NOV Crane Maintenance Manual

Operation and Maintenance Manual
AmClyde Unit Model 10000

Crane
Serial Number 2710100
RIG/PLANT
REFERENCE
REFERENCE DESCRIPTION
GSP-Upetrom Jackup Drilling Rig Saturn
AmClyde Unit Model 10000
Crane
ADDITIONAL CODE
SDRL CODE
TOTAL PGS
REMARKS
National Oilwell Varco SO16176
MAIN TAG NUMBER
DISCIPLINE
CLIENT PO NUMBER
This document contains proprietary and confidential information

which belongs to National Oilwell Varco, L.L.P.; it is loaned for
limited purposes only and remains the property of National Oilwell
Varco, L.L.P. Reproduction, in whole or in part; or use of this design
or distribution of this information to others is not permitted without
the express written consent of National Oilwell Varco, L.L.P. This
document is to be returned to National Oilwell Varco, L.L.P. upon
request and in any event upon completion of the use for which it
was loaned.
National Oilwell Varco, L.L.P.
National Oilwell Varco, L.L.P

73765 Penn Mill Road
Covington, Louisiana 70435
USA
Phone 985-892-8216
Fax 985-871-8630
CLIENT DOCUMENT NUMBER
DOCUMENT NUMBER
REV
2710100-MAN-001
2710100-MAN-001
01
www.nov.com

AmClyde Unit Model 10000 Crane



Document number
Revision
Page
2710100-MAN-001
01
ii
REVISION HISTORY
Rev
Date (dd.mm.yyyy)
CHANGE DESCRIPTION
Revision Change Description
01
First Issue
www.nov.com
Reason for Issue
Prepared
Checked
Approved
Document number
Revision
Page
2710100-MAN-001
01
iii
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
WARRANTY
1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.1 General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.2 Operating Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.3 Maintenance Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Operator Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5 Inclement Weather Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Crane Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Crane Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Control Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 General Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.1 Horn Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.2 Boom Angle Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.3 Load and Radius Indicator System . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.4 Window Wiper Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.5 Operators Cab Air Conditioner/Heater 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 Maintenance Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.10 Boom Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.6 Power Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
iv
2.6.1 Diesel Engine Throttle Controls. . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.6.2 ENGINE KILL Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6.3 EMERGENCY ENGINE KILL Control. . . . . . . . . . . . . . . . . . . . . 2-9
2.6.4 Diesel Engine Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.5 Diesel Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.6 AIR STARTER Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.6.7 Hydraulic Oil Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
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
2.8 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.8.1 Pre-Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.8.1.1 Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.8.1.2 Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.8.2 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.8.3 Pre-Operating Checks (After Engine Start-Up) . . . . . . . . . . . . . . . 2-18
2.8.3.1 AntiTwo-Block System . . . . . . . . . . . . . . . . . . . . . . 2-18
2.8.3.2 Boom Angle Limit System . . . . . . . . . . . . . . . . . . . . . 2-19
2.8.4 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.8.5 Emergency Stop Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.8.6 Emergency Load Lowering . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
v
3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Introduction and General Instructions . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.1 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.2 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.2.1 Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2.2 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2.3 Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.4 Swing Gear and Pinions. . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.5 Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.6 Boom Hoist Pawl . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.7 Hoist Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2.8 Swing Drive Gearboxes . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.1 As Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Before Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.3 After Every Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.4 Before Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.5 Every 8 Hours of Operation or Every Day . . . . . . . . . . . . . . . . . . 3-7
3.3.6 Every 40 Hours of Operation or Every Week . . . . . . . . . . . . . . . . . 3-8
3.3.7 First 100 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.8 Every 250 Hours of Operation or Every Three Months . . . . . . . . . . . . 3-8
3.3.9 Every 500 Hours of Operation or Every 6 Months . . . . . . . . . . . . . . 3-9
3.3.10 Every 12 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.4.1 Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.1 Air System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.2 Releasing Pressure from Air System . . . . . . . . . . . . . . . . . . . . 3-10
3.6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6.1 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 3-11
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
vi
3.6.1.1 Hydraulic Oil Sampling (National Oilwell Varco Drawing 604289) . 3-12
3.6.1.2 Hydraulic System Contamination Levels
(National Oilwell Varco Drawing 604289) . . . . . . . . . . . . . 3-15
3.6.2 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.3 Hydraulic Piping and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.4 O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6.4.1 O-Ring Sizes for Bosses and Tube Fittings . . . . . . . . . . . . 3-18
3.6.4.2 Four Bolt O-Ring Flange . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.5 Releasing Pressure from Hydraulic System . . . . . . . . . . . . . . . . . 3-20
3.6.6 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.6.1 Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . 3-20
3.6.6.2 Adding Hydraulic Oil to the Reservoir . . . . . . . . . . . . . . . 3-21
3.6.7 Draining and Filling Hydraulic System. . . . . . . . . . . . . . . . . . . . 3-21
3.6.7.1 Draining Hydraulic System . . . . . . . . . . . . . . . . . . . . . 3-22
3.6.7.2 Filling Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 3-23
3.6.8 Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.7 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.8 Non-Operational Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.8.1 Short-Term Storage7 Days Up to 30 Days . . . . . . . . . . . . . . . . 3-24
3.8.2 Long-Term Storage30 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. 4
Emergency Hoist Load Lowering Kit . . . . . . . . . . . . . . . . . . . 603457-L01 Rev. 9
4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Crane Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Hoist and Wire Rope Information . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Power Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.3 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
vii
4.2 Tightening Values for SAE Coarse Thread Bolts

(National Oilwell Varco Drawing 1525177). . . . . . . . . . . . . . . . . . . . . . 4-4
Load Rating Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1585851 Rev. 0
5 API RECOMMENDED PRACTICE 2D SIXTH EDITION, MAY 2007 (API RP 2D)
INSERT FOR API RP 2D SIXTH EDITION (APPENDIX I)
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
viii
FOREWORD
This technical manual gives information for the recommended operation and maintenance of the equip ment. This technical manual is written for the original design application of the equipment. If the appli cation of the equipment changes, the operation and maintenance information and procedures could
change. This technical manual is not a substitute for comprehensive operator and maintenance train ing. Read and completely understand this technical manual, equipment functions, and equipment
safety features before operating or doing maintenance to the equipment.
If additional technical manuals are needed, they are available for an added cost.
The serial number of the equipment must be given with all communication for correct identification 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 10000 crane, serial
number 2710100. The complete technical manual consists of the following documents:
Operation and Maintenance Manual, document number 2710100-MAN-001

Parts and Vendor Data Manual, document number 2710100-MAN-002
T2008-09.02
www.nov.com
WARRANTY
Products covered hereby are subject to the following warranty and no other: "The Manufacturer
warrants each new Product made by the Manufacturer to be free from defects in material and
workmanship, its obligation and liability under this Warranty being expressly limited to repairing
or, at the Manufacturer's option, replacing free of charge at its factory any part proving defective
under normal use and service within - twelve (12) - months or one thousand (1000) hours,
whichever comes first, after date the Product is first delivered to a user, provided written claim
hereunder is received by the Manufacturer within 15 days after expiration of said period. Parts
claimed to be defective and for which repair or replacement is desired shall, if requested by the
Manufacturer, be returned transportation prepaid to the Manufacturer's factory for inspection.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY
PARTICULAR PURPOSE, AND THE OBLIGATION AND LIABILITY OF THE MANUFACTURER
UNDER THIS WARRANTY SHALL NOT INCLUDE ANY TRANSPORTATION OR OTHER CHARGES
OR THE COST OF INSTALLATION OR ANY LIABILITY FOR LOSS OF PRODUCT TIME OR ANY
OTHER DIRECT, INDIRECT, OR CONSEQUENTIAL DAMAGES OR DELAY RESULTING FROM THE
DEFECT. Any operation beyond rated capacity or the improper use or application of the Product
or the substitution upon it of parts not approved by the Manufacturer or any alteration or repair by
others in such manner as, in the Manufacturer's judgement, to affect the Product materially and
adversely shall void this Warranty. No representative of the Manufacturer is authorized to change
this Warranty in any way, and no attempt, effort, or promise to repair Products of the Manufacturer
either by the Manufacturer or by any representative of Manufacturer at any time shall change or
extend this Warranty in any way.
This Warranty covers only new and unused Products
manufactured by the Manufacturer. Products manufactured by others are covered only by such
warranties as are extended to the Manufacturer by its suppliers."
2/2003
Document number
Revision
Page
1 SAFETY
1.1 Safety Warning
It is the responsibility of the owner and user of
this equipment to know the safety codes; insurance requirements; and national, federal,
provincial, state, and local laws and regulations
affecting all uses of the equipment. This technical manual does not provide regulatory information, 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 Practice 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 equipment and death or injury to personnel.
National Oilwell Varco provides technical manuals 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. Therefore, the owner and user must establish a regularly 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.
www.nov.com
2710100-MAN-001
01
1-1
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 manufacturers operating and maintenance procedures.
Read and understand the technical manuals
provided with this equipment before operating
or doing maintenance to the equipment. Assistance 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 operation 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.
Document number
Revision
Page
!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 carelessness.
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 information in this section is not meant to replace
safety codes; insurance requirements; or
national, federal, provincial, state, and local
laws and regulations.
2710100-MAN-001
01
1-2
1.3.1 General Safety Rules

1. Wear protective clothing and safety equipment 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 operators 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 technical manual.
2. This equipment must be operated only by
personnel who are trained and authorized
for its operation.
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
1-3
3. Do not operate this equipment if you are ill

or physically or mentally not fit to operate it
correctly and safely.
11. Do not operate the equipment with any

personnel near the wire rope or moving
equipment.
4. Do not exceed the rated load capacity of

the equipment (see Section 4, Load Rating
Chart, drawing 1585851). Lifting 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 structural failure or
collapse of the boom or crane and death or
injury to personnel.
12. Do not operate the equipment without the

safety guards installed.
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 functions work correctly.
7. Test the brakes for correct operation whenever 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
operators vision is restricted. Some applications 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 operation. 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.
www.nov.com
13. Do not bypass, disconnect, or ignore safety

and warning devices of the equipment.
Safely shut down the equipment and investigate 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 conditions. Shut down the equipment immediately if the display or gauges are out of the
normal operating ranges. Investigate and
correct the problem before continuing operation.
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 overload the crane.
Document number
Revision
Page
2710100-MAN-001
01
1-4
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.
20. When making a lift, the boom (hook) must

be directly over the load, not the side of the
load. Side loading can cause structural failure or collapse of the boom or crane and
injury to personnel.
31. Do not permit the wire rope to wind wrong

on the hoist drum (see figure 11).
30. The hoists must have at least five full wraps

of wire rope on the drum at all times during
operation.
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.
23. Personnel must be clear of the work area
before making the lift.
A1929
Figure 11. Wire Rope Wound Wrong on Drum
24. Do not quickly accelerate or quickly decelerate a moving load.
1.3.3 Maintenance Safety Rules

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 attachment over personnel. Do not permit personnel 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.
www.nov.com
1. Shut down the equipment before doing

maintenance. Only qualified, trained
personnel must do maintenance, adjustment, and inspection procedures, following
the procedures outlined in the technical
manual.
2. All replacement and repaired parts must
meet the manufacturers current specifications.
3. After making a repair or adjustment, always
check the functioning of the equipment
parts before putting the equipment into full
operation.
Document number
Revision
Page
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 equipment unless approved in writing by National
Oilwell Varco.
1.4 Operator Qualification

To prevent injury and property damage, the
crane operator must be qualified by training and
physical capability. The operator must understand the manufacturers 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 operators ability to see the
signal person or load is hampered by darkness,
fog, rain, etc.
www.nov.com
2710100-MAN-001
01
1-5
1.6 Safety Labels

Safety labels are located on the equipment in
prominent places to advise operating and maintenance personnel of hazards. The labels are
reproduced here to improve recognition and
thereby increase label effectiveness. Before
operating or doing maintenance to the
equipment, be sure you understand the meaning of these labels. Drawing 1587840, 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.
Document number
Revision
Page
WARNING
Read and fully understand
operation, service and parts
manuals before operating or
servicing equipment.
Failure to obey warnings and follow
instructions could result in
personal injury, death, damage to
equipment or property.
2710100-MAN-001
01
1-6
Operating and maintenance personnel must read

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 authorized for its operation.
p/n 604287
WARNING
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 operators manual for
additional swing control
information.
Operating and maintenance personnel must read

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 authorized for its operation.
p/n 603164
WARNING
Machinery must
be completely
stopped before
maintenance can
be done. Make
reference to
maintenance
manual for correct
procedures.
p/n 604283
www.nov.com
Shut down the equipment before doing maintenance. Only qualified, trained maintenance
personnel must do maintenance, adjustment, and
inspection procedures, following the procedures
outlined in the maintenance manual.
Document number
Revision
Page
2710100-MAN-001
01
1-7
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 maintenance. Only qualified, trained maintenance personnel must do maintenance, adjustment, and
inspection procedures, following the procedures
outlined in the maintenance manual.
p/n 604284
DANGER
To prevent injury,
do not walk or
stand under crane
boom, hooks, or
load.
Do not access this area while the crane is

operating. The equipment can start or stop without
warning. Not following this procedure can result in
death or serious injury.
p/n 603187
CAUTION
OPENING/CLOSING
CAB WINDOWS
p/n 603762
www.nov.com
Be careful when opening or closing windows of

operators cab. Keep area clean and free of debris
to prevent tripping hazards.
Document number
Revision
Page
2710100-MAN-001
01
1-8
WARNING
Exposed, moving equipment parts can cause serious injury or death. Keep hands, feet, and clothing
away from moving equipment parts while the equipment is operating. Do not operate the equipment
without the safety guards installed.
p/n 604285
WARNING
WATCH YOUR
HANDS
AND
FINGERS
Exposed, moving equipment parts can cause serious injury or death. Keep hands, feet, and clothing
away from moving equipment parts while the equipment is operating. Do not operate the equipment
without the safety guards installed.
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 operated according to applicable standards. Not following this procedure can result in death or serious
injury.
Electric shock
hazard. Authorized
personnel only.
p/n 604788
www.nov.com
Document number
Revision
Page
WARNING
This enclosure
has more than
one source of
power. Disconnect
all sources
before doing
maintenance.
2710100-MAN-001
01
1-9
Electrical power is supplied to this equipment from

multiple sources. All sources of electrical power
must be shut off before accessing the indicated
equipment. Only qualified, trained maintenance
personnel must do maintenance, adjustment, and
inspection of the electrical equipment. Not following
this procedure can result in death or serious injury.
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 operated according to applicable standards. Not following this procedure can result in death or serious
injury.
p/n 604796
www.nov.com
Document number
Revision
Page
This page intentionally left blank.
www.nov.com
2710100-MAN-001
01
1-10
Document number
Revision
Page
2 OPERATION
2.1 Introduction
The following paragraphs describe the operators 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, and the installation as well as
the foundation itself must be strong enough to
withstand the maximum pedestal reactions.
Refer to the crane general arrangement drawing for the foundation loading information (see
Parts and Vendor Data Manual, Section 2,
drawing 1585795, 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.
www.nov.com
2710100-MAN-001
01
2-1
Document number
Revision
Page
2710100-MAN-001
01
2-2
2.3 Crane Nomenclature
Wind Speed Sensor

Obstruction Light
(see paragraph 2.5.7)
Area Lighting
Bridle
Boom Wire Rope
A-Frame Ladder
and Cage
Main Wire Rope
Maintenance Crane
Auxiliary Wire Rope
Auxiliary Hoist
Main Hoist
A-Frame
Boom Hoist
Diesel
Engine
Boom Stop
Air
Reservoir
Operators
Cab
Boom Flood Light

Boom
Boom Angle Indicator (far side)

Turntable
Boom Foot Pin
Diesel Fuel Tank

Swing
Bearing
Hydraulic Oil
Heat Exchanger
Pedestal
A3266
Figure 21. Crane
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
2-3
Auxiliary Hoist Load Sensor

Obstruction Light
Pendant
Wind Speed Sensor
Main Hoist
Load Sensor
AntiTwo-Block
System Weight
Auxiliary Overhaul
Ball and Hook
A-Frame Ladder and

Cage
Main Hook Block

and Hook
Air Conditioning/
Heating Units (see
paragraph 2.5.5)
A-Frame
Operators Cab
Window Wipers
(see paragraph
2.5.4)
Horn
Front Elevation
Swing Drive
(boom not shown for clarity)
A3266
Figure 21. Crane (continued)
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
2-4
2.4 Control Nomenclature

The controls of the operators control station (see figure 22) direct the functioning of the crane equipment and show information important to the operation of the crane. Detailed descriptions of the operators 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 22 on the following page.
ITEM
NUMBER
DESCRIPTION
1
2
3
4
5
Diesel engine throttle pedal (see paragraph 2.6.1)

BOOM/SWING control (see paragraph 2.7.4)
Swing brake pedal (see paragraph 2.7.1)
Horn control (see paragraph 2.5.1)
MAIN/AUXILIARY hoist control (see paragraph 2.7.5)
6
7
8
9
10
Load and radius indicator system (see paragraph 2.5.3)

SWING PRESSURE gauge (see paragraph 2.6.9)
MAIN/AUX PRESSURE gauge (see paragraph 2.6.9)
BOOM PRESSURE gauge (see paragraph 2.6.9)
PILOT PRESSURE gauge (see paragraph 2.6.9)
11
12
13
14
16
AIR PRESSURE gauge (see paragraph 2.6.10)

Boom angle indicator (see paragraph 2.5.2)
SWING BRAKE OFF/ON control (see paragraph 2.7.2)
Diesel ENGINE THROTTLE control (see paragraph 2.6.1)
EMERGENCY ENGINE KILL control (see paragraph 2.6.3)
15
17
18
19
20
AIR STARTER control (see paragraph 2.6.6)

ENGINE KILL control (see paragraph 2.6.2)
SWING LOCK OFF/ON control (see paragraph 2.7.3)
ENGINE TACHOMETER/HOUR METER (see paragraph 2.6.4)
COOLANT TEMPERATURE gauge (see paragraph 2.6.4)
21
22
23
24
25
OIL PRESSURE gauge (see paragraph 2.6.4)

UPPER WIPER control (see paragraph 2.5.4)
WINDOW WASHER control (see paragraph 2.5.4)
FRONT WIPER control (see paragraph 2.5.4)
PANEL LIGHTS switch (see paragraph 2.5.8)
26 Seat
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
2-5
7
SWING PRESSURE
MAIN/AUX PRESSURE
BOOM PRESSURE
PILOT PRESSURE
9
10
11
12
RAISE
O
F
F
PANEL LIGHTS
SWING LEFT
BOOM RAISE
FRONT WIPER
25 24
23
17
18
19
20
OIL PRESSURE
UPPER WIPER
26
16
ENGINE TACHOMETER/ COOLANT TEMPERATURE

HOUR METER
SWING RIGHT
BOOM LOWER
15
ENGINE KILL
ON
EMERGENCY ENGINE KILL
RAISE
SWING LOCK
LOWER
MAIN
AIR STARTER
ON
O
F
F
ENGINE THROTTLE
SWING BRAKE
LOWER
AUX
14
21
22
A3267
Figure 22. Control Station
www.nov.com
10
5
30
25
20
15
35
40
60
55
50
13
45
BOOM ANGLE INDICATOR

DEGREES FROM HORIZONTAL
80
75
70
65
AIR PRESSURE
Document number
Revision
Page
2.5 General Control Devices

2.5.1 Horn Control
Push the horn control (figure 22, item 4) on
the floor in front of the operators seat to sound
the horn located on the operators cab (see
figure 21). The control is a manually engaged
spring-released, foot-operated air valve.
2.5.2 Boom Angle Indicator

The boom angle indicator (figure 22, item 12)
is located on the boom (see figure 21) and can
be viewed from the operators cab. The dial
shows the angle of the boom in degrees from
horizontal.
At loads of 110 percent of rated capacity or

more, hoist movement stops and main/auxiliary
hoist raising and boom lowering functions are
disabled. To restore normal operation, operate
the corresponding main/auxiliary hoist in the
lowering direction, or raise the boom, until the
load on the hoist becomes less than 110
percent.
Leave the load and radius indicator system
continuously powered during crane operation.
See the manufacturers information for the
operating instructions (see Parts and Vendor
Data Manual, Section 11, Aanderaa Data
Instruments).
!WARNING
2.5.3 Load and Radius Indicator System

The load and radius indicator system display
(figure 22, item 6) is located in the operators
cab and shows the radius, load, rated load
capacity (safe working load), and percent of
rated load capacity.
!WARNING
Except at 110 percent of hoist

capacity, 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.
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.
www.nov.com
2710100-MAN-001
01
2-6
Do not exceed the rated load capacity

of the crane (see Section 4, Load
Rating Chart, drawing 1585851). 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.
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 22, item 24) and
UPPER WIPER control (item 22) control the
corresponding window wiper of the operators
cab. Each WIPER control is a two-position
switch.
In the PARK position, the wiper returns to its
parking position and stops.
Document number
Revision
Page
2710100-MAN-001
01
2-7
In the RUN position, the wiper operates.
2.5.8 PANEL LIGHTS Switch
Push the knob of the washer control (item 23)

to spray washer fluid on the windows. The
reservoir for the washer fluid is located on the
exterior rear corner of the operators cab.
The PANEL LIGHTS switch (figure 22,

item 25) controls the illumination of the gauges
on the gauge control panel.
With the switch in the on position, the gauges
are illuminated.
2.5.5 Operators Cab Air Conditioner/

Heater Controls
The controls for the operators cab air conditioning/heating units are located on the control
panel of the cab ceiling units (see figure 21).
Data Manual, Section 11, RVP).
2.5.6 Area Lighting

Two 400 W flood lights (see figure 21) are
located on the boom. The lights are controlled
by a switch located inside the operators cab.
One 400 W flood light (see figure 21) is
located on the A-frame, illuminating the engine
and hoist areas. The light is controlled by a
switch inside the operators cab.
One fluorescent light (two 40 W lamps) is
located inside the operators cab. The light is
controlled by a switch located inside the operators cab.
2.5.7 Obstruction Lights

Red aircraft obstruction lights (see figure 21)
are located at the tip of the boom, and on the
top of the A-frame. The lights are controlled by
circuit breaker CB0242 located in circuit
breaker panel CBP0208, inside the operators
cab.
www.nov.com
With the switch in the off position, the gauges

are not illuminated.
2.5.9 Maintenance Crane

The maintenance jib (see figure 21) is located
on the back of the crane A-frame. The maintenance jib has a manually operated chain hoist.
The boom of the maintenance jib can be put in
a wind locked position to prevent the boom
from rotating.
Data Manual, Section 11, Budgit).
2.5.10 Boom Stops

The crane has cushioned boom stops (see
figure 21) 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 suspension system will contract, causing the boom
angle to increase a small amount and the load
radius to decrease.
Document number
Revision
Page
When lifting loads at high boom angles, the

operator must take care when setting down the
load. The crane operator must also lower the
boom 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.
CAUTION
When setting loads down at high boom

angles, the boom must be lowered a
small amount so the boom is not
pulled back into the boom stops
causing damage to the inner section of
the boom.
CAUTION
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
capacity chart for the load being lifted.
2710100-MAN-001
01
2-8
2.6 Power Control Devices

2.6.1 Diesel Engine Throttle Controls
The diesel engine throttle foot pedal
(figure 22, item 1) is the left pedal located in
front of the operators seat. The hand-operated
diesel ENGINE THROTTLE control (item 14) is
located on the control console.
Engine speed can be increased by either
depressing the foot throttle or pulling up the
hand throttle. To decrease engine speed,
release the foot throttle and depress the button
on top of the hand throttle knob while pushing
the knob down.
Engine speed can be locked at any speed by
depressing the foot throttle 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 (figure 22, item 17)
(with black handle) 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.
www.nov.com
Document number
Revision
Page
2.6.3 EMERGENCY ENGINE KILL

Control
2710100-MAN-001
01
2-9
CAUTION
The EMERGENCY ENGINE KILL control

(figure 22, item 16) (with red handle) is used
for emergency stopping of the diesel engine.
Only use the EMERGENCY ENGINE

KILL control for an emergency. Use of
the EMERGENCY ENGINE KILL control
can cause damage to 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.
2.6.4 Diesel Engine Gauges

The gauges listed in table 21 are located on
the control console and show the operating
condition of the diesel engine. See the diesel
engine manufacturers information for the
engine operating instructions (see Parts and
Vendor Data Manual, Section 11, Caterpillar).
CAUTION
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 manufacturers information for the procedure to reset the
air inlet shutoff (see Parts and Vendor Data
Manual, Section 11, Caterpillar).
Do not operate the equipment when a

gauge is reading outside of its normal
operating range (see table 21).
2.6.5 Diesel Fuel Level Gauge

The gauge on the top of the diesel fuel tank
(see figure 21) shows the level of diesel fuel
remaining in the diesel fuel tank.
Table 21. Diesel Engine Gauges

NORMAL OPERATING
RANGE
FIGURE AND ITEM

NUMBERS
See engine manufacturers

manual
figure 22, item 19
COOLANT
Coolant water temperature
TEMPERATURE

manual
figure 22, item 20
OIL PRESSURE

manual
figure 22, item 21
LABEL
FUNCTION MONITORED
ENGINE
TACHOMETER/
HOUR METER
Engine speed, total run time
www.nov.com
Lubrication oil pressure
Document number
Revision
Page
2.6.6 AIR STARTER Control
CAUTION
The AIR STARTER control (figure 22, item 15)

controls the air starter motor for the diesel
engine. The control is a manually engaged,
spring-released air valve.
Push and hold the AIR STARTER control to

start the diesel engine.
Do not operate the equipment with a

hydraulic oil temperature that is too
high (more than 180F [82C]).
Operating with the hydraulic oil
temperature too high can reduce the
life of hydraulic equipment parts.
2.6.9 Hydraulic Pressure Gauges
2.6.7 Hydraulic Oil Level Gauge

The sight gauge on the side of the hydraulic oil
reservoir (see figure 21) shows the level of the
hydraulic oil in the reservoir (see Checking
Hydraulic Oil Level, paragraph 3.6.6.1).
The gauges listed in table 22 show the operating pressures of the corresponding hydraulic
pumping circuits. The pressures are shown in
pounds per square inch (psi).
CAUTION
CAUTION
2710100-MAN-001
01
2-10

level of hydraulic oil that is too low or
too high.
Do not operate the equipment when a

gauge is reading outside of its normal
operating range as listed in table 22.
2.6.8 Hydraulic Oil Temperature Gauge
2.6.10 AIR PRESSURE Gauge
The temperature gauge on the side of the

hydraulic oil reservoir (see figure 21) shows
the temperature of the hydraulic oil in the reservoir. Do not operate the equipment with a
hydraulic oil temperature that is too high (more
than 180F [82C]).
The AIR PRESSURE gauge (figure 22,

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).
Table 22. Hydraulic Pressure Gauges

FUNCTION
MONITORED
LABEL
SWING
PRESSURE
BOOM
PRESSURE
Swing drive hydraulic pumping circuit

Main/auxiliary hoist
hydraulic pumping
circuit
Boom hoist hydraulic
pumping circuit
PILOT
PRESSURE
Hydraulic system
pilot pressure
MAIN/AUX
PRESSURE
www.nov.com
NORMAL OPERATING RANGE

100 to 2700 psi (6.8206.8 bar)
FIGURE AND
ITEM NUMBERS
figure 22, item 7
Raising: up to 2900 psi (200.6 bar)

Lowering: 10002300 psi (68.9158.5 bar)
figure 22, item 8
Raising: up to 2950 psi (203.4 bar)

Lowering: 10002300 psi (68.9158.5 bar)
figure 22, item 9
475 psi (32.7 bar)
figure 22, item 10
Document number
Revision
Page
CAUTION
Do not operate the equipment when

the air pressure gauge is reading
outside of its normal operating range
of 120125 psi (8.38.6 bar).
2.7 Crane Function Control Devices

2.7.1 Swing Brake Pedal
The swing brake foot pedal (figure 22, item 3)
located in front of the operators seat controls
the brake of the swing drive as a holding brake
(variable holding power).
NOTICE
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.
2710100-MAN-001
01
2-11
2.7.2 SWING BRAKE OFF/ON Control

The SWING BRAKE OFF/ON control
(figure 22, item 13) 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
only be released when the diesel engine is
operating.
CAUTION
Do not use the SWING BRAKE OFF/ON

control to stop crane rotation. Only put
the SWING BRAKE control in the ON
position after crane rotation has been
completely stopped.
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 22, item 18) to
the ON position to lower the swing lock pin.
Move the handle to the OFF position to raise
the swing lock pin.
www.nov.com
Document number
Revision
Page
CAUTION
2710100-MAN-001
01
2-12
Lower
Boom
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.
Swing
Left
Swing
Right
A1575
Raise
Boom
Figure 23. Boom/Swing Control
2.7.4 BOOM/SWING Control

The BOOM/SWING control (figure 22, item 2)
on the left armrest of the operators chair
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 23). The BOOM/
SWING control is a manually operated, proportional hydraulic valve for directional control. The
lever of the BOOM/SWING control, when
released, returns to its neutral (center) position.
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 back toward

the operator to raise the boom. Push the lever
forward away from the operator to lower the
boom. The speed of the boom increases the
www.nov.com
farther 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 overrunning. 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 assembly 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
Document number
Revision
Page
remove the load from the pawl, permitting the

pawl to release. Then the boom can be
lowered.
NOTICE
!WARNING
The boom hoist must have at least five

full wraps of wire rope on the drum at
all times.
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 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 to the

operators left to rotate the crane left (counterclockwise). Move the lever to the operators
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.
www.nov.com
The speed of rotation can also be

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.
CAUTION
NOTICE
2710100-MAN-001
01
2-13
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
22, item 5) on the right armrest of the operators chair 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

part of 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) positions. The left lever controls the
auxiliary hoist drum, and the right lever controls
the main hoist drum.
Document number
Revision
Page
!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.
!WARNING
CAUTION
Move the MAIN and AUXILIARY hoist
control levers slowly, to prevent
abrupt changes in the speed of the
load.
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 the farther the lever is
moved away from its neutral position. To
decrease the speed, move the lever toward its
neutral position.
NOTICE
The speed of the load can also be

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 counterbalance valve stops the load.
www.nov.com
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 antitwo-block
system.
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 corresponding control until the motion begins.
!WARNING
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 main and auxiliary hoists must

have at least five full wraps of wire
rope on the drums at all times.
NOTICE
2710100-MAN-001
01
2-14
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.
Document number
Revision
Page
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.
2710100-MAN-001
01
2-15
API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) (current
edition) is a useful guide for owners and operators in developing operating and maintenance
practices and procedures. All guidelines in this
recommended practice should be followed.
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.
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 22,
item 13) 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 2.8.6).
www.nov.com
2.8.1.1 Daily Inspection

Do the following at the beginning of each workday, before starting the crane.
1. Check the preventive maintenance records
to make sure the scheduled lubrication (see
paragraph 3.2.2) and inspections and maintenance (see paragraph 3.3) have been
done at the correct intervals.
2. Check the crane and pedestal foundation
for possible damage. Check for damaged,
distorted, worn, cracked, corroded, loose,
or missing parts, fasteners, and welds.
!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.
Document number
Revision
Page
!WARNING
If any device or structural member is

damaged or in need of repair, such
repairs must be made before operating
the crane.
!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, abrasion, or advanced weathering that could
cause a hose to burst under operating pressure.
2710100-MAN-001
01
2-16
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
fasteners.
13. Make sure that all guards are in place and
secured.
14. Check the operation of the obstruction
lights.
15. Check the crane load and radius indicator
display for correct operation.
5. Check the gearboxes for leaks and

damage.
2.8.1.2 Before Start-up
6. Check the boom hoist ratchet and pawl for

wear and damage.
Do the following before each start-up of the

crane.
7. Check control mechanisms for correct operation.

8. Check the diesel engine start and stop
controls.
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, drawing
1585851).
9. Check all the wire ropes, including

pendants, for deterioration or damage.
2. Check that all tools and other items are

away from moving equipment parts.
!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.
www.nov.com
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 22, item 13) must
be in the ON position.
Document number
Revision
Page
5. Check that the handle of the ENGINE KILL

control (item 17) (with black handle) is
pushed all the way down.
6. Check that the handle of the EMERGENCY
ENGINE KILL control (item 26) (with red
handle) 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
2710100-MAN-001
01
2-17
2.8.2 Startup Procedure

1. Complete the pre-start procedure (paragraph 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 21).
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 paragraph 2.8.2).
If the hydraulic oil in the reservoir is 0F

(17C) or warmer (ISO Grade 46
hydraulic oil minimum start-up temperature, see Hydraulic Oil, paragraph 3.6.2), continue with step 5.
If the hydraulic oil is colder, warm the
hydraulic oil with the reservoir heater
until the temperature is 0F (17C) or
warmer. Then continue with step 5.
NOTICE
The diesel engine has been supplied

with an engine block water heater to
improve the ability to start the engine
in cold weather. See the diesel engine
manufacturers information for
additional information on the diesel
engine starting and operating
procedures (see Parts and Vendor
Data Manual, Section 11, Caterpillar).
5. Push the AIR STARTER control (figure 22,

item 14) for 13 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 manufacturers information for additional information on the
diesel engine starting and operating proce-
www.nov.com
Document number
Revision
Page
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 hydraulic oil temperature gauge
located on the side of the hydraulic oil
reservoir.
If the hydraulic oil in the reservoir is

55F (13C) 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 temperature is 55F (13C) or warmer. Then
continue with step 8.
8. Adjust the diesel engine throttle to the

desired engine speed (see paragraph 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 2100 rpm.
9. Check the cab-mounted instrument gauges

for proper engine operation.
10. The crane is now ready for the pre-operating checks (see paragraph 2.8.3).
www.nov.com
2710100-MAN-001
01
2-18
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 AntiTwo-Block System

Antitwo-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 antitwo-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
antitwo-block weight (see Parts and Vendor
Data Manual, Section 4, drawing 750577-L01
[Main] and 750577-L02 [Auxiliary],
AntiTwo-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 antitwo-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
Document number
Revision
Page
main or auxiliary hoist raising. To return to

normal operation, lower the hook block or overhaul ball (or raise the boom), until both weights
are hanging freely.
NOTICE
To check the antitwo-block system:
CAUTION
!WARNING
Use extreme care when engaging the

antitwo-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

antitwo-block weight. Use caution to make
sure the hoist raising function stops after
the weight is raised (approximately 34 in
[810 cm] after contacting the weight). Stop
the hoist before the hook block contacts the
boom sheaves if it does not stop automatically.
If the main hoist does not stop or the

boom can be lowered after the
antitwo-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).
www.nov.com
2710100-MAN-001
01
2-19
The exposed surfaces of the valve

spools for the antitwo-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 antitwo-block system. If this
happens, the signalperson or a
deckhand must maintain a downward
load on the antitwo-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 horizontal and 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
Document number
Revision
Page
valve is normally extended (hydraulic circuit

closed) (see Parts and Vendor Data Manual,
Section 4, drawing 750663-L02, Boom Limit
Mechanics). 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:
2710100-MAN-001
01
2-20
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 platform or deck. Stop the boom before this
occurs if it does not stop automatically.
4. After the boom stops, raise the boom away
from limit cam engagement.
5. The crane is ready for normal operation.
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.
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.
2.8.4 Shutdown Procedure

1. Remove the load from the crane.
2. Rotate the crane to its parking position.
!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.
www.nov.com
3. Engage the swing lock (see paragraph 2.7.3).

4. Engage the static brake of the swing drive.
Turn the lever of the SWING BRAKE
OFF/ON control (figure 22, item 13) to the
ON position.
Document number
Revision
Page
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 45 minutes
to cool down.
8. Pull the handle of the ENGINE KILL control
(item 17) (with black handle) 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 (figure 22, item 16)
(with red handle) all the way up to immediately stop the diesel engine.
!WARNING

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

KILL control for an emergency. Use of
the EMERGENCY ENGINE KILL control
can cause damage to the diesel
engine.
www.nov.com
2710100-MAN-001
01
2-21
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
manufacturers information for the procedure to
reset the air intake shutoff (see Parts and
Vendor Data Manual, Section 11, Caterpillar).
2.8.6 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 operators cab
and in this manual.
Table 23 lists the emergency load lowering
procedures and kit drawing. See Section 3 of
this manual for the drawings.
Table 23. Emergency Load Lowering
Procedures and Kit Drawing
HOIST
Main
Auxiliary
EMERGENCY
LOWERING
PROCEDURE
DRAWING
EMERGENCY
LOWERING
KIT
DRAWING
603511
603457-L01
Document number
Revision
Page
This page intentionally left blank.
www.nov.com
2710100-MAN-001
01
2-22
Document number
Revision
Page
2710100-MAN-001
01
3-1
3 MAINTENANCE
3.2 Lubrication
3.1 Introduction and General

Instructions
3.2.1 Lubrication Procedures
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 drawings.
API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) (current
edition) is a useful guide for owners and operators 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 maintenance of the equipment.
Permit only qualified service personnel who
have received training in the proper maintenance, adjustment, and inspection of the equipment 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.
www.nov.com
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 lubricants because of possible incompatibility.
3.2.2 Lubrication Schedule

See the Lubrication Schedule (table 31) and
the Lubricant Legend (table 32) for the lubrication schedule, lubrication points, types of lubricant, and fluid capacities.
Document number
Revision
Page
2710100-MAN-001
01
3-2
Table 31. Lubrication Schedule

INTERVAL OF
LUBRICATION
As required
DESCRIPTION
Wire ropes
See
manufacturers Diesel engine
information
Boom foot
bushings
Sheaves
Hook block
and overhaul
Every 40 hours ball
of operation or
weekly, which- Swing bearing
ever occurs
first
Swing drives
Safety valves
TYPE OF
LUBRICANT
WRL
Boom wire rope

Main wire rope
Auxiliary wire rope
Pendants
ELO
Diesel engine lubrication

oil
AF
Every 40 hours
of operation or Hoists
every three
months, whichever occurs
first
Swing drives
www.nov.com
Diesel engine coolant

(includes radiator)
CAPACITY
REFERENCE
PARAGRAPH
As required
3.2.2.1
26 qt
(25 L)
11.0 gal
(41.6 L)
3.2.2.2
HPG
Boom foot
As required
3.2.2.3
HPG
Boom point sheaves and

pendant anchors
A-Frame sheaves
Bridle sheaves
As required
3.2.2.3
HPG
Sheaves and hooks
As required
3.2.2.3
HPG
Swing bearing
As required
3.2.2.3
OGL
Gear teeth
As required
3.2.2.4
OGL
Pinion gears
As required
3.2.2.4
Two boom limit safety

valves
Two antitwo-block
safety valves
As required
3.2.2.5
Ratchet and pawl
As required
Pawl cylinder rod and

pins
As required
Boom hoist gearbox

check level of lubricant
As required
3.2.2.7
Main hoist gearbox

As required
3.2.2.7
Auxiliary hoist gearbox

As required
3.2.2.7
Gearboxcheck level of
lubricant
3.2.2.8
HO
HPG
Boom hoist
LUBRICATION LOCATION
HO
HHO
GO
As required
3.2.2.6
Document number
Revision
Page
2710100-MAN-001
01
3-3
Table 31. Lubrication Schedule (continued)

INTERVAL OF
LUBRICATION
DESCRIPTION
Every 500
hours of opera- Hoists
tion or every
six months,
whichever
occurs first
Swing drives
Every 12
months of
operation
Swing brakes
TYPE OF
LUBRICANT
HHO
GO
CAPACITY
REFERENCE
PARAGRAPH
Boom hoist gearbox

drain and refill
70 pt
(33.1 L)
3.2.2.7
Main hoist gearbox

drain and refill
90.0 pt
(42.6 L)
3.2.2.7
Auxiliary hoist gearbox

drain and refill
17.0 pt
(8.0 L)
3.2.2.7
Gearboxdrain and
refill
12.75 pt
(6.0 L)
each
3.2.2.8
As required
3.2.2.9
LUBRICATION LOCATION
See Parts
and Vendor
Data
Swing brakecheck
level and condition
Manual,
Section 11,
MICO
Table 32. Lubricant Legend
SYMBOL
NATIONAL
OILWELL
VARCO
PART
NUMBER
AF
903062
Engine anti-freeze
ELO
939084
Engine lubrication oilSAE 15W-40 (See Parts and Vendor Data Manual,
Section 11, Caterpillar)
GO
939049
Gear oilSAE 90
HHO
939074
Hydraulic hoist gear oilindustrial EP gear oil, specifically Exxon Spartan

EP150 as recommended by Braden Hoists
HO
939064
Hydraulic oil ISO-46such as Shell Tellus 46
HPG
939048
High pressure greasemulti-purpose extreme pressure grease
OGL
939063
Open gear lubricantblack soda lead grease
WRL
939075
Wire rope lubricantblack viscous lubricant such as Texaco Crater A
DESCRIPTION
3.2.2.1 Wire Ropes

Wire rope should be lubricated at regular intervals to guard against wire corrosion. When
www.nov.com
corrosion is noticed, the wire rope should be

closely inspected for damage.
See Section 5, API Recommended Practice 2D,
Document number
Revision
Page
Maintenance of Offshore Cranes (API RP2D)

for the wire rope lubrication procedures.
3.2.2.2 Diesel Engine

See the diesel engine manufacturers information (see Parts and Vendor Data Manual,
Section 11, Caterpillar) for the lubrication
instructions, intervals, and lubricant specifications.
3.2.2.3 Grease Fittings
NOTICE
measured amount of lubricant. Periodic

over-lubrication is needed to remove all old
lubricant from the bearing. When to over-lubricate 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.
3.2.2.4 Swing Gear and Pinions
The warranties for the swing bearing

and crane will be void if the swing
bearing is not lubricated as specified.
NOTICE
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.
2710100-MAN-001
01
3-4
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
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.
Clean the exposed surfaces of the valve spools

for the boom limit and antitwo-block safety
valves and apply a light oil to prevent corrosion.
When putting new or repaired bearings into

service, add lubricant, rotate the bearing, and
add more lubricant until a small amount of lubricant begins to show from the bearing. This will
make sure that the bearing is completely lubricated.
3.2.2.6 Boom Hoist Pawl
At designated intervals, relubricate the bearings. When relubricating a bearing, add only a
www.nov.com
Check the entire drum ratchet surface and pawl

of the boom hoist for a full coverage of lubricant. 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.
Document number
Revision
Page
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 necessary. See the hoist manufacturers information
for the lubrication instructions (see Parts and
Vendor Data Manual, Section 11, Braden).
3.3 Inspection and Maintenance

Schedule
!WARNING
Drain and refill the gearboxes with new lubricant after the first 100 hours of operation, then
every 500 hours of operation or every six
months, whichever occurs first.
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.
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 lubricant as necessary. See the gearbox manufacturers information for the lubrication
instructions (see Parts and Vendor Data
Manual, Section 11, Eskridge).
Drain and refill the gearboxes with new lubricant after the first 100 hours of operation, then
every 500 hours of operation or every six
months, whichever occurs first.
2710100-MAN-001
01
3-5
NOTICE
Other inspections can be required by

local regulations and must also be
made.
3.3.1 As Necessary
Diesel Engine
See the manufacturers information for

maintenance instructions, intervals, and
procedures (see Parts and Vendor Data
Manual, Section 11, Caterpillar).
3.2.2.9 Swing Brakes
Paint
Check the level and condition of cooling oil in

the swing brakes every 12 months of operation.
Add or change oil as necessary. See the swing
brake manufacturer's information for lubrication
instructions (see Parts and Vendor Data
Manual, Section 11, MICO).
Paint any damaged paint surfaces to

prevent corrosion.
3.3.2 Before Every Start-Up

Crane and Pedestal Foundation
www.nov.com
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.
Document number
Revision
Page
2710100-MAN-001
01
3-6
Hydraulic System
3.3.3 After Every Start-Up
Hydraulic Oil Filters
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.
With the hydraulic oil at normal operating

temperature and the engine operating at
2100 rpm, check the filter indicators (see
Hydraulic Oil Filters, paragraph 3.6.8). If the
indicator is activated, replace the filter
element.
Fuel System
Crane
Check the diesel fuel tank for the correct

fuel level.
Check for leaks.
Air System
Check for leaks.

Check control mechanisms for correct

operation.
Check the diesel engine start, stop, and
emergency stop controls.
Check the crane load indicator for correct
operation (see Parts and Vendor Data
Manual, Section 11, Aanderaa Data Instruments).
Electrical System
Check the general condition of the wiring

for deterioration, cracked or frayed insulation, and loose connections.
Check for damaged, corroded, loose, or
missing parts and fasteners.
3.3.4 Before Each Use

Wire Ropes
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 operator at the control station.
Check the control labels. Replace all
damaged or missing labels.
www.nov.com
Inspections must be made by competent,

experienced personnel who know the operation 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 Recommended Practice 2D, Recommended Practice for Operation and Maintenance of
Offshore Cranes (API RP2D) for the wire
rope inspection procedure.
To establish the correct time for replacement 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.
Document number
Revision
Page
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
fasteners.
Crane
Check the boom limit and antitwo-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 operator at the control station.
Electrical System
Check the operation of the crane obstruction warning lights.
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, whichever 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
2100 rpm, check the filter indicators (see
paragraph 3.6.8). If the indicator is activated, 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
www.nov.com
2710100-MAN-001
01
3-7
Inspections must be made by competent,

experienced personnel who know the operation 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 Recommended Practice 2D, Recommended Practice for Operation and Maintenance of
Offshore Cranes (API RP2D) for the wire
rope inspection procedure.
To establish the correct time for replacement 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.
Document number
Revision
Page

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 paragraph 3.2.2.8).
2710100-MAN-001
01
3-8
Swing Drives
Drain and refill the lubricant (see paragraph 3.2.2.8).

Every Three Months
Check the following items every 250 hours of
operation or every three months, whichever
occurs first.
Hoists
Check the level of lubricant (see paragraph 3.2.2.7).

Check that the wire rope wedges are
seated correctly in the drums.
Handrails, Ladders, Walkways, and Safety

Guards
Check for damaged, worn, cracked,

corroded, loose, or missing parts, fasteners, and welds.
Sheaves
Safety Labels
Check the sheaves for groove wear,

cracks, wire rope path alignment, and bearing condition.
Check the safety labels (see paragraph 1.6

for the label locations). Replace all
damaged or missing labels.
Clean labels for good legibility.
Crane Controls
Hoists
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, fasteners, and welds.
3.3.7 First 100 Hours of Operation
Do a brake test procedure for the main,

auxiliary, and boom hoists per API Recommended Practice 2D, Recommended Practice 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).
Do maintenance to the following items after the

first 100 hours of operation:
Hydraulic Power Plant
Hoists
www.nov.com
Check for proper performance and compliance with safety requirements.
Document number
Revision
Page

Every 6 Months
Hoists
!WARNING
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 paragraph 3.6.1.1).
Hydraulic Oil Return Filters
Replace the filter elements (see paragraph

3.6.8).
Hoists
Swing Drives
An annual inspection is required for safe operation 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.
www.nov.com
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 components per API Recommended Practice 2D,
Maintenance of Offshore Cranes (API
RP2D) and Braden hoist recommended
procedures. The hoist must be reassembled and tested to Braden recommendations and standards (see Section 5, API
RP2D and Parts and Vendor Data Manual,
Section 11, Braden).
Swing Bearing
3.3.10 Every 12 Months
2710100-MAN-001
01
3-9
Check per API Recommended Practice 2D,

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).
Document number
Revision
Page
2710100-MAN-001
01
3-10
3.4 Electrical System
3.5.1 Air System Maintenance
Electric power for the crane is supplied from the

vessel at 220 VAC. The 220 VAC is also
converted by a power supply to 24 VDC for use
by control system equipment.
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 equipment.
The electrical schematic shows the relationship

of the electrical system equipment. See Parts
and Vendor Data Manual, Section 10, Electrical
Schematic, drawing 1585636.
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 industry-standard lockout procedures. Electrical
equipment must be maintained and operated
according to applicable standards.
Clean the work area before installing or removing 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 120125 psi (8.38.6 bar) to a
reservoir located on the crane. The air system
controls and operates the diesel engine air
starter and the operators cab window wipers
and horn.
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 manufacturers 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).
The air piping drawings show the relationship of

the air system equipment. See Volume 2, Parts
and Vendor Data Manual, Section 9.
www.nov.com
2. Release pressure from the air system until

the AIR PRESSURE gauge (see paragraph
2.6.10) in the operators cab reads 0 psi.
Document number
Revision
Page
!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 the 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
605090.
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 hydraulic 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 pressure, refer to the hydraulic schematic and make
the first pressure check with a test gauge of a
large enough scale to prevent gauge failure.
See Parts and Vendor Manual, Section 8,
www.nov.com
2710100-MAN-001
01
3-11
Hydraulic Schematic, drawing 605090. 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 preventive 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 hydraulic system overheating:
high hydraulic oil reservoir temperaturemore than 180F (82C)

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 abrasive 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, paragraph 3.6.1.2.
Document number
Revision
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.
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 5090 percent full.
I.
Remove the sample bottle with the

sampling valve still in the open position. Put the cover on the sample bottle
and close the sampling valve.
J.
Properly dispose of the hydraulic oil

collected in the waste container.
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 operating temperature and maximum
speed, if possible.
E. Clean the nozzle of the hydraulic oil
sampling valve with a clean, lint-free
cloth to remove any visual signs of
contamination.
F.
Put the waste container under the

sampling valve.
www.nov.com
2710100-MAN-001
01
3-12
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 information 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
2. Send the hydraulic oil sample and the

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 31. The actual cleanliness
level must be plotted on a graph and a
curve made by connecting the points.
Document number
Revision
Page
3. If the analysis results exceed the maximum

operating contamination levels permitted
(see paragraph 3.6.1.2), correct the problem 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 nonconformity can be the result of one of the following:
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 equipment (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 paragraph 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.
www.nov.com
2710100-MAN-001
01
3-13
Document number
Revision
Page
10
2710100-MAN-001
01
3-14
10
30
ISO
SOLID
CONTAMINANT
CODE
29
2.5
28
10
1.3
27
6.4
26
3.2
5
4
3
2
CODE: 18/16
5
4
3
2
10
24
10
8.0
23
5
4
3
4.0
22
2.0
21
10
1.0
10
20
5.0
19
2.5
18
10
1.3
17
6.4
16
3.2
15
1.6
10
14
8.0
13
4.0
12
5
4
3
RANGE NUMBER - quote at 5 um & 8 um levels only
NUMBER OF PARTICLES PER MILLILITRE GREATER THAN INDICATED SIZE
1.6
5
2
10
5
4
3
2
4
10
5
4
3
2
2.0
11
1.0
10
10
10
5.0
5
4
3
9
2.5
1.3
10
6.4
6
5
15
25
27
CURVED
5 / 15 / 25 /100
DATA
(USE 5 /15 POINTS)
23
CODE: 27/23
15
25
100
100
1.6
-1
16
5
4
3
3.2
10
18
8
1
STRAIGHT LINE DATA
10
Reference
ANSI/B93.30-1980
25
CODING METHOD
NUMBER OF PARTICLES PER 100 MILLILITRES GREATER THAN INDICATED SIZE
5.0
10
8.0
5
4
3
4.0
2
2.0
1
1
10
-2
10
15
20
25
30
40
50
60
70 80 90 100
Figure 31. Particle Count Analysis Form
www.nov.com
A1534
Document number
Revision
Page
2710100-MAN-001
01
3-15
3.6.1.2 Hydraulic System Contamination Levels

(National Oilwell Varco Drawing 604289)
Table 33 shows the maximum permitted hydraulic system contamination levels. The water content of
the hydraulic system must be less than 0.03% by volume.
Table 33. Hydraulic System Contamination Levels
NUMBER OF PARTICLES/mL LARGER THAN INDICATED SIZE
PARTICLE SIZE
MAXIMUM COMMISSIONING LEVEL(A)
MAXIMUM OPERATING LEVEL(B)
IN MICRONS
(C)
ISO 18/15
ISO 17/14(C)
5
2500
1300
15
320
160
25
80
40
50
10
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 equipment can be operated to circulate the system hydraulic oil until the maximum operating contamination 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 34 compares similar obsolete SAE and NAS Cleanliness Standards to the present ISO
Standards:
Table 34. Hydraulic System Cleanliness Standards
LEVEL
ISO CODE
SAE CLASS
NAS CLASS
Maximum commissioning level
18/15
Maximum operating level
17/14
www.nov.com
Document number
Revision
Page
must be filtered. Send the hydraulic oil through

a 3-micron filter with no bypass while adding it
to the hydraulic oil reservoir.
3.6.2 Hydraulic Oil
CAUTION
2710100-MAN-001
01
3-16
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 35. Original 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.
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.
Analyze the hydraulic oil (see paragraph 3.6.1.1) for cleanliness, viscosity, proper
additives, and water content every 500 hours of
occurs first.
Filter all hydraulic oil to comply with the maximum contamination levels permitted (see paragraph 3.6.1.2) before adding it to the hydraulic
reservoir. Even new oil from a new container
Table 35. Hydraulic Oil Grade

MINIMUM HYDRAULIC OIL MINIMUM HYDRAULIC OIL MAXIMUM HYDRAULIC OIL
TEMPERATURE BEFORE TEMPERATURE FOR FULL
OPERATING
(B)
(C)
STARTUP
POWER
OPERATION
TEMPERATURE
HYDRAULIC
(7500 SUS MAXIMUM
(750 SUS MAXIMUM
(60 SUS MINIMUM
OIL GRADE(A)
VISCOSITY)
VISCOSITY)
VISCOSITY)
F
ISO15
30
34
15
125
51
ISO32
10
23
45
ISO46
ISO68
ISO100
0
20
30
17
6
1
55
75
90
175
13
(D)
24
(D)
33
(D)
79
180
(D)
82
180
(D)
82
180
(D)
82
(A) The viscosity/temperature curve varies with different hydraulic oil manufacturers. Consult the hydraulic oil manufacturer. Table 35 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 viscosity, 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.
www.nov.com
Document number
Revision
Page
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, abrasion, 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 tapeit will contaminate the
hydraulic system.
NOTICE
Use sealants according to the

manufacturers recommended
procedures.
CAUTION
Flush all new hydraulic piping, hoses,

and other equipment parts to meet the
requirements of Hydraulic System
Contamination Levels, paragraph
3.6.1.2.
www.nov.com
2710100-MAN-001
01
3-17
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 paragraph 3.6.4.1), O-ring face seal, or the SAE
four bolt O-ring flange type (see paragraph 3.6.4.2).
Document number
Revision
Page
2710100-MAN-001
01
3-18
3.6.4.1 O-Ring Sizes for Bosses and Tube Fittings
NOTICE
O-rings listed in table 36 must be 90 durometer Buna N material.

Table 36. 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
ARP 568
UNIFORM
DASH
NUMBER
AN-6290
TUBE
SIZE
(in)
904
905
906
908
910
912
914
ACTUAL O-RING
SIZE
NOMINAL O-RING
SIZE
I.D.
(in)
WALL
(in)
I.D.
(in)
1
4
0.351
0.072
11
32
5
16
0.414
0.072
13
0.078
25
1
2
0.087
41
64
10
12
14
8
4
8
0.468
0.644
0.755
0.924
1.047
0.097
0.116
59
0.166
32
32
4
64
64
11
64
WALL
(in)
5
3
3
7
7
7
NATIONAL
OILWELL
VARCO PART
NUMBER FOR
O-RING
64
946198
64
946210
64
946199
32
946196
32
946211
64
946190
64
946260
64
946200
916
16
1.171
0.116
920
20
1 14
1.475
0.118
115 32
1
8
946201
924
24
1
2
1.720
0.118
23
32
1
8
946213
932
32
2.337
0.118
21132
1
8
946214
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
3-19
3.6.4.2 Four Bolt O-Ring Flange

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

1. Clean the contact surfaces.
Split
Flange
Bolt
2. Check the O-ring (see figure 32) for

damage. Replace the O-ring if it is
damaged.
Split
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 32. 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.
8. Tighten the four bolts of the split flange in
sequence (see figure 33) evenly, until all
the bolts make contact with the top of the
flanges.
9. Tighten the four bolts in sequence (see
figure 33) one-half turn at a time. Repeat
as necessary to the torque value shown in
the following tables.
A217
Figure 33. Flange Tightening Sequence
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
3-20
NOTICE
O-rings listed in table 37 must be 90 durometer Buna N material except where noted.
Table 37. Code 61 Standard Pressure Series Four Bolt O-Ring Flange
NOMINAL
BOLT
FLANGE
THREAD
SIZE
UNC-2A
(in)
TORQUE
(inlb)
O-RING
ARP 568
UNIFORM
DASH
NUMBER
ACTUAL O-RING
SIZE
I.D.
(in)
WALL
(in)
WALL
(in)
NATIONAL
OILWELL
VARCO PART
NUMBER FOR
O-RING
NOMINAL O-RING
SIZE
I.D.
(in)
1
2
5
16
18
175225
210
0.734
0.139
1
8
944103
16
250350
214
0.984
0.139
1
8
925535
5
16
1
8
925561
16
325425
219
1.296
0.139
425550
222
1.484
0.139
1 12
1
8
925333
944107
1 14
7
16
1
2
1
2
550700
225
1.859
0.139
1
8
1
2
650800
228
2.234
0.139
2 14
1
8
925334
925591
944206
2
2
1
2
14
13
13
1
2
13
11
9501100
16501800
232
(A)
2.734
0.139
1
8
237
(A)
3.359
0.139
33 8
1
8
(A) 70 durometer Buna N material
3.6.5 Releasing Pressure from

Hydraulic System
3.6.6 Hydraulic Oil Level
3.6.6.1 Checking Hydraulic Oil Level
2. Move all the control levers back and forth,

then release the levers to their neutral
(center) position.
3. Permit the hydraulic oil to cool (see Hydraulic System Maintenance, paragraph 3.6.1).
!WARNING

hydraulic piping. Read and understand
the hydraulic schematic to identify
possible areas of residual pressure in
the hydraulic system. Use caution
when removing any hydraulic piping or
hose. Accidentally releasing hydraulic
oil at high pressure can cause injury to
you and others, and can cause
damage to the equipment.
www.nov.com
Check the level of hydraulic oil in the hydraulic

oil reservoir using the sight gauge located on
the side of the reservoir. The level of hydraulic
oil must be above the midpoint of the sight
gauge. See paragraph 3.6.6.2 for the procedure
to add hydraulic oil.
CAUTION

level of hydraulic oil that is too low or
too high.
Document number
Revision
Page
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 hydraulic oil that meets the recommended specifications (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.
www.nov.com
2710100-MAN-001
01
3-21
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 metallic 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 equipment part, make a particle count test to find out
if the hydraulic system needs flushing. If possible, take the hydraulic oil sample with the
equipment operating. The hydraulic oil cleanliness must comply with the maximum operating
contamination levels permitted (see paragraph 3.6.1.2).
Document number
Revision
Page
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

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.
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.
www.nov.com
2710100-MAN-001
01
3-22
5. Flush clean all hydraulic piping, hoses, and

other equipment parts to meet the requirements 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 reservoir to remove any visual signs of contamination. 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 hydraulic 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).
Document number
Revision
Page
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.)
2710100-MAN-001
01
3-23
10. Check the hydraulic oil reservoir for the

correct oil level. Add filtered hydraulic oil to
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.
1. Use only new, clean, moisture-free hydraulic oil that meets the recommended specifications (see paragraph 3.6.2).
14. Check the hydraulic oil reservoir for the

correct oil level. Add filtered hydraulic oil to
the reservoir as necessary.
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).
15. Make a particle count test of the hydraulic

oil before putting the equipment into operation. The hydraulic oil cleanliness must
comply with the maximum operating
contamination levels permitted (see paragraph 3.6.1.1).
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 corresponding steps in paragraph 2.8.2). Check for
pressure build-up.
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 condition 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
occurs first.
CAUTION
8. Check for hydraulic system leaks.
9. Stop the diesel engine (see the corresponding steps in paragraph 2.8.4).
www.nov.com

Keep all the parts clean. (See
paragraph 3.6.1.)
Document number
Revision
Page
2710100-MAN-001
01
3-24
3.7 Wire Rope
3.8 Non-Operational Storage
Operation, inspection, and maintenance of all

wire rope should be done in accordance with
API Recommended Practice 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes (API RP2D) (see
Section 5). Also, the Parts and Vendor Data
Manual contains the following drawings that are
beneficial to wire rope maintenance:
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.
hoist manufacturers 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.
3.8.1 Short-Term Storage7 Days Up to

30 Days
When the crane will not to 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 Storage30 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 paragraph 3.2.2). Do all the steps that would
occur during the storage period.
5. Prepare the diesel engine for storage. See
the diesel engine manufacturers information (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.
www.nov.com
Document number
Revision
Page
7. To prevent corrosion, apply Dow Corning

brand Metal Protective Coating or an equivalent 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 paragraph 3.6.6).
10. Close all cab windows and doors.
11. Cover the engine, valves, and operators
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 paragraph 3.6.6).
www.nov.com
2710100-MAN-001
01
3-25
5. Prepare the diesel engine for operation.

See the diesel engine manufacturers information 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 paragraph 3.2.2) and inspections and maintenance (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
Revision
Page
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.
www.nov.com
2710100-MAN-001
01
3-26
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.
2. Emergency Lowering Procedure
a.
Remove the lockwire on the valve handle, and close the valve tightly.
603511 Rev. 4 (ECN 333421)

Page 1 of 2
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. 4 (ECN 333421)

Page 2 of 2
Document number
Revision
Page
2710100-MAN-001
01
4-1
4 SPECIFICATIONS
4.1 Crane Specifications
Crane Model:
10000
Serial Number:
2710100
Boom:
Main length70 ft (21.3 m)
Inner section30 ft (9.1 m)
Outer section30 ft (9.1 m)
Center section(s)1 @ 10 ft (3.0 m)
Maximum Hook Travel:
Main hook, 4 parts of line400 ft (121.9 m)
Main hook, 6 parts of line270 ft (82.3 m)
Auxiliary hook300 ft (91.4 m)
Maximum Hook Radius:
Main hook74.7 ft (22.7 m)
Auxiliary hook79.4 ft (24.2 m)
Minimum Hook Radius:
Main hook14.4 ft (4.3 m)
Auxiliary hook15 ft (4.5 m)
Maximum Available Hook Speed
(with the hook positioned at the supply boat elevation and the platform at operational conditions):
Main hook41.8 fpm (12.7 mpm) (4 parts, 1st layer)
Main hook62.7 fpm (19.1 mpm) (6 parts, 1st layer)
Auxiliary hook283 fpm (86.2 mpm) (1 part, 1st layer)
Operators Station:
Enclosed, left-hand
Load and Radius Indicator System:
Aanderaa Data Instruments model Mipeg 2000
Emergency Load Lowering:
Per drawings 603511 and 603457-L01
www.nov.com
Document number
Revision
Page
4.1.1 Hoist and Wire Rope Information

Hoist Make/Model:
BoomBraden CH210A
MainBraden CH240A
AuxiliaryBraden CH165A
Boom Hoist Wire Rope:
7/8 in 6x26 EIPSIWRC
Length900 ft (274.3 m)
Breaking strength39.8 tons (36.1 MT)
Main Hoist Wire Rope:
3/4 in Dyform 34LR, grade 2160
Length1770 ft (539.5 m)
Breaking strength40 tons (36.2 MT)
Auxiliary Hoist Wire Rope:
5/8 in Dyform 34LR grade 2160
Length420 ft (128.0 m)
Breaking strength28.2 tons (25.5 MT)
4.1.2 Power Plant

Type:
Diesel/hydraulic
Diesel Engine:
Caterpillar 3126
249 hp @ 2100 rpm
Diesel Fuel Tank Capacity:
150 gal (567.8 L)
Diesel Engine Coolant Capacity:
Engine and radiator11.0 gal (41.6 L)
Radiator only7.5 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)
www.nov.com
2710100-MAN-001
01
4-2
Document number
Revision
Page
2710100-MAN-001
01
4-3
4.1.3 Air System

Supply (from vessel):
120125 psi (8.38.6 bar)
Air Reservoir Tank:
Capacity120 gal (454 L)
4.1.4 Electrical System

Supply (from vessel):
220 VAC, 50 Hz, 1 ph, 2 wires plus ground, 60 A
Power Supply PS0228 converts 220 VAC to 24 VDC
System Voltage
LOAD
SOURCE
VOLTAGE
Circuit Breaker Panel

CBP0208
220 VAC, 50 Hz
Control Panel
1585644
24 VDC
Air conditioning units

Flood lighting
Area lighting
Obstruction lights
Power receptacle
Electrical collector ring anti-condensation heater
Diesel engine heater
Hydraulic oil reservoir heater
Load and radius indicator system
Gauge panel lighting
Wind speed indicator system
www.nov.com
Document number
Revision
Page
2710100-MAN-001
01
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 721310-L05, Turntable.
Table 41. Tightening Values for SAE J429 Coarse Thread Bolts
GRADE 5
GRADE 8
DIAMETER
THREADS/INCH
TIGHTENING
TORQUE (ftlb) (A)
1
TIGHTENING
TORQUE (Nm) (A)
TIGHTENING
TORQUE (ftlb) (A)
TIGHTENING
TORQUE (Nm) (A)
20
12
18
13
18
18
25
16
23
31
33
44
14
37
50
52
71
13
57
77
80
108
12
81
111
115
156
11
113
153
159
215
10
200
271
282
382
322
437
455
617
18
483
655
682
924
1- 187
595
807
966
1309
1- 47
840
1139
1363
1848
1-3 86
1102
1494
1787
2423
1462
1983
2371
3215
16
3
7
16
1
9
16
5
3
8
4
1- 26
(A) ftlb = 0.7375 x torque in Nm, Nm = 1.356 x torque in ftlb
www.nov.com

NOV Crane Maintenance Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

NOV Crane Maintenance Manual

Uploaded by

Copyright:

Available Formats

Operation and Maintenance Manual

AmClyde Unit Model 10000

GSP-Upetrom Jackup Drilling Rig Saturn

AmClyde Unit Model 10000

This document contains proprietary and confidential information

National Oilwell Varco, L.L.P

CLIENT DOCUMENT NUMBER

Operation and Maintenance Manual

Operation and Maintenance Manual

Operation and Maintenance Manual

Operation and Maintenance Manual

Reason for Issue

2.6.1 Diesel Engine Throttle Controls. . . . . . . . . . . . . . . . . . . . . . . . 2-8

4.2 Tightening Values for SAE Coarse Thread Bolts

National Oilwell Varco

Operation and Maintenance Manual, document number 2710100-MAN-001

This Warranty covers only new and unused Products

Correct training, inspection, and maintenance

1.2 Safety Signal Words

Danger is used to show a hazard that

Warning is used to show a hazard or

Caution is used to show a hazard that

Caution used without the safety alert

Notice is used to call attention to

1.3 Safety Rules

1.3.1 General Safety Rules

1.3.2 Operating Safety Rules

3. Do not operate this equipment if you are ill

11. Do not operate the equipment with any

4. Do not exceed the rated load capacity of

12. Do not operate the equipment without the

5. Do not rely on the load monitoring system

13. Do not bypass, disconnect, or ignore safety

19. Loads must be safely rigged before lifting.

29. The operator must not leave the control

20. When making a lift, the boom (hook) must

31. Do not permit the wire rope to wind wrong

30. The hoists must have at least five full wraps

21. Use extreme caution when rotating the

Figure 11. Wire Rope Wound Wrong on Drum

24. Do not quickly accelerate or quickly decelerate a moving load.

1.3.3 Maintenance Safety Rules

1. Shut down the equipment before doing

4. The power plant must be stopped and cool

1.4 Operator Qualification

1.5 Inclement Weather Precautions

1.6 Safety Labels

Operating and maintenance personnel must read

Operating and maintenance personnel must read

Do not access this area while the crane is

Be careful when opening or closing windows of

Electrical power is supplied to this equipment from

Only qualified, trained maintenance personnel must

This page intentionally left blank.

2.2 Crane Installation

The pedestal installation and the

2.3 Crane Nomenclature

Wind Speed Sensor

Auxiliary Wire Rope

Boom Flood Light

Boom Angle Indicator (far side)

Boom Foot Pin

Diesel Fuel Tank

Figure 21. Crane