boom angle used is to be handled.
8. The operator must watch the load at all
times. Do not operate the equipment if the
operator’s vision is restricted. Some appli-
cations require a signal person. The signal
person must be visible to the operator at all
times. The operator and the signal person
must agree on the signals to be used
before operating the equipment.
9. Communication must be maintained
between all personnel involved in any oper-
ation. The operator must obey a signal to
stop from anyone in the area. The signal
person must give all other signals.
10. Do not permit personnel to get on or off the
equipment while it is operating.
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11. Do not operate the equipment with any
personnel near the wire rope or moving
equipment.
12. Do not operate the equipment without the
safety guards installed.
13. Do not bypass, disconnect, or ignore safety
and warning devices of the equipment.
Safely shut down the equipment and inves-
tigate the problem. Correct the problem
before continuing operation.
14. Do not operate the equipment after an
inspection reveals a safety hazard or if any
equipment parts require maintenance or
replacement. Always look for equipment
damage or abnormal functioning during
operation. If found, safely shut down the
equipment and correct the damage before
continuing operation.
15. Before rotating the crane, make sure that
the crane tailswing as well as the swing
paths of the boom and load are free of
obstructions and personnel. Not following
this procedure can result in damage to the
crane, the load, or other equipment or
structures, and death or injury to personnel.
16. Operate the equipment at a slow speed
when first learning.
17. Check the load indicating display and all
gauges often for normal operating condi-
tions. Shut down the equipment immedi-
ately if the display or gauges are out of the
normal operating ranges. Investigate and
correct the problem before continuing oper-
ation.
18. When making a lift, the hook must be
directly over the estimated center of gravity
of the load before the load is attached to
the rigging. Do not attach capacity loads at
maximum outreach, because an outward
swing of the load, caused by vessel list or
trim, or outward drift of the boom, can over-
load the crane.
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19. Loads must be safely rigged before lifting.
Do not overload slings. Slings must be
attached to the throat of the hook. Do not
permit hook latches to support any part of
the load. Hook latches keep loose slings
from coming off the hooks.
29. The operator must not leave the control
station with a load suspended in the air.
30. The hoists must have at least five full wraps
of wire rope on the drum at all times during
operation.

20. When making a lift, the boom (hook) must 31. Do not permit the wire rope to wind wrong
be directly over the load, not the side of the on the hoist drum (see figure 1–1).
load. Side loading can cause structural fail-
ure or collapse of the boom or crane and
injury to personnel.

21. Use extreme caution when rotating the

crane with a load suspended. When lifting a
heavy or bulky load, it is recommended that
taglines (ropes) be attached to each side of
the load to prevent the load from rotating or
swinging.

22. When using handlines (ropes) to guide or

snub a load, do not permit personnel to
wrap the rope around any part of their body. A1929

23. Personnel must be clear of the work area

before making the lift.
24. Do not quickly accelerate or quickly decel-
erate a moving load.
25. Loads must be moved at as low a level as
possible. If the load slips, it must be
lowered with caution immediately.
26. Do not swing or position the load or attach-
ment over personnel. Do not permit person-
nel to be in a hazardous position between a
swinging load and a fixed object.
27. The operator must watch the load at all
times. The load must be completely
lowered before looking away from the load.
28. The operator must not leave the control
station until the equipment has been shut
down and is completely stopped.
Figure 1–1. Wire Rope Wound Wrong on Drum
1.3.3 Maintenance Safety Rules
1. Shut down the equipment before doing
maintenance. Only qualified, trained
personnel must do maintenance, adjust-
ment, and inspection procedures, following
the procedures outlined in the technical
manual.
2. All replacement and repaired parts must
meet the manufacturer’s current specifica-
tions.
3. After making a repair or adjustment, always
check the functioning of the equipment
parts before putting the equipment into full
operation.

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4. The power plant must be stopped and cool
before checking fluids.
5. Do not add fuel to the fuel tank while the
equipment is operating. When adding fuel,
keep the nozzle in contact with the fuel tank
to prevent static electricity sparks. If
provided, connect the ground wire before
adding fuel. NO SMOKING! Do not permit
open flames or sparking devices near the
fuel filling area. Remove all spilled fuel
before starting the equipment. Add fuel to
the fuel tank in a well-ventilated location
only.
6. Do not make modifications to the equip-
ment unless approved in writing by National
Oilwell Varco.
1.6 Safety Labels
Safety labels are located on the equipment in
prominent places to advise operating and main-
tenance personnel of hazards. The labels are
reproduced here to improve recognition and
thereby increase label effectiveness. Before
operating or doing maintenance to the
equipment, be sure you understand the mean-
ing of these labels. Drawing 604888, Decal and
Nameplate Installation (see Parts and Vendor
Data Manual, Section 2) shows the locations of
all the National Oilwell Varco-supplied safety
labels. This drawing is a useful reference for
the inspection and maintenance of the safety
labels (see paragraph 3.3.8). Replace all
damaged or missing safety labels.

1.4 Operator Qualification

To prevent injury and property damage, the

crane operator must be qualified by training and
physical capability. The operator must under-
stand the manufacturer’s intended use, and the
operation and maintenance procedures. The
operator should be familiar with and follow the
practice of API Recommended Practice 2D,
Recommended Practice for Operation and
Maintenance of Offshore Cranes (API RP2D)
current edition.

1.5 Inclement Weather Precautions

Crane operation should be suspended and the

boom lowered during periods of inclement
weather, including wind strong enough to affect
load control (especially loads with large “sail”
areas) or when the operator can not clearly see
the signal person or load because of darkness,
fog, rain, etc.

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WARNING Operating and maintenance personnel must read

Read and fully understand and understand the manuals provided with the
operation, service and parts equipment before operating or doing maintenance
manuals before operating or to the equipment. The equipment must be operated
servicing equipment. only by personnel who are responsible and autho-
rized for its operation.
Failure to obey warnings and follow
instructions could result in
personal injury, death, damage to
equipment or property.

p/n 604287

WARNING Operating and maintenance personnel must read

Swing brake must not be applied
while the crane is in motion.
Serious damage may occur to
the swing gear box components
if this procedure is not followed.
Refer to operator’s manual for
additional swing control
information.
and understand the manuals provided with the
equipment before operating or doing maintenance
to the equipment. The equipment must be operated
only by personnel who are responsible and autho-
rized for its operation.

p/n 603164

WARNING
Shut down the equipment before doing mainte-
Machinery must nance. Only qualified, trained maintenance
be completely personnel must do maintenance, adjustment, and
stopped before inspection procedures, following the procedures
outlined in the maintenance manual.
maintenance can
be done. Make
reference to
maintenance
manual for correct
procedures.

p/n 604283

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WARNING
Only trained authorized personnel
are to do maintenance or make
adjustments to hydraulic, air and
electrical systems. See
Maintenance Manual for
instructions.
Shut down the equipment before doing mainte-
nance. Only qualified, trained maintenance person-
nel must do maintenance, adjustment, and
inspection procedures, following the procedures
outlined in the maintenance manual.

p/n 604284

DANGER
Do not access this area while the crane is
To prevent injury, operating. The equipment can start or stop without
warning. Not following this procedure can result in
do not walk or death or serious injury.
stand under crane
boom, hooks, or
load.
p/n 603187

CAUTION Be careful when opening or closing windows of

operator’s cab. Keep area clean and free of debris
to prevent tripping hazards.

OPENING/CLOSING
CAB WINDOWS
p/n 603762

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WARNING
Exposed, moving equipment parts can cause seri-
ous injury or death. Keep hands, feet, and clothing
away from moving equipment parts while the equip-
ment is operating. Do not operate the equipment
without the safety guards installed.

p/n 604285

WARNING Exposed, moving equipment parts can cause seri-

ous injury or death. Keep hands, feet, and clothing
away from moving equipment parts while the equip-
WATCH YOUR ment is operating. Do not operate the equipment
HANDS without the safety guards installed.
AND
FINGERS

p/n 603698

WARNING
Only qualified, trained maintenance personnel must
do maintenance, adjustment, and inspection of the
electrical equipment. Each maintenance person
must install a lockout at each electric power area.
Electrical equipment must be maintained and oper-
ated according to applicable standards. Not follow-
ing this procedure can result in death or serious
injury.
Electric shock
hazard. Authorized
personnel only.

p/n 604788

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WARNING
Electrical power is supplied to this equipment from
multiple sources. All sources of electrical power
This enclosure must be shut off before accessing the indicated
has more than equipment. Only qualified, trained maintenance
one source of personnel must do maintenance, adjustment, and
power. Disconnect inspection of the electrical equipment. Not following
all sources this procedure can result in death or serious injury.
before doing
maintenance.

p/n 604791

Only qualified, trained maintenance personnel must

do maintenance, adjustment, and inspection of the
electrical equipment. Each maintenance person
must install a lockout at each electric power area.
Electrical equipment must be maintained and oper-
ated according to applicable standards. Not follow-
ing this procedure can result in death or serious
injury.
p/n 604796

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2 OPERATION

2.1 Introduction

The following paragraphs describe the opera-

tor’s controls and general operating instructions
for the crane as outlined by the table of
contents.

2.2 Crane Installation

The crane pedestal must be properly secured to

the foundation. The installation and foundation
must be strong enough to withstand the maxi-
mum pedestal reactions. Refer to the crane
general arrangement drawing for the foundation
loading information (see Parts and Vendor Data
Manual, Section 2, drawing 605045, General
Arrangement).

!DANGER
• The pedestal installation and the
foundation must be strong enough to
withstand the maximum pedestal
reactions. The pedestal must be
properly secured to the foundation
before installing the crane.

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2.3 Crane Nomenclature

Obstruction Light (see

paragraph 2.5.7)

Boom Wire
Rope

Area Lighting
(see paragraph
2.5.6) A-Frame
Platform
A-Frame Ladder
and Cage A-Frame
Main Hoist
Auxiliary Hoist
Boom Hoist (behind cab) Bridle

Hydraulic oil Main Wire Rope

Reservoir
Auxiliary Wire Rope
Diesel
Engine
Operator’s Cab

BOOM ANGLE INDICATOR

DEGREES FROM HORIZONTAL
0
80

5
10
75

15
70

20
65

25
60

30
55

35
50
45
40

Diesel Boom Angle Indicator

Fuel Tank Boom
(see paragraph 2.5.2)
Turntable Boom Foot Pin
Pedestal

A3228

Figure 2–1. Crane

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A-Frame Ladder A-Frame

and Cage Boom Hoist

Air Conditioning Unit Main Hoist

(see paragraph 2.5.5) Auxiliary Hoist

Window Wipers (see Boom Stops

paragraph 2.5.4)
Air Reservoir
Operator’s Cab

Horn (see
paragraph 2.5.1) Swing Drives
Front Elevation
Pendant (boom not shown for clarity)
Auxiliary Hoist
Load Sensor

Obstruction
Light (see
paragraph
2.5.7)

Main Hoist Anti–Two-Block

Load Sensor System Weight

Boom Flood Light

(see paragraph 2.5.6)

Main Hook Block Auxiliary

and Hook Overhaul
Ball and Hook

A3228

Figure 2–1. Crane (continued)

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2.4 Control Nomenclature

The controls of the operator’s control station (see figure 2–2) direct the functioning of the crane equip-
ment and show information important to the operation of the crane. Detailed descriptions of the opera-
tor’s controls are given in the following paragraphs as outlined by the table of contents. The control
descriptions are divided into three groups: general control devices, power control devices, and crane
function control devices.

This legend refers to figure 2–2 on the following page.

ITEM
NUMBER DESCRIPTION

1 OIL PRESSURE gauge (see paragraph 2.6.4)

2 COOLANT TEMPERATURE gauge (see paragraph 2.6.4)
3 ENGINE TACHOMETER/HOUR METER (see paragraph 2.6.4)
4 SWING LOCK OFF/ON control (see paragraph 2.7.3)
5 ENGINE KILL control (see paragraph 2.6.2)

6 EMERGENCY ENGINE KILL control (see paragraph 2.6.3)

7 AIR STARTER control (see paragraph 2.6.6)
8 Diesel ENGINE THROTTLE control (see paragraph 2.6.1)
9 SWING BRAKE OFF/ON control (see paragraph 2.7.2)
10 Boom angle indicator (see paragraph 2.5.2)

11 AIR PRESSURE gauge (see paragraph 2.6.10)

12 PILOT PRESSURE gauge (see paragraph 2.6.9)
13 BOOM PRESSURE gauge (see paragraph 2.6.9)
14 MAIN/AUXILIARY PRESSURE gauge (see paragraph 2.6.9)
15 SWING PRESSURE gauge (see paragraph 2.6.9)

16 Load and radius indicator system (see paragraph 2.5.3)

17 Diesel engine throttle pedal (see paragraph 2.6.1)
18 BOOM/SWING control (see paragraph 2.7.4)
19 Horn control (see paragraph 2.5.1)
20 Swing brake pedal (see paragraph 2.7.1)

21 MAIN and AUXILIARY hoist controls (see paragraph 2.7.5)

22 Seat
23 PANEL LIGHTS switch (see paragraph 2.5.8)
24 FRONT WIPER control (see paragraph 2.5.4)
25 Window washer control (see paragraph 2.5.4)

26 UPPER WIPER control (see paragraph 2.5.4)

27 AUXILIARY HOIST RELEASE control (see paragraph 2.7.7)
28 MAIN HOIST RELEASE control (see paragraph 2.7.7)

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15

14
SWING PRESSURE

13 MAIN/AUX PRESSURE

12 16 17 18 19 20 21
BOOM PRESSURE

11
PILOT PRESSURE

10
AIR PRESSURE

BOOM ANGLE INDICATOR

DEGREES FROM HORIZONTAL
0
80

5
10
75

15
70

20
65

25
60

30
55

35
50
45
40

9
8
ENGINE THROTTLE

SWING BRAKE
AIR STARTER

ON

7
O
F
F

LOWER LOWER
EMERGENCY ENGINE KILL

AUX MAIN

6
SWING LOCK

RAISE RAISE
ENGINE KILL

ON

5
O
F
F

BOOM LOWER
SWING RIGHT
SWING LEFT
COOLANT TEMPERATURE ENGINE TACHOMETER/

4 BOOM RAISE
PANEL LIGHTS
HOUR METER

MAIN HOIST RELEASE

3
FRONT WIPER

2
AUX HOIST RELEASE

1
OIL PRESSURE

UPPER WIPER

28 27 26 25 24 23 22

A3163

Figure 2–2. Control Station

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2.5 General Control Devices
2.5.1 Horn Control
Push the horn control (figure 2–2, item 19) on
the floor in front of the operator’s seat to sound
the horn located on the operator’s cab (see
figure 2–1). The control is a manually engaged
spring-released, foot-operated air valve.
2.5.2 Boom Angle Indicator
The boom angle indicator (figure 2–2, item 10)
is located on the boom (see figure 2–1) and can
be viewed from the operator’s cab. The dial
shows the angle of the boom in degrees from
horizontal.
2.5.3 Load and Radius Indicator System
The load and radius indicator system display
(figure 2–2, item 16) is located in the operator’s
cab and shows the radius, load, rated load
capacity (safe working load), and percent of
rated load.
At loads of 85 percent or more of the rated
capacity, an audible alarm sounds and the
circular analogue scale of the display flashes
yellow to warn the crane operator.
At loads of 100 percent or more of the rated
capacity, an audible alarm sounds and the
circular analogue scale of the display flashes
red to warn the crane operator.
!WARNING
• The load and radius indicator system
does not stop crane movement at the
capacity and position limits. The
operator must respond as necessary
to alerts from the load and radius
indicator system.
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Leave the load and radius indicator system
continuously powered during crane operation.
The information shown on the load and radius
indicator system display can be shown in metric
or imperial units. Use the METRIC/IMPERIAL
switch located on the control panel for the load
and radius indicator system to select the
desired units. The control panel is located on
the inside back wall of the operator’s cab. See
the manufacturer’s information for the operating
instructions (see Parts and Vendor Data Man-
ual, Section 11, Aanderaa Data Instruments).
!WARNING
• Do not exceed the rated load capacity
of the crane (see Section 4, Load
Rating Chart, drawings 831564 and
831563). Lifting loads greater than
those shown on the load rating chart
or operations at positions not shown,
or lifting when the boom is solid
against the boom stops, can cause
structural failure or collapse of the
boom or crane and death or injury to
personnel.
• The main hook of the crane can be
reeved with either 4 parts of line or
with 6 parts of line. Before handling a
load, check that the load and radius
indicator system is configured to
correspond to the crane configuration
in use (correct number of falls, correct
load curve). Not following this
procedure can give inaccurate load
capacity readings and prevent
overload warnings from operating.
This can result in damage to the crane,
the load, or other equipment or
structures, and death or injury to
personnel.
• Do not attach capacity loads at
maximum outreach, because an
outward swing of the load, caused by
vessel list or trim, or outward drift of
the boom, can overload the crane.

2.5.4 Window Wiper Controls
The FRONT WIPER (figure 2–2, item 24) and
UPPER WIPER control (item 26) control the
corresponding window wiper of the operator’s
cab. Each WIPER control is a two-position
switch.
In the PARK position, the wiper returns to its
parking position and stops.
In the RUN position, the wiper operates.
Push the knob of the washer control (item 25)
to spray washer fluid on the windows. The
reservoir for the washer fluid is located on the
exterior rear corner of the operator’s cab.
2.5.5 Operator’s Cab Air Conditioning
Controls
The controls for the operator’s cab air condi-
tioning unit are located on the control panel of
the unit on the ceiling of the operator’s cab (see
figure 2–1). See the manufacturer’s information
for the operating instructions (see Parts and
Vendor Data Manual, Section 11, RVP).
2.5.6 Area Lighting
Two 400W flood lights (see figure 2–1) are
located on the boom. The lights are controlled
by a switch located inside the operator’s cab.
One 400W light is located over the machinery
area. The light is controlled by a switch located
inside the operator’s cab.
One fluorescent light (two 40W Biax lamps) is
located inside the operator’s cab. The light is
controlled by a switch located inside the opera-
tor’s cab.
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2.5.7 Obstruction Lights
Red aircraft obstruction lights (see figure 2–1)
are located at the tip of the boom, and on the
top of the A-frame. The lights are controlled by
circuit breaker CB0247 located in circuit
breaker panel CBP0207, inside the operator’s
cab.
2.5.8 PANEL LIGHTS Switch
The PANEL LIGHTS switch (figure 2-2, item 23)
controls the illumination of the gauges on the
gauge control panel.
In the “on” position, the gauges are illuminated.
In the “off” position, the gauges are not illumi-
nated.
2.5.9 Boom Stops
The crane has cushioned boom stops (see
figure 2–1) to retard the backward motion of the
boom as the boom nears high boom angles.
When a load is lifted, the boom suspension
system stretches, causing the boom angle to
decrease and the load radius to increase. The
crane operator should compensate for this by
raising the boom a small amount as the load is
lifted.
When the load is set down, the boom suspen-
sion system will contract, causing the boom
angle to increase a small amount and the load
radius to decrease.

CAUTION
• When lifting loads at high boom
angles, take care when setting down
the load. The boom must be lowered a
small amount so the boom is not
pulled back into the boom stops. The
inner section of the boom may be
damaged if the boom is pulled back
into the boom stops.
• The boom stops are a cushion against
minor accidental shocks and an early
warning device. They must not be
regarded as a failsafe protection
against the boom being raised too far
or the boom falling over backwards.
Do not lift a load when the boom is
solid against the boom stops. When
landing a load, keep the boom angle a
small amount lower as necessary to
compensate for the boom rising when
the load is put down. Do not exceed
the boom operating range on the load
rating chart for the load being lifted
(see Section 4, Load Rating Chart,
drawings 831564 and 831563).
2.6 Power Control Devices
2.6.1 Diesel Engine Throttle Controls
The diesel engine throttle pedal (figure 2–2,
item 17) is the left foot pedal located in front of
the operator’s seat. The hand-operated diesel
ENGINE THROTTLE control (item 8) is located
on the control console.
Engine speed can be increased by either
depressing the throttle pedal or pulling up the
hand throttle. To decrease engine speed,
release the throttle pedal and depress the
button on top of the hand throttle knob while
pushing the knob down.
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Engine speed can be locked at any speed by
depressing the throttle pedal to the desired
speed and pulling up the hand throttle. The
engine speed can be finely adjusted by turning
the knob of the hand throttle.
NOTICE
• Higher engine speeds result in faster
crane motions due to higher hydraulic
pump flows.
2.6.2 ENGINE KILL Control
The ENGINE KILL control (with black handle)
(figure 2–2, item 5) is used for normal stopping
of the diesel engine.
Pull the handle of the ENGINE KILL control all
the way up to stop the diesel engine (fuel is
shut off). The handle must be pushed all the
way down to operate the engine.
2.6.3 EMERGENCY ENGINE KILL
Control
The EMERGENCY ENGINE KILL control (with
red handle) (figure 2–2, item 6) is used for
emergency stopping of the diesel engine.
!WARNING
• Explosive vapors in the air intake to
the diesel engine can cause the engine
to continue operating even after the
ENGINE KILL control (see
paragraph 2.6.2) is pulled all the way
up. In an emergency when such
vapors are present, use the
EMERGENCY ENGINE KILL control to
stop the engine by closing off the air
intake. This prevents the vapors from
continuing to feed the engine.
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Pull the handle of the EMERGENCY ENGINE
KILL control all the way up to immediately stop
the diesel engine. This closes the engine air
inlet shutoff. After the emergency stop, the air
inlet shutoff must be reset to the open position
and the engine must be checked for damage.
The air inlet shutoff is located on the engine air
intake housing. See the diesel engine manufac-
turer’s information for the procedure to reset the
air inlet shutoff (see Parts and Vendor Data
Manual, Section 11, Caterpillar).
CAUTION
2.6.5 Diesel Fuel Level Gauge
The gauge on the top of the diesel fuel tank
(see figure 2–1) shows the level of diesel fuel
remaining in the diesel fuel tank.
2.6.6 AIR STARTER Control
The AIR STARTER control (figure 2–2, item 7)
controls the air starter motor for the diesel
engine. The control is a manually engaged,
spring-released air valve.

• Only use the EMERGENCY ENGINE
KILL control for an emergency. Use of
the EMERGENCY ENGINE KILL control
can cause damage to the diesel
engine.
Push and hold the AIR STARTER control to
start the diesel engine.
2.6.7 Hydraulic Oil Level Gauge

The sight gauge on the side of the hydraulic oil

2.6.4 Diesel Engine Gauges
reservoir (see figure 2–1) shows the level of the
hydraulic oil in the reservoir (see Checking
The gauges listed in table 2–1 are located on
Hydraulic Oil Level, paragraph 3.6.6.1).
the control console and show the operating
condition of the diesel engine. See the diesel
engine manufacturer’s information for the CAUTION
engine operating instructions (see Parts and
• Do not operate the equipment with a
Vendor Data Manual, Section 11, Caterpillar).
level of hydraulic oil that is too low or
too high.
CAUTION
• Do not operate the equipment when a
gauge is reading outside of its normal
operating range (see table 2–1).

Table 2–1. Diesel Engine Gauges

NORMAL OPERATING FIGURE AND ITEM
LABEL FUNCTION MONITORED
RANGE NUMBERS
ENGINE
See engine manufacturer’s
TACHOMETER/ Engine speed, total run time figure 2–2, item 3
manual
HOUR METER
COOLANT See engine manufacturer’s
Coolant water temperature figure 2–2, item 2
TEMPERATURE manual
See engine manufacturer’s
OIL PRESSURE Lubrication oil pressure figure 2–2, item 1
manual

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2.6.8 Hydraulic Oil Temperature Gauge

The temperature gauge on the side of the
hydraulic oil reservoir (see figure 2–1) shows
the temperature of the hydraulic oil in the reser-
voir.
CAUTION
• Do not operate the equipment when a
gauge is reading outside of its normal
operating range as listed in table 2–2.

CAUTION 2.6.10 AIR PRESSURE Gauge

• Do not operate the equipment with a
hydraulic oil temperature that is too
high (more than 180°F [82°C]).
Operating with the hydraulic oil
temperature too high can reduce the
life of hydraulic equipment parts.
2.6.9 Hydraulic Pressure Gauges
The gauges listed in table 2–2 show the operat-
ing pressures of the corresponding hydraulic
pumping circuits. The pressures are shown in
pounds per square inch (psi).
The AIR PRESSURE gauge (figure 2–2,
item 11) shows the air pressure at the control
console of the crane air system. The pressure
is shown in pounds per square inch (psi).
CAUTION
• Do not operate the equipment when
the AIR PRESSURE gauge is reading
outside of its normal operating range
of 120–125 psi (8.3–8.6 bar).

Table 2–2. Hydraulic Pressure Gauges

FUNCTION FIGURE AND
LABEL NORMAL OPERATING RANGE
MONITORED ITEM NUMBERS
SWING Swing drive hydrau-
100 to 2700 psi (6.8–186.1 bar) figure 2–2, item 15
PRESSURE lic pumping circuit
MAIN/ Main/auxiliary hoist Raising: up to 2800 psi (193 bar)
AUXILIARY hydraulic pumping figure 2–2, item 14
PRESSURE circuit Lowering: 1000–2300 psi (68.9–158.5 bar)

BOOM Boom hoist hydraulic Raising: up to 2950 psi (203.3 bar)

figure 2–2, item 13
PRESSURE pumping circuit Lowering: 1000–2300 psi (68.9–158.5 bar)
PILOT Hydraulic system
475 psi (32.7 bar) figure 2–2, item 12
PRESSURE pilot pressure

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2.7 Crane Function Control Devices
2.7.1 Swing Brake Pedal
The swing brake pedal (figure 2–2, item 20)
located in front of the operator’s seat controls
the brake of the swing drive as a holding brake
(variable holding power).
CAUTION
• Normal crane operation does not
require use of the swing brake pedal to
stop crane rotation. To stop rotation,
put the lever of the SWING control
(paragraph 2.7.4) in its neutral (center)
position. Rotation will slowly come to
a stop due to friction in the swing
system. The swing brake pedal is
provided to temporarily engage the
swing brake without using the SWING
BRAKE OFF/ON control.
Push the pedal down to engage the brake of
the swing drive. As the pedal is pushed down,
the brake has more holding power. Release the
pedal upward to release the brake. As the
pedal is released upward, the brake has less
holding power.
2.7.2 SWING BRAKE OFF/ON Control
The SWING BRAKE OFF/ON control
(figure 2–2, item 9) controls the brake of the
swing drive as a static (parking) brake (fully
engaged or fully released).
In the ON position, the brake of the swing drive
is engaged. The crane cannot rotate (swing).
In the OFF position, the brake will release
according to the position of the swing brake
pedal (see paragraph 2.7.1). The brake can
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only be released when the diesel engine is
operating.
CAUTION
• Do not use the SWING BRAKE OFF/ON
control to stop crane rotation. After
crane rotation has been completely
stopped, put the SWING BRAKE
control in the ON position.
2.7.3 SWING LOCK OFF/ON Control
The swing lock consists of a pin that can be
lowered into a hole in the top of the pedestal to
mechanically prevent the crane from rotating.
The pin can be lowered at any of the 8 points
45 degrees apart in the rotation of the crane.
The pin is actuated by a hydraulic cylinder.
When the crane is in position to permit the pin
to be lowered, move the handle of the SWING
LOCK OFF/ON control (figure 2–2, item 4) to
the ON position to lower the swing lock pin.
Move the handle to the OFF position to raise
the swing lock pin.
CAUTION
• The crane may need to be rotated a
small amount for the pin of the swing
lock to align with the hole in the top of
the pedestal. This should be done at a
slow speed. Fully stop the rotation of
the crane using the SWING control
before engaging the swing lock. Not
following this procedure can cause
damage to the equipment.

2.7.4 BOOM/SWING Control
The BOOM/SWING control (figure 2–2, item 18)
on the left armrest of the operator’s seat
controls the
• direction and speed of boom movement
(boom function)
• direction and speed of crane rotation (swing
function)
The boom and swing functions are combined in
one dual-axis control, permitting both functions
to be controlled at the same time with one
control lever (see figure 2–3). The BOOM/
SWING control is a manually operated, propor-
tional hydraulic valve for directional control. The
lever of the BOOM/SWING control, when
released, returns to its neutral (center) position.
Lower
Boom
Swing Swing
Left Right
A1575
Raise
Boom
Figure 2–3. Boom/Swing Control
2.7.4.1 Boom Control
CAUTION
• Move the BOOM control lever slowly,
to prevent abrupt changes in the
speed of the boom.
Pull the lever of the BOOM control (figure 2–2,
item 18) back toward the operator to raise the
boom. Push the lever forward away from the
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operator to lower the boom. The speed of the
boom increases as the lever is moved away
from its neutral (center) position. To decrease
the speed, move the lever toward its neutral
position.
NOTICE
• The speed of the boom can also be
controlled in combination with engine
speed (see paragraph 2.7.6).
To stop and hold the boom, slowly return the
lever to its neutral position. The boom stops
and the boom hoist friction brake engages if
released.
The spring-engaged friction brake and one-way
(overrunning) clutch on the hoist hold the hoist
drum from rotating in the lowering direction.
This friction brake remains engaged during
boom raising, with the one-way clutch overrun-
ning. The friction brake is automatically
released during lowering, engaging again to
serve as a parking brake after the hydraulic
system counterbalance valve stops the boom.
The boom hoist has a ratchet and pawl assem-
bly that provides an automatic lock to prevent
the boom from lowering. The pawl automatically
disengages when the boom hoist control lever
is pushed forward to lower the boom.
If the boom will not lower, it may be necessary
to first raise the boom a small amount to
remove the load from the pawl, permitting the
pawl to release. Then the boom can be
lowered.
!WARNING
• The boom hoist must have at least five
full wraps of wire rope on the drum at
all times.

NOTICE
• The control system protects against
raising or lowering the boom beyond
its operating limit. See paragraph
2.8.3.2 for a description of the boom
angle limit system.
2.7.4.2 Swing Control
NOTICE
• Before rotating the crane, the SWING
BRAKE OFF/ON control (see
paragraph 2.7.2) must be in the OFF
position and the dynamic swing brake
pedal (see paragraph 2.7.1) must be
fully released.
CAUTION
• Move the SWING control lever slowly,
to prevent abrupt changes in the
speed of crane rotation and minimize
the side-loading forces on the boom.
Move the lever of the SWING control (figure
2–2, item 18) to the operator’s left to rotate the
crane left (counterclockwise). Move the lever to
the operator’s right to rotate the crane right
(clockwise). The speed of rotation increases as
the lever is moved away from its neutral
(center) position. To decrease the speed, move
the lever toward its neutral position.
NOTICE
• The speed of rotation can also be
controlled in combination with engine
speed (see paragraph 2.7.6).
To stop rotation, slowly return the lever to its
neutral position. Rotation will slowly come to a
stop due to friction in the swing system.
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CAUTION
• Do not use the SWING BRAKE OFF/ON
control (see paragraph 2.7.2) to stop
crane rotation.
2.7.5 MAIN and AUXILIARY Hoist
Controls
The MAIN and AUXILIARY hoist controls (figure
2–2, item 21) on the right armrest of the opera-
tor’s seat control the
• rotation direction and speed of the main
hoist drum (direction and speed of the main
hook block)
• rotation direction and speed of the auxiliary
hoist drum (direction and speed of the
auxiliary hook)
The MAIN and AUXILIARY hoist controls are a
dual-lever, manually operated, proportional
hydraulic valve for directional control. The
levers of the MAIN and AUXILIARY hoist
controls, when released, return to their neutral
(center) position. The left lever controls the
auxiliary hoist drum, and the right lever controls
the main hoist drum.
!WARNING
• Before lifting a load, always put the
SWING BRAKE OFF/ON control (see
paragraph 2.7.2) in the OFF position
and release the swing brake pedal (see
paragraph 2.7.1) to permit the crane
boom to center over the load.
CAUTION
• Move the MAIN and AUXILIARY hoist
control levers slowly, to prevent
abrupt changes in the speed of the
load.
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Pull the lever of the MAIN or AUXILIARY hoist
control back toward the operator to raise the
load on the corresponding hook. Push the lever
forward away from the operator to lower the
load on the corresponding hook. The speed of
the load increases as the lever is moved away
from its neutral position. To decrease the
speed, move the lever toward its neutral posi-
tion.
NOTICE
• The speed of the load can also be
controlled in combination with engine
speed (see paragraph 2.7.6).
To stop and hold the load, slowly return the
lever to its neutral position. The load stops and
the hoist friction brake engages if released.
The spring-engaged friction brake and one-way
(overrunning) clutch on the hoist hold the hoist
drum from rotating in the lowering direction.
This friction brake remains engaged during load
raising, with the one-way clutch overrunning.
The friction brake is automatically released
during lowering, engaging again to serve as a
parking brake after the hydraulic system coun-
terbalance valve stops the load.
2.7.6 Swing and Hoist Speed Control
The swing and hoist speed can be controlled by
displacing the controls and changing the diesel
engine speed. Maximum speeds are obtained
by displacing the corresponding control the
maximum distance and adjusting the engine
speed to its highest recommended speed.
Minimum speeds are attained by operating the
engine at idle speed and displacing the corre-
sponding control until the motion begins.
!WARNING
• Under certain loads the diesel engine
may stall at low engine speeds when
trying to operate crane functions.
The control valves provide precise metering of
the hydraulic oil. This precise metering allows
for precise speed control of the various crane
functions.

!WARNING
• The main and auxiliary hoists must
have at least five full wraps of wire
rope on the drums at all times.

NOTICE
• The control system protects against
raising the load beyond its upper
operating limit, preventing
two-blocking. See paragraph 2.8.3.1 for
a description of the anti–two-block
system.

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2.7.7 MAIN and AUXILIARY HOIST
RELEASE Controls
NOTICE
• Hydraulic pressure must be available
to the system to perform an
emergency release.
The MAIN HOIST RELEASE control
(figure 2–2, item 28) and the AUXILIARY
HOIST RELEASE control (item 27) control the
emergency release of the corresponding main
or auxiliary hoist (see paragraph 2.8.6). The
controls are manually operated two-position
detented hydraulic valves.
To perform an emergency release of a hoist,
push the knob of the corresponding control all
the way down. The friction brake of the hoist
releases and the normal hydraulic equipment
parts regulating flow are bypassed, free hydrau-
lic flow is permitted through the hydraulic motor,
and the hoist begins to pay out as fast as it is
pulled by the hook and any associated load.
To stop the emergency release of a hoist, pull
the knob of the corresponding control all the
way out. Hydraulic flow is blocked and payout
of the hoist stops.
!WARNING
• Emergency release of the hoist can
damage the hoist motor and other
equipment parts. The equipment used
in the emergency release must be
checked for damage and either
repaired or replaced before the hoist
can return to normal operation.
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2.8 Crane Operation
The crane operates by hydraulic power. Slowly
move the control levers by applying gradual
pressure, even when returning a lever to its
neutral (center) position. Not following this
procedure will result in over-control of the crane
functions and erratic crane response.
CAUTION
• Do not release or jerk a control lever
as this will cause sudden movements
of the crane and/or load. This sudden
movement will cause a hydraulic
shock in the hydraulic system which
could damage the hydraulic equipment
parts and/or crane structural parts.
NOTICE
• The hydraulic system permits the
boom, swing, and hoist functions to
operate simultaneously. The boom and
swing have priority over the hoist, so
hoisting may be slower when rotating
the crane or raising the boom.
In the event of diesel engine failure or control
malfunction during operation:
1. Return all the control levers to their neutral
(center) position.
2. When the crane has stopped rotating
(swinging), turn the lever of the SWING
BRAKE OFF/ON control (figure 2–2, item 9)
to the ON position to engage the static
swing brake.
3. If practical, lower the suspended load using
the emergency load lowering procedure
(see paragraph 2.8.7).
API Recommended Practice 2D, Recom-
mended Practice for Operation and Mainte-
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nance of Offshore Cranes (API RP2D) (current

edition) is a useful guide for owners and opera-
tors in developing operating and maintenance
practices and procedures. All guidelines in this
recommended practice should be followed.
!WARNING
• If any device or structural member is
damaged or in need of repair, such
repairs must be made before operating
the crane.

2.8.1 Pre-Starting Procedure

Before operating the crane, it is important to
make an inspection of the crane and to follow
all pre-starting procedures. The following
inspections are considered mandatory by
National Oilwell Varco. They make sure the
equipment is in a safe operating condition.
Other inspections can be required by local
regulations and must also be made.
2.8.1.1 Daily Inspection
Do the following at the beginning of each work-
day, before starting the crane.
1. Check the preventive maintenance records
to make sure the scheduled lubrication (see
paragraph 3.2.2) and inspections and main-
tenance (see paragraph 3.3) have been
done at the correct intervals.
2. Check the crane and pedestal foundation
for damaged, distorted, worn, cracked,
corroded, loose, or missing parts, fasten-
ers, and welds.
!WARNING
• Do not operate the crane in an unsafe
or damaged condition.
3. Check the hydraulic equipment for leakage
or damage.
4. Check the hydraulic hoses for leaks, abra-
sion, or advanced weathering that could
cause a hose to burst under operating pres-
sure.
5. Check the gearboxes for leaks and
damage.
6. Check the boom hoist ratchet and pawl for
wear and damage.
7. Check control mechanisms for correct oper-
ation.
8. Check the diesel engine start and stop
controls.
9. Check all the wire ropes, including
pendants, for deterioration or damage.

!DANGER
• Do not operate the crane with a
damaged boom or if any portion of the
boom has been repaired by a company
other than National Oilwell Varco.
!WARNING
• Do not operate the crane with worn or
damaged wire rope.
10. Check that the wire rope is reeved
correctly, operating freely, and spooling
correctly.

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11. Check the crane hook and latch for
damaged, distorted, worn, cracked,
corroded, loose, or missing parts and
fasteners.
12. Check loose gear to be used (such as
slings, sling hooks, and shackles) for
damaged, distorted, worn, cracked,
corroded, loose, or missing parts and
fasteners.
13. Make sure that all guards are in place and
secured.
14. Check the operation of the obstruction
lights.
2.8.1.2 Before Start-Up
Do the following before each start-up of the
crane.
1. Check that the correct load rating chart for
the crane configuration in use is visible to
the crane operator at the control station
(see Section 4, Load Rating Chart, draw-
ings 831564 and 831563).
2. Check that all tools and other items are
away from moving equipment parts.
3. Check that the crane and the operating
area of the crane are free of all obstructions
and personnel. Not following this procedure
can result in damage to the crane or load
and injury to personnel.
4. Check that the static swing brake is
engaged. The lever of the SWING BRAKE
OFF/ON control (figure 2–2, item 9) must
be in the ON position.
5. Check that the handle of the ENGINE KILL
control (with black handle) (item 5) is
pushed all the way down.
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6. Check that the handle of the EMERGENCY
ENGINE KILL control (with red handle)
(item 6) is pushed all the way down. If the
handle has been pulled, check that the
reason for the emergency stop has been
found and corrected, and that the air inlet
shutoff of the diesel engine has been reset
to the open position (see Emergency Stop
Procedure, paragraph 2.8.5).
!CAUTION
• The control levers must be in the
neutral (center) position to prevent
sudden movements when the diesel
engine is started.
7. Check that all the control levers are in their
neutral (center) position. This will ensure
that the load and/or crane will not move
when the diesel engine is started.
8. The crane can now be started (see para-
graph 2.8.2).
2.8.2 Startup Procedure
1. Complete the pre-starting procedure (para-
graph 2.8.1).
2. Check that all the control levers are in their
neutral (center) position.
3. Put the diesel engine throttle control (see
paragraph 2.6.1) in the “idle” position.
4. Check the temperature of the hydraulic oil.
Use the temperature gauge (see paragraph
2.6.8) located on the side of the hydraulic
oil reservoir (see figure 2–1).
• If the hydraulic oil in the reservoir is 0°F
(–17°C) or warmer (ISO Grade 46
hydraulic oil minimum start-up tempera-
ture, see Hydraulic Oil, para-
graph 3.6.2), continue with step 5.

• If the hydraulic oil is colder, warm the
hydraulic oil with a reservoir heater until
the temperature is 0°F (–17°C) or
warmer. Then continue with step 5.
5. Push the AIR STARTER control (figure 2–2,
item 7) for 1–3 seconds or until the diesel
engine starts. If the engine does not start
after several attempts, have the engine
checked by a qualified service technician.
See the diesel engine manufacturer’s infor-
mation for additional information on the
diesel engine starting and operating proce-
dures (see Parts and Vendor Data Manual,
Section 11, Caterpillar).
6. Operate the diesel engine at “idle”.
7. Check the temperature of the hydraulic oil.
Use the temperature gauge located on the
side of the hydraulic oil reservoir.
• If the hydraulic oil in the reservoir is
55°F (13°C) or warmer (ISO Grade 46
hydraulic oil minimum temperature for
full power operation, see Hydraulic Oil,
paragraph 3.6.2), continue with step 8.
• If the hydraulic oil is colder, continue to
operate with no load until the tempera-
ture is 55°F (13°C) or warmer. Then
continue with step 8.
8. Adjust the diesel engine throttle to the
desired engine speed (see para-
graph 2.6.1).
NOTICE
• The diesel engine control system will
automatically stop the diesel engine
for engine overspeed, low engine oil
pressure, and high coolant
temperature.
• The maximum governed diesel engine
speed under load is 2200 rpm.
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9. Check the cab-mounted instrument gauges
for proper engine operation.
10. Check that the configuration of the crane
load and radius indicator system (see para-
graph 2.5.3) corresponds to the crane
configuration in use. Check the crane load
and radius indicator system for correct
operation (see Parts and Vendor Data
Manual, Section 11, Aanderaa Data Instru-
ments).
!WARNING
• The main hook of the crane can be
reeved with either 4 parts of line or
with 6 parts of line. Before handling a
load, check that the load and radius
indicator system (see paragraph 2.5.3)
is configured to correspond to the
crane configuration in use (correct
number of falls, correct load curve).
Not following this procedure can give
inaccurate load capacity readings and
prevent overload warnings from
operating. This can result in damage to
the crane, the load, or other equipment
or structures, and death or injury to
personnel.
11. The crane is now ready for the pre-operat-
ing checks (see paragraph 2.8.3).

2.8.3 Pre-Operating Checks (After
Engine Start-Up)
After the diesel engine has been started, the
following procedures must be done to make
sure that the crane safety systems function
correctly.
2.8.3.1 Anti–Two-Block System
Anti–two-block systems are provided for the
main and auxiliary hoists to prevent accidental
contact of the main hook block and auxiliary
overhaul ball with the boom point sheaves.
!WARNING
• Hook block and overhaul ball contact
with the boom point sheaves can
cause damage to the wire rope, boom,
boom sheaves, and/or hook block and
overhaul ball. The wire rope can be
damaged and the load can fall.
The anti–two-block safety valves are located
near the boom tip, one for the main hook block
and one for the auxiliary overhaul ball. The
spool of each valve is normally held retracted
(hydraulic circuit closed) by the downward force
on the lever arm of the suspended
anti–two-block weight (see Parts and Vendor
Data Manual, Section 4, drawing 750577-L01
[Main] and 750577-L02 [Auxiliary],
Anti–Two-Block). If the hook block or overhaul
ball makes contact with the weight, relieving the
downward force on the lever arm, the spool of
the anti–two-block valve extends (hydraulic
circuit opens), venting some hydraulic pilot
pressure lines in the hydraulic system. The
boom stops if in a lowering motion and the
boom hoist friction brake engages. The main
and auxiliary hoists stop if in a raising motion
and the main and auxiliary hoist friction brakes
remain engaged. The hydraulic system
prevents further boom lowering and further
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main or auxiliary hoist raising. To return to
normal operation, lower the hook block or over-
haul ball (or raise the boom), until both weights
are hanging freely.
To check the anti–two-block system:
CAUTION
• Use extreme care when engaging the
anti–two-block system. Operate the
hoist slowly and stop the hoist before
the hook block contacts the boom
sheaves.
1. Slowly raise the main hook block into the
anti–two-block weight. Use caution to make
sure the hoist raising function stops after
the weight is raised (approximately 3–4 in
[8–10 cm] after contacting the weight). Stop
the hoist before the hook block contacts the
boom sheaves if it does not stop automati-
cally.
!WARNING
• If the main hoist does not stop or the
boom can be lowered after the
anti–two-block weight has been lifted,
shut down the crane and contact the
National Oilwell Varco Service
Department for instructions.
2. After the main hoist function stops, check
that the boom lowering is inhibited by trying
to lower the boom. The boom must not
lower.
3. Lower the load until the weight hangs
freely.
4. Repeat steps 1 through 3 for the auxiliary
hoist.
5. The crane is ready for the boom limit
system check (see Boom Angle Limit
System, paragraph 2.8.3.2).

NOTICE
• The exposed surfaces of the valve
spools for the anti–two-block safety
valves must be lubricated to prevent
corrosion (see Safety Valves,
paragraph 3.2.2.5). Corrosion may
prevent proper operation of the valve.
• Under certain conditions, lowering the
boom onto the boom rest may engage
the anti–two-block system. If this
happens, the signal person or a
deckhand must maintain a downward
load on the anti–two-block system by
pulling on the weight cable while the
boom is lowered into the stowed
position. Use extreme caution to avoid
injury from moving equipment parts or
the weight cable.
2.8.3.2 Boom Angle Limit System
A boom angle limit system is provided to
prevent the boom from being raised or lowered
outside of the normal operating range.
The limits are preset at the factory, but can be
adjusted in the field. The boom limit should be
set with no load on the boom. The boom upper
limit should be set at 78 degrees above hori-
zontal. The boom lower limit should be set at 10
degrees below horizontal.
!WARNING
• Do not activate the boom angle limit
system with the boom moving at high
speed. The boom will quickly stop,
causing the load to swing
uncontrollably and the boom to
bounce violently.
The boom angle safety valves are located at
the boom foot, one for the boom upper limit and
one for the boom lower limit. The spool of each
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valve is normally extended (hydraulic circuit
closed) (see Parts and Vendor Data Manual,
Section 4, drawing 751442, Boom Travel Limit).
If a cam on the boom makes contact with a
valve spool, the spool retracts (hydraulic circuit
opens), venting some hydraulic pressure lines
in the hydraulic system. If the boom upper limit
safety valve is actuated, the boom raising
motion stops and the boom hoist friction brake
remains engaged. The hydraulic system
prevents further boom raising. To return to
normal operation, lower the boom. If the boom
lower limit safety valve is actuated, the boom
stops and the boom hoist friction brake
engages. The hydraulic system prevents further
boom lowering. To return to normal operation,
raise the boom.
To check the boom limit system:
CAUTION
• Use extreme care when engaging the
boom angle limit system. Operate the
boom hoist slowly and stop the hoist
before the boom contacts the
cushioned boom stops or any
obstruction.
1. Slowly raise the boom to the upper limit
cam engagement. Use caution to make
sure the boom raising function stops before
the boom contacts the cushioned boom
stops. Stop the boom before contacting the
boom stops if it does not stop automatically.
!WARNING
• If the boom does not stop when the
boom angle limit safety valve contacts
the boom limit cam, shut down the
crane and contact the National Oilwell
Varco Service Department for
instructions.

2. After the boom stops, lower the boom away
from the boom stops and away from limit
cam engagement.
!WARNING
• The boom hoist must have at least five
full wraps of wire rope on the drum at
all times.
3. Slowly lower the boom into lower limit cam
engagement. Use caution to make sure the
boom does not strike any object on the plat-
form or deck. Stop the boom before this
occurs if it does not stop automatically.
!WARNING
• If the boom does not stop when the
boom angle limit safety valve contacts
the boom limit cam, shut down the
crane and contact the National Oilwell
Varco Service Department for
instructions.
4. After the boom stops, raise the boom away
from limit cam engagement.
5. The crane is ready for normal operation.
NOTICE
• The exposed surfaces of the valve
spools for the boom limit safety valves
must be lubricated to prevent
corrosion (see Safety Valves,
paragraph 3.2.2.5). Corrosion may
prevent proper operation of the valve.
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2.8.4 Shutdown Procedure
1. Remove the load from the crane.
2. Rotate the crane to its parking position.
3. Engage the swing lock (see para-
graph 2.7.3).
4. Engage the static brake of the swing drive.
Turn the lever of the SWING BRAKE
OFF/ON control (figure 2–2, item 9) to the
ON position.
5. Raise or lower the boom to the desired
angle.
6. Raise or lower the main hook block and
auxiliary hook to the desired height.
7. Put the diesel engine throttle control (see
paragraph 2.6.1) in the “idle” speed position
and let the engine operate for 4–5 minutes
to cool down.
8. Pull the handle of the ENGINE KILL control
(with black handle) (item 5) all the way up
to stop the diesel engine.
9. Write down and report any corrective action
that must be taken before operation is
resumed.

2.8.5 Emergency Stop Procedure
1. Release all control levers to the neutral
position.
2. Pull the handle of the EMERGENCY
ENGINE KILL control (with red handle)
(figure 2–2, item 6) all the way up to imme-
diately stop the diesel engine.
!WARNING
• Only use the EMERGENCY ENGINE
KILL control when use of the ENGINE
KILL control (see paragraph 2.6.2) fails
to stop the diesel engine or there are
explosive gases near the engine air
intake.
CAUTION
• Only use the EMERGENCY ENGINE
KILL control for an emergency. Use of
the EMERGENCY ENGINE KILL control
can cause damage to the diesel
engine.
After the reason for the emergency stop has
been found and corrected, the air inlet shutoff
of the diesel engine must be reset to the open
position. The air inlet shutoff is located on the
engine air intake housing. The diesel engine
must be checked for damage (example:
damage to seals from the suction created by
blocking the air intake). See the diesel engine
manufacturer’s information for the procedure to
reset the air inlet shutoff (see Parts and Vendor
Data Manual, Section 11, Caterpillar).
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2.8.6 Main and Auxiliary Hoist
Emergency Load Release
In the event of an emergency that requires the
immediate payout of either the main or auxiliary
hoist, the control system permits the emergency
release of the hoists.
To perform an emergency release of the main
hoist, push the knob of the MAIN HOIST
RELEASE control (figure 2–2, item 28) all the
way down. To perform an emergency release of
the auxiliary hoist, push the knob of the
AUXILIARY HOIST RELEASE control (item 27)
all the way down. In each case, the friction
brake of the hoist releases and the normal
hydraulic equipment parts regulating flow are
bypassed, free hydraulic flow is permitted
through the hydraulic motor, and the hoist
begins to pay out as fast as it is pulled by the
hook and any associated load.
To stop the emergency release of a hoist, pull
the knob of the corresponding control all the
way out. Hydraulic flow is blocked and payout
of the hoist stops.
!WARNING
• Emergency release of the hoist can
damage the hoist motor and other
equipment parts. The equipment used
in the emergency release must be
checked for damage and either
repaired or replaced before the hoist
can return to normal operation.
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2.8.7 Emergency Load Lowering

The crane is equipped with an emergency load

lowering kit that permits the operator to lower a
suspended load in the event of a hydraulic or
diesel engine failure. A printed procedure is
provided in the kit, inside the operator’s cab
and in this manual.

Table 2–3 lists the emergency load lowering

procedures and kit drawing. See Section 3 of
this manual for the drawings.

Table 2–3. Emergency Load Lowering

Procedures and Kit Drawing

EMERGENCY EMERGENCY
LOWERING LOWERING
HOIST
PROCEDURE KIT
DRAWING DRAWING
Main
603511 603457-L01
Auxiliary

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3 MAINTENANCE
3.1 Introduction and General
Instructions
This section includes general maintenance
schedules and maintenance instructions for the
equipment as outlined by the table of contents.
At the end of this section are reference draw-
ings.
API Recommended Practice 2D, Recom-
mended Practice for Operation and Mainte-
nance of Offshore Cranes (API RP2D) (current
edition) is a useful guide for owners and opera-
tors in developing operating and maintenance
practices and procedures. All guidelines in this
recommended practice should be followed.
Maintenance must be done at regular intervals.
Failure to do the necessary maintenance will
result in damage to the equipment parts. The
lubrication schedule (see paragraph 3.2.2) and
the inspection and maintenance schedule (see
paragraph 3.3) are guides for the correct main-
tenance of the equipment.
Permit only qualified service personnel who
have received training in the proper mainte-
nance, adjustment, and inspection of the equip-
ment to do these procedures.
After making a repair or adjustment, always
check the function of the equipment parts
before putting the equipment into full operation.
Do not make modifications to the equipment
unless approved in writing by National Oilwell
Varco.
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3.2 Lubrication
3.2.1 Lubrication Procedures
Do not operate the equipment without proper
lubrication. Lubricants that do not meet the
requirements of the equipment or lubricants that
have deteriorated to a level of unacceptable
service must not be used, or must be replaced
with acceptable lubricants before operating the
equipment.
CAUTION
• Clean the work area and lubrication
fittings before and after adding the
lubricant. Remove any extra lubricant
that has been forced through a
bearing. When the equipment is
operated, extra lubricant will work its
way out of the bearing. This lubricant
must be removed.
Do not mix different types and brands of lubri-
cants because of possible incompatibility.
3.2.2 Lubrication Schedule
See the Lubrication Schedule (table 3–1) and
the Lubricant Legend (table 3–2) for the lubrica-
tion schedule, lubrication points, types of lubri-
cant, and fluid capacities.
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Table 3–1. Lubrication Schedule

INTERVAL OF TYPE OF REFERENCE
DESCRIPTION LUBRICATION LOCATION CAPACITY
LUBRICATION LUBRICANT PARAGRAPH
• Boom wire rope
• Main wire rope
As required Wire ropes WRL As required 3.2.2.1
• Auxiliary wire rope
• Pendants
• Diesel engine lubrication 29.6 qt
See ELO
oil (28 L)
manufacturer’s Diesel engine 3.2.2.2
information • Diesel engine coolant 11.0 gal
AF
(includes radiator) (41.6 L)
Boom foot
HPG • Boom foot As required 3.2.2.3
bushings
• Boom point sheaves and
pendant anchors
Sheaves HPG As required 3.2.2.3
• A-frame sheaves
• Bridle sheaves
Hook block
and overhaul HPG • Sheaves and hooks As required 3.2.2.3
Every 40 hours ball
of operation or
weekly, which- Swing bearing HPG • Swing bearing As required 3.2.2.3
ever occurs OGL • Gear teeth As required 3.2.2.4
first Swing drives OGL • Pinion gears As required 3.2.2.4
• Two boom limit safety
valves
Safety valves HO As required 3.2.2.5
• Two anti–two-block
safety valves
HPG • Ratchet and pawl As required
Boom hoist • Pawl cylinder rod and 3.2.2.6
HO As required
pins
• Boom hoist gearbox—
As required 3.2.2.7
check level of lubricant
Every 40 hours
of operation or Hoists • Main hoist gearbox—
HHO As required 3.2.2.7
every three check level of lubricant
months, which- • Auxiliary hoist gearbox—
ever occurs As required 3.2.2.7
check level of lubricant
first
• Gearbox—check level of
Swing drives GO As required 3.2.2.8
lubricant

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Table 3–1. Lubrication Schedule (continued)

INTERVAL OF TYPE OF REFERENCE
DESCRIPTION LUBRICATION LOCATION CAPACITY
LUBRICATION LUBRICANT PARAGRAPH
• Boom hoist gearbox— 48 pt
3.2.2.7
drain and refill (22.7 L)
Every 500 • Main hoist gearbox— 130 pt
hours of opera- Hoists HHO
drain and refill (61.5 L)
3.2.2.7
tion or every
six months, • Auxiliary hoist gearbox— 90 pt
3.2.2.7
whichever drain and refill (42.6 L)
occurs first • Gearbox—drain and 12.75 pt
Swing drives GO refill (6.0 L ) 3.2.2.8
each

Table 3–2. Lubricant Legend

NATIONAL
OILWELL
SYMBOL VARCO DESCRIPTION
PART
NUMBER
AF 903000 Engine anti-freeze
Engine lubrication oil—SAE 15W-40 (See Parts and Vendor Data Manual,
ELO 939084
Section 11, Caterpillar)
GO 939049 Gear oil—SAE 90
Hydraulic hoist gear oil—industrial EP gear oil, specifically Exxon Spartan
HHO 939074
EP150 as recommended by Braden Hoists
HO 939064 Hydraulic oil ISO-46—such as Shell Tellus 46
HPG 939048 High pressure grease—multi-purpose extreme pressure grease
OGL 939063 Open gear lubricant—black soda lead grease
WRL 939075 Wire rope lubricant—black viscous lubricant such as Texaco Crater A

3.2.2.1 Wire Ropes 3.2.2.2 Diesel Engine

Wire rope should be lubricated at regular inter- See the diesel engine manufacturer’s informa-
vals to guard against wire corrosion. When tion (see Parts and Vendor Data Manual,
corrosion is noticed, the wire rope should be Section 11, Caterpillar) for the lubrication
closely inspected for damage. instructions, intervals, and lubricant specifica-
tions.
See Section 5, API Recommended Practice 2D,
Recommended Practice for Operation and
Maintenance of Offshore Cranes (API RP2D)
for the wire rope lubrication procedures.

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3.2.2.3 Grease Fittings
NOTICE
• The warranties for the swing bearing
and crane will be void if the swing
bearing is not lubricated as specified.
CAUTION
• Clean the work area and lubrication
fittings before and after adding the
lubricant. Remove any extra lubricant
that has been forced through a
bearing. When the equipment is
operated, extra lubricant will work its
way out of the bearing. This lubricant
must be removed.
Use caution regarding the rate and pressure at
which lubricant is forced into a bearing, to avoid
damaging the seal of the bearing, which can
cause damage to the bearing.
When putting new or repaired bearings into
service, add lubricant, rotate the bearing, and
add more lubricant until a small amount of lubri-
cant begins to show from the bearing. This will
make sure that the bearing is completely lubri-
cated.
At designated intervals, relubricate the bear-
ings. When relubricating a bearing, add only a
measured amount of lubricant. Periodic
over-lubrication is needed to remove all old
lubricant from the bearing. When to over-lubri-
cate a bearing is dependent on the duty cycle
of the equipment and its severity of use.
Extra lubricant forced out from a bearing must
be removed. Check the removed lubricant for
water content and particles of metal. Particles
of metal in the lubricant indicate bearing wear.
If a lubricant fitting will not take lubricant (too
much pressure), the problem must be found
and corrected before continuing operation.
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3.2.2.4 Swing Gear and Pinions
NOTICE
• The warranties for the swing bearing
and crane will be void if the swing gear
and pinions are not lubricated as
specified.
Wipe the swing gear and pinion clean and
apply lubricant liberally to all machined surfaces
of both the swing gear and pinion.
3.2.2.5 Safety Valves
Clean the exposed surfaces of the valve spools
for the boom limit and anti–two-block safety
valves and apply a light oil to prevent corrosion.
3.2.2.6 Boom Hoist Pawl
Check the entire drum ratchet surface and pawl
of the boom hoist for a full coverage of lubri-
cant. Apply lubricant as needed. Clean the
exposed surfaces of the pawl cylinder rod and
apply a light oil to prevent corrosion. Apply a
light oil to the pawl cylinder pivot pins.
3.2.2.7 Hoist Gearboxes
Check the level of lubricant in the boom, main,
and auxiliary hoist drive gearboxes every 40
hours of operation or every three months,
whichever occurs first. Add lubricant as neces-
sary. See the hoist manufacturer’s information
for the lubrication instructions (see Parts and
Vendor Data Manual, Section 11, Braden).
Drain and refill the gearboxes with new lubri-
cant after the first 100 hours of operation, then
every 500 hours of operation or every six
months, whichever occurs first.

3.2.2.8 Swing Drive Gearboxes
Check the level of lubricant in both swing drive
gearboxes every 40 hours of operation or every
three months, whichever occurs first. Add lubri-
cant as necessary. See the gearbox manufac-
turer’s information for the lubrication
instructions (see Parts and Vendor Data
Manual, Section 11, Eskridge).
Drain and refill the gearboxes with new lubri-
cant after the first 100 hours of operation, then
every 500 hours of operation or every six
months, whichever occurs first.
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3.3 Inspection and Maintenance
Schedule
!WARNING
• Do not operate the equipment if an
inspection reveals a possible safety
hazard or if any of the equipment parts
require replacement or maintenance.
Always look for equipment damage
during operation. If damage is found,
safely shut down the equipment and
correct the damage before continuing
operation.
NOTICE
• Other inspections can be required by
local regulations and must also be
made.
3.3.1 As Necessary
Diesel Engine
• See the manufacturer’s information for
maintenance instructions, intervals, and
procedures (see Parts and Vendor Data
Manual, Section 11, Caterpillar).
Paint
• Paint any damaged paint surfaces to
prevent corrosion.
3.3.2 Before Every Start-Up
Crane and Pedestal Foundation
• Check for damaged, distorted, worn,
cracked, corroded, loose or missing parts,
fasteners, and welds. If a fastener is found
to be defective, replace it and check the
remaining fasteners in the group.
• Check for correct lubrication.

Hydraulic System
• Check the hydraulic oil reservoir for the
correct oil level (see paragraph 3.6.6.1).
• Check for leaks.
• Check the hoses and piping for damage.
• Check the hoses for abrasion or advanced
weathering that could cause a hose to burst
under operating pressure.
Fuel System
• Check the diesel fuel tank for the correct
fuel level.
• Check for leaks.
• Check the hoses and piping for damage.
Air System
• Check for leaks.
• Check the hoses and piping for damage.
Electrical System
• Check the general condition of the wiring
for deterioration, cracked or frayed insula-
tion, and loose connections.
• Check for damaged, corroded, loose, or
missing parts and fasteners.
Gearboxes
• Check for leaks and damage.
Boom Hoist
• Check the boom hoist ratchet and pawl for
wear and damage.
Operator Controls
• Check that the correct load rating chart for
the crane configuration in use is visible to
the crane operator at the control station.
• Check the control labels. Replace all
damaged or missing labels.
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3.3.3 After Every Start-Up
Hydraulic Oil Filters
• With the hydraulic oil at normal operating
temperature and the engine operating at
2200 rpm, check the filter indicators (see
Hydraulic Oil Filters, paragraph 3.6.8). If the
indicator is activated, replace the filter
element.
Crane
• Check control mechanisms for correct
operation.
• Check the diesel engine start, stop, and
emergency stop controls.
• Check the crane load and radius indicator
system for correct operation (see Parts and
Vendor Data Manual, Section 11, Aanderaa
Data Instruments).
3.3.4 Before Each Use
Wire Ropes
• Inspections must be made by competent,
experienced personnel who know the oper-
ation of the wire rope. They must have
previous experience with wire rope in order
to make a correct and safe judgment of the
wire rope. See Section 5, API Recom-
mended Practice 2D, Recommended Prac-
tice for Operation and Maintenance of
Offshore Cranes (API RP2D) for the wire
rope inspection procedure.
• To establish the correct time for replace-
ment of the wire rope, keep dated and
detailed records, and review them at each
inspection. This will give a comparison of
the changes in the wire rope and will be a
good aid in determining when to replace
the wire rope.

Hooks and Latches
• Check for damaged, distorted, worn,
cracked, corroded, loose, or missing parts
and fasteners.
Loose Gear
• Check loose gear to be used such as
slings, sling hooks, and shackles for
damaged, distorted, worn, cracked,
corroded, loose, or missing parts and
fasteners.
Crane
• Check the boom limit and anti–two-block
safety systems for correct operation.
• Check that the wire rope is reeved
correctly, operating freely, and is spooled
properly.
• Check that the correct load rating chart for
the crane configuration in use is visible to
the crane operator at the control station.
• Check that the configuration of the crane
load and radius indicator system (see para-
graph 2.5.3) corresponds to the crane
configuration in use.
Electrical System
• Check the operation of the crane obstruc-
tion warning lights.
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3.3.5 Every 8 Hours of Operation or
Every Day
Do maintenance to or check the following items
every 8 hours of operation or every day, which-
ever occurs first.
Fuel Tank
• Drain the sediment and water condensation
from the fuel tank.
• Fill the fuel tank.
Hydraulic Oil Return Filters
• With the hydraulic oil at normal operating
temperature and the engine operating at
2200 rpm, check the filter indicators (see
paragraph 3.6.8). If the indicator is acti-
vated, replace the filter element.
Hydraulic Oil Heat Exchanger
• Check for leaks and damage.
• Clean debris from the hydraulic oil heat
exchanger air intake.
Wire Ropes
• Inspections must be made by competent,
experienced personnel who know the oper-
ation of the wire rope. They must have
previous experience with wire rope in order
to make a correct and safe judgment of the
wire rope. See Section 5, API Recom-
mended Practice 2D, Recommended Prac-
tice for Operation and Maintenance of
Offshore Cranes (API RP2D) for the wire
rope inspection procedure.
• To establish the correct time for replace-
ment of the wire rope, keep dated and
detailed records, and review them at each
inspection. This will give a comparison of
the changes in the wire rope and will be a
good aid in determining when to replace
the wire rope.

3.3.6 Every 40 Hours of Operation or
Every Week
Do maintenance to or check the following items
every 40 hours of operation or every week,
whichever occurs first.
Swing Drives
• Check the level of lubricant (see para-
graph 3.2.2.8).
Hoists
• Check the level of lubricant (see para-
graph 3.2.2.7).
• Check that the wire rope wedges are
seated correctly in the drums.
Sheaves
• Check the sheaves for groove wear,
cracks, wire rope path alignment, and bear-
ing condition.
Crane Controls
• Check all control linkages and pins for
excessive wear and corrosion.
Crane Structural Equipment Parts
• Visually check for damaged, worn, cracked,
corroded, loose, or missing parts, fasten-
ers, and welds.
3.3.7 First 100 Hours of Operation
Do maintenance to the following items after the
first 100 hours of operation:
Hoists
• Drain and refill the lubricant (see para-
graph 3.2.2.7).
Swing Drives
• Drain and refill the lubricant (see para-
graph 3.2.2.8).
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3.3.8 Every 250 Hours of Operation or
Every Three Months
Check the following items every 250 hours of
operation or every three months, whichever
occurs first.
Handrails, Ladders, Walkways, and Safety
Guards
• Check for damaged, worn, cracked,
corroded, loose, or missing parts, fasten-
ers, and welds.
Safety Labels
• Check the safety labels (see paragraph 1.6
for the label locations). Replace all
damaged or missing labels.
• Clean labels for good legibility.
Hoists
• Do a brake test procedure for the main,
auxiliary, and boom hoists per API Recom-
mended Practice 2D, Recommended Prac-
tice for Operation and Maintenance of
Offshore Cranes (API RP2D) and Braden
hoist recommended procedures (see
Section 3, Brake Test Procedure, drawing
603511; Section 5, API RP2D; and Parts
and Vendor Data Manual, Section 11,
Braden).
Hydraulic Power Plant
• Check for proper performance and compli-
ance with safety requirements.

3.3.9 Every 500 Hours of Operation or
Every 6 Months
Do maintenance to the following items every
500 hours of operation or every six months,
whichever occurs first.
Hydraulic Oil
• Analyze for cleanliness, viscosity, proper
additives, and water content (see para-
graph 3.6.1.1).
Hydraulic Oil Return Filters
• Replace the filter elements (see paragraph
3.6.8).
Hoists
• Drain and refill the lubricant (see para-
graph 3.2.2.7).
Swing Drives
• Drain and refill the lubricant (see para-
graph 3.2.2.8).
3.3.10 Every 12 Months
An annual inspection is required for safe opera-
tion of the equipment. This inspection must be
signed by an authorized inspector. Do all the
inspections outlined in paragraphs 3.3.1
through 3.3.9, plus the following:
Welds
• Check the welds 100 percent visually.
Cracked paint with a rust line at the weld is
an indication the weld may be cracked.
Check any such area by magnetic particle
testing after removal of paint. All welds
must be free of cracks. All nondestructive
testing must conform to the latest edition of
AWS D1.1.
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Hoists
!WARNING
• Failure to do the proper hoist
maintenance can result in loss of load
control and void the hoist and crane
warranty.
• A qualified Braden hoist service technician
must disassemble and inspect all compo-
nents per API Recommended Practice 2D,
Recommended Practice for Operation and
Maintenance of Offshore Cranes (API
RP2D) and Braden hoist recommended
procedures. The hoist must be reassem-
bled and tested to Braden recommenda-
tions and standards (see Section 5, API
RP2D and Parts and Vendor Data Manual,
Section 11, Braden).
Swing Bearing
• Check per API Recommended Practice 2D,
Recommended Practice for Operation and
Maintenance of Offshore Cranes (API
RP2D) (see Section 5).
Hydraulic Pressure Gauges
• Check for correct calibration.
Crane Load and Radius Indicator System
• Check for correct calibration (see Parts and
Vendor Data Manual, Section 11, Aanderaa
Data Instruments).

3.4 Electrical System
Electric power for the crane is supplied from the
vessel at 460 VAC. The electric power is
converted by a transformer to 208–120 VAC for
use by the electrical system. The 120 VAC
electric power is also converted by a power
supply to 24 VDC for use by control system
equipment.
The electrical schematic shows the relationship
of the electrical system equipment. See Parts
and Vendor Data Manual, Section 10, Electrical
Schematic, drawing 751753.
3.4.1 Electrical System Maintenance
Use caution when doing maintenance on or
near the electrical system equipment. Before
working on the electrical system, a lockout must
be installed by each maintenance person at
each electric power source following indus-
try-standard lockout procedures. Electrical
equipment must be maintained and operated
according to applicable standards.
Clean the work area before installing or remov-
ing electric wires from the equipment. When
removing electric wires, check that the wires
are correctly labeled and install caps on all the
connectors to prevent corrosion.
3.5 Air System
Compressed air for the crane is supplied from
the vessel at 120–125 psi (8.3–8.6 bar) to a
reservoir located on the crane. The air system
controls and operates the diesel engine air
starter and the operator’s cab window wipers
and horn.
The air piping drawings show the relationship of
the air system equipment (see Parts and
Vendor Data Manual, Section 9).
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3.5.1 Air System Maintenance
Release pressure from the air system (see
paragraph 3.5.2) before doing maintenance to
the air system equipment. Residual pressure
can remain in the air piping. Use caution when
removing any piping or hose. Accidentally
releasing air at high pressure can cause injury
to you and others, and can damage the equip-
ment.
Regular inspection and maintenance of the air
system is necessary for reliable performance of
the equipment. A good preventive maintenance
program will help prevent condensation and air
system failures.
Cleanliness is very important in the operation
and maintenance of the air system. No dirt or
abrasive particles can be permitted to enter the
system.
Some contaminants enter the system when it is
opened. Do everything you can to keep the
system as clean as possible. Clean the work
area and tools before opening any part of the
system. Install caps on all open air piping and
hoses. Install plugs in all open air ports. Do not
leave the air system open to dust and other
airborne particles. Do not accept replacement
parts that are not in their original protective
packages. Wash parts according to the manu-
facturer’s instructions and permit them to dry
before assembly.
3.5.2 Releasing Pressure from Air
System
1. Shut down the crane (see paragraph 2.8.4).
2. Release pressure from the air system until
the AIR PRESSURE gauge (see paragraph
2.6.10) in the operator’s cab reads 0 psi.

!WARNING
• Residual pressure can remain in the
air piping. Use caution when removing
any air piping or hose. Release of the
air at high pressure by accident can
cause personal injury and damage to
the equipment.
3.6 Hydraulic System
Hydraulic power for the crane is produced by
hydraulic pumps driven by the diesel engine.
The hydraulic system controls and operates the
hoists and swing drive. A small hydraulic pump
mounted near the front of the diesel engine
powers a hydraulic motor that drives the fan of
the hydraulic oil heat exchanger. The fan
provides air flow across the heat exchanger to
cool the hydraulic oil. The hydraulic schematic
shows the relationship of the hydraulic system
equipment (see Parts and Vendor Data Manual,
Section 8, Hydraulic Schematic, drawing
605030).
3.6.1 Hydraulic System Maintenance
Release pressure from the hydraulic system
and permit the system to cool (see paragraph
3.6.5) before doing maintenance to the hydrau-
lic system equipment.
Residual pressure can remain in the hydraulic
piping. Use caution when removing any piping
or hose. Accidentally releasing hydraulic oil at
high pressure can cause injury to you and
others, and can damage the equipment. Be
careful of the flow of hydraulic oil when the
hydraulic system is opened. Some parts of the
system will lose hydraulic oil when opened.
When personnel are not sure of a port pres-
sure, refer to the hydraulic schematic and make
the first pressure check with a test gauge of a
large enough scale to prevent gauge failure
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(see Parts and Vendor Manual, Section 8,
Hydraulic Schematic, drawing 605030). Not
following this procedure can cause injury to
personnel.
Regular inspection and maintenance of the
hydraulic system is necessary for reliable
performance of the equipment. A good preven-
tive maintenance program will help prevent
oxidation, condensation, aeration, and hydraulic
system failures.
Check the hydraulic system equipment parts for
overheating. The following are signs of hydrau-
lic system overheating:
• high hydraulic oil reservoir tempera-
ture—more than 180°F (82°C)
• smell of “burned” oil near the hydraulic oil
reservoir breather
• discolored paint or metal surfaces
• too much radiant heat
• reduced crane performance
Cleanliness is very important in the operation
and maintenance of the hydraulic system.
Small, abrasive particles, invisible to the eye,
can decrease the useful life of valves, pumps,
and motors. The clearance between hydraulic
equipment parts is very small. Particles can
squeeze through the clearances and be abra-
sive to the mating surfaces. The result is early
wear, equipment damage, and a loss of power.
Some contaminants enter the system when it is
opened. Keep the system as clean as possible.
Clean the work area and tools before opening
any part of the system. Install caps on all open
hydraulic hoses and piping. Install plugs in all
open hydraulic ports. Do not leave the hydraulic
system open to dust and other airborne
particles. Do not accept new filter elements or
replacement parts that are not in their protective
packages. Wash parts in clean solvent and
permit them to air-dry before assembly. Flush
all new hydraulic piping, hoses, and other
equipment parts to meet the requirements of
Hydraulic System Contamination Levels, para-
graph 3.6.1.2.
 Document number
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Page
!WARNING
• The hydraulic system contains many
adjustable equipment parts preset at
the factory for optimum performance
and safety. Do not adjust these
equipment parts. Contact the National
Oilwell Varco Service Department for
assistance.
3.6.1.1 Hydraulic Oil Sampling (National
Oilwell Varco Drawing 604289)
Do a hydraulic oil analysis every 500 hours of
operation or every six months, whichever
occurs first.
1. To take a sample of hydraulic oil:
A. Install a hydraulic oil sampling valve
(supplied by others) in the hydraulic
return circuit at an elbow or in a place
where the flow is turbulent during
normal operation. The sampling valve
must be sized to permit a flow rate
through the valve of 30 ft/sec
(9.1 m/sec).
B. A sampling bottle that has been
cleaned to a known cleanliness level
and then capped is needed.
C. A container to catch up to 1 gal (3.8 L)
of waste hydraulic oil is needed.
D. The hydraulic system must be at oper-
ating temperature and maximum
speed, if possible.
2. Send the hydraulic oil sample and the
E. Clean the nozzle of the hydraulic oil
sampling valve with a clean, lint-free
cloth to remove any visual signs of
contamination.
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F. Put the waste container under the
sampling valve.
G. Open the sampling valve and permit
about 1 qt (0.95 L) of hydraulic oil to
flow through the valve.
H. With the sampling valve still in the
“open” position, open the sampling
bottle and fill it 50–90 percent full.
I. Remove the sample bottle with the
sampling valve still in the “open” posi-
tion. Put the cover on the sample bottle
and close the sampling valve.
J. Properly dispose of the hydraulic oil
collected in the waste container.
K. Check the level of hydraulic oil in the
reservoir and add hydraulic oil as
necessary (see paragraph 3.6.6).
L. Record and submit the following infor-
mation with the sample:
• model number
• serial number
• hours of operation on the system
• hours of operation on the hydraulic oil
• sample date
• oil temperature
• sample location
• name of person taking sample
• sample appearance: clean, cloudy,
milky, visible particles
• reason for sample
• additional comments
• hydraulic oil type
recorded data to a laboratory for a particle
count analysis. The analysis results must
be reported by the laboratory on a form
similar to figure 3–1. The actual cleanliness
level must be plotted on a graph and a
curve made by connecting the points.
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3. If the analysis results exceed the maximum

operating contamination levels permitted
(see paragraph 3.6.1.2), correct the prob-
lem before continuing operation. Additional
sampling, analysis, and testing may be
necessary (example: a chemical analysis
could assist in determining the cause or
source of contamination). The nonconfor-
mity can be the result of one of the follow-
ing:

A. A large quantity of new hydraulic oil

was added shortly before the sample
was taken. If so, operate the hydraulic
system (engine) for two hours, but do
not operate the hydraulic-driven equip-
ment (crane boom, hoist, and swing
functions). Then take and analyze a
new hydraulic oil sample.

B. One or more return filter elements are

bypassing most of the time. If so,
replace the clogged filter element(s)
and operate the hydraulic system for
two hours, but do not operate the
hydraulic-driven equipment. Then take
and analyze a new hydraulic oil
sample.

C. One or more parts in the hydraulic

system are in the process of failing. If
so, find and replace the failing part(s).
After replacement, all the hydraulic oil
must be drained and the system filled
with new hydraulic oil (see para-
graph 3.6.7).

D. The hydraulic oil was contaminated

during the replacement of a hydraulic
equipment part. If so, have the situation
reviewed by the National Oilwell Varco
Service Department before operating
the equipment.

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7 9
10 10
30
5.0 5
29 ISO 4
3
CODING METHOD
2.5
28 SOLID 2
STRAIGHT LINE DATA
10
6
1.3
27
CONTAMINANT 10
8

6.4 CODE 5
CODE: 18/16
26 4
3.2 3
Reference 18
25 ANSI/B93.30-1980 2

NUMBER OF PARTICLES PER 100 MILLILITRES GREATER THAN INDICATED SIZE

1.6
5 24 7
16
10 10
NUMBER OF PARTICLES PER MILLILITRE GREATER THAN INDICATED SIZE

8.0
23 5
4.0 4
22 3
2.0 2
21
4 6
10 1.0 10
20
5.0 5
RANGE NUMBER - quote at 5 um & 8 um levels only

4
19 3 5 15 25 100
2.5
2 27
18 CURVED
3
1.3 5
5 / 15 / 25 /100
10 10 DATA
17
6.4 (USE 5 /15 POINTS)
5
16 4 23
3.2
CODE: 27/23
3
15 2
1.6

10
2 14 10
4
8.0
13 5
4.0 4
3
12
2.0 2
11
3
10 1.0 10
10
5.0 5 5 15 25 100
4
9 3
2.5
2
8
1.3 A1534
2
1 10
7
6.4
6 5
4
3.2 3
5 2
1.6

10
-1 4 10
8.0
3 5
4.0 4
2 3
2.0 2
1
-2
10
1 5 10 15 20 25 30 40 50 60 70 80 90 100
Figure 3–1. Particle Count Analysis Form

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3.6.1.2 Hydraulic System Contamination Levels

(National Oilwell Varco Drawing 604289)

Table 3–3 shows the maximum permitted hydraulic system contamination levels. The water content of
the hydraulic system must be less than 0.03% by volume.

Table 3–3. Hydraulic System Contamination Levels

NUMBER OF PARTICLES/mL LARGER THAN INDICATED SIZE
PARTICLE SIZE
IN MICRONS MAXIMUM COMMISSIONING LEVEL(A) MAXIMUM OPERATING LEVEL(B)
(C)
ISO 18/15 ISO 17/14(C)
5 2500 1300
15 320 160
25 80 40
50 10 5
100 0.8 0.4

(A) Maximum Commissioning Level: This is the maximum contamination level permitted for accepting
new and rebuilt hydraulic systems into service. Do not operate the hydraulic system in excess of
this contamination level. The commissioning level is the contamination level at which the equip-
ment can be operated to circulate the system hydraulic oil until the maximum operating contamina-
tion levels are reached. This circulation of hydraulic oil must be done at no load and maximum
hydraulic oil flow.

(B) Maximum Operating Level: This is the maximum operating contamination level permitted. Operate
the hydraulic system at low pressure until a contamination level below this is reached using the
standard filter system.

(C) Table 3–4 compares similar obsolete SAE and NAS Cleanliness Standards to the present ISO
Standards:

Table 3–4. Hydraulic System Cleanliness Standards

LEVEL ISO CODE SAE CLASS NAS CLASS
Maximum commissioning level 18/15 6 9
Maximum operating level 17/14 5 8

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3.6.2 Hydraulic Oil
CAUTION
• Do not mix different types and brands
of hydraulic oil unless they are
compatible. Mixing different types and
brands can cause a chemical reaction
which can cause damage to the
hydraulic equipment parts.
• Hydraulic oil containers that are not
stored correctly can collect water in
the bottom of the container. Hydraulic
oil that is water-contaminated has a
cloudy visual appearance and must
not be added to the hydraulic system.
Filter all hydraulic oil to comply with the maxi-
mum contamination levels permitted (see para-
graph 3.6.1.2) before adding it to the hydraulic
reservoir. Even new oil from a new container
must be filtered. Send the hydraulic oil through
a 3-micron filter with no bypass while adding it
to the hydraulic oil reservoir.
Use a premium quality, high viscosity index
(V.I.), anti-wear, petroleum-based hydraulic oil
compatible with Buna N and Viton A seals for
use in high pressure hydraulic systems
(3000 psi [207 bar]). Choose an ISO grade that
corresponds well to climactic conditions based
on the characteristics listed in table 3–5. Origi-
nal fill of the hydraulic system was Shell Tellus
46 (National Oilwell Varco p/n 939064). If you
have a question about a hydraulic oil, contact
the National Oilwell Varco Service Department.
Analyze the hydraulic oil (see para-
graph 3.6.1.1) for cleanliness, viscosity, proper
additives, and water content every 500 hours of
operation or every six months, whichever
occurs first.

Table 3–5. Hydraulic Oil Grade

MINIMUM HYDRAULIC OIL MINIMUM HYDRAULIC OIL MAXIMUM HYDRAULIC OIL
TEMPERATURE BEFORE TEMPERATURE FOR FULL OPERATING
(B) (C)
HYDRAULIC STARTUP POWER OPERATION TEMPERATURE
OIL GRADE(A) (7500 SUS MAXIMUM (750 SUS MAXIMUM (60 SUS MINIMUM
VISCOSITY) VISCOSITY) VISCOSITY)
°F °C °F °C °F °C
ISO–15 –30 –34 15 –9 125 51
ISO–32 –10 –23 45 8 175 79
(D) (D)
ISO–46 0 –17 55 13 180 82
(D) (D)
ISO–68 20 –6 75 24 180 82
(D) (D)
ISO–100 30 –1 90 33 180 82
(A) The viscosity/temperature curve varies with different hydraulic oil manufacturers. Consult the hy-
draulic oil manufacturer. Table 3–5 is based on Mobil DTE 10M series hydraulic oil.
(B) If the hydraulic oil is below the minimum startup temperature or above the maximum startup viscos-
ity, warm the hydraulic oil with a hydraulic oil reservoir heater until the hydraulic oil reaches the
minimum startup temperature (maximum startup viscosity). The temperature of the hydraulic oil can
be checked using the temperature gauge on the side of the hydraulic oil reservoir.
(C) After startup, operate the hydraulic system at reduced pressure until the hydraulic oil reaches this
minimum temperature (maximum operating viscosity).
(D) The maximum hydraulic oil operating temperature is limited by the life of oil seals in the hydraulic
system.

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3.6.3 Hydraulic Piping and Hoses
Replace any piping that is bent or has become
flat. This will cause a restriction of the hydraulic
oil flow, which will cause heat buildup and slow
hydraulic action.
Replace hoses that show wear, damage, abra-
sion, bubbles in the outer covering of the hose,
or weather-cracked rubber. Look for areas where
two hoses have rubbed together and worn
through the outer covering to the wire braid
below.
Use Loctite brand Hydraulic Sealant or PST
Pipe Sealant on all pipe threads. Do not use
PFTE or teflon tape—it will contaminate the
hydraulic system.
NOTICE
• Use sealants according to the
manufacturer’s recommended
procedures.
CAUTION
• Flush all new hydraulic piping, hoses,
and other equipment parts to meet the
requirements of Hydraulic System
Contamination Levels (see paragraph
3.6.1.2).
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3.6.4 O-Ring Replacement
CAUTION
• Clean the work area before doing
maintenance to the hydraulic system.
Keep all the parts clean. Install caps
on all open hydraulic piping. Install
plugs in all open hydraulic ports. Dirt
and contamination will damage the
hydraulic system equipment parts if
they enter the hydraulic system (see
Hydraulic System Maintenance,
paragraph 3.6.1).
O-ring failure can occur at piping or hose end
connections or at equipment part interfaces.
The piping or hose end connection can be of
the O-ring boss and tube type (see para-
graph 3.6.4.1), O-ring face seal, or the SAE
four-bolt O-ring flange type (see para-
graph 3.6.4.2).
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3.6.4.1 O-Ring Sizes for Bosses and Tube Fittings

NOTICE
• O-rings listed in table 3–6 must be 90 durometer Buna N material.

Table 3–6. O-Ring Sizes for Bosses and Tube Fittings

The following O-rings are intended for use with internal straight thread bosses and tube fittings, and
10049, 10050, MS33656, MS33657, SAE straight thread O-ring and mating fittings.
O-RING ACTUAL O-RING NOMINAL O-RING NATIONAL
ARP 568 TUBE SIZE SIZE OILWELL
UNIFORM AN-6290 SIZE VARCO PART
DASH (in) I.D. WALL I.D. WALL NUMBER FOR
NUMBER (in) (in) (in) (in) O-RING
1 11 5
–904 4 4 0.351 0.072 32 64 946198
5 13 5
–905 5 16 0.414 0.072 32 64 946210
3 25 5
–906 6 8 0.468 0.078 32 64 946199
1 41 3
–908 8 2 0.644 0.087 64 32 946196
5 3 3
–910 10 8 0.755 0.097 4 32 946211
3 59 7
–912 12 4 0.924 0.116 64 64 946190
7
–914 14 8 1.047 0.166 13 64 7
64 946260
11 7
–916 16 1 1.171 0.116 1 64 64 946200
–920 20 1 14 1.475 0.118 115 32 1
8 946201
1 23 1
–924 24 1 2 1.720 0.118 1 32 8 946213
–932 32 2 2.337 0.118 21132 1
8 946214

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3.6.4.2 Four-Bolt O-Ring Flange

Piping or
To assemble a four-bolt O-ring flange: Hose

1. Clean the contact surfaces.

Bolt Split
2. Check the O-ring (see figure 3–2) for Flange
damage. Replace the O-ring if it is Split
damaged. Flange O-Ring

3. Apply clean white petroleum jelly to the

O-ring.

4. Install the O-ring in the piping or hose end.

A296

5. Install one-half of the split flange loose. Figure 3–2. Four-Bolt O-Ring Flange
Installation
6. Install the piping or hose in the split flange.

7. Install the other half of the split flange

loose.
3 2
8. Tighten the four bolts of the split flange in
sequence (see figure 3–3) evenly, until all
the bolts make contact with the top of the 1 4
flanges.

9. Tighten the four bolts in sequence (see

figure 3–3) one-half turn at a time. Repeat
as necessary to the torque value shown in A217
the table 3–7.
Figure 3–3. Flange Tightening Sequence

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NOTICE
• O-rings listed in table 3–7 must be 90 durometer Buna N material except where noted.

Table 3–7. Code 61 Standard Pressure Series Four-Bolt O-Ring Flange

NOMINAL O-RING ACTUAL O-RING NOMINAL O-RING NATIONAL

BOLT ARP 568 SIZE SIZE OILWELL
FLANGE TORQUE
THREAD UNIFORM VARCO PART
SIZE (in×lb) DASH I.D. WALL I.D. WALL NUMBER FOR
UNC-2A
(in) NUMBER (in) (in) (in) (in) O-RING
1 5 3 1
2 16 –18 175–225 –210 0.734 0.139 4 8 944103
3 3 1
4 –16
8 250–350 –214 0.984 0.139 1 8 925535
3
1 –16
8 325–425 –219 1.296 0.139 1516 1
8 925561
1 7 1 1
1 4 16 –14 425–550 –222 1.484 0.139 1 2 8 925333
1 1 7 1
1 2 2 –13 550–700 –225 1.859 0.139 1 8 8 944107
1 1 1
2 2 –13 650–800 –228 2.234 0.139 2 4 8 925334
1 1 (A) 3 1
2 2 2 –13 950–1100 –232 2.734 0.139 2 4 8 925591
5 (A) 3 1
3 –11
8 1650–1800 –237 3.359 0.139 3 8 8 944206
(A) 70 durometer Buna N material

3.6.5 Releasing Pressure from 3.6.6 Hydraulic Oil Level

Hydraulic System
3.6.6.1 Checking Hydraulic Oil Level
1. Shut down the crane (see paragraph 2.8.4).
Check the level of hydraulic oil in the hydraulic
2. Move all the control levers back and forth,
oil reservoir using the sight gauge located on
then release the levers to their neutral
the side of the reservoir. The level of hydraulic
(center) position.
oil must be above the midpoint of the sight
3. Permit the hydraulic oil to cool (see Hydrau- gauge. See paragraph 3.6.6.2 for the procedure
lic System Maintenance, paragraph 3.6.1). to add hydraulic oil.

!WARNING CAUTION
• Residual pressure can remain in the • Do not operate the equipment with a
hydraulic piping. Read and understand level of hydraulic oil that is too low or
the hydraulic schematic to identify too high.
possible areas of residual pressure in
the hydraulic system. Use caution
when removing any hydraulic piping or
hose. Accidentally releasing hydraulic
oil at high pressure can cause injury to
you and others, and can cause
damage to the equipment.

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3.6.6.2 Adding Hydraulic Oil to the
Reservoir
CAUTION
• Clean the work area and hydraulic oil
handling equipment before adding
hydraulic oil to the hydraulic oil
reservoir. Dirt and contamination will
damage the hydraulic system
equipment parts if they enter the
hydraulic system (see Hydraulic
System Maintenance, paragraph 3.6.1).
• Do not overfill the hydraulic system.
1. Release pressure from the hydraulic
system (see paragraph 3.6.5).
2. Use only new, clean, moisture-free hydrau-
lic oil that meets the recommended specifi-
cations (see paragraph 3.6.2).
3. All hydraulic oil added to the hydraulic
system must be filtered to comply with the
maximum operating contamination levels
permitted (see paragraph 3.6.1.2).
4. Add hydraulic oil through the fill port
located on top of the hydraulic oil reservoir.
Add hydraulic oil as necessary to raise the
level in the reservoir above the midpoint of
the sight gauge. The sight gauge is located
on the side of the reservoir.
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3.6.7 Draining and Filling Hydraulic
System
When the hydraulic system shows signs of
contamination (for example: sludge, water, or
chemicals), the hydraulic system must be
completely drained, flushed, and refilled (see
paragraphs 3.6.7.1 and 3.6.7.2).
The hydraulic oil can become contaminated as
a result of wear of equipment parts, adding
hydraulic oil that was not filtered correctly, or
replacing equipment parts in the system with
contaminated parts. The hydraulic oil can also
become contaminated with chemicals or metal-
lic substances dissolved or suspended in the
hydraulic oil, or the additives in the hydraulic oil
can become depleted because of the changing
of equipment parts. Hydraulic oils will “shear” or
thin out with use, requiring replacement of the
hydraulic oil. High operating temperatures or
age can cause oxidation of the hydraulic oil;
this can be seen by a change in color or odor,
increased acidity, and formation of sludge, gum,
or varnish in the system. Check the condition of
the hydraulic oil by periodically taking a sample
and having it analyzed for particle or chemical
contamination (see paragraph 3.6.1.1).
If the contamination is caused by a failed equip-
ment part, make a particle count test to find out
if the hydraulic system needs flushing. If possi-
ble, take the hydraulic oil sample with the
equipment operating. The hydraulic oil cleanli-
ness must comply with the maximum operating
contamination levels permitted (see para-
graph 3.6.1.2).

3.6.7.1 Draining Hydraulic System
1. If possible, operate the corresponding
equipment using all operations until the
hydraulic oil is warmed to normal operating
temperature.
CAUTION
• Clean the work area before doing
maintenance to the hydraulic system.
Keep all the parts clean (see Hydraulic
System Maintenance, paragraph 3.6.1).
2. Release pressure from the hydraulic
system (see paragraph 3.6.5).
3. Put tags on all the hydraulic piping and
hoses for reassembly purposes.
!WARNING
• The hydraulic oil will be hot if the
equipment has been operating.
Residual pressure can remain in the
hydraulic piping. Use caution when
removing any hydraulic piping or hose.
Accidentally releasing hydraulic oil at
high pressure can cause injury to you
and others, and can damage the
equipment.
4. Containers must be used to collect the
hydraulic oil. Open the drain valve to drain
the hydraulic oil reservoir. Remove all the
hydraulic piping and hoses from the pumps
and other equipment parts. Permit all the
hydraulic oil to drain. Properly dispose of
the hydraulic oil collected in the waste
containers.
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5. Flush clean all hydraulic piping, hoses, and
other equipment parts to meet the require-
ments of Hydraulic System Contamination
Levels, paragraph 3.6.1.2.
6. Disassemble the hydraulic oil filters. Clean
the filter housings to remove any visual
signs of contamination. Install new filter
elements and assemble the filters.
7. Flush the inside of the hydraulic oil reser-
voir to remove any visual signs of contami-
nation. Clean or replace the strainers.
8. Check all the O-rings, hoses, and wearing
parts before assembly. Replace with new
parts if any show signs of wear or damage.
All the valves, pumps, etc., must not be
sticking or binding because of hydraulic oil
contamination. If a part does not move
easily, it must be disassembled and
completely cleaned. Any part in the hydrau-
lic system that is not operating correctly is a
possible source of future problems and
equipment downtime.
9. Assemble all the parts, hoses, and piping.
Close the drain valve of the hydraulic oil
reservoir. The hydraulic system is now
ready to be filled with new hydraulic oil (see
paragraph 3.6.7.2).

3.6.7.2 Filling Hydraulic System
CAUTION
• Clean the work area and hydraulic oil
handling equipment before adding
hydraulic oil to the hydraulic oil
reservoir. Dirt and contamination will
damage the hydraulic system
equipment parts if they enter the
hydraulic system (see Hydraulic
System Maintenance, paragraph
3.6.1).
1. Use only new, clean, moisture-free hydrau-
lic oil that meets the recommended specifi-
cations (see paragraph 3.6.2).
2. All hydraulic oil added to the hydraulic
system must be filtered to comply with the
maximum operating contamination levels
permitted (see paragraph 3.6.1.2).
3. Fill the hydraulic oil reservoir with filtered
hydraulic oil (see paragraph 3.6.6.2).
4. Fill all the hoses with filtered hydraulic oil,
as possible.
5. Fill the hydraulic pumps and hydraulic
motors with filtered hydraulic oil. Bleed the
air from each pump and motor housing and
permit the oil from the reservoir to fill each
housing.
6. Reconnect all hydraulic piping and hoses.
7. Start the diesel engine (see the correspond-
ing steps in paragraph 2.8.2). Check for
pressure build-up.
8. Check for hydraulic system leaks.
9. Stop the diesel engine (see the correspond-
ing steps in paragraph 2.8.4).
10. Check the hydraulic oil reservoir for the
correct oil level. Add filtered hydraulic oil to
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the hydraulic oil reservoir as necessary
(see paragraph 3.6.6).
11. Start the diesel engine.
12. Operate the crane until all the air has been
purged from the hydraulic system. Erratic
equipment operation can be expected until
the air has been purged.
13. Stop the diesel engine.
14. Check the hydraulic oil reservoir for the
correct oil level. Add filtered hydraulic oil to
the reservoir as necessary.
15. Make a particle count test of the hydraulic
oil before putting the equipment into opera-
tion. The hydraulic oil cleanliness must
comply with the maximum operating
contamination levels permitted (see para-
graph 3.6.1.2).
3.6.8 Hydraulic Oil Filters
The power plant has four hydraulic oil return
filters and two pressure filters. The filters are
equipped with an indicator that shows when the
element requires replacement. The filter condi-
tion must be checked at start-up and after every
eight hours of operation. It is normal for the
filter to indicate a blocked condition during cold
starting conditions because of the increased
viscosity of the hydraulic oil.
Replace the filter elements every 500 hours of
operation or every six months, whichever
occurs first.
CAUTION
• Clean the work area before doing
maintenance to the hydraulic system.
Keep all the parts clean (see
paragraph 3.6.1).

3.7 Wire Rope
Operation, inspection, and maintenance of all
wire rope should be done in accordance with
API Recommended Practice 2D, Recom-
mended Practice for Operation and Mainte-
nance of Offshore Cranes (API RP2D) (see
Section 5). The Parts and Vendor Data Manual
contains the following drawings that are benefi-
cial to wire rope maintenance:
• hoist manufacturer’s information (see
Section 11, Braden)
• wire rope reeving diagrams (see Section 3)
• wire rope dead end installation drawings
(see Section 5)
!WARNING
• Do not operate the crane with
damaged wire rope.
After new wire rope has been installed properly,
the crane should be carefully operated through
an operating cycle very slowly. During this trial
operation, closely watch all working parts
(sheaves, hoists, etc.) to make sure the wire
rope moves freely and there are no spooling
problems. Operate several more times using a
light load at reduced speeds. This will permit
the wire rope to work in and prevent any future
problems.
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3.8 Non-Operational Storage
Equipment put in storage or removed from
service must be protected from deterioration
during storage. This will make sure that it can
be restored to active service with a minimum of
effort.
3.8.1 Short-Term Storage—7 Days Up to
30 Days
When the crane will not be used for a period of
7 days but less than 30 days, do the following:
1. Lubricate the exposed machined surfaces
such as shafts and hydraulic valve spools.
3.8.2 Long-Term Storage—30 Days or
More
When the crane will not be used for a period of
30 days or more, do the following:
1. Clean the equipment.
2. Apply lubricant to exposed machined
surfaces.
3. Lubricate all the equipment (see para-
graph 3.2.2). Do all the steps that would
occur during the storage period.
4. Shut down the crane (see paragraph 2.8.4).
5. Prepare the diesel engine for storage. See
the diesel engine manufacturer’s informa-
tion (see Parts and Vendor Data Manual,
Section 11, Caterpillar) for diesel engine
storage procedures.
6. Inspect the crane for paint surface damage.
Make repairs as necessary to prevent
corrosion.

7. To prevent corrosion, apply Dow Corning
brand Metal Protective Coating or an equiv-
alent anti-corrosion coating to the following.
The coating must be non-tacky and be able
to be removed before operation.
• Exposed machined surfaces of shaft
bores and hydraulic valve spools.
• All other non-painted surfaces.
8. Completely fill the diesel fuel tank.
9. Check the level of hydraulic oil in the
hydraulic oil reservoir. Add filtered hydraulic
oil to the reservoir as necessary (see para-
graph 3.6.6).
10. Close all cab windows and doors.
11. Cover the engine, valves, and operator’s
cab with waterproof coverings to prevent
corrosion and deterioration.
12. Once a month the diesel engine must be
started and all functions operated for a
minimum of one-half hour in each direction
at various speeds with no loads.
3.8.3 Removal from Long-Term Storage
1. Remove the anti-corrosion coatings from all
surfaces.
2. Clean the equipment.
3. Check the cylinder rod of the boom hoist
drum pawl actuator for damage, pits, and
scratches that can cause damage to the
cylinder seal. Check for cleanliness.
4. Check the level of hydraulic oil in the
hydraulic oil reservoir. Add filtered hydraulic
oil to the reservoir as necessary (see para-
graph 3.6.6).
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Document number 2703100-MAN-001
Revision 01
Page 3-25
5. Prepare the diesel engine for operation.
See the diesel engine manufacturer’s infor-
mation for the diesel engine removal from
storage procedures (see Parts and Vendor
Data Manual, Section 11, Caterpillar).
6. Start the crane (see paragraph 2.8.2). If
possible, operate the crane through all
functions until all the air is purged from the
hydraulic system. Erratic operation can be
expected until the air is purged. Check for
correct operation.
7. Check the hydraulic system for leaks.
Check hoses and piping for damage.
8. Make a hydraulic oil particle count (see
paragraph 3.6.1.1) before continuing. The
hydraulic oil particle count must comply
with the maximum operating contamination
levels permitted (see paragraph 3.6.1.2).
9. Do all necessary lubrication (see para-
graph 3.2.2) and inspections and mainte-
nance (see paragraph 3.3).
10. Check the equipment for paint surface
damage. Make repairs as necessary.
11. The crane is now ready for operation.
 Document number 2703100-MAN-001
Revision 01
Page 3-26

3.9 Welding Instructions

Using the wrong weld procedures on any part of

the equipment can weaken the material and
cause material failure, resulting in equipment
damage, injury to personnel, or both. Contact
the National Oilwell Varco Service Department
before welding any part of the equipment.

When welding, attach the electric grounding

cable directly to the part or area being welded.
Not following this procedure can cause damage
to the bearings, bushings, or spacers.

!WARNING
• Do not weld on hooks or shackles.
Welding on these items can weaken
the material, causing failure.

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 Brake Test and Emergency Lowering Procedures
For Hoists Ordered for API 2C Cranes

All Braden planetary hoists have a spring-applied, hydraulically-released, multiple-disc brake

located inside the drum. This brake acts to hold a suspended load in a stationary position when the
directional control valve is in neutral or in the event of loss of hydraulic power. A brake clutch
assembly permits the power train and drum to rotate in the direction to lift a load even if the brake is
engaged. A load cannot be lowered, however, without first releasing the brake by applying
hydraulic pressure to the release port.

Hoists ordered for API 2C cranes will have a needle valve located in the brake release line. Those
hoists also have a tee located in the brake release line between the needle valve and the brake
release port on the hoist. One opening in the tee is plugged. With the valve closed and the plug
removed from the tee, the brake is isolated from system pressure and vented to atmosphere. The
brake cannot be released under these conditions by actuating the directional control valve.

One purpose of the valve/tee combination is to provide a means to test the brake; the other is to
provide a means to lower a load in the event of loss of hydraulic power.

1. Brake Test Procedure

a. Remove the lockwire on the valve handle, and close the valve tightly.

b. Remove the plug in the tee.

c. With the hydraulic power unit running, move the hoist directional control valve handle to
the full-open lowering position.

d. Increase the engine speed, if necessary, to bring system pressure up to the relief valve
setting. The winch drum should remain stationary.

e. If the drum rotates, the brake should be examined for wear. Also, the brake springs
should be measured for correct length in those hoists using helical compression springs.

f. Replace any parts showing excessive wear, and any spring whose length is shorter than
the minimum shown in the Braden service manual.

g. Reassemble the brake and hoist and repeat the above steps.

h. When testing is complete, be sure to re-install the plug in the tee, fully open the valve
and replace the lockwire.

The above procedure tests the brake's ability to resist about 115% of the rated hoist load.

603511 Rev. 3
Page 1 of 2
2. Emergency Lowering Procedure

a. Remove the lockwire on the valve handle, and close the valve tightly.

b. Remove the plug in the tee.

c. Remove both main hoses from the motor, and attach a standpipe to the motor port on
the opposite side of the motor from the brake valve (counterbalance valve).

d. Fill the standpipe with hydraulic oil, making certain that oil is not running out of the brake
valve (counterbalance valve). If oil is running out of the brake valve (counterbalance
valve), remove the spring retainer and tap the spool to the closed position.

e. Connect a hand pump to the opening in the tee.

f. Pump the hand pump up to about 1000 psi. A suspended load will slowly come down;
releasing the pressure on the hand pump will cause the load to stop. If a chattering
noise is heard while the load is coming down, pump the hand pump to a higher pressure
until the noise stops. Do not touch the motor or standpipe while using this procedure;
these items will become very hot.

CAUTION - The above lowering procedure opens the multiple-disc brake while leaving
the brake valve (counterbalance valve) closed. Since hydraulic motors are not zero leak
devices, internal motor leakage permits the load to slowly rotate the motor even though
its outlet is blocked by the closed brake valve (counterbalance valve). This procedure
will not work if there is little or no oil in motor. Attempting to use this procedure with no
oil in the motor will cause the load to free fall. This procedure will also cause the load to
free fall if the brake valve (counterbalance valve) is stuck in the open position. The
purpose of the standpipe is to insure that the motor is full of oil. The standpipe is simply
a length of pipe (about 1 foot long) attached to a 90° elbow. The other end of the elbow
is attached to a short nipple and fitting suitable for mounting on the motor port or
manifold. The standpipe is installed with the 1 foot pipe pointed up and in a vertical
position. While lowering, oil must be added to the standpipe as necessary. The pipe
size should be at least as big as the motor port size.

WARNING- Never allow the standpipe to run out of oil. The load will free fall if there is
little or no oil in the stand pipe.

NOTE- The hydraulic oil used to fill the stand pipe must be filtered oil to prevent
contaminated hydraulic oil from entering the hydraulic motor. Filter the hydraulic oil to
meet a cleanliness level of ISO 16/13 or cleaner.

603511 Rev. 3
Page 2 of 2
 Document number 2703100-MAN-001
Revision 01
Page 4-1

4 SPECIFICATIONS

4.1 Crane Specifications

Crane Model:
• 10000XHD

Serial Number:
• 2703100

Boom:
• Main length—120 ft (36.6 m)
• Inner section—30 ft (9.1 m)
• Inner center section—20 ft (6.0 m)
• Center section—40 ft (12.1 m)
• Outer section—30 ft (9.1 m)

Maximum Hook Travel:

• Main hook, 4 parts of line—350 ft (106.6 m)
• Main hook, 6 parts of line—230 ft (70.1 m)
• Auxiliary hook—400 ft (121.9 m)

Maximum Hook Radius:

• Main hook—124.7 ft (38 m)
• Auxiliary hook—130.5 ft (39.7 m)

Minimum Hook Radius:

• Main hook—23.8 ft (7.2 m)
• Auxiliary hook—25.3 ft (7.7 m)

Maximum Available Hook Speed (with the hook positioned at the supply boat elevation and the platform
at operation conditions):
• Main hook, 4 parts of line—44 fpm (13.4 mpm) (4 part 1st layer)
• Main hook, 6 parts of line—31 fpm (9.4 mpm) (6 part 1st layer)
• Auxiliary hook—241 fpm (73.4 mpm) (1 part 1st layer)

Operator’s Station:
• Enclosed, right-hand

Load and Radius Indicator System:

• Aanderaa Data Instruments model Mipeg 2000

Emergency Load Lowering:

• Per drawings 603511 and 603457-L01

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 Document number 2703100-MAN-001
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Page 4-2

4.1.1 Hoist and Wire Rope Information

Hoist Make/Model:
• Boom—Braden CH240A
• Main—Braden CH400B
• Auxiliary—Braden CH240A

Boom Hoist Wire Rope:

• 7/8 in 6x26 EIPS—IWRC
• Length—900 ft (274.3 m)
• Breaking strength—39.8 tons (36.1 MT)

Main Hoist Wire Rope:

• 7/8 in Dyform 34LR, grade 2160
• Length—1800 ft (548.6 m)
• Breaking strength—54.8 tons (49.7 MT)

Auxiliary Hoist Wire Rope:

• 7/8 in Dyform 34LR grade 2160
• Length—570 ft (173.7 m)
• Breaking strength—54.8 tons (49.7 MT)

4.1.2 Power Plant

Type:
• Diesel/hydraulic

Diesel Engine:
• Caterpillar 3126
• 250 hp @ 2200 rpm

Diesel Fuel Tank Capacity:

• 150 gal (567.8 L)

Diesel Engine Coolant Capacity:

• Engine and radiator—11.0 gal (41.6 L)
• Radiator only—7.5 gal (28.3 L)

Hydraulic Oil Reservoir Capacity:

• 250 gal (946.3 L)

Hydraulic System Capacity:

• 265 gal (1003.1 L)
Hydraulic Oil:
• Shell Tellus 46,
(for hydraulic oil viscosity selection see Hydraulic Oil, paragraph 3.6.2)

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 Document number 2703100-MAN-001
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Page 4-3

4.1.3 Air System

Supply (from vessel):

• 120–125 psi (8.3–8.6 bar)

Air Reservoir:
• Capacity—200 gal (757 L)

4.1.4 Electrical System

Supply (from vessel):

• 460 VAC, 60 Hz, 3 ph, 3 wires plus ground
• Transformer T0205 converts 460 VAC to 208–120 VAC
• Power Supply PS0230 converts 120 VAC to 24 VDC

System Voltage
LOAD SOURCE VOLTAGE
Air conditioning unit
Flood lighting
Area lighting Circuit breaker panel
120 VAC, 60 Hz
Obstruction lights CBP0207
Power receptacle
Electrical collector ring anti-condensation heater
Load and radius indicator system
Control panel 751834 24 VDC
Gauge panel lighting

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 Document number 2703100-MAN-001
Revision 01
Page 4-4

4.2 Tightening Values for SAE Coarse Thread Bolts

(National Oilwell Varco Drawing 1525177)

Threaded parts must be clean, with no rust or contamination.

• Black or plated Grade 5 and Grade 8 bolts: Torque lubricated. Submerge entire bolt and nut in a
container of SAE 30W motor oil just before assembly.
• Stand-Cote bolts (Teflon coated, blue in color): Torque dry. Do not use lubricant.

!WARNING
• Swing bearing bolts require different torque values. See Parts and Vendor Data Manual,
Section 2, drawing 721557, Turntable.

Table 4–1. Tightening Values for SAE J429 Coarse Thread Bolts
GRADE 5 GRADE 8

DIAMETER–
THREADS/INCH
TIGHTENING TIGHTENING TIGHTENING TIGHTENING
TORQUE (ft·lb) (A) TORQUE (N·m) (A) TORQUE (ft·lb) (A) TORQUE (N·m) (A)
1
4 –20 6 8 9 12
5
16 –18 13 18 18 25
3
8 –16 23 31 33 44
7
16 –14 37 50 52 71
1
2 –13 57 77 80 108
9
16 –12 81 111 115 156
5
8 –11 113 153 159 215
3
4 –10 200 271 282 382
7
8–9 322 437 455 617
1–8 483 655 682 924
1- 18–7 595 807 966 1309
1
1- 4–7 840 1139 1363 1848
1-3 8–6 1102 1494 1787 2423
1
1- 2–6 1462 1983 2371 3215
(A) ft·lb = 0.7375 x torque in N·m, N·m = 1.356 x torque in ft·lb

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