User Manual

OC3932KCE Knuckle Boom Crane No. 1

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

ENSCO DS-4 V3054 OC3932KCE-(17-85)-(42-18)(27) No 1
ADDITIONAL CODE SDRL CODE TOTAL PGS
8 This document contains proprietary and confidential Postbox 401
information which belongs to National Oilwell Varco; it is Lundsiden
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in 4604 Kristiansand S
MAIN TAG NUMBER DISCIPLINE part; or use of this design or distribution of this information NORWAY
to others is not permitted without the express written Phone +47 38 19 20 00
consent of National Oilwell Varco. This document is to be
CLIENT PO NUMBER returned to National Oilwell Varco upon request and in Fax +47 38 19 26 04
any event upon completion of the use for which it was
loaned.
© Copyright National Oilwell Varco - 2019

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

V3054-Z-MA-001 5
 Document number V3054-Z-MA-001
Revision 5
Page 2

REVISION HISTORY

5 3-Apr-2019 Reissued for Implementation BEAN JUFL TOHO

4 24-Oct-2017 Reissued for Implementation KAPE AAKE TIN
3 27-Mar-2014 Reissued for Implementation KAPE HACE BRA
2 28-Jan-2013 Reissued for Implementation SHEG HACE AMH
1 26-Sep-2011 Reissued for Implementation JOSI KAPE EITR
0 21-Feb-2010 Issued for Implementation SELU DoBi AMH
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change description

5 Updated according to NOV-1023517 and NOV-1043352.
Section 4:
V3054-Z-MA-007 updated to rev. 4.
Section 10.6:
V3054-E0012 updated to rev. 2.
V3054-E0021 updated to rev. 2.
Section 10.7:
V3054-E0112 updated to rev. 1.
V3054-E0121 updated to rev. 2.
Section 10.8:
V3054-E0212 updated to rev. 3.
Section 10.9:
V3054-E0300 updated to rev. 2.
Section 10.10:
V3054-E0511 updated to rev. 2.
4 Updated according to NOV-836714.
Section 10.3:
OC3932KM02-A4001 voided.
D1500-13-A4001 added.
16609503-INF added.
3 Section 4 Operating Instructions:
V3054-Z-MA-007 has been updated to rev. 3.
Section 7 Preparation:
V3054-Z-KA-002 has been updated to rev. 1.
Section 10.5 Flow Diagram:
V3054-H0002 has been updated to rev. 4.
V3054-H0003 has been updated to rev. 4.
V3054-H0004 has been updated to rev. 4.
V3054-H0005 has been updated to rev. 3.
V3054-H0008 has been updated to rev. 3.
2 Section 10.5:
V3054-H0002 updated to rev 3
V3054-H0006 updated to rev 3
1 Section 1 Introduction:
Introduction updated to rev.2
Section 4 Operating Instructions:
 Document number V3054-Z-MA-001
Revision 5
Page 3

V3054-Z-MA-007 updated to rev.2

Section 10 Drawing and Parts lists:
10.2: OC3932KM02-L0001 removed, OC3932KM01-L0003 has been implemented.
10.5: V2054-H0004 updated to rev.3
10.6: V3054-E0021 updated to rev.1
10.7: V3054-E0104 updated to rev.1
V3054-E0121 updated to rev.1
10.10: V3054-E0511 updated to rev.1
0
TABLE OF CONTENTS Document number
Revision
V3054-Z-MA-001 TOC
5
Page 1

Section Title Remarks

1 Introduction
2 Data Sheets
3 Technical Description
4 Operating Instructions
5 Maintenance Instructions
6 Spare Parts List
7 Preparation
8 Verifying Documentation
9 Standard Documentation
10 Drawings & Parts Lists
10.1 General Arrangement Drawing
10.2 Lubrication Chart
10.3 Assembly Drawing
10.4 Installation Drawing
10.5 Flow Diagram
10.6 Block Diagram
10.7 Termination Drawing
10.8 Loop Diagram
10.9 Layout Drawing
10.10 Circuit Diagram

nov.com
 Document number V3054-Z-MA-001 section 1
TABLE OF CONTENTS Revision: 1
Page: 1

Vol. Section Title Add. code Rev. Document number

Other document number

1 1 Introduction
User Manual, Introduction for User Manual 2 74309174

R5325 Deep Ocean Clarion (Former Pride 2)

V3054 OC3932KCE-(17-85)-(42-18)(27) No 1

www.nov.com
 Document number V3054-Z-MA-001 section 2
TABLE OF CONTENTS Revision: 1
Page: 1

Vol. Section Title Add. code Rev. Document number

Other document number

1 2 Data Sheets
Product Data Sheet, OC3932KCE Knuckle Boom Crane No. 1 6 V3054-Z-DS-001
Pride No. 2

R5325 Deep Ocean Clarion (Former Pride 2)

V3054 OC3932KCE-(17-85)-(42-18)(27) No 1

www.nov.com
 Product Data Sheet
Knuckle Boom Crane No.1
Pride No. 2

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Pride 2 V3054 OC3932KCE Knuckle Boom Crane No 1
ADDITIONAL CODE SDRL CODE TOTAL PGS
19 This document contains proprietary and confidential National Oilwell Varco Norway AS
information which belongs to National Oilwell Varco; it is Servicebox 401
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in N-4604 Kristiansand
MAIN TAG NUMBER DISCIPLINE part; or use of this design or distribution of this information Norway
to others is not permitted without the express written
3D61100 M. consent of National Oilwell Varco. This document is to be
CLIENT PO NUMBER returned to National Oilwell Varco upon request and in Phone +47 38 19 20 00
any event upon completion of the use for which it was Fax +47 38 19 26 04
loaned.
© Copyright National Oilwell Varco - 2010

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

V3054-Z-DS-001 6
 Document number V3054-Z-DS-001
Revision 6
Page 3 of 19

TABLE OF CONTENTS

1 GENERAL DATA ................................................................................................................ 5

2 CERTIFICATION AND THIRD PARTY APPROVAL ......................................................... 5
3 ENVIRONMENT .................................................................................................................. 6
3.1 Environmental Conditions ......................................................................................... 6
3.2 Area Classification .................................................................................................... 6
4 CRANE DESIGN CRITERIA ............................................................................................... 6
4.1 Classification Rules .................................................................................................. 6
4.2 Crane Design Codes ................................................................................................ 6
4.3 Crane Classification FEM 1.001 ............................................................................... 7
4.4 Design Dynamic Factors........................................................................................... 7
5 DIMENSIONS AND WEIGHTS ........................................................................................... 8
5.1 Main Dimensions ...................................................................................................... 8
5.2 Weights and C.O.G................................................................................................... 9
6 PERFORMANCE DATA ..................................................................................................... 9
6.1 Operational Range .................................................................................................... 9
6.2 Lifting Capacities .................................................................................................... 10
6.3 Velocities................................................................................................................. 10
7 MATERIAL AND SURFACE PROTECTION .................................................................... 11
7.1 Materials ................................................................................................................. 11
7.2 Surface Protection .................................................................................................. 11
7.2.1 National Oilwell system no. 1 used on all structural carbon steel ............... 11
7.2.2 National Oilwell system no. 4 used inside foundation and king (cranes).... 12
7.2.3 National Oilwell system no. 5 used inside oil tanks (cranes) ...................... 12
8 MECHANICAL INTERFACE ............................................................................................. 12
8.1 Foundation Loads ................................................................................................... 12
8.2 Boom Rest Loads ................................................................................................... 12
9 SYSTEMS INTERFACE .................................................................................................... 13
9.1 Electrical Power Supply .......................................................................................... 13
10 MECHANICAL EQUIPMENT DATA ................................................................................. 13
10.1 Hooks ...................................................................................................................... 13
10.2 Wire Ropes ............................................................................................................. 14
10.3 Wire Rope Sheaves ................................................................................................ 14
10.4 Winch ...................................................................................................................... 14
 Document number V3054-Z-DS-001
Revision 6
Page 4 of 19

10.5 Slew Bearing ........................................................................................................... 15

10.6 Slewing Machinery .................................................................................................. 15
10.7 Hydraulic Cylinders ................................................................................................. 15
10.7.1 Main boom cylinder ................................................................................... 15
10.7.2 Knuckle boom cylinder .............................................................................. 16
10.8 Prime Movers - Electric Motors .............................................................................. 16
11 HYDRAULIC SYSTEMS ................................................................................................... 17
11.1 Hydraulic System Main Components ..................................................................... 17
11.2 Hydraulic Oil Tank .................................................................................................. 17
11.3 Cooling System ....................................................................................................... 17
12 ELECTRICAL/ INSTRUMENT EQUIPMENT DETAIL DATA .......................................... 18
12.1 Lighting ................................................................................................................... 18
12.2 Crane Safety System .............................................................................................. 18
12.3 Fire & Gas systems ................................................................................................ 18
12.4 Communication Systems ........................................................................................ 18
13 DRIVERS CABIN .............................................................................................................. 19
14 MARKING.......................................................................................................................... 19
15 TESTING AND INSPECTION ........................................................................................... 19
 Document number V3054-Z-DS-001
Revision 6
Page 5 of 19

1 GENERAL DATA

Project name: PRIDE 2

Contractor: Samsung Heavy Industries Co, LTD
Installation type: Drillship Hull no. 1756
Service: Pipe handling, internal and external load handling, personnel
lift.
Package description: Knuckle Boom Crane, type 3932
Size: OC3932KCE-85 / 20 x 42 -1.33
Tag no.: 3D61100 - Starboard / Forward Crane
Location area: Main Deck
Machine number: V3054-0510
Reference drawing: V3054-C3932K-G0001

2 CERTIFICATION AND THIRD PARTY APPROVAL

Equipment to be formally certified: Yes

Basis document for the certification: ABS
Guide for Certification of Lifting
Appliances, 2007
Certification by third party: Yes
Verification by third party: Yes
Basis document for the verification: Project Purchase Order
Name of third party: ABS + CDS
Third party activities including:
- Design approval Yes
- Manufacturing survey Yes
- Witness of test and final inspection Yes
 Document number V3054-Z-DS-001
Revision 6
Page 6 of 19

3 ENVIRONMENT

3.1 Environmental Conditions

Temperatures
- Min. ambient -10° C
- Max. ambient +45° C
- Test temperature, steel -20° C

Design wind velocity

- Operational: 25 m/s Sea Lift
25 m/s Internal Lift
- Personnel Lift 10 m/s
- Stowed position: 60 m/s

Wave height Case 2 Hs 8,4m

3.2 Area Classification

Pedestal: Safe zone

Rotating column: Safe zone
Boom: Safe zone

4 CRANE DESIGN CRITERIA

For Reaction Forces see doc.: V3054-N-RD-001

4.1 Classification Rules

ABS, Guide for Certification of Lifting Appliances, 2007

4.2 Crane Design Codes

FEM – “Rules for the design of Hoisting Appliances”, (1998)

 Document number V3054-Z-DS-001
Revision 6
Page 7 of 19

4.3 Crane Classification FEM 1.001

Lifting Appliance: Crane as a Whole Hoisting Duty Pipe Handling Duty

Appliance Group A3 A3 A3
Class of Utilization U2 U2 U2
Load spectrum Class Q2 Q2 Q3

Machinery: Hoisting Folding Lufifng

Mechanism Group M4 M6 M6
Class of Utilization T4 T6 T6
Load Spectrum Class L2 L2 L2

Structural: Pedestal King Booms

Mechanism Group E2 E2 E2
Class of Utilization B3 B3 B3
Load Spectrum Class P2 P2 P2

4.4 Design Dynamic Factors

Mode of Main Internal Lift Sea Lift Personnel

Winch operation : Lift
1 fall w/hook
Dynamic Factor 1,4 1,4 -
Duty Factor 1,0 1,0 -
 Document number V3054-Z-DS-001
Revision 6
Page 8 of 19

5 DIMENSIONS AND WEIGHTS

5.1 Main Dimensions

Crane datum point: Crane slewing axis, top of Steel Pedestal

Crane datum point elevation: EL 43.235 mm

Crane datum point, height above main deck (EL19.000) 24.235 mm

Pedestal Adapter:
Height: 2500 mm
Diameter, upper end: 3980 mm
Diameter, lower end: 3970 mm
Pedestal wall thickness: 35 mm
Lower end connection: Welded

Deck Pedestal:
Height (excl.adapter) 15685 mm
Lower end connection: Welded

Crane King:

Boom pivot point above crane datum point: 4248 mm

Boom pivot point forward of crane slewing axis: 0 mm
Crane King total height (Ladder excluded): 6259 mm
Crane King total width (Incl. platform): 6970 mm
Crane King total length(Incl. platform & cabin) : 7015 mm
Tail swing radius: 5465 mm

Main boom:

Boom total length: 27585 mm

Boom total height: 4390 mm
Boom total width: 3900 mm

Knuckle boom:

Boom total length: 20200 mm

Boom total height: 3000 mm
Boom total width: 1785 mm

Total dimensions: (parked position)

Max. height: 18050 mm
Max. length: 31245 mm
Max. width: 6970 mm
Distance from CL Crane to suggested boom rest: 20600 mm
 Document number V3054-Z-DS-001
Revision 6
Page 9 of 19

5.2 Weights and C.O.G.

Dry weight complete Crane: ~137, 6 tonne

Operating weight complete Crane: ~141, 6 tonne

Crane centre of gravity:

Above crane datum point [Z]: 3000 mm

Forward of slew centre [X]: 8593 mm
Left of slew centre: 84 mm

6 PERFORMANCE DATA

6.1 Operational Range

Load radius main winch hook (one fall):

Max: 42300 mm
Min: 8000 mm

Boom angles above horizontal:

Main Boom max. (°): 86, 8°

Main Boom min. (°): 00, 0°
Knuckle Boom min. (°): 114, 5°
Knuckle Boom max. (°): 11, 3°

Hook level main winch:

Configuration Hook level above datum point (m)
At min. load radius At max. load radius
Min. Max. Min. Max.
One fall ~ m ~m ~m

Slewing range: 360° Unlimited

 Document number V3054-Z-DS-001
Revision 6
Page 10 of 19

6.2 Lifting Capacities

Type of Lifting data Dynamic data

lifts

Hook Load Wire Wave Dynamic Duty Heel Off + Wind

load Radii Falls height factor Factor + Side speed
SWL Trim Lead
T M Pcs Hs,m Dgr Dgr m/sec
Internal 17 42 1 N/A 1.4 1.0 5+2 38
on deck 34 39 2 N/A 1.4 1.0 5+2 38
85 18 5 N/A 1.4 1.0 5+2 38
-External 17 42 1 6 1.4 1.0 5+2 25
Sealift 34 39 2 6 1.4 1.0 5+2 25
85 18 5 2 1.4 1.0 5+2 25
Personnel 1.5* 42 1 2 -** -** 5+2 10
Handling

* Ref. Derating tables, doc. No.: V3054-Z-RD-003. Max 33% of normal derated capacity
at Hs=2m
** Personnel handling not critical for structural design.

6.3 Velocities

Hoisting speed main winch:

Normal mode at layer 3/4: SWL: 17ton Reduced load:

Up: 50 m/min. 100 m/min.
Down: 50 m/min. 100 m/min.

Personnel handling: 48 m/min.

Luffing speed from min to maximum radius: 65 sec.

Slewing speed (rpm):

Max slew speed: 1

NOTE!
The above speeds are based on average volumetric efficiencies provided by our
suppliers of hydraulic components. A speed tolerance of +10% to –5% is within the
accepted range.
 Document number V3054-Z-DS-001
Revision 6
Page 11 of 19

7 MATERIAL AND SURFACE PROTECTION

7.1 Materials

Primary, welded structure:

Plates: S355 K2G3 / NVE 36

Secondary, welded structure:

Plates: S235 JRG2

Hydraulic system:

Hydraulic tubes, outdoor: Stainless steel

Hydraulic fittings, outdoor: Gold chrome protected mild steel, stainless steel nuts
and rings. Hose couplings protected by anti-corrosive
Densotape.

Hydraulic fittings, indoor: Gold chrome protected mild steel

7.2 Surface Protection

7.2.1 National Oilwell system no. 1 used on all structural carbon steel

Blast Cleaning : Sa 2 ½ (ISO 8501-1)

Surface Roughness : Grade medium G, 50-85µm (ISO 8503)
Then Apply : 1 layer Jotun Barrier 40 µm DFT
1 layer Jotun Jota mastic 87 Aluminium 250 µm DFT
1 layer Jotun Hardtop AS 50 µm DFT
Total Dry Film Thickness (DFT) 340 µm DFT

Color top layer Booms: RAL 9016 Traffic White

Color top layer King: RAL 2004 Orange
Color top layer Pedestal: RAL 7042 Traffic Grey A
 Document number V3054-Z-DS-001
Revision 6
Page 12 of 19

7.2.2 National Oilwell system no. 4 used inside foundation and king (cranes)

Blast Cleaning : SA 2½ (ISO 8501-1)

Surf. Roughness : Grad medium G (50-85µm) (ISO 8503)
Then Apply : 1 layer Jotun Barrier 50 µm DFT
1 layer Jotun Penguard topcoat (RAL 7068) 50 µm DFT

Total Dry Film Thickness (DFT) 100 µm DFT

7.2.3 National Oilwell system no. 5 used inside oil tanks (cranes)

Blast Cleaning : SA 2½ (ISO 8501-1)

Surf. Roughness : Grad medium G (50-85µm) (ISO 8503)
Then Apply : 1 layer Jotun Barrier 50 µm DFT
Total Dry Film Thickness (DFT) 50 µm DFT

8 MECHANICAL INTERFACE

8.1 Foundation Loads

Ref. Doc. V3054-N-RD-001 Reaction Forces

8.2 Boom Rest Loads

Ref. Doc. V3054-N-RD-001 Reaction Forces

 Document number V3054-Z-DS-001
Revision 6
Page 13 of 19

9 SYSTEMS INTERFACE

9.1 Electrical Power Supply

Electrical power supplied to the crane:
Power supply no.1: 440V/60Hz/3ph, 485 kW
Power supply no.2: 440V/60Hz/3ph, 485 kW

Auxiliary supply: 440V/60Hz/3ph, 30 kW

UPS: 220V/60Hz/1ph, 2 kW

Aviation Lights: 220V/60Hz/1ph, 0.6 kW

10 MECHANICAL EQUIPMENT DATA

10.1 Hooks

Application Main Winch

Type 1 fall Swivel Hook - Single
Hook Type 8V acc. DIN 15401
Design load (t) 17,5
SWL (t) 17,5
Swivel Yes
Safety latch Yes

Application Main Winch

Type 2 fall Hook Block -Ramshorn
Hook Type 20V acc. DIN 15402
Design load (t) 35
SWL (t) 35
Swivel Yes
Safety latch Yes

Application Main Winch

Type 5 fall Hook Block -Ramshorn
Hook Type 32V acc. DIN 15402
Design load (t) 100
SWL (t) 100
Swivel Yes
Safety latch Yes
 Document number V3054-Z-DS-001
Revision 6
Page 14 of 19

10.2 Wire Ropes

Application Main winch

Type Lang's lay, RH
Construction 34LR
Diameter (mm) 34
Strength (N/mm2) 1960
Min. breaking load (kN) 1060
Surface treatment Galvanized
Length (m) 350
Number of falls 1/2/5
Drum end termination 3 ea.Clamps
Outer end termination Thimble DIN 3091
Thimble Drill Hole Ø66

10.3 Wire Rope Sheaves

Application Main hoist

Material S355J2G3
PCD (mm) 680mm
Bearing type 2 row roller bearing
Lubrication Grease nipple in bolt

10.4 Winch

Application Main hoist

Drum design Lebus Engineering
No. of layers 4
PCD (mm) 833 on 3de layer
Min. no. of safety 5
turns
Gear box type/ ratio Planetary/ 56,8
Brake design Multi-lamella, spring
activated, wet
No. of gear brakes 2
 Document number V3054-Z-DS-001
Revision 6
Page 15 of 19

10.5 Slew Bearing

Manufacturer: Rothe Erde
Design: Roller bearing
Roller circle diameter (mm): 3932
Weight (kg): 5014
Module: M18
Bolt no. / Size / Quality: 94 /96 - M42 / 10.9
Monitoring system (yes/no): No

10.6 Slewing Machinery

No. of slewing gears: 4
Gear box design: Planetary
Gear box ratio: 126, 9:1

10.7 Hydraulic Cylinders

10.7.1 Main boom cylinder

Application Luffing
Type Double acting
Number of cylinders 2
Piston diameter Ø450
Rod diameter (mm) Ø340
Block Length 1450
Cylinder tube diameter(mm) Ø546
Stroke (mm) 5080
Minimum length 6530
Maximum length 11610
Max. work pressure (bar) 300/100
Design pressure (bar) 316
Test pressure (bar) 430/ 130
Connection type Fork eye
Connection bolt Ø250
Dry weight per cylinder (kg) 7520
 Document number V3054-Z-DS-001
Revision 6
Page 16 of 19

10.7.2 Knuckle boom cylinder

Application Luffing / Folding

Type Double acting
Number of cylinders 2
Piston diameter Ø380
Rod diameter (mm) Ø260
Block Length 1500
Cylinder tube diameter(mm) Ø454
Stroke (mm) 3800
Minimum length 5300
Maximum length 9100
Max. work pressure (bar) -
Design pressure (bar) 333/251
Test pressure (bar) 370/ 200
Connection type Fork eye
Connection bolt Ø200
Dry weight per cylinder (kg) 4400

10.8 Prime Movers - Electric Motors

Type: M2CA315LC4/V3
Manufacturer: ABB
Number of motors: 2
Voltage: 440/60/3
Rated power (kW): 485kW S6-40%
Rated current (IN): 768A, S6-40%
Starting current (IS):
Starting system/ location: Star/Delta
Still-stand heater (yes/no): Yes
 Document number V3054-Z-DS-001
Revision 6
Page 17 of 19

11 HYDRAULIC SYSTEMS

11.1 Hydraulic System Main Components

System Unit type No. Description Max. op.

off Pressure
(bar)
Main Winch Motor 2 A6VM200EP2D/63W 295
Main boom Cylinder 2 300
K. Boom Cylinder 2 280
Slewing Motor 4 AA2FM 125/61W- 265
VSD520
Pump stack no.1 Pump 1 1 PV270R1L1MMNFFP 310
Pump stack no.1 Pump 2 1 PV270R1L1BBNFRP 310
Pump stack no.1 Pump 3 1 T6CM-B28-3R00-C1 5
Circulation
Pump stack no.2 Pump 1 1 PV270R1L1MMNFFP 310
Pump stack no.2 Pump 2 1 PV270R1L1BBNFRP 310
Pump stack no.2 Pump 3 1 T6CM-B28-3R00-C1 5
Circulation
Main Control 1 CVG-52-33 310
Valve Crane

11.2 Hydraulic Oil Tank

Design: Integrated in Crane King Structure
Location: Inside Crane King
Oil volume: ~ 5500 litres

11.3 Cooling System

Electric driven air fans for the oil coolers with automatic regulation of the temperature.
 Document number V3054-Z-DS-001
Revision 6
Page 18 of 19

12 ELECTRICAL/ INSTRUMENT EQUIPMENT DETAIL DATA

12.1 Lighting
- 4 ea. self levelling flood lights on Main Boom.
- 2 flood light at Knuckle Boom.
- 1 flood light under Driver’s cabin.
- Light inside Driver’s cabin.
- Light inside machine room.
- Light inside pedestal.
- 1 light for access route outside Driver’s cabin.
- Light at Top platform
- Helicopter lights on main winch, end of Main Boom and knuckle boom

12.2 Crane Safety System

- Crane control system by PLC.
- Emergency stop of crane.
- Overload alarms and crane stop functions.
- Load indication system with display for actual and permitted load.
- Selector switch for Internal and Sea Lift mode
- Radius indicator.
- Oil temperature Alarm.
- Pressure relief valves in all hydraulic circuits.
- Hook stop in both upper and lower position.
- Indicator for wire length payed out.
- Fail safe multi-disc brakes on both winch and slew gears.
- Emergency lowering of main winch.
- Emergency lowering of boom.
- Emergency lowering of knuckle boom.
- Emergency slew brake release.

12.3 Fire & Gas systems

Not included.

12.4 Communication Systems

- VHF/ UHF system.
- Loud speaker system.
- Alarm horn.
- Phone system (free issued).
- PA system (free issued).
 Document number V3054-Z-DS-001
Revision 6
Page 19 of 19

13 DRIVERS CABIN
- Cabin location: Left hand side.
- Control panel with crane safety information.
- Spring centred joy-stick controls for full crane operation.
- Start/stop of prime mover.
- Insulated cabin.
- Instruction and name plates in English.
- Selector switch crane modus
- Dynamic load radius chart / curves.
- Heating and ventilation system.
- Window wiper and washer.
- Fire extinguisher.
- Cabin of seawater resistant aluminium material.
- Protection bars over roof window.
- All windows of safety glass.
- Comfortable ergonomic operator chair with integrated control handles.
- Foot rest.
- Air conditioning.
- Sun screens.

14 MARKING
Language for instructive marking: English
Language for safety marking: English

15 TESTING AND INSPECTION

- Full load testing at works.
- Full performance testing at works.
- Factory acceptance test (FAT).
- Commissioning onboard test (COM)
 Document number V3054-Z-MA-001 section 3
TABLE OF CONTENTS Revision: 1
Page: 1

Vol. Section Title Add. code Rev. Document number

Other document number

1 3 Technical Description
Technical Description, OC3932KCE Knuckle Boom Crane No. 1 2 V3054-Z-SA-001
Pride No. 2

R5325 Deep Ocean Clarion (Former Pride 2)

V3054 OC3932KCE-(17-85)-(42-18)(27) No 1

www.nov.com
 Technical Description
OC3932KCE Knuckle Boom Crane No. 1
Pride No. 2

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Pride No 2 V3054 OC3932KCE Knuckle Boom Crane No 1
ADDITIONAL CODE SDRL CODE TOTAL PGS
24 This document contains proprietary and confidential National Oilwell Norway AS
information which belongs to National Oilwell Varco; it is Servicebox 401
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in N-4604 Kristiansand
MAIN TAG NUMBER DISCIPLINE part; or use of this design or distribution of this information Norway
to others is not permitted without the express written
3D61100 consent of National Oilwell Varco. This document is to be
CLIENT PO NUMBER returned to National Oilwell Varco upon request and in Phone +47 38 19 20 00
any event upon completion of the use for which it was Fax +47 38 19 23 11
loaned.
© Copyright National Oilwell Varco - 2009

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

V3054-Z-SA-001 2

www.nov.com
 Document number V3054-Z-SA-001
Revision 2
Page 2 of 24

REVISION HISTORY

2 17.06.2009 Reissued for Information AMH AMH FRO

1 04.06.2008 Reissued for Information AMH AMH FRO
0 03.01.2008 For Information AMH FRO FRO
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change description

2 Remote lubr. of slew bearing added in sections 1.3.2.1 and 1.3.4.4
1 Customer comments implemented
0

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 3 of 24

Table of Contents

1 TECHNICAL DESCRIPTION ............................................................................................ 5

1.1 General ................................................................................................................... 5
1.2 Product Description................................................................................................. 5
1.3 The Mechanical System.......................................................................................... 6
1.3.1 General........................................................................................................ 6
1.3.1.1 Pedestal Adapter ...................................................................................... 6
1.3.1.2 King .......................................................................................................... 6
1.3.2 Driver’s Cabin .............................................................................................. 7
1.3.2.1 Crane Booms ........................................................................................... 7
1.3.3 Hoisting System .......................................................................................... 7
1.3.3.1 Hoisting Winch ......................................................................................... 8
1.3.3.2 Hoisting Wire Rope................................................................................... 8
1.3.3.3 Wire sheaves............................................................................................ 8
1.3.3.4 Swivel Hook and Blocks ........................................................................... 8
1.3.4 Slewing System ........................................................................................... 9
1.3.4.1 Slew Ring Bearing .................................................................................... 9
1.3.4.2 Slewing Gears .......................................................................................... 9
1.3.4.3 Slewing Ring Bolts & Nuts........................................................................ 9
1.3.4.4 Lubrication................................................................................................ 9
1.3.5 Luffing and Folding System ....................................................................... 10
1.3.5.1 Main and Knuckle Boom Cylinders......................................................... 10
1.3.5.2 Cylinder Bolts ......................................................................................... 10
1.3.5.3 Boom Bolts ............................................................................................. 10
1.3.5.4 Boom Bearings ....................................................................................... 10
1.3.6 Lifting Yokes and Optional Systems .......................................................... 11
1.3.6.1 Yokes for Drill Pipe / Casing................................................................... 11
1.3.6.2 Riser Yoke.............................................................................................. 11
1.3.6.3 Slip Joint Spreader Beam....................................................................... 11
1.4 Hydraulic System .................................................................................................. 12
1.4.1 HPU System – H0002 ............................................................................... 12

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 4 of 24

1.4.1.1 Oil Reservoir........................................................................................... 13

1.4.1.2 Hydraulic Filters...................................................................................... 13
1.4.1.3 Cooling System ...................................................................................... 14
1.4.1.4 The circulation system............................................................................ 14
1.4.1.5 Main pumps............................................................................................ 14
1.4.1.6 Main Control Valve (MCV)...................................................................... 14
1.4.1.7 Emergency Hand Pump System ............................................................ 14
1.4.2 Slew System – H0003 ............................................................................... 15
1.4.3 Main Boom & Knuckle Boom System – H0004 – H0005 ........................... 16
1.4.4 Winch System – H0006 ............................................................................. 16
1.4.5 Pilot System – H0007 ................................................................................ 18
1.4.6 Yoke Control System – H0008 .................................................................. 19
1.4.6.1 Main Control Valve H02/2 (MCV) ........................................................... 19
1.4.6.2 Pressure transmitter ............................................................................... 19
1.4.6.3 Hydraulic quick connectors..................................................................... 19
1.4.7 Hoses ........................................................................................................ 19
1.4.8 Pipes and Couplings.................................................................................. 19
1.5 The Electrical System ........................................................................................... 20
1.5.1 Electric Components ................................................................................. 21
1.5.1.1 Joysticks................................................................................................. 21
1.5.1.2 Control Panel.......................................................................................... 21
1.5.1.3 Communications..................................................................................... 21
1.5.1.4 Auxiliary Instrumentation ........................................................................ 22
1.5.2 Crane Control System (CCS) .................................................................... 22
1.5.2.1 Crane Safety and Control System Instrumentation ................................ 23
1.5.2.2 Sensors .................................................................................................. 23
1.5.2.3 Emergency Stops ................................................................................... 23
1.5.2.4 Slack Wire Detection System ................................................................. 24
1.5.2.5 Load Surveillance Camera. (Option) ...................................................... 24
1.5.2.6 Customer supplied equipment. (Options) ............................................... 24

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 5 of 24

1 TECHNICAL DESCRIPTION

1.1 General

Design and function is described to facilitate a better understanding of the different parts
of the operating and maintenance instructions.
Since the complete Crane consists of several systems, the main system is described
first, followed by descriptions for each subsystem and their interconnections.

1.2 Product Description

The NOV Knuckle Boom Crane is mounted on a fixed pedestal and is a self-contained
unit, only to be connected to the vessels main electric power system.

The Crane is a combination Crane designed for loading / unloading of supply vessels
and for load handling internally on the vessel.

Unlike most other Cranes this type has two booms instead of one and therefore has the
possibility to place the load very precisely in nearly every position within the working
area.
To shift the load the Crane utilises either the Main winch or the Booms or a combination
of both.

Optionally the Crane can be equipped with various lifting yokes and other accessories
for internal handling of risers, pipes and containers.

The Crane is a very compact and complex machine, which is made up of several
subsystems wrapped in a robust and compact steel structure; hereafter named the
Crane Structural System.

The cranes main systems are:

• The Mechanical System (Structural)

• The Hydraulic System
• The Electric System
• The Crane Control System (CCS)

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 6 of 24

1.3 The Mechanical System

1.3.1 General

The Crane is built to withstand the high loads and corrosive atmosphere present in an
offshore environment. Special attention is given to avoid corrosion by using well known
anti corrosion systems.

The Crane Structural System consists of the following main parts:

• Pedestal Adapter
• King
• Drivers Cabin
• Crane Booms (Main and Knuckle Boom)

1.3.1.1 Pedestal Adapter

The Pedestal Adapter supports the rotating part of the Crane and it is welded to the
vessel or rigs substructure (Pedestal).

The lower end of the adapter is beveled for weld connection to the Pedestal of the
vessel or rig.

Provisions are made on the adapter for jacking the Crane clear of the Slew Ring
Bearing in order to facilitate bearing replacement if necessary.

1.3.1.2 King

The King is the rotating part of the Crane, mounted on a high quality Slew Ring Bearing
on top of the pedestal.

The hydraulic system, tank and components are weather protected inside the King. A
inspection door in the King gives good access for maintenance and inspection.

The Crane Boom pivot points, as well as the main boom cylinder brackets, are parts of
the Crane King structure.

Platforms are mounted on the King for easy access to the Drivers Cabin and the winch
area on the top.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 7 of 24

1.3.2 Driver’s Cabin

A spacious Driver’s Cabin is mounted on four vibration dampers on the Cabin Platform.
The Cabin is fitted with sufficient windows to give good visibility of the entire working
area.

The Driver’s Cabin is made of marine aluminium and is insulated, which reduces noise
and vibration levels. It is also equipped with air conditioning.

All windows are composed of safety glass, and can not be opened. The front window is
inclined at an angle sufficient to maximise the area of visibility.

Mounting of windows is possible from the inside.

Front, side and roof window is provided with wipers and washers. The top window is
supplied with safety bars.

1.3.2.1 Crane Booms

The Crane Booms are made of a closed box steel construction.

There is a railing along the main boom on both sides for safe access when inspecting
the junction boxes, wire guides and light fixtures.

Another railing is installed at the end of the Knuckle Boom to give access to the wire –
sheaves and load cell placed here.

Lifting points for maintenance are placed in centre of the bolts and cylinders to be lifted.

Provisions for an optional maintenance crane/gallows is made on the Main Boom.

Bearings on boom/boom cylinders that can not be accessed from permanent platforms
are equipped with remote lubrication systems for maintaining the bearings’ grease
sealing system.

1.3.3 Hoisting System

The Crane Hoisting System consists of;

• Hoisting Winch
• Hoisting Wire Rope
• Wire sheaves
• Swivel hooks and blocks

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 8 of 24

1.3.3.1 Hoisting Winch

The Hoisting Winch consists of a steel drum with welded Lebus grooved sleeves, a
winch foundation, planetary gearboxes and hydraulic variable displacement motors.

As a safety measure the winch foundation is equipped with a protection screen.

Proximity switches located in the winch foundation count the steel drum rotations when
the cut-outs in the steel drum flange passes each switch.
The anchorage on the hoisting winch drum is designed to withstand the breaking load of
the wire.
The planetary winch gearboxes are equipped with a fail-safe dynamic multi-disk brake
and a one-way roller clutch (Sprague clutch) immersed and working in gear oil.
Vital brake parts are suitably protected.

The hydraulic motors that drive the gears are directly flanged on the gearboxes.

1.3.3.2 Hoisting Wire Rope

The Hoisting Wire Rope is “non-rotating” type and specified in the Knuckle Boom Crane
Datasheet, Z-DS-001.

1.3.3.3 Wire sheaves

The Wire sheaves in the system are located on the knuckle boom in wire sheave
brackets (WSB) arranged in a way that prevents the wire rope from slipping off.

1.3.3.4 Swivel Hook and Blocks

The Whip hook is a swivel hook supported in a thrust bearing giving full rotational
freedom for the connection link and the safety hook.

The Auxiliary Block is equipped with rams-horn hook with safety latches and one wire
sheave with roller bearing. The rams-horn hook is supported by a thrust bearing giving
full rotational freedom. Two handles are machined out in the side plates for easy and
safe handling of the block. Guiding pins with quick lock rings for easy reeving.

The Main Block is equipped with a rams-horn hook with safety latches and two wire
sheaves with maintenance-free roller bearings and a dead end bolt. The rams-horn
hook is supported by a thrust bearing giving full rotational freedom. Two handles are
machined out in the side plates for easy and safe handling of the block. The
blocks/hooks have guiding pins with quick lock rings for easy reeving.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 9 of 24

1.3.4 Slewing System

The Crane Slewing System consists of;

• Slew Ring Bearing
• Slewing gears
• Slew Ring Bearing Bolts & Nuts

1.3.4.1 Slew Ring Bearing

The Slew Ring Bearing used in the Crane is of a high quality make and of the 3-row
roller bearing type with a retaining device built in, specially designed and calculated for
use on offshore cranes.
The Slew Ring Bearing is capable of withstanding all axial and radial forces and the
resultant overturning moments.
The stationary part (inner ring) of the Slew Ring Bearing is produced with internal gear
teeth, into which the pinions of the slew gearboxes are meshed.

1.3.4.2 Slewing Gears

The Slewing Gear pinion is meshed with the internal geared inner ring of the Slew Ring
Bearing.

The Slewing Gears for the Crane consist of three planetary gears with built-in automatic
acting multi-disc fail-safe brake.
The brake torque is designed to hold the Crane with maximum allowable load and
dynamic additional load at maximum list.
The hydraulic motors, which drive the gears are directly flanged to the gearbox.

1.3.4.3 Slewing Ring Bolts & Nuts

The Slew Ring Bearing Bolts & Nuts are certified according to the pertinent
Classification Rules for the Crane.
When connecting the Crane King / Slew Ring Bearing to the Crane foundation, the Slew
Ring Bearing Bolts have to be pre-stressed by using a special hydraulic tensioning tool
and by following a Tensioning Procedure developed for the purpose.

1.3.4.4 Lubrication

Lubrication of the slew bearing raceways can be performed from a remote lubrication
station, located beside the operator’s cabin. Procedure for lubrication is described in
the cranes user manual.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 10 of 24

1.3.5 Luffing and Folding System

The Crane Luffing and Folding System consists of;

• Main and Knuckle Boom Cylinders

• Cylinder Bolts
• Boom Bolts

1.3.5.1 Main and Knuckle Boom Cylinders

The Main and Knuckle Boom Cylinders for the boom luffing and folding motions are
based on a rugged well-proven construction. The knuckle boom cylinders are double
acting, while the main boom cylinders are single acting.

All the Cylinders have integrated tapered bushings in Orkot® TLM bearings.
Load control valves are mounted directly on the cylinder and are activated by hydraulic
pilot signals when operating the booms.

The piston rods of all cylinders are made of double chrome coated bars in S355K2
quality to obtain good corrosion protection and extended lifetime.

1.3.5.2 Cylinder Bolts

The Cylinder Bolts are special designed bolts by NOV. The bolts have tapered ends to
facilitate easy change out and maintenance.
The Cylinder bolts are equipped with lubrication nipples in both ends.

1.3.5.3 Boom Bolts

The Boom Bolts are special designed bolts by NOV. The bolts have tapered ends to
facilitate easy change out and maintenance.
The Boom Bolts are equipped with lubrication nipples in both ends and threaded in the
centre for fitting of a lifting ring / lug to ease installation or maintenance.

1.3.5.4 Boom Bearings

The Boom Bearings are made of Orkot TXM Marine® self-lubrication bearings to ensure
a long lifetime and facilitate easy maintenance during inspection or change out.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 11 of 24

1.3.6 Lifting Yokes and Optional Systems

The Crane can be equipped with various lifting yokes and other options for internal
handling of various loads, risers and other tubulars:

• Riser handling Tool

• Gripper Yoke
• Riser Yoke
• Slip Joint Spreader Beam

1.3.6.1 Yokes for Drill Pipe / Casing

Magnet and Gripper Yoke are used when handling drill pipe and casing to and from the
catwalk machine. The Gripper Yoke uses grip claws for lifting the tubulars and the
Magnet Yoke utilises electromagnets for the same purpose. (Ref. is made to data book
and user manuals for the Magnet and Gripper Yoke.)

1.3.6.2 Riser Yoke

The Riser Yoke is used for handling risers to and from the catwalk machine. The Riser
Yoke uses grip fingers for securing and lifting of risers. The yoke is also provided with
internal lifting lugs for lifting of pup-pieces and etc. (Ref. is made to data book and user
manuals for the Riser Yoke)

1.3.6.3 Slip Joint Spreader Beam.

A steel structure connected to the riser yoke turning device, used when lifting slip joints.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 12 of 24

1.4 Hydraulic System

Hydraulic Logic Block Diagram – H0001

Reference to the Hydraulic Logic Block Diagram, with regard to the different sub-
stations or branches of the hydraulic system studying this diagram, may be helpful to
get a good understanding of the system.

The drawings are split in the different sub systems and this will ease the understanding
of systems and individual components.

Ref. hydraulic drawings:

H01 : Hydraulic Logic Flow Diagram

H02 : Hydraulic Power Unit System
H03 : Slew System
H04 : Main Boom System
H05 : Knuckle Boom System
H06 : Winch System
H07 : Pilot System
H08 : Yoke Control System

1.4.1 HPU System – H0002

Code hoses: 500

The system is an integrated part of the crane king and includes:

Oil reservoir with equipment

Hydraulic filters

Oil coolers

Circulation pumps

Main pumps

Main control valve (MCV)

Emergency hand pump

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 13 of 24

1.4.1.1 Oil Reservoir

The reservoir contains the following components

Visual oil level indicator with level sensor.

Air breather filters

Temperature sensor

Oil return- and leak filters with ∆p sensors (only electrical sensors)

The HPU has an oil reservoir integrated as a part of the crane king. This oil reservoir is
designed to maintain the necessary volume of hydraulic oil for crane operation. Visual
inspection and cleaning of the oil reservoir is possible through the inspection hatch.

Filling and draining of the oil reservoir is made possible by separate lines with easy
accessible hand operated valves. When filling, the oil is forced to pass through return
filters and by this have an extra security for having clean oil into the reservoir.

All drain oil is led through a separate drain filter.

All filters are equipped with ∆p indicators and are connected up to the CCS for alarm
setting.

1.4.1.2 Hydraulic Filters

Pressure Filters:
Full flow fine filters are installed and sized for full flow operation and to keep the total oil
volume to cleanliness class 8 according NAS 1638.

Return Filters:
3 pc of return filters with both optical and electrical indicator are mounted in the oil
reservoir. The filters are tank mounted.

Leak Oil Filter:

1 filter with both optical and electrical indicator. The design protects the system against
heavy contamination in case of hydraulic pump/motor breakdown, and will normally also
give the operator an early warning of an imminent breakdown. The filter is tank
mounted.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 14 of 24

1.4.1.3 Cooling System

The cooling system contains the following components:

Oil cooler

Temperature indicator

For oil cooling, some of the flow from the circulation pumps and return oil is led over the
cooler (s) (H09/1-2) and the CCS start and stops the fan according to the oil
temperature.

Temperature indicator is mounted in the oil tank.

The oil temperature shall not exceed the recommended maximum value during full
operation of the Crane.

1.4.1.4 The circulation system

The circulation pump (H01/5-6) will ensure clean and correctly tempered oil at any time,
as the fluid circulates in the system through the oil coolers and filters in the hydraulic oil
tank.

1.4.1.5 Main pumps

Two pump towers, each consisting of 2 variable displacement pumps, and 1 vane pump
for circulation, are connected to separate electric motors with a flexible coupling in
between.

The main pumps deliver the oil flow to the MCV. The MCV routes the oil flow to the
different crane consumers.

The oil flow from the pumps is infinitely variable from zero to max by changing the pump
displacement. This is made possible by turning the swash plate.

Different pressure relief valves limit the maximum pressure. This in addition to limits set
by the PLC.

1.4.1.6 Main Control Valve (MCV)

The proportional valves located on the main control block (H02) controls the oil flow
from the pumps out to the different systems.

The main control valve is equipped with pressure compensator ensuring load
independent speed control.

1.4.1.7 Emergency Hand Pump System

See procedure located on crane (close to hand pump).
The system is equipped with a selector valve (N04) for routing the oil from the hand
pump (N01) to the consumers.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 15 of 24

1.4.2 Slew System – H0003

Code hoses: 300

The slew system is made as an open loop system.
The system is built up of a slew ring which is driven by mechanical planet gear. The
gears are equipped with mechanical parking brakes. A positive hydraulic pressure has
to be applied to the brake unit to release the brake when in parking position.
Each gear is driven by a hydraulic motor mounted on top of the gear.
The slew system is operated by means of the main control valve (H02)

The system also contains valve block (S60) that contains counter balance valves which
are opened by hydraulic pressure and will provide a smooth retardation, short cut valve,
main control valve and emergency system for releasing of brakes (hand pump N01).
The slew system has refilling from the return/replenishment system to prevent
cavitations.

The setting of the bypass valve and releasing of slew brakes are programmed to work
together. This is done to prevent the possibility of slew brake torque moment and motor
moment being active at the same time.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 16 of 24

1.4.3 Main Boom & Knuckle Boom System – H0004 – H0005

Code hoses Main boom: 200

Code hoses Knuckle boom: 700

Main Boom:
The hydraulic boom cylinders are based on a rugged well proven construction.
Locking valve is mounted directly on the cylinder bottom (B02/1-2) and short cut valves
(B02/3-4) for equalising of pressure when lowering. These are opened by hydraulic
pressure when operating boom down. When driving boom up the oil passes through a
one way valve. If case of hose rupture, the cylinder locking valves will close and the
boom motion stop when joy stick is in centre position or towards hoisting.
A pressure transmitter is installed for measuring pressure on the load side and a
potentiometer is installed to measure the boom position. The boom speed is load
independent.

The system also contains emergency hand pump (N01), that opens the counter balance
valves when emergency lowering.

Knuckle Boom;
The hydraulic boom cylinders are based on a rugged well proven construction.
Locking valve is mounted directly on the cylinder bottom (K02/1-2) and directly on the
cylinder top (K02/3-4). These are opened by hydraulic pressure when operating boom
in/out. If case of hose rupture, the cylinder locking valves will close and the boom
motion stop when joy stick is in centre position or towards opposite position.
A potentiometer is installed to measure the boom position.

General
The booms are operated by means of the main control valve (H02).

The system also contains emergency hand pump (N01), that opens the counter balance
valves when emergency lowering.

1.4.4 Winch System – H0006

Code hoses: NA.

The Winch system is an open loop system.

The brake is of the fail-safe type, i.e. a positive pressure has to be supplied to the brake
unit to release the brake. When this pressure is not present, e.g. in a situation of hose
failure, the brake is automatically engaged.
A sprague clutch will allow the winch to rotate in hoist direction without releasing the
brake, the gear brake is working as a parking brake.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 17 of 24

The gearbox is driven by a direct flanged-on continuous variable pressure controlled

piston motor.

The system also contains valve block (W65)

Short cut valve (W65/4) is connected to the MOPS valve (N63) and are the main parts
in the MOPS system (see descriptions below).

Hydraulic Motors:
There are 2 axial piston units of bent axis design with variable stroke, this gives
automatically higher speed at reduced load. They may operate as hydraulic pumps or
as hydraulic motors.

When the unit is used as a motor, the drive speed is proportional to the flow feed to the
unit.
The torque produced by the motor increases as the pressure drop increases between
the high and low-pressure sides.

When operating as a pump, the unit converts hydrostatic energy into mechanical
energy.

Sea Lift Mode, Constant Tension. (CT)

To be used when lifting of from supply vessel.

The winch has following modes:

• Normal up and down operation

• Emergency lowering when totals power blackout (See procedure located near
hand pump)
• MOPS/ MER (Manual Overload Protection System)
• Personnel lift (If applicable)
• Sea lift mode witch includes: (Lifting from/ to Supply Vessel)

AOPS (Automatic Overload Protection System)

CT (Constant tension )

Normal Mode:
Normal mode allows control of winch / hook according to operator joystick input.

Emergency Lowering:
In case of power loss it is possible to lower the winch by use of the hand pump N01.

Manual Overload Protection System (MOPS):

The Activation handle is located in the operator’s cabin near by the operator’s seat for
rapid access. It is permanently marked and protected against inadvertent use.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 18 of 24

The MOPS system is a manually activated system and is therefore available

independently of crane mode or load situation.

The system will be kept in this mode until released by the operator. The hydraulic
system is secured in case of power failure by an accumulator system, sized to activate
the system minimum three times and keep it activated for at least five minutes.

When the MOPS handle is activated the load will incontinently drop to the ground. If
released, the hydraulic motors can be damaged and have to be checked.
A continuously illuminated Red lamp “MOPS” visually indicates activated system,
together with an external acoustic signal that will sounds as long as MOPS is activated.

Personnel Lift (If applicable):

In this mode the MOPS are disabled.

Sea Lift Mode, Automatic Overload Protection System (AOPS)

If a defined overload occur, the CCS takes appropriate action relevant to the hydraulic
AOPS control valve and instrument panel, the mechanical brake will be released and
the winch maintains a retaining force not less than the corresponding SWL. An activated
system overruns the lower hook stop.

A continuously illuminated Red lamp “AOPS” visually indicates activated system,

together with an external acoustic signal that will sounds as long as AOPS is activated.

Sea Lift Mode, Constant Tension (CT))

CT mode can not be entered with load in hook.
When activated, the winch will hold the wire rope tight and maintain a low holding force.
When deactivating CT, the system will switch back to normal holding force.

1.4.5 Pilot System – H0007

Code hoses pilot system: NA

Main components in pilot system are:

• Accumulator for Winch MOPS system, N66

• Solenoid valves
• Hydraulically operated valves /consumers
• AOPS / CT system

Main motions as hoisting winch, slew, main boom and knuckle boom operation are
operated by electrical joysticks in the cabin. Signals goes to the PLC and then to
electric/hydraulic proportional solenoid valves for each operation.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 19 of 24

1.4.6 Yoke Control System – H0008

Code hoses: 800

The system is for operating of different Yokes, and includes:

Main Control Valve H02/2

Pressure transmitter.

Hydraulic quick connectors.

Relief valve

1.4.6.1 Main Control Valve H02/2 (MCV)

The proportional valves located on the main control block (H02/2) controls the oil flow
from the pumps out to the different yoke systems.

The main control valve is equipped with pressure compensator ensuring load
independent speed control.

1.4.6.2 Pressure transmitter

The Pressure transmitter reads the pressure from the different yoke consumers, and
sends the signal to CCS (PLC), which uses the signal to control pump- pressure and
flow.

1.4.6.3 Hydraulic quick connectors

The Hydraulic quick connectors are for connecting the different yokes to the crane’s
hydraulic system.

1.4.7 Hoses

Only flexible hoses of the best quality with type approval certificate are used. They are
properly clamped to the structure and well protected during painting etc.

Hose couplings (fittings) used are of cadmium plated carbon steel sealed with Denso
tape (only external couplings) after assembling and mounting.

1.4.8 Pipes and Couplings

From 10 to 38 mm pipe – Walform S-type.

All exposed hydraulic piping is stainless steel AISI 316L incl. nuts and sleeve. Internal
hydraulic piping < 16mm are AISI 316L, pipes > 12mm are cadmium plated carbon
steel.

Pipe/ Tube > 38mm – GS Hydro Flange System.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 20 of 24

1.5 The Electrical System

General

The main power supply to the Crane is 2 times 485 kW, 440 V / 3 ph, 60 Hz for the two
HPU motors + 30 kW, 440 V / 3 ph 6 Hz for Aux. equipment. The feeding cables from
the vessel are connected to the slipring unit in the Crane pedestal via a termination box.

The motor starter for each main motor is located inside pedestal. The start method is
star/delta. The start/stop switches for the motors are located inside the operator cabin.
Emergency Stop switches are located in cabin, king and pedestal.
The main motors are equipped with anti- condensation heating elements, which
automatically switch on when the motors are not in service. The main motors are
provided with thermistor protection.

The oil cooler motors are controlled from control panel in the king. The start and stop of
the oil cooler motors is controlled by the PLC. If the oil cooler switch in operator’s panel
in the cabin is in Manual position, the oil cooler motors are running continuously. If the
switch is in the Auto position the oil cooler motors start when receiving signal from the
PLS, depending on temperature. The oil cooler motors are equipped with the following
protection:

- Over current protection

- Short circuit protection.

The power supply for the lighting and heating system is supplied via a transformer
located inside the pedestal. All switches for controlling the floodlights and auxiliary lights
are located on the operator panel in the cabin. The 2 floodlights on the Knuckle-boom
are EEx rated for zone 1 T3.

The Crane Control System has a separate UPS power supply via the slipring, 1 x
220VAC 60 Hz
The aviation lights have a separate UPS power supply via the slipring, 1 x 220 VAC 60
Hz.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 21 of 24

The drawings are split in the different sub-systems and will ease the understanding of
systems and individual components:

Ref. electrical drawings:

E0001 El. Block Diagram, Electrical 1

E0002 El. Block Diagram, Electrical 2

E0003 El. Block Diagram, Electrical 3

E0004 El. Block Diagram, Electrical 4

E0010 El. Block Diagram, Instrument 1

E0011 El. Block Diagram, Instrument 2

E0012 El. Block Diagram, Instrument 3

E0013 El. Block Diagram, Instrument 4

E0020 El. Block Diagram, Telecom

E0021 El. Block Diagram, Telecom and CCTV

1.5.1 Electric Components

1.5.1.1 Joysticks

The joysticks are mounted on the Drivers chair, one on each side for armrest operation.
They are self-centring. The joysticks have functions as slewing left and right, slewing of
yoke, up and down functions of booms and main winch tension. (Ref. chapter 6.
Operating Instructions)

1.5.1.2 Control Panel

There is also a control panel mounted on operator’s right eye level with various control
functions and alarm lamps. The control panel also has a display for showing various
safety and status functions of the Crane. Operator can also make parameter settings
inputs on the display.

1.5.1.3 Communications

A loudhailer system is installed for one way communication from Crane operator to
deck.

The Crane is equipped with PA-A, and telephone systems inside the Drivers Cabin.
These signals are routed via the EExd slipring and the equipment is for zone 1
installation.

Inside the Drivers Cabin a VHF radio is installed. The power supply to the radios is from
the vessels UPS power supply.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 22 of 24

1.5.1.4 Auxiliary Instrumentation

There is the following auxiliary instrumentation:

Aviation Lights

Flood Light on Main Boom - front and aft, Cabin front and Knuckle Boom

Cabin heaters, one with fan beneath the operator chair and one of the convection
type.

Inside cabin light, platform light, light in king, light at winch area, light in pedestal

Front- and side window wipers with screen washer and top window wiper

Warning horn

Hydraulic Oil Cooler Fan 1

Hydraulic Oil Cooler Fan 2

1.5.2 Crane Control System (CCS)

General:
From the joysticks in the operator chair via the PLC, the proportional valves control the
slew, boom and winch motions. The signals from the joysticks run through Profibus DP
Communication. In the PLC the signals are going through a ramp function and different
safety functions: hook stop, load safety and speed reductions functions.
The results of the signals treatment gives output signals to the proportional valve
amplifiers. From the proportional valve amplifiers a command signal to the proportional
valves results in soft and accurate motions of the Crane.

On the joystick there are push buttons to choose different Crane modes. All these digital
signals are routed to the PLC. The PLC treats the signal and the necessary actions are
taking place, solenoid valves, lamps or alarms are activated.

There are several sensors in the Crane; typically: emergency pay out, motor running, oil
level low, emergency pilot accumulator pressure and filter alarm switches. All these
signals are routed to the PLC and different alarms and information on the operator
display are controlled by the PLC.

The Main boom is equipped with angle sensors, i.e. potentiometers that measure the
absolute angle between the Main boom and the King.

The Knuckle boom is also equipped with angle sensors that measure the relative angle
between the Main boom and the Knuckle Boom. This is a system similar to the sensors
at the Main boom.

The actual working radius and SWL are calculated in the PLC using the angle sensors
as the reference. These sensors are also used to reduce the boom speeds in the end-
positions for the boom cylinders.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 23 of 24

The system has a temperature transmitter mounted in the oil reservoir. The transmitter
gives out an analogue output signal to the PLC. High oil temperature alarms and start /
stop of oil coolers are controlled by the PLC based on the input from the temperature
transmitter.

The load measurement is performed by a load cell bolt, mounted in the wire sheave at
the inner end of the main boom. There is a load cell amplifier in the control panel in the
cabin. The amplifier gives an analogue input signal to the PLC.
Two proximity switches (initiators) control the hook stop function of the winch. The
sensor signals are input to the PLC, which counts pulses from the sensors and also
detects the direction of motion. Via the operator display it is possible to reset the
counting to zero and set span for the motion. The operator display will continuously
show the actual wire paid out on the winch. (I.e. from hook stop up position)

1.5.2.1 Crane Safety and Control System Instrumentation

1.5.2.2 Sensors

There are the following sensors for the Crane Safety and Control System.

Load cell for load sensing, mounted on knuckle boom inner-most end

Load cells for yokes

Boom angle transmitters

Boom cylinder pressure transmitters

Slew position tachometer

Hoisting winch length measuring sensors

Hydraulic pressure switch for emergency pay out

Filter alarms

Alarm horn (not a sensor).

1.5.2.3 Emergency Stops

There are 3 emergency stop buttons.

Locations are:
- Inside the Drivers Cabin
- Inside the King (Machine room)
- Inside the Pedestal adapter, below the King.

www.natoil.com
 Document number V3054-Z-SA-001
Revision 2
Page 24 of 24

1.5.2.4 Slack Wire Detection System

To be able to detect and prevent a dangerous situation a slack wire detection system is
installed under the winch drum to pick up any slackening of the wire on the winch drum
during operation.
If a situation occurs, the device will send a signal to the PLC and an alarm will be
displayed in the Operator’s panel

1.5.2.5 Load Surveillance Camera. (Option)

A Load Surveillance Camera may be mounted on the knuckle boom tip. In the Driver’s
Cabin the Crane driver can easily follow the load on the screen, operating in tight
spaces or on the supply vessel. Zoom and contrast facilities are standard equipment.

1.5.2.6 Customer supplied equipment. (Options)

In some of the contracts customer will supply free issued items such as;

- Smoke detectors
- Gas sensors
- UHF and VHF radios
- Radio / CD player
- Telephone and loudspeakers A/B
- PA system

These items can be installed by NOV upon request or according to the contract.

www.natoil.com
TABLE OF CONTENTS Document number
Revision
V3054-Z-MA-001 TOC section 4
5
Page 1

Section Title Document Number Rev.

Other Document Number

4 Operating Instructions
Operating Instructions, OC3932KCE Knuckle Boom Crane No. 1 Pride No. 2 V3054-Z-MA-007 4

nov.com
 Operating Instructions
OC3932KCE Knuckle Boom Crane No. 1
Pride No. 2

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

ENSCO DS-4 V3054 OC3932KCE-(17-85)-(42-18)(27) No 1
ADDITIONAL CODE SDRL CODE TOTAL PGS
8 90 This document contains proprietary and confidential Postbox 401
information which belongs to National Oilwell Varco; it is Lundsiden
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in 4604 Kristiansand S
MAIN TAG NUMBER DISCIPLINE part; or use of this design or distribution of this information NORWAY
to others is not permitted without the express written Phone +47 38 19 20 00
consent of National Oilwell Varco. This document is to be
CLIENT PO NUMBER returned to National Oilwell Varco upon request and in Fax +47 38 19 26 04
any event upon completion of the use for which it was
loaned.
© Copyright National Oilwell Varco - 2018

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

V3054-Z-MA-007 4
 Document number V3054-Z-MA-007
Revision 4
Page 2 of 90

REVISION HISTORY

4 10-Dec-2018 Reissued for Implementation TOLV PESK SIHL

3 10-Jun-2014 Reissued for Implementation HASW OLJA FRO
2 21-Sep-2011 Reissued for Implementation JOHN EITR EITR
1 16-Feb-2011 Reissued for Implementation HAOS BRA BRA
0 2-Mar-2010 Issued for Implementation HAOS FRO FRO
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change description

4 1.6.9.1 Display Hierarchy - updated
1.6.9.10 Limits Menu - updated
1.6.9.21 Anti Collision Limits - deleted
1.6.9.21 Virtual Wall System - added
1.6.9.43 Dealing with Alarms. Alarms 129,130,187 and 188 added. Alarms 185 and 186
updated
1.10 Training Programs for Operating and Maintenance Personnel - revised
3 Updated:
1.6.9.1 Display Hierarchy
1.6.9.5 Crane Display - Main Winch
1.6.9.6 Crane Display - Gripper Yoke
1.6.9.10 Limits Menu
Added:
1.6.9.22 Anti Collision Cradle Park
2 1.6.9.10 Replaced Limits Menu screen (new button)
1.6.9.21 Added Anti-collision Limits screen
1.6.9.42 Added alarm text lines for anti-collision system
1 1.3 - Safety Summary. WARNING text added.
1.5 - Em. Stops and Shutdown Functions. 'Functions' description revised.
1.6 - Normal Operation. 'Normal Stop - End of Operation', NOTE added.
1.6.7 - Monitoring System. Added.
0
 Document number V3054-Z-MA-007
Revision 4
Page 3 of 90

TABLE OF CONTENTS

1 OPERATING INSTRUCTIONS................................................................................................................... 6
1.1 Introduction .................................................................................................................................... 6
1.2 General Information ....................................................................................................................... 7
1.3 Safety Summary ............................................................................................................................ 8
1.4 UPS ............................................................................................................................................... 9
1.5 Emergency Stop and Shutdown Functions ................................................................................... 10
1.6 Normal Operation......................................................................................................................... 11
1.6.1 Main Operator Station ...................................................................................................... 13
1.6.2 Functions on the Left Hand Joystick and -Armrest ............................................................ 14
1.6.3 Functions on the Right Hand Joystick and -Armrest .......................................................... 15
1.6.4 Control Cabinet – IB001 ................................................................................................... 16
1.6.5 Foot Pedal........................................................................................................................ 17
1.6.6 Air Condition Unit ............................................................................................................. 17
1.6.7 Monitoring System............................................................................................................ 18
1.6.8 Defroster System.............................................................................................................. 19
1.6.9 Operator Display – IB002 ................................................................................................. 20
1.6.9.1 Display Hierarchy .......................................................................................................... 21
1.6.9.2 Display Status Bar ......................................................................................................... 22
1.6.9.3 Password Protected Screens......................................................................................... 24
1.6.9.4 Main Menu .................................................................................................................... 25
1.6.9.5 Crane Display – Main Winch.......................................................................................... 26
1.6.9.6 Crane Display – Gripper Yoke ....................................................................................... 28
1.6.9.7 Secondary Info – Main Winch and Gripper Yoke ............................................................ 30
1.6.9.8 Mode Select .................................................................................................................. 31
1.6.9.9 System Menu ................................................................................................................ 32
1.6.9.10 Limits Menu ................................................................................................................. 34
1.6.9.11 Main Winch Limits ....................................................................................................... 35
1.6.9.12 Boom Angle Settings ................................................................................................... 36
1.6.9.13 Main Winch Load Cell .................................................................................................. 37
1.6.9.14 Reload Load Cell Main Winch ...................................................................................... 39
1.6.9.15 Yoke Load Cell ............................................................................................................ 41
1.6.9.16 Reload Load Cell Yoke ................................................................................................ 42
1.6.9.17 Crane Slew Limits (Slew Zero) ..................................................................................... 43
1.6.9.18 Set Slew Limit Sectors ................................................................................................. 44
1.6.9.19 Set Sea Lift Sector....................................................................................................... 45
1.6.9.20 Yoke Slew Limits (Yoke Slew Reset) ........................................................................... 46
1.6.9.21 Virtual Wall System ..................................................................................................... 47
1.6.9.22 Anti Collision Cradle Park ............................................................................................ 49
 Document number V3054-Z-MA-007
Revision 4
Page 4 of 90

1.6.9.23 Test Menu ................................................................................................................... 51

1.6.9.24 Digital Input, Screens 1-3............................................................................................. 52
1.6.9.25 Digital Output, Screens 1-2 .......................................................................................... 53
1.6.9.26 Analog Input ................................................................................................................ 54
1.6.9.27 Analog Output, Screens 1-3 ......................................................................................... 55
1.6.9.28 Joysticks ..................................................................................................................... 56
1.6.9.29 Counters ..................................................................................................................... 57
1.6.9.30 Loadcells ..................................................................................................................... 58
1.6.9.31 Movements.................................................................................................................. 59
1.6.9.32 Statistics (Hour Counter).............................................................................................. 61
1.6.9.33 AOPS Reset ................................................................................................................ 62
1.6.9.34 Lift Logger ................................................................................................................... 63
1.6.9.35 Dynamic Overload Reset ............................................................................................. 64
1.6.9.36 Wipers and Washers ................................................................................................... 65
1.6.9.37 Flood Lights................................................................................................................. 66
1.6.9.38 Cabin Ventilation ......................................................................................................... 67
1.6.9.39 Sea Lift Significant Wave Height .................................................................................. 68
1.6.9.40 Main Motors ................................................................................................................ 69
1.6.9.41 Alarm Page ................................................................................................................. 71
1.6.9.42 Alarm History............................................................................................................... 72
1.6.9.43 Dealing with Alarms ..................................................................................................... 73
1.6.9.44 How to Recover after PLC Breakdown ......................................................................... 79
1.7 Load Handling.............................................................................................................................. 80
1.7.1 Load Measuring System ................................................................................................... 80
1.7.2 Procedures....................................................................................................................... 81
1.7.2.1 Personnel Lift ................................................................................................................ 81
1.7.2.2 Internal Load Handling................................................................................................... 81
1.7.2.3 Sea Lift .......................................................................................................................... 82
1.7.2.4 Preparing the Crane for Yoke Operation ........................................................................ 83
1.7.2.5 Hook Stop Up Setting .................................................................................................... 83
1.7.2.6 Hook Stop Down Setting................................................................................................ 83
1.7.2.7 Slew Zero and Sealift Sector Setting.............................................................................. 84
1.7.2.8 Slew Limit Sector Setting ............................................................................................... 84
1.7.2.9 Boom Angle Setting ....................................................................................................... 85
1.7.2.10 Winch Load Cell Calibration......................................................................................... 85
1.7.2.11 Reload Winch Load Cell Values ................................................................................... 86
1.7.2.12 Yoke Load Cell Calibration .......................................................................................... 86
1.7.2.13 Reload Yoke Load Cell Values .................................................................................... 86
1.8 Emergency Operation .................................................................................................................. 87
1.8.1 Emergency Lowering Procedure ....................................................................................... 87
 Document number V3054-Z-MA-007
Revision 4
Page 5 of 90

1.8.2 MOPS .............................................................................................................................. 89

1.9 Disturbance of Operation ............................................................................................................. 90
1.10 Training Programs for Operating and Maintenance Personnel ...................................................... 90
1.11 Attachment .................................................................................................................................. 90
 Document number V3054-Z-MA-007
Revision 4
Page 6 of 90

1 OPERATING INSTRUCTIONS

1.1 Introduction

This document describes the National Oilwell Varco TM Knuckle Boom Crane for the rig/user stated at the
document front page.

The operating instructions are based on the assumption that the equipment has been installed and
commissioned, and thus are ready for ordinary routine operation. It is also assumed that the operator has
studied the technical description and drawings and is familiar with the overall system.

The National Oilwell Varco TM Knuckle Boom Crane is mounted on a fixed pedestal and is a self-
contained unit, only to be connected to the platform/vessels main power system.

The crane is a combination crane designed for loading/unloading of supply vessels and for load handling
on ships or platforms.

Unlike most other cranes, this type has two booms instead of one, and therefore has the possibility to
place the load very precisely down in nearly every position within the area of the working radius.
To shift the load the crane utilises either the main winch or the booms or a combination of both.

The crane can be equipped with various lifting yokes and other accessories for internal handling of risers,
pipes and containers
 Document number V3054-Z-MA-007
Revision 4
Page 7 of 90

1.2 General Information

The following documents may be referred to in the Operating Instructions:

Document Name Document No. Section

Introduction for User Manual 74309174 Introduction
Product Data Sheet Z-DS-001 Data Sheet
Technical Description Z-SA-001 Technical Description
Derating Charts Z-RD-003
Verifying Documentation
Crane Load Diagram Z-RD-010
Drawings & Parts Lists NA Drawings & Parts Lists
Standard Documentation Z-MA-010 Standard Documentation
User Manual for the Gripper Yoke 20” Issued separately (Doc. No.: V3116-Z-MA-001)
The following abbreviations may be used in the User Manual
AER Automatic Emergency Release
AOPS Automatic Overload Protection System
ASOPS Automatic Subsea Overload Protection System
AHC Active Heave Compensation
APV Air Pressure Vessel
AW Auxiliary Winch
CCS Crane Control System
CPU Central Processing Unit (Part of PLC)
CT Constant Tension
FAT Factory Acceptance Test
F&G Fire and Gas
HC Heave Compensation
HP High Pressure
HPU Hydraulic Power Unit
LP Low Pressure
NOV National Oilwell Varco (previously Hydralift ASA, now a part of National Oilwell Varco, Inc.
MER Manual Emergency Release
MOPS Manual Overload Protection System
MRU Motion Reference Unit
MW Main Winch
NS Norwegian Standard
OD Outer Diameter
PLC Programmable Logic Controller
RPM Revolutions Per Minute
SP Set point
SWL Safe Working Load
TW Tugger Winch
UPS Uninterrupted Power Supply
 Document number V3054-Z-MA-007
Revision 4
Page 8 of 90

1.3 Safety Summary

The following types of safety messages may appear in various segments of this section
WARNING: Must be observed to prevent serious injury.
CAUTION: Must be observed to prevent damage of equipment and/or loss of operating effectiveness.
NOTE: Must be observed for correct and efficient operation.
It is the responsibility and duty of all personnel involved in the operation and maintenance of this equipment to
fully understand the SAFETY measures, by which hazards are reduced or eliminated. Personnel must familiarize
themselves with all aspects of safety and operation of the equipment before starting any operation or
maintenance.
The following points sum up the safety aspects related to operation:
 Only qualified personnel shall operate the crane. The vessel/rig operator is solely responsible to assure
necessary qualification of the crane operator according to the national authorities requirements
 Get familiar with the emergency equipment on the crane.
 Instructions and warnings given on the crane must be read and followed.
 The crane must only be used for the prescribed purpose, and in accordance with the given operating
instructions.
 Do not operate the crane when the wind speed and other weather conditions exceed the crane specifications.
 Ensure correct use of the safety latches on the hook blocks and swivels. In subsea mode (if applicable) the
subsea safety latch must be mounted on the hook and secured with bolt before load handling can be started
 Ensure that the lay down area is apt for the maximum load imposed
 A portable fire extinguisher is mounted easily accessible inside the crane cabin. Instructions for use are found
on the fire extinguisher itself.
 Beware of the risk of hose/pipe bursting, resulting in pressurized oil flowing out. If any personnel get hydraulic
oil into their eyes or open wounds, wash at once with lots of fresh water. Consult a medic if necessary.
 The operator must always be able to see the landing area for the load or be in direct contact with a flag-/
slinger-/ signal- man who can see the landing area.
 Never walk under hanging load or leave the load hanging without supervision.
 If any personnel not involved in the lifting operations enter the working area, the crane operator must be
informed immediately.
 Always use hearing protection outside of the cabin when the crane is running. Keep cabin door, windows,
hatch on king and natural ventilation openings closed when crane is running in order to maintain lowest
possible noise level within the cabin.
 Keep alert for any alarms.
 Ensure correct spooling of wire on winch (-es) (if applicable).
 Extreme care must also be shown when operating the winch up and boom up motion when the boom angle is
near its maximum value and the hook is close to the hook stop, as the load may hit the underside of the boom
or the boom cylinder.
 Never deliberately overload the crane.
 If defects or abnormal performance is observed, the crane should be removed from service at once.
 Prior to operation of personnel lift (if applicable), refer to procedures for personnel lift.
 During operation of personnel lift (if applicable), crane driver must have continuous communication with either
the personnel to be lifted or a flag-/ slinger-/ signal- man.
 When personnel are required to work the crane for inspection, maintenance or other reasons, the crane shall
be taken out of service and a system shall be put in operation to ensure that they are not endangered by
movement of the crane and that a secure working place is provided.
 Do not adjust the various relief valve settings to other values than those shown on the hydraulic diagram.

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 9 of 90

The following points sum up the safety aspects related to operation (continued):

Applicable to offshore cranes fitted with yoke and pipehandling cranes

 When operating the drill pipe gripper, always remember to operate the locking device before lifting. Always
make sure that the grippers are fastened properly before lifting.
Applicable to pipehandling cranes
 The pipehandling crane must not be used for lifting operations together with the other cranes (if applicable), if
the total load exceeds the SWL of the pipehandling crane
WARNING!
BEFORE ENTERING THE CRANE, THE CRANE OPERATOR MUST BE INFORMED IF PERSONNEL ARE
INSIDE THE CRANE MACHINERY HOUSE/KING, PEDESTAL OR ON THE BOOM.
WARNING!
THE CRANE OPERATOR MUST NEVER LEAVE THE OPERATOR CABIN WHILE THE CRANE IS RUNNING.

1.4 UPS

The UPS (Uninterrupted Power Supply) to the crane is essential for safe operation, hence irregularity with
the UPS power must be taken care of, and the crane operator must be warned immediately. In case of
irregularity on the UPS system, the crane must only be operated in normal mode until the problem is
solved.
 Document number V3054-Z-MA-007
Revision 4
Page 10 of 90

1.5 Emergency Stop and Shutdown Functions

Location, function and procedures for the Emergency Stops

All emergency functions have red coloured buttons or levers. Activating an Emergency Stop cuts the electrical
supply to the hydraulic valves and stops all motors.

In total there are three emergency stop buttons for the crane, located as following:
Location

 One inside the crane cabin

 One inside the foundation
 One inside the crane king

The purpose of the emergency stop is to provide a quick way of stopping the crane in an emergency
situation if the crane is out of control or if the ordinary stop function does not work.

Pushing an Emergency Stop button cuts the electrical supply to the hydraulic valves and stops all motors.
In addition, all brakes are immediately activated and all valves are set in fail-safe position.

All handles and buttons for operation of the crane, are spring centred to neutral. This means that any
movement will stop when releasing the handle or button.
Functions

To protect against unintended activation of the emergency stops, all emergency stop buttons are covered by
protection covers

All emergency stop functions will still work, regardless of any malfunction of the programmable control
system.

If restart is not possible, the load can be lowered by means of the emergency lowering system. Ref.
segment regarding Emergency Operation further on in this section.

NOTE:
Starting procedure after an Emergency Stop
WARNING!
PRIOR TO RESTART AFTER AN EMERGENCY STOP, ENSURE THAT THE REASON FOR THE
EMERGENCY STOP IS IDENTIFIED AND THAT ANY DANGEROUS SITUATION (-S) IS CLEARED UP.
1. Pull out the activated Emergency Stop push-button to release the switch
Start the crane according to normal starting procedure. Ref. the segment regarding Pre-start on the next
2.
page

Inside the cabin Inside the king Inside the pedestal

 Document number V3054-Z-MA-007
Revision 4
Page 11 of 90

1.6 Normal Operation

Normal Operation
If the crane is to be used in load handling operations in yoke mode, please ref. to the User Manual for the
connected yoke. The segment regarding Load Handling (Procedures) further on in this section shall also be used
as reference. The procedures described in the segment below are general procedures for crane usage
Procedures
Prior to starting the crane, the following checks and inspections must be carried out:
Description
1. Make sure the weather conditions are within the crane specifications given in the product data sheet.
2. Emergency stops are not activated.
3. MOPS is not activated.
4. Emergency lowering valves are repositioned for normal operation.
No personnel uninformed of start are located in the crane base, pedestal platform, king (machinery
5.
house), top of king, or on the boom.
Clear and unrestricted view of the load and working area. If not, the crane operator should be in direct
6. contact with a flag-/ slinger-/ signal- man who can see the landing area. Check the communication
system between the supervisor/slinger man and the crane operator, thus ensuring safe operation.
The crane must only be used for the prescribed purpose, and in accordance with the given operating
7.
instructions and the cranes capacities such as SWL/WLL, working radius/height.
8. Take into consideration environmental conditions like visibility (fog, snow etc), icing and such.
All lifting gear (including shackles and slings) must be in good condition and certified for the lifting
9.
Pre-start

operation.
Check that the main and knuckle boom angle indicators show correct value before lifting the crane
10.
from the boom rest support.
11. Check correct function of all other indicators relevant.
Verify that the steel wire rope runs free on the boom and through the sheaves. Remove any
12.
obstructions.
13. Turn on the winch camera monitor (if applicable) and activate the camera (-s).
14. Ensure that all aviation lights are lit (if applicable).
Use the key switch for “System On”. Both joysticks in neutral position and joystick switch in OFF
15.
position.
16. Oil circulation pump switch (if applicable) in auto position.
17. Oil cooler switch in auto position.
18. Ventilation fan switch in auto position.
19. Check the crane configuration (crane mode, wire rope fall (-s) etc.).
20. Perform a function check of the operating controls and limiting devices.
Ensure correct function of the protection/safety systems such as, but not limited to: AOPS, MOPS and
21.
those systems they are composed of are within the parameters of their operation.
Description
1. Plan the lift (weight, working radius, significant wave height). Study the load charts and derating tables.
2. Start the motors.
3. Check the ‘active alarm’ page.
4. Check the display information.
5. Check that the angle indicators changes value as soon as the boom starts moving.
6. The hook has to be disconnected from its fixed points in deck or lifted out of the hook cradle
Start

When the crane is parked in a boom cradle, the first boom movement shall be the ‘Knuckle Boom In’
7. function, this to compensate for eventual creeping of the knuckle boom that might have occurred
during the parking period, further easing the exit from the boom cradle.
Lift the main boom up until the knuckle boom is completely free of the boom cradle. Be especially
8. aware of the risk of the wire getting hooked up to the structure. The wire shall be unobstructed at all
times.
When the crane is completely free of the boom cradle, the knuckle boom can be folded out and the
9.
crane operated according to procedures.
 Document number V3054-Z-MA-007
Revision 4
Page 12 of 90

Description
1. Ensure that loads do not exceed the cranes limitations.
Ensure correct use of slings (rope or chain). The hoist rope, or if applicable the hoist chain, shall be
vertical throughout the hoisting operation. The load shall initially be lifted just clear of the supporting
During Operation

surface and be brought to rest while the slings, balance of the load, etc. are checked, before
2.
proceeding. Proper care shall be exercised by the driver at all times to avoid shock or side loadings on
the jib or structure. Care should be taken to avoid the load lifting attachment coming into contact with
the structure.
3. Use calm and smooth movements when operating the crane. Avoid sudden movements.
In case of emergency movements, these are to be stopped gently if possible, or by releasing the
4.
controls.
5. No more than two movements should be combined at any given time.
6. Monitor limiting conditions like wind speed, angle of heel/pitch etc.
7. Take precautions to avoid contact between the load or the load lifting accessories and the structure.
8. Take into consideration environmental conditions like visibility (fog, snow etc), icing and such.
Description
NOTE:
The crane must be placed in the boom cradle when not in use, during sea transit, under conditions
exceeding crane limitations. The crane must also be placed in the boom cradle during maintenance if
moving the crane is unnecessary for the maintenance work.
NOTE:
To ensure a longer service life for the cylinder rod it is recommended that all crane cylinders are extended
and retracted on a weekly basis. Preferably the operation shall be performed more frequent if possible.
Normal Stop - End of Operation

NOTE:
For procedures regarding disconnection- and parking of yoke, please ref. to the corresponding User Manual
When placing the crane in the boom cradle the knuckle boom shall be completely folded in.
1. Turn the crane carefully over the boom cradle. Ensure a sufficient boom height to avoid clash between
the boom cradle and the crane. Caution shall be taken to the steel wire rope hanging below the boom.
When the knuckle boom is in approx. the correct position above the boom cradle, gently lower the
2.
main boom and observe that the knuckle boom enters between the two vertical support stiffeners.
The crane driver must attentively monitor the whole stowing operation and ensure that the steel wire
3. rope (-s) is/are unobstructed at all times, and does not get pinched between the knuckle boom and
boom cradle or comes in contact with one of the vertical support stiffeners.
When the crane driver sees that the knuckle boom is in correct position above the boom cradle, lower
4.
the main boom gently until the knuckle boom fully rests on its support.
The hook (-s) then have to be secured to fixed points on deck or located in specially designed hook
5.
cradles (Customers responsibility).
6. Switch joystick control to “Off” position.
7. Select off mode (no active mode lamps).
8. Stop the main motors.
9. Select system switch “Off”
10. Make all essential information for further use of the crane available for the next crane operator.
11. Lock the cabin/controls so that they cannot be accessed by unauthorized personnel.
NOTE:
The cylinder piston rods are maintenance free and coated with multilayer chrome to obtain good corrosion
protection and a long service life. This however, is not sufficient for a continuous long term exposure to a harsh
marine environment. The recommended continuous exposure time should not repeatedly exceed 8 hours.

Therefore, when the crane is not in operation, all cylinders shall be retracted in order to maintain a sufficient
corrosion protection of the rods.
 Document number V3054-Z-MA-007
Revision 4
Page 13 of 90

1.6.1 Main Operator Station

Main Operator Station – Inside the Crane Cabin

In the cabin there are two joysticks for controlling the main motions of the crane. The valves are controlled via
the two joysticks, which are connected to the PLC via profibus DP. The hydraulic valves are connected to the
PLC output cards. By operating the respective joysticks, the required motion of the crane will be executed. A
legend positioned directly in front of the operator shows all crane functions.
CAUTION:
DURING OPERATION OF THE CRANE, THE JOYSTICKS MUST BE OPERATED SLOWLY AND
SMOOTHLY IN ORDER NOT TO INDUCE A SWINGING MOTION IN THE HANGING LOAD.
CD/Radio

Control Cabinet Operator Display

Fire Extinguisher

Distribution Box

Defroster/Foundation Box
Camera Monitor

Air Condition Unit

Right Hand Joystick

Operator Chair
Left Hand Joystick

VHF/UHF

TYPICAL CABIN LAYOUT

 Document number V3054-Z-MA-007
Revision 4
Page 14 of 90

1.6.2 Functions on the Left Hand Joystick and -Armrest

Left Hand Joystick Functions Description

Boom Down Push the joystick away from the operator
Boom Up Pull the joystick towards the operator
Slew Left Move the joystick to the left
Slew Right Move the joystick to the right
Functions on top of the Left Hand Joystick Description
Yoke Tilt In/Out Move the thumb wheel up/down to tilt the yoke in/out
Horn Push the black push-button to activate the warning horn
Spare The red- and green push-buttons are not in use
Functions on the Left Hand Armrest Description
Two position switch for turning the joystick ON/OFF. The
Joystick ON/OFF purpose of this switch is to prevent any unintended crane
movement. Joystick switch in “ON” position will give normal
crane operation from the joysticks
WARNING!
ALWAYS TURN THE JOYSTICK SWITCH TO “OFF” POSITION WHEN LEAVING THE OPERATOR CHAIR
AND BETWEEN LIFTING OPERATIONS
WARNING!
TURNING THE JOYSTICK OFF WILL NOT ISOLATE THE CRANE
Gripper Close Push the black push-button to close the grip fingers on the
yoke
Gripper Open Red push-button. To open the grip fingers on the yoke, both
Gripper Open buttons (on the left- and right hand armrest)
has to be pushed simultaneously
NOTE:
When opening the yoke, both “Gripper Open” buttons (on the left- and right hand armrest) must be activated
simultaneously. To open or close the gripper fingers, the load cell also has to be offloaded i.e. the yoke has to be
on the pipe deck or in the catwalk to allow opening- or closing of the grip fingers.
 Document number V3054-Z-MA-007
Revision 4
Page 15 of 90

1.6.3 Functions on the Right Hand Joystick and -Armrest

Right Hand Joystick Functions Description

Winch/Telescope Down Push the joystick away from the operator
Winch/Telescope Up Pull the joystick towards the operator
Knuckle Boom In Move the joystick to the left
Knuckle Boom Out Move the joystick to the right
NOTE:
Combined movements are possible. Pulling the joystick in direction “-45 deg.” for instance will result in combined
movements of “winch/telescope down” and “knuckle boom in”. However, do not use more than two movements
simultaneously to operate the crane.
Functions on top of the Right Hand Joystick Description
Yoke Slew CW/CCW Move the thumb wheel up/down to slew the yoke
clockwise/counter clockwise
Wiper/Washer Select wipers and washers from the Operator Display, and
then push the green push-button to start the wipers.
By pressing the button for 1 ½ seconds, the washers will also
be activated
CT (Constant Tension) Black push-button. This mode can be used for tightening up
the wire while hooked up to a load landed/placed on another
vessel
Spare The red push-button is not in use
Functions on the Right Hand Armrest Description
Gripper Open Red push-button. To open the grip fingers on the yoke, both
Gripper Open buttons (on the left- and right hand armrest)
has to be pushed simultaneously
NOTE:
When opening the yoke, both “Gripper Open” buttons (on the left- and right hand armrest) must be activated
simultaneously. To open or close the gripper fingers, the load cell also has to be offloaded i.e. the yoke has to be
on the pipe deck or in the catwalk to allow opening- or closing of the grip fingers.
 Document number V3054-Z-MA-007
Revision 4
Page 16 of 90

1.6.4 Control Cabinet – IB001

Control Cabinet IB001 - Functions

The Control Cabinet IB001 is located inside the crane cabin close to the crane operator. The following functions
can be activated:
Functions Switches Description
System OFF/ON Two position key-switch System must be in “On” position before the main motors
can be started and the crane can be operated
Two position key-switch for enabling/disabling personnel
Personnel Lift OFF/ON Two position key-switch lift mode. In this mode the MOPS function is disabled.
Follow the lifting procedures given further on in the
Operating Instructions
NOTE:
The lifting capacity for personnel lift is 1,5 tons, including the lifting basket
WARNING!
LIFTING OF PERSONNEL MUST ONLY BE PERFORMED USING LIFTING ACCESSORIES ESPECIALLY
DESIGNED FOR LIFTING OF PERSONNEL IN MARINE ENVIRONMENTS
Cabin Light OFF/ON Two position switch Turns the cabin lights On/Off
Outside Light OFF/ON Two position switch Turns the outside lights On/Off
 Document number V3054-Z-MA-007
Revision 4
Page 17 of 90

1.6.5 Foot Pedal

Foot Pedal - Description

The foot pedal mounted in front of the operator chair enables speech through the gooseneck microphone
(VHF/UHF)

Foot pedal, with- and without protective cover

1.6.6 Air Condition Unit

Information regarding the Air Condition Unit

Reference can be made to:
- Standard Documentation, Care and Maintenance of the Air Conditioner, SimCool
The air condition unit is placed in a duct on the back wall inside the cabin. The remote control is mounted close to
crane operator

Air condition unit Remote control

 Document number V3054-Z-MA-007
Revision 4
Page 18 of 90

1.6.7 Monitoring System

Information regarding the Monitoring System

The boom tip camera monitor is placed inside the cabin in direct view from the operator chair. Utilizing the
monitoring system enables better visual control of the load handling.

This camera system has a joystick which controls the lens functions (zoom and focus). The operation of the
camera station is performed via the three axes joystick, mounted on the control box (picture below).

Camera monitor (typical) Camera joystick (typical) Hernis boom tip camera (typical)

Operation of the Camera System

ZOOM Push the joystick forward to ZOOM IN and pull back to ZOOM OUT.
FOCUS Push the joystick to the left for FOCUS near and right for FOCUS far.
IRIS Twist the joystick clockwise to CLOSE the IRIS and anti-clockwise to OPEN the IRIS
Standard Menu
A standard menu is displayed by pressing and holding the left hand button (located at the top of the joystick) until
the first menu item is displayed on the monitor. The standard menu will display the items in white text. Each time
this button is pushed, the next function is displayed on the monitor. The button on the right hand side is used for
toggling between the different options within each function. In the standard menu, the following options are
available:
Tracking
ON/OF
Zoom

Enables the operator to select whether the automatic object (container) tracking is enabled or disabled.
Press the right hand button to toggle between ON/OFF.
Container

20’/40’

Enables the operator to toggle between the two standard container sizes during operation.
Size

Press the right hand button to toggle between 20`/40`.

ON/OFF
Focus
Auto

Enables the operator to switch the auto focus function ON and OFF.
Press the right hand button to toggle between ON/OFF.

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 19 of 90

Operation of the Camera System (continued)

Configuration Menu
A configuration menu is displayed by pressing and holding the right hand button until the first menu item is
displayed on the monitor. The configuration menu will display the items in yellow text. The button on the left hand
side is used for toggling between the different options within each function. In the configuration menu you have
the following options:
Before the automatic zoom tracking can be used, this setting must be performed. Remember to select
Wide Set

container size before the zoom is set and lift the container to the highest level. Calibrate the “Zoom
Zoom

Wide” setting, by pressing the right hand button once. The menu text will start flashing. Then press the
right hand button once more to store the position. The text will stop flashing when the position is
stored.
Tele Set

Before the automatic zoom tracking can be used, this setting must also be performed. Lower the
Zoom

container to the lowest level. Adjust the zoom until desired angle of view. The procedure to store the
Tele position is identical to Zoom Wide Set.

The three axes joystick must be calibrated before the system can be used. The joystick calibration is
Calibration
Joystick

the first step to do in the set up menu. Press the right hand button. The text will change to “JOYSTICK
CALIBRATING” (flashing). Move the joystick in all directions; make sure that the joystick is in end-
point. Turn the top of the joystick “Left-max” and “Right-max”. Press right hand button again. The text
will change to “JOYSTICK CALIBRATED”, and the joystick is ready for use.
NOTE:
The menu will disappear from the monitor screen after approximately 1 minute from the last command.
NOTE:
The boom camera monitor should always be turned off when the crane is not in operation (longer lifetime).

1.6.8 Defroster System

Defroster System - Description

Reference can be made to:
- Drawings & Parts Lists, Assembly Drawing, Cabin
The heater and fan is mounted in the duct under the operator chair. It is controlled by the PLC. The reset button
for ‘heater overheated’ is placed inside a cover on the duct. The air inlet for this unit is located under the crane
cabin.
 Document number V3054-Z-MA-007
Revision 4
Page 20 of 90

1.6.9 Operator Display – IB002

Information regarding the Operator Display

The operator display is mounted close to the operator chair, at eye-level.

The operator display is a touch-screen terminal for setting, checking and altering a number of operating
parameters. Some of these parameters can be altered by the operator, and some are password protected and
only available for NOV’s service personnel

The first access point is the Main Menu screen display. Each display has a status bar at the bottom, showing
the last triggered alarm. Some of the displays have a ‘Menu’-button and a ‘Next/Exit’ button. Touching the
‘Menu’-button brings you back to the Main Menu and touching the ‘Next/Exit’ button brings you to the
next/previous screen display.
 Document number V3054-Z-MA-007
Revision 4
Page 21 of 90

1.6.9.1 Display Hierarchy

The screen displays are available to the crane operator in a hierarchy as shown below. The Main Menu is the starting point for accessing any of the other displays. The displays are the following:
Main Menu

Crane Display Mode Select System Menu Wipers and Washers Flood Lights Cabin Ventilation Sea Lift Sign. Wave Height Main Motor Alarm Page

Main Winch Main Winch Limits Menu Main Motors Alarm History

Secondary Info 1 Fall Main Winch Limits Oil Coolers

Gripper Yoke 2 Fall Boom Angle Settings Ventilation Fan

Secondary Info 5 Fall Main Winch Load Cell

20” Gripper Reload MW Load Cell

Yoke Load Cell

Reload Yoke Load Cell

Crane Slew Limits

Set Slew Limit Sectors

Set Sea Lift Sector

Yoke Slew Limits

Virtual Wall System (VWS)

Anti Collision Cradle Park

Test Menu

Digital Input

Digital Output

Analog Input

Analog Output

Joysticks

Counters

Loadcells

Movements

110% Ref. Load Horn Test

NOV Menu

Statistics (Hour Counter)

AOPS Reset

Override Hook Stop

Lift Logger

Dynamic Overload Reset

 Document number V3054-Z-MA-007
Revision 4
Page 22 of 90

1.6.9.2 Display Status Bar

Each display contains a status bar with the following information:

The red warning lamp is lit when MOPS is activated (Alarm horn and buzzer
MOPS
are also activated)
The red warning lamp is lit when AOPS is activated. The lamp will extinguish
AOPS when the operator acknowledges/confirms the AOPS alarm. This is done from
the ‘AOPS Reset’ screen display (described separately)
AOPS enabled The green lamp is lit when the AOPS function is enabled (Sea Lift mode only)
CT The yellow lamp is lit when Constant Tension is activated
The yellow warning lamp displays a steady light when the load reaches 90% of
90% SWL
SWL (Alarm horn and buzzer are also activated)
The red warning lamp displays a steady light when the load is above 110% of
110% SWL
SWL (Alarm horn and buzzer will also be activated)
The red warning lamp displays a steady light when the load is above 110% of
110% DYN
SWL x dynamic factor (Alarm horn and buzzer will also be activated)
Pers. lift The yellow lamp is lit when personnel lift mode is activated
(Mode Info Text) The selected mode will be displayed in this tab/window (in
1 FALL INTERNAL LIFT
this case; 1 Fall Internal Lift mode)
Act. Load The actual load in the hook/yoke will be displayed here.
Working radius The actual working radius for both winch hook and yoke will be displayed here
Sea lift wave height Displays the set wave height in Sea Lift mode

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 23 of 90

Each display contains a status bar with the following information (continued):
M1/2 The green lamp is lit when the motors are running
Push-button. Push the button to enter the Alarm Page screen display. This
ALARM PAGE screen displays all active alarms with date and time of activation. An alarm
history is also available from this screen.
MAIN MOTOR Push-button. Push the button to enter the Main Motors screen display
 Document number V3054-Z-MA-007
Revision 4
Page 24 of 90

1.6.9.3 Password Protected Screens

Some screens are password protected. Please enter the following

User Client
Password NOV project no. without initial letter, e.g. V1234 -> 1234
 Document number V3054-Z-MA-007
Revision 4
Page 25 of 90

1.6.9.4 Main Menu

Activated Manually by pushing “MENU” from other screens

Functions in this screen Information menu for the crane operator to find other relevant screens

Details

CRANE DISPLAY Info screen for crane operation

MODE SELECT Screen for selection of different winch and yoke modes.
WIPERS/WASHERS Control screen for the wipers and washers
SYSTEM MENU Screen with various sub-menus
FLOOD LIGHTS Control screen for the floodlights
CABIN VENTILATION Control screen for the cabin ventilation
SEA LIFT SIGN. WAVE HEIGHT Displays allowable load for sea lifts at a given significant wave height
 Document number V3054-Z-MA-007
Revision 4
Page 26 of 90

1.6.9.5 Crane Display – Main Winch

Manually by pushing “CRANE DISPLAY” from the Main Menu, when in MW

Activated
mode

Functions in this screen Most important crane data for safe operation of the crane when in MW mode

Details

The Sea Lift area indicates the boom tip position related to the recommended
lifting height in sea lift mode. Sea Lift area will be green when the boom tip is
SEA LIFT AREA inside the recommended height (ref. the Load Chart). If the boom tip is outside
the recommended height, an alarm will be activated, and the bar graph will
change color to red
Displays the safe working load digitally (reference and derated SWL) and as a
SWL
bar graph
LOAD Displays the actual load digitally and as a bar graph (hook load)
WIRE PAYED OUT Displays payed out wire in meters, calculated from hook stop up point
TRIP LENGTH Trip counter for actual wire payed out
Will “zero” trip counter (trip length) for wire payed out. When running from this
TRIP RESET
point, the trip counter will display payed out wire from the new set point
WINCH MOVEMENT Green bar (right hand side) displays winch movement (speed dependent)
PARK Push-button to enter screen for the Anti Collision Cradle Park assistant.

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 27 of 90

Details (continued)

Green arrows Operation enabled / allowed

ARROWS Red arrows Operation disabled / prohibited
Blue arrows The joystick is activated in this direction
NEXT Switches to the Secondary Info - Main Winch screen
 Document number V3054-Z-MA-007
Revision 4
Page 28 of 90

1.6.9.6 Crane Display – Gripper Yoke

Manually by pushing “CRANE DISPLAY” from the Main Menu, when in Gripper
Activated
Yoke mode

Most important crane data for safe operation of the crane when in Gripper
Functions in this screen
Yoke mode

Details

SWL Displays the safe working load both digitally and as a bar graph
LOAD Displays the actual load digitally and as a bar graph (yoke load)
YOKE SLEW Displays the yokes actual slew angle
Push-button to activate the pipe support. Ref. the User Manual for 20” Gripper
Yoke. For safety reasons, the pipe support will always be activated
PIPE SUPPORT
automatically when the gripper is closed independently of whether the pipe
support is activated or deactivated from the Operator Display
Push-button to activate Slew Yoke Auto mode. When slewing the crane, the
AUTO SLEW
yoke will maintain a parallel position to e.g. the catwalk and the pipe rack
GRIPPER OPEN The yellow lamp is lit when the gripper is opened
GRIPPER CLOSED The red lamp is lit when the gripper is closed
GRIPPER UNLOADED The green lamp is lit when the gripper yoke is unloaded
PARK Push-button to enter screen for the Anti Collision Cradle Park assistant.

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 29 of 90

Details (continued)

Green arrows Operation enabled / allowed

ARROWS Red arrows Operation disabled / prohibited
Blue arrows The joystick is activated in this direction
NEXT Switches to the Secondary Info – Gripper Yoke screen
 Document number V3054-Z-MA-007
Revision 4
Page 30 of 90

1.6.9.7 Secondary Info – Main Winch and Gripper Yoke

Manually by pushing “NEXT” from the Crane Display. The Secondary Info
Activated screen contains the same information regardless of crane mode, and is
therefore only described once in the Operating Instructions

Functions in this screen Secondary important data

Details

CRANE SLEW ANGLE Displays the actual slew angle

MAIN BOOM ANGLE Displays the angle between the king and the main boom
KNUCKLE BOOM ANGLE Displays the angle between the main boom and the knuckle boom
OIL TEMPERATURE Displays the oil temperature in the hydraulic oil tank
BOOM TIP HEIGHT Display the boom tip height referenced to the slew bearing (level)
WORKING RADIUS Displays actual radius of boom tip position related to centre of the crane
(Main Control Valve) Displays the load sense pressure for the hydraulic
LOAD SENSE MCV
pumps
MAIN BOOM PRESSURE Displays actual main boom pressure
LOAD SENSE YOKE (Yoke Control Valve) Displays the load sense pressure for the hydraulic pumps
SWL Displays the cranes safe working load
 Document number V3054-Z-MA-007
Revision 4
Page 31 of 90

1.6.9.8 Mode Select

Activated Manually by pushing “MODE SELECT” from the Main Menu

Selection of control mode

Functions in this screen
Displays status information for the actual selected mode

Details

WINCH MODE Selection of 1-, 2- or 5 falls and winch tension

This mode must be used for tightening up the wire while yoke mode is active
WINCH TENSION
and the wire end is connected to the knuckle boom
YOKE MODE Selection of the Gripper Yoke mode
Activation will enable full operation of all crane functions. For safety reasons,
Change Yoke mode is only active for 10 minutes after pressing the button. Be
CHANGE YOKE
aware that the Change Yoke mode overrides all restrictions of the crane
movements, also when the yoke is unloaded
 Document number V3054-Z-MA-007
Revision 4
Page 32 of 90

1.6.9.9 System Menu

Activated Manually by pushing “SYSTEM MENU” from the Main Menu

Functions in this screen Information menu for the crane operator to find other relevant screens

Details

Screen for setting winch hook limits, crane- and yoke slew limits and load cell
LIMITS MENU
calibration.
TEST MENU Menu with various test screens
NOV MENU Screen for NOV service personnel only (password protected)
STATISTICS Screen with statistical information for the active use of the crane
AOPS RESET Screen for resetting the AOPS alarm.
Push-button to override all hook stop limits.
The crane is equipped with a dynamic hook stop system which calculates the
hook stop up position independently of the main- and knuckle boom position. If
OVERRIDE HOOK STOP the hook has reached the hook stop up position, all wire-shortening
movements (winch up, boom down and knuckle boom in) will be stopped.
Therefore, override of hook stop will override main boom down stop, knuckle
boom in stop and winch up and down stop.
NOTE:
For safety reasons, hook stop override is only active for as long as the button is pressed.

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 33 of 90

Details (continued)

LIFT LOGGER Screen for disabling/enabling the lift logger and replacing the memory card
DYNAMIC OVERLOAD Screen for resetting of the 110% dynamic overload alarm. If the alarm has
RESET been triggered, contact NOV. The alarm cannot be reset by the operator
 Document number V3054-Z-MA-007
Revision 4
Page 34 of 90

1.6.9.10 Limits Menu

Activated Manually by pushing “LIMITS MENU” from the System Menu

Functions in this screen Information menu for the crane operator to find other relevant screens

Details

MAIN WINCH LIMITS Screen for setting the winch end limits
MAIN WINCH LOAD CELL Screen for calibration of load cell (Password protected)
CRANE SLEW LIMITS Screen for setting slew limits
BOOM ANGLE SETTINGS Screen for setting boom angles
YOKE LOAD CELL Screen for calibration of yoke load cells (Password protected)
YOKE SLEW LIMITS Screen for setting yoke slew zero position
VIRTUAL WALL SYSTEM
Screen for setting and overriding virtual wall system.
(VWS)
ANTI COLLISION CRADLE
Screen for setting the Anti-Collision Cradle Park assistant.
PARK
 Document number V3054-Z-MA-007
Revision 4
Page 35 of 90

1.6.9.11 Main Winch Limits

Activated Manually by pushing “MAIN WINCH LIMITS” from the Limits Menu

Setting of winch end limits

Functions in this screen Ref. the Load Handling (Procedures) segment further on in this section
The ‘ACT DOWN LIMIT MW’ function is password protected

Details

Setting new up limit must be done when the wire has been shortened and
SET UP LIMIT
when changing falls
WARNING:
SET UP LIMIT HAS TO BE SET WHEN THE MAIN BOOM IS IN LOWEST POSITION AND THE
KNUCKLE BOOM IS FOLDED IN
Set Down Limit should normally only be used when replacing wire on the
SET DOWN LIMIT
winch
WARNING:
A NEW SETTING OF DOWN LIMIT ALSO AFFECTS THE LIMIT UP STOP. HOOK LIMIT UP MUST
THEREFORE ALWAYS BE SET AFTER A NEW DOWN LIMIT
By pushing the “INFO” button the following help text appears:

INFO
 Document number V3054-Z-MA-007
Revision 4
Page 36 of 90

1.6.9.12 Boom Angle Settings

Activated Manually by pushing “BOOM ANGLE SETTINGS” from the Limits Menu

Calibration of the main boom- and knuckle boom potentiometers

Functions in this screen Ref. the Load Handling (Procedures) segment further on in this section
The ‘ACT’ function is password protected

Details

Must be activated to allow calibration of boom angles (Password

ACT
protected)
Set main boom in lowest position. Set new angle by pushing the “SET”
LOWER MAIN BOOM ANGLE
button. Check “Main boom angle”
Set main boom upper most position. Set new angle by pushing the
UPPER MAIN BOOM ANGLE
“SET” button. Check “Main boom angle”
Set knuckle boom in inner most position. Set new angle by pushing the
INNER KNBOOM ANGLE
“SET” button. Check “Knboom Angle”
Set knuckle boom in outer most position. Set new boom angle by
OUTER KNBOOM ANGLE
pushing the “SET” button. Check “Knboom Angle”
Pushing this button will override boom end stops.
OVERRIDE
Override time = 120 seconds
 Document number V3054-Z-MA-007
Revision 4
Page 37 of 90

1.6.9.13 Main Winch Load Cell

Manually by pushing “MAIN WINCH LOAD CELL” from the Limits Menu (The
Activated
screen is password protected)

Calibration of load cell

Functions in this screen
Ref. the Load Handling (Procedures) segment further on in this section

Details

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 38 of 90

Details (continued)

By pushing the “INFO” button the following help text appears:

Explanation:

1) Activate ACT button: This button must be pressed to activate

the load cell calibration mode

INFO 2) Set Adjustment Weight (same as test load): The weight of the
test load you are planning to use in the calibration must be
entered here.

3) Unload and activate Zero button: Make sure that the hook is
approximately 2 meters from the knuckle boom end. There
should be no load in hook.

4) Hook up test load, activate Adjust button

5) Deactivate ACT button

The load cell is now calibrated. Note the values and keep them in a safe place
in case there should be a need for a reloading of calibration data later on
Push-button. Push this button to enter the Reload Load Cell Main Winch
RELOAD
screen
 Document number V3054-Z-MA-007
Revision 4
Page 39 of 90

1.6.9.14 Reload Load Cell Main Winch

Activated Manually by pushing “RELOAD” from the Main Winch Load Cell screen

Reload of raw values from an earlier calibration if the load cell card is replaced
Functions in this screen and a test load for recalibration is not available
Ref. the Load Handling (Procedures) segment further on in this section

Details

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 40 of 90

Details (continued)

By pushing the INFO button the following help text appears:

Explanation:

1) Activate ACT button: This button must be pressed to activate

the load cell calibration mode
INFO
2) Set Adj. Weight, Zero and Adjust (from earlier calibration):
These values must be available from an earlier calibration to
make the reload function possible

3) Activate RELOAD button

4) Unload and activate MOVE ZERO button: Make sure that the
hook is approximately 2 meters from the knuckle boom end.
There should be no load in the hook

5) Deactivate ACT button

 Document number V3054-Z-MA-007
Revision 4
Page 41 of 90

1.6.9.15 Yoke Load Cell

Manually by pushing “YOKE LOAD CELL” from the Limits Menu (The screen is
Activated
password protected)

Calibration of yoke load cells

Functions in this screen
Ref. the Load Handling (Procedures) segment further on in this section

Details

By pushing the INFO button the following help text appears:

INFO

The load cell is now calibrated. Note the values and keep them in a safe place
in case there should be a need for a reloading of calibration data later on
 Document number V3054-Z-MA-007
Revision 4
Page 42 of 90

1.6.9.16 Reload Load Cell Yoke

Activated Manually by pushing “RELOAD” from the Yoke Load Cell screen

Adjustment of load cell, calibration of raw values

Functions in this screen
Ref. the Load Handling (Procedures) segment further on in this section

Details

NOTE:
If the yoke has been connected to this crane previously, the calibration data (raw values, test weight, etc)
are reloaded from an earlier calibration. This is performed automatically when the yoke is connected
Push button. When activating this button, raw values (manually stored from an
ACT
earlier calibration) can be reloaded to the system
By pushing the INFO button the following help text appears:

INFO
 Document number V3054-Z-MA-007
Revision 4
Page 43 of 90

1.6.9.17 Crane Slew Limits (Slew Zero)

Activated Manually by pushing “CRANE SLEW LIMITS” from the Limits Menu

Setting of slew limit sectors, sea lift sectors and slew zero
Functions in this screen Ref. the Load Handling (Procedures) segment further on in this section
The ‘SLEW ZERO’ function is password protected

Details

Push this button to initialize the slew counter. The slew angle is then set to
SLEW ZERO zero. Before the slew is initialized, the crane must be placed in zero-position
defined for the crane
By pushing the INFO button the following help text appears:

INFO

SET SLEW LIMIT Push the button to enter the screen for setting of slew limit sectors.
SECTORS
SET SEA LIFT SECTOR Push the button to enter the screen for setting of sea lift sector.
 Document number V3054-Z-MA-007
Revision 4
Page 44 of 90

1.6.9.18 Set Slew Limit Sectors

Activated Manually by pushing “SET SLEW LIMIT SECTORS” from the Crane Slew
Limits (Slew Zero) screen

Setting of slew limit sectors. Slew limit sectors can be used to stop the crane
slew if the crane enters a restricted area due to mechanical obstructions
Functions in this screen
Ref. the Load Handling (Procedures) segment further on in this section
The ‘SLEW LIMIT SECTOR 1/2’ functions are password protected

Details

Actual angle Displays the crane slew position in degrees

RIGHT / LEFT LIMIT 1/2 Displays the actual limit sector in degrees
SLEW LIMIT SECTOR 1/2 Must be activated in order to be able to set slew limit sectors
By pushing the INFO button the following help text appears:

INFO
 Document number V3054-Z-MA-007
Revision 4
Page 45 of 90

1.6.9.19 Set Sea Lift Sector

Activated Manually by pushing “SET SEA LIFT SECTOR” from the Crane Slew
Limits (Slew Zero) screen

Setting of sea lift sectors

Functions in this screen Ref. the Load Handling (Procedures) segment further on in this section
The ‘SEA LIFT SECTOR’ function is password protected

Details

Sea Lift mode is for load handling to and from another vessel. When correct sea lift sector has been set,
the system will enter sea lift mode automatically when the crane is slewed into the sea lift sector
RIGHT / LEFT SEA LIFT LIMIT Displays the actual limit sector in degrees
Actual angle Displays the cranes slew position in degrees
SEA LIFT SECTOR Must be activated in order to be able to set sea lift sectors
By pushing the INFO button the following help text appears:

INFO
 Document number V3054-Z-MA-007
Revision 4
Page 46 of 90

1.6.9.20 Yoke Slew Limits (Yoke Slew Reset)

Activated Manually by pushing “YOKE SLEW LIMITS” from the Limits Menu

Screen for resetting the yoke slew counter. Ref. the User Manual for the
Functions in this screen
Gripper Yoke for setting of zero position
 Document number V3054-Z-MA-007
Revision 4
Page 47 of 90

1.6.9.21 Virtual Wall System

Activated:
Press” VIRTUAL WALL SYSTEM” from the Limits Menu.
Functions on this screen:
 Virtual wall settings
 Activating/deactivating the virtual wall
 Overriding virtual wall
Details:
The Virtual Wall System is designed to prevent crane operators from manoeuvring too closely to fixed
objects.
The system features draw virtual wall which enables the operator to define the crane’s working limits
by simply manoeuvring the crane along any objects to be avoided.
When the virtual wall is activated, the crane movements ramp down and stop at the limits defined by
the User.

Virtual Wall System – Setting Limits

Touch this button to draw the virtual wall. Then, while slewing the crane
DRAW
slowly, manoeuvre the boom tip carefully in and out as needed to avoid fixed
VIRTUAL WALL
objects while extending the crane to max radius wherever possible.
To remove the limit in a specific sector, touch this button and slew the crane
DRAW through the sector to be reset. Afterwards touch the button once more to
OPEN SECTOR deactivate. Removing this limit redefines the max radius in this sector to
100m, which is above the crane’s maximum possible radius.
Details (continued)
 Document number V3054-Z-MA-007
Revision 4
Page 48 of 90

NOTE:
Draw virtual wall mode may be used within a limited sector or around the crane’s full circle of
operation. This implementation of a 360 degree learning mode eliminates the constraints of
“restricted sector” definitions that block entire sectors, and enables the crane to work a
“variable radius” as it slews around the circle.
RESET Touching this button removes all limits around the full circle.
VIRTUAL WALL The Virtual Wall will have to be drawn again.
This button activates/deactivates the virtual wall. An alarm is displayed for as
long as the virtual wall is deactivated.
ACTIVATE
When virtual wall is activated, an alarm is generated when the crane reaches
VIRTUAL WALL
a limit.
Password-protected with a client password.
Touch this button to override the virtual wall if it is necessary to enter a
restricted zone.
OVERRIDE
An alarm will be displayed as long as the virtual wall are overridden.
The override function is protected with a client password or key switch.

Running crane with virtual wall activated

X = slew angle
Y = max radius

Red line shows the

max radius (in metres)
at each slew angle (0--
360 degrees).

Blue line shows the

current slew angle and
radius.

Max radius at current slew position is displayed.

Blocked movements are displayed as red arrows in the LIMITS field (similar
LIMITS to Crane Display screens).
The screen shot shown above shows knuckle boom out and main boom
down movements blocked and slew right movement blocked.
Displays additional information that may be useful when setting and testing
limits:
RED. FACTOR field: - reduction factors for the different movements
ACTUAL field: - current boom angles
SHOW MORE INFO - current slew angle
(toggles display of - current working radius
additional info) LIMITS field: - main boom radius
- indication of when main boom has largest radius
(Main boom radius in use indicator turns green if
main boom radius is greater than working (boom
tip) radius.
 Document number V3054-Z-MA-007
Revision 4
Page 49 of 90

1.6.9.22 Anti Collision Cradle Park

Activated:
Press “ANTI COLLISION CRADLE PARK” from the Limits Menu.
Functions on this screen:
A screen for setting anti-collision cradle position

CAUTION:
THIS FUNCTION WILL NOT STOP KNUCKLE BOOM FROM SLEWING INTO CRADLE WHEN BOOM IS
ABOVE LIMIT, SINCE THIS IS NOT PART OF PARKING OPERATION.
Details:
SET CRADLE Push-button to set the cradle position.
POSITION
Minimum main boom limit for when to activate slew ramping. (Should be a bit above
M boom min angle limit
the angle where the crane hits the cradle)
Max knuckle boom angle allowed when booming in/out of cradle. (Should be as low
K boom max angle as possible)

The width (in degrees) of one side of the cradle. (To define when above the flange of
Cradle width each side
the cradle)

Continued on the next page

Details (continued)
 Document number V3054-Z-MA-007
Revision 4
Page 50 of 90

How many degrees deviation allowed to define crane within cradle. (depends on
Cradle deviation
opening inside cradle)
Slew ramping angle How many degrees before limit (Slew angle position + Cradle width) to start ramping
Min slew flow at end of ramp down. (as low as possible but high enough to move
Slew min flow
slew)
Status Shows angles to help adjusting and troubleshooting the system.
Inhibits Shows status of inhibits to help adjusting and troubleshooting the system.
 Document number V3054-Z-MA-007
Revision 4
Page 51 of 90

1.6.9.23 Test Menu

Activated Manually by pushing “TEST MENU” from the System Menu

Information menu for various analogue/digital inputs and outputs of raw

values from the various sensors. The values are calculated by the PLC,
Functions in this screen
and displayed on the screens.
Test of the 110% load horn

Details

110% REF. LOAD HORN TEST Push this button to test the load horn.
 Document number V3054-Z-MA-007
Revision 4
Page 52 of 90

1.6.9.24 Digital Input, Screens 1-3

Activated Manually by pushing “DIG IN” from the Test Menu

Functions in this screen Test/service information – digital input

Details

If the displayed functions are active, the lamps will illuminate

NEXT/EXIT Use these push-buttons to navigate between the different screens

 Document number V3054-Z-MA-007
Revision 4
Page 53 of 90

1.6.9.25 Digital Output, Screens 1-2

Activated Manually by pushing “DIG OUT” from the Test Menu

Functions in this screen Test/service information

Details

If there is a malfunction, the control lamps will still illuminate to show activated function. I.e. the fault lies
somewhere else and must be checked (E.g. a broken cable or fuse)

NEXT/EXIT Use these push-buttons to navigate between the different screens

 Document number V3054-Z-MA-007
Revision 4
Page 54 of 90

1.6.9.26 Analog Input

Activated Manually by pushing “ANA IN” from the Test Menu

Functions in this screen Information from various analogue sensors

 Document number V3054-Z-MA-007
Revision 4
Page 55 of 90

1.6.9.27 Analog Output, Screens 1-3

Activated Manually by pushing “ANA OUT” from the Test Menu

Functions in this screen Test/service information

Details

NEXT/EXIT Use these push-buttons to navigate between the different screens

 Document number V3054-Z-MA-007
Revision 4
Page 56 of 90

1.6.9.28 Joysticks

Activated Manually by pushing “JOYSTICKS” from the Test Menu

Information screen which displays raw values from the joysticks inside the
Functions in this screen
crane cabin
 Document number V3054-Z-MA-007
Revision 4
Page 57 of 90

1.6.9.29 Counters

Activated Manually by pushing “COUNTERS” from the Test Menu

Functions in this screen Displays counter values for crane components

 Document number V3054-Z-MA-007
Revision 4
Page 58 of 90

1.6.9.30 Loadcells

Activated Manually by pushing “LOADCELLS” from the Test Menu

Functions in this screen Displays raw values and tons for the load cells.
 Document number V3054-Z-MA-007
Revision 4
Page 59 of 90

1.6.9.31 Movements

Activated Manually by pushing “MOVEMENTS” from the Test Menu

Information menu of the crane movements.

 Shows analogue inputs from the joystick movements
Functions in this screen
 Shows analogue outputs to the control valves
Testing of main boom- and knuckle boom speed movements

Details

Shows the joystick signal for the main boom, knuckle boom, slew and main
Joystick
winch
Shows the valve signal for the main boom, knuckle boom, slew and main
Valve
winch
Speed Shows components speed
Displacement Shows the displacement signal in % for the main winch
Down Indicator for the main boom load holding valve (on/off)
In Indicator for the knuckle boom load holding valve in (on/off)
Out Indicator for the knuckle boom load holding valve out (on/off)
Bypass Indicator for the slew bypass valve (on/off)
Brake Indicator for the brake valves, slew and main winch (on/off)
CT Shows constant tension signal for the main winch when this mode is selected

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 60 of 90

Details (continued)

Push the button to initialise testing of main boom- and knuckle boom speed
SPEED TEST OF BOOMS
movements. Follow the procedure given in the info text below
By pushing the INFO button the following help text appears:

INFO
 Document number V3054-Z-MA-007
Revision 4
Page 61 of 90

1.6.9.32 Statistics (Hour Counter)

Activated Manually by pushing “STATISTICS” from the System Menu

Displays statistical information for the active use of the crane (hours)
Functions in this screen
The ‘ACTIVATE FORCE’ function is password protected

Details

Push button to activate setting of counter values for the various crane
ACTIVATE FORCE
components.
Procedure:
1. Activate the ‘ACTIVATE FORCE’ button (a password is needed)
2. Input the desired force value in the ‘FORCE VALUE’ tab by use of the pop-up key-pad
3. Press the ‘SET’ button by the corresponding component
 Document number V3054-Z-MA-007
Revision 4
Page 62 of 90

1.6.9.33 AOPS Reset

Activated Manually by pushing “AOPS RESET” from the System Menu, or by pressing
the ‘AOPS/AOPS enabled’ field in the status bar

Alarm status
Functions in this screen
Resetting of activated AOPS alarm lamp on the Operator Display

Details

When the AOPS alarm is activated, the operator acknowledges the alarm by
AOPS
pushing the button. The text on the button will then change from AOPS
ACTIVATED/CONFIRMED
ACTIVATED to AOPS CONFIRMED
 Document number V3054-Z-MA-007
Revision 4
Page 63 of 90

1.6.9.34 Lift Logger

Activated Manually by pushing “LIFT LOGGER” from the System Menu

Functions in this screen Disabling/enabling of the lift logger and replacing the memory card

Details

By pushing the INFO button the following help text appears:

INFO
 Document number V3054-Z-MA-007
Revision 4
Page 64 of 90

1.6.9.35 Dynamic Overload Reset

Activated Manually by pushing “DYNAMIC OVERLOAD RESET” from the System Menu

Alarm status
Functions in this screen
Manual resetting of the 110% DYN alarm text and activated alarm lamp

Details

CAUTION:
IF THE ALARM HAS BEEN TRIGGERED, NOV SHALL BE CONTACTED. NOV WILL THEN DECIDE
UPON WHAT MEASURES SHALL BE TAKEN BEFORE THE CRANE/YOKE CAN BE TAKEN BACK
INTO OPERATION. THE ALARM CANNOT BE RESET BY THE OPERATOR
 Document number V3054-Z-MA-007
Revision 4
Page 65 of 90

1.6.9.36 Wipers and Washers

Activated Manually by pushing “WIPERS WASHERS” from the Main Menu

Select/de-select desired wipers and washers

Functions in this screen
Selection of wiper mode

Details

WIPER MODES:
Select this mode to operate the wipers at the pre-set interval time. The ‘interval
INTERVAL time’ can be set by inputting desired value by use of the pop-up key pad. The
interval time is in this case set to 0 seconds
CONTINOUS Select this mode for continuous wiper operation
ONE SWEEP Select this mode to run the wiper (-s) across the window once.
NOTE:
Activation / de-activation of the selected washers and wipers (in the selected operation mode) are done by
use of the green push-button on the right hand joystick.

Pop-up key-pad
 Document number V3054-Z-MA-007
Revision 4
Page 66 of 90

1.6.9.37 Flood Lights

Activated Manually by pushing “FLOODLIGHTS” from the Main Menu

Activation / deactivation of the floodlights on the main boom, knuckle boom

Functions in this screen
and under the cabin platform
 Document number V3054-Z-MA-007
Revision 4
Page 67 of 90

1.6.9.38 Cabin Ventilation

Activated Manually by pushing “CABIN VENTILATION” from the Main Menu

Functions in this screen Regulation of the ventilation fan and -heater

Details

When the ventilation fan is on, it is possible to regulate the fan speed up to
VENTILATION FAN 100%. This is done by holding the SPEED+/- button down until desired fan
speed is reached
When the ventilation heater is on, it is possible to adjust the temperature set
VENTILATION HEATER point up to 30°C (min. 10 °C). This is done by holding the TEMP+/- button
down until desired temperature set point is reached
NOTE:
The ventilation heater can only be activated if the ventilation fan is running
 Document number V3054-Z-MA-007
Revision 4
Page 68 of 90

1.6.9.39 Sea Lift Significant Wave Height

Activated Manually by pushing “SEA LIFT SIGN. WAVE HEIGHT” from the Main Menu

Functions in this screen Setting of significant wave height for sea lifting operations

Details

The set significant wave height for sea lift operation is displayed in the status bar. The derated SWL for the
set significant wave height is displayed on the Crane Display screen
 Document number V3054-Z-MA-007
Revision 4
Page 69 of 90

1.6.9.40 Main Motors

Activated Manually by pushing “MAIN MOTOR” from the Status Bar

Start/stop of the main motors and selection between automatic/manual mode

Functions in this screen
for the oil coolers and the ventilation fan

Details

SELECT MOTOR 1/2 Push the button (-s) to select the motor (-s)
Starts/stops the selected motor (-s). It is possible to operate the crane with
START/STOP
only one motor running, but at a reduced speed

Continued on the next page

 Document number V3054-Z-MA-007
Revision 4
Page 70 of 90

Details (continued)

Selection between AUTO/MANUAL/OFF mode for the oil coolers. AUTO has
to be selected in order to start the main motors

When AUTO is selected:

 Oil cooler 1 will be activated when oil temp reaches 45º C and deactivated
when temp drops to 40 ºC
 Oil cooler 2 will be activated when oil temp reaches 50 ºC and deactivated
OIL COOLERS when temp drops to 45 ºC
(AUTO/MAN/OFF)
If the oil temperature reaches 65º C, the high oil temp. alarm is activated
If the oil temperature reaches 75º C, the high-high oil temp. alarm is activated

When MANUAL is selected:

The oil cooler fan will run continuously, regardless of oil temperature

When OFF is selected:

The oil cooler fan will not run, regardless of oil temperature
Selection between AUTO/MANUAL/OFF mode for the ventilation fan. When
VENTILATION FAN AUTO is selected the ventilation fan is started/stopped according to when the
(AUTO/MAN/OFF) main motor is running i.e. if the main motor is running the ventilation fan will
also be running
By pushing the INFO button the following help text appears:

INFO
 Document number V3054-Z-MA-007
Revision 4
Page 71 of 90

1.6.9.41 Alarm Page

Manually by pushing “ALARM PAGE” from the Status Bar or by pushing the
Activated red alarm text line on the bottom of the screen (alarm banner) (available from
all screen displays)

Functions in this screen Gives a list of the last activated- and previous alarms

Details

All active alarms will be displayed with the date and time of activation

RED FIELD Displays historic alarms

Displays the current alarm. The current alarm will also appear in each screen
BLUE FIELD
display (bottom bar)
Push-button. Push this button to enter the Alarm History. All previous alarms
HISTORY
are here displayed with the date and time of activation
 Document number V3054-Z-MA-007
Revision 4
Page 72 of 90

1.6.9.42 Alarm History

Activated Manually by pushing “HISTORY” from the Alarm Page

All previous alarms will here be displayed with the date and time of activation
Functions in this screen
To close the window, press the ‘X’ in the upper right hand corner
 Document number V3054-Z-MA-007
Revision 4
Page 73 of 90

1.6.9.43 Dealing with Alarms

Information regarding Alarm Management

The last activated/triggered alarm is shown in the Alarm Banner (bottom bar) of most operator screen displays,
including the Main Menu screen display. Lists of active and historic (no longer active) alarms are available by
touching the Alarm Page button. This button is available from all screens.

When an alarm is triggered, the cause of the alarm must be investigated and remedied. When an alarm is no
longer active, it will be transferred from the Alarm Page to the Alarm History screen.

The following alarms may be triggered (table below)

# Messages Cause Check

Either the transmitter is defect, or
BrkW - Oil temperature Reading of the analogue input
1 the connections/fuse to the
transmitter signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
BrkW - Main boom cylinder Reading of the analogue input
2 the connections/fuse to the
pressure signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
BrkW - Knuckle boom angle Reading of the analogue input
3 the connections/fuse to the
potmeter 2 signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
Reading of the analogue input
4 BrkW - Boom angle potmeter 2 the connections/fuse to the
signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
BrkW - Knuckle boom angle Reading of the analogue input
5 the connections/fuse to the
potmeter 1 signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
Reading of the analogue input
6 BrkW - Boom angle potmeter 1 the connections/fuse to the
signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
Reading of the analogue input
7 BrkW - Load cell main winch the connections/fuse to the
signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
BrkW - Cabin temperature Reading of the analogue input
9 the connections/fuse to the
transmitter signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
Reading of the analogue input
13 BrkW - Press load sense MCV the connections/fuse to the
signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
Reading of the analogue input
14 BrkW - Winch brake 1 pressure the connections/fuse to the
signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
Reading of the analogue input
15 BrkW - Winch brake 2 pressure the connections/fuse to the
signal to the PLC is not possible.
transmitter is/are damaged.
Communication problem with the Check connections, power
28 Error - Boom joystick
left hand joystick. supply and bus cable.
Communication problem with the Check connections, power
29 Error - Slew joystick
left hand joystick. supply and bus cable.
Communication problem with the Check connections, power
30 Error - Winch joystick
right hand joystick. supply and bus cable.
Communication problem with the Check connections, power
31 Error - Knuckle boom joystick
right hand joystick. supply and bus cable.
Communication problem with the Check connections, power
32 Error - Yoke tilt joystick
left hand joystick. supply and bus cable.
Communication problem with the Check connections, power
33 Error - Yoke slew joystick
right hand joystick. supply and bus cable.
 Document number V3054-Z-MA-007
Revision 4
Page 74 of 90

# Messages Cause Check

Check the mechanical fastening
The deviation between the two
of the angle sensors and sensor
34 Knuckle Boom Angle Deviation knuckle boom angles sensors
arm. Check the electrical
are above 5 degrees.
connections.
Check the mechanical fastening
The deviation between the two
of the angle sensors and sensor
35 Main Boom Angle Deviation main boom angle sensors is
arm. Check the electrical
above 5 degrees.
connections.
The oil temperature is higher
52 Oil temp Hi-Hi > 75 C Check the oil cooling system.
than 75º Celsius.
The oil temperature is higher
53 Oil temp Hi > 65 C Check the oil cooling system.
than 65º Celsius.
The oil temperature is lower than Run the HPU for a while until
54 Oil temp Lo < 10 C
10º Celsius. temperature gets higher.
There is too little oil in the Check for major leaks in the
55 Oil level low
hydraulic oil tank. system.
There is too little oil in the Check for major leaks in the
56 Oil level lowlow
hydraulic tank. system.
The motor fails to start or there is Check the power to the motor
61 Cooler 1 alarm a loss of running signal while the and the HPU Control System.
motor is running. (Check the motor protection)

The motor fails to start or there is Check the power to the motor
62 Cooler 2 alarm a loss of running signal while the and the HPU Control System.
motor is running. (Check the motor protection)
NOTE! Check the error message
Error signal to the PLC from the on the faulty pump card
63 Main motor 1 fault pump control card. The pump will (Description in the pump card
automatically stop. manual), and try to fix the
problem that initiated the fault.
NOTE! Check the error message
Error signal to the PLC from the on the faulty pump card
64 Main motor 2 fault pump control card. The pump will (Description in the pump card
automatically stop. manual), and try to fix the
problem that initiated the fault.
The motor fails to start or there is Check the power to the motor
66 Ventilation fan alarm a loss of running signal while the and the HPU Control System.
motor is running. (Check the motor protection)
Alarm if sequential order of
phases are incorrect. Alarm if
73 Main motor 1 low voltage failure on one of the phases. Check the cranes power supply.
Alarm if over- or under voltage
phases.
Alarm if sequential order of
phases are incorrect. Alarm if
74 Main motor 2 low voltage failure on one of the phases. Check the cranes power supply.
Alarm if over- or under voltage
phases.
The ‘hook limit down’ has been
76 Hook limit down mw reached; there is only 5 turns left No more wire can be payed out.
on the drum.
The load on the winch is greater
than 90% of SWL. An internal
78 Load > 90% SWL alarm is activated inside the
crane cabin to alert the crane
operator
79 Load > 100% SWL The load on the winch is greater Overload situation. Some
 Document number V3054-Z-MA-007
Revision 4
Page 75 of 90

# Messages Cause Check

than 100% of SWL. An internal movements are restricted.
alarm is activated inside the
crane cabin to warn the crane
operator and a buzzer alarm is
activated outside the crane cabin
to warn people on deck.
The load on the winch is greater
Overload situation. Some
than 110% of SWL. An internal
movements are restricted.
alarm is activated inside the
80 Load > 110% SWL crane cabin to warn the crane
operator and a buzzer alarm is
activated outside the crane cabin
to warn people on deck
Check the emergency stop push-
buttons. Only deactivate if the
emergency situation is cleared
An emergency stop push-button
81 Emergency stop activated up, or other reasons for
has been activated.
activating the emergency stop is
over (E.g. maintenance
operations)
Deactivate/turn the switch to
The MOPS push-button is in
82 MOPS activated normal if the emergency situation
emergency position.
is over.
Low pressure on the MOPS
83 MOPS accumulator low press Check for oil leaks.
accumulator.
Activated by an extreme
84 AOPS activated overload situation. Due to e.g. Unload winch/hook.
hook stuck to another vessel.
The load on the main winch is
greater than 110% of SWL x
dynamic factor. An internal alarm
is activated inside the crane
cabin to warn the crane operator Overload situation. Crane has to
Load winch > 110% dynamic
85 and a buzzer alarm outside the be thoroughly inspected for
load
crane cabin is activated to warn possible damages. Contact NOV.
people on deck. The visual alarm
cannot be reset before the crane
is thoroughly inspected for
possible damages.
This alarm will be triggered if
MOPS should not be activated in
86 MOPS initiated but not activated MOPS is activated in personnel
personnel lift mode.
lift mode.
The load on the yoke is greater
than 110% of SWL x dynamic
factor. An internal alarm is
activated inside the crane cabin
to warn the crane operator and a Overload situation. Yoke has to
87 Load yoke > 110% dynamic load buzzer alarm outside the crane be thoroughly inspected for
cabin is activated to warn people possible damages. Contact NOV.
on deck. The visual alarm cannot
be reset before the yoke is
thoroughly inspected for possible
damages.
The crane has reached restricted
89 Crane in restricted area 1
area 1
The crane has reached restricted
90 Crane in restricted area 2
area 2
92 Crane out of sea lift area The working radius/boom tip is The working radius/boom tip
 Document number V3054-Z-MA-007
Revision 4
Page 76 of 90

# Messages Cause Check

not within the area for entering must be inside the area for
CT. entering CT.
Slew counter max. revolutions
93 Slew counter out of range Set slew zero.
have been reached.
Lower the main boom and fold in
94 Hook stop not allowed The booms are not folded in.
the knuckle boom.
The load in the hook + length of
Abort the operation. Hoist and
95 Load is too high for sealift mode wire restricts further payout of
unload the hook.
wire
The load is too high for entering
Check the weight of the current
96 Load is too high for CT transition CT-sea lift. The load has to be
load ->reduce to less than 1 ton
less than 1 ton
This alarm will be activated if one Check valves and equipment for
97 24VDC Fuse error or more fuses on the 24V system faults that could have caused the
has released. fuse release.
This alarm will be activated if one
Check the power supply and
98 24VDC Power failure of the 24V power supplies is out
replace it if necessary.
of order.
This alarm will be activated if one
Check the power supply and
99 12VDC Power failure of the 12V power supplies is out
replace it if necessary.
of order.
101 Slack wire MW The wire on the winch is slack
106 AOPS/CT valve fault
117 Crane safety out of function Crane safety out of function Sensor failure. Critical for safety.
Service override has been The alarm can be reset by
125 Service override activated selected from the password turning the system key to off-
protected NOV menu position.
Check the power to the card. If
127 MW Loadcell module error PLC load cell card failure necessary, contact National
Oilwell
Slew tacho not
129 Slew Prox. Deviation Alarm Recalibrate slew tacho.
calibrated/damaged
Slew prox width has not been
130 Slew Prox. Area Not set Perform slew zero procedure.
set.
Either the filter needs to be
replaced, or there is a problem
131 Return filter alarm The oil filter is contaminated. with the sensor/fuse -> check the
sensor with connections and fuse
for faults
Either the filter needs to be
replaced, or there is a problem
133 Leak filter alarm The oil filter is contaminated. with the sensor/fuse -> check the
sensor with connections and fuse
for faults
Either the filter needs to be
replaced, or there is a problem
134 Pressure filter 1 alarm The oil filter is contaminated. with the sensor/fuse -> check the
sensor with connections and fuse
for faults
Either the filter needs to be
replaced, or there is a problem
135 Pressure filter 2 alarm The oil filter is contaminated. with the sensor/fuse -> check the
sensor with connections and fuse
for faults
Low winch brake pressure (in
147 The brake pressure is too low. Check the winch brake system.
yoke mode)
Load is too high for selecting This alarm will be activated if the Never change fall with a hanging
148
number of fall operator tries to change fall with load.
 Document number V3054-Z-MA-007
Revision 4
Page 77 of 90

# Messages Cause Check

a hanging load. The alarm will be
trigged if the load is above 2 ton.
This alarm will be activated if the
Joystick on turn off for selecting Turn the joystick on/off switch to
149 operator tries to change fall with
number of fall off position.
the joystick switch in on position.
150 Sealift disabled - No AOPS Crane leaving sealift
SWL override has been activated
Turn the system key to off
151 SWL limits override from the password protected
position
NOV menu
Fall has been changed without
152 Set Hook Stop Up Set hook stop up
setting new hook stop position
The pressure is too low for winch
Winch brake pressure LowLow - brake release. Set point Stop immediately. Check for
153
STOP automatically increased to max. leaks.
pressure
The pressure is too low for winch
brake release. Set point
154 Winch brake pressure Low Check for leaks.
automatically increased to max.
pressure
This alarm will be activated when
the crane is rigged with a yoke Check the winch tension system
155 Winch wire load is > 7.0 ton and the winch wire tension or contact NOV service
(connected to the knuckle boom department.
end) is above 7 ton.
This alarm will be activated when The crane must not be operated
the crane is rigged with a yoke before this problem is sorted out.
156 Winch wire load is > 10.0 ton and the winch wire tension Check the winch tension system
(connected to the knuckle boom or contact NOV service
end) is above 10 ton. department.
Feedback error MOPS not Error on the MOPS feedback Check the MOPS enable/disable
166
enable valve valve
Feedback error MOPS not Error on the MOPS feedback Check the MOPS enable/disable
167
disable valve valve
The lift logger is stopped Check MMC card and start the lift
168 Lift logger not running
manually. logger
Activating CT mode is only
169 No CT in internal lift
possible in sea lift mode
Trying to enter personnel lift
Check that the joystick is
Personnel lift not possible (check mode with either; joystick on,
switched off, load < SWL, 1 fall
170 joyst. off, load < SWL, 1 fall and load higher than SWL, not in 1
mode is selected and in internal
internal lift) fall mode or with sea lift mode
lift mode
enabled
Personnel lift not possible in 2 Personnel lift mode is not Change to 1 fall mode before
171
fall mode possible in 2 fall mode activating personnel lift mode
Always set hook up stop after fall Fall has been changed without
172 Set hook stop up
change setting new hook stop position
CT mode is not possible in
173 No CT in personnel lift
personnel lift mode
Personnel lift not possible in 5 Personnel lift mode is not Change to 1 fall mode before
174
fall mode possible in 5 fall mode activating personnel lift mode
Personnel lift switch position
175 does not match actual crane
mode
Activating yoke mode
176 not possible (joystick on in sealift
or load > limit)
177 Start of HPU not possible
 Document number V3054-Z-MA-007
Revision 4
Page 78 of 90

# Messages Cause Check

(joystick on cooler not in auto or
oil level lowlow)
Crane outside virtual wall sector
185 Outside Virtual Wall set by operator. Some Exit restricted area.
movements are restricted.
186 Virtual wall override active Override activated. NA
Not active alarm, function is Activate the function during
187 Virtual Wall not activated
disabled. normal operations.
Crane is close to virtual wall set
Close to Virtual Wall, movement
188 by operator. Some movements NA
stopped
are restricted.
265 Yoke not connected Yoke is not connected Connect yoke.
266 Yoke mode not selected Yoke mode is not selected Select yoke mode.
267 Yoke not ready Yoke connected, but not reset Reset yoke position.
Either an incorrect yoke is
268 Incorrect yoke connected Check connection.
connected, or the plug is defect.
Limit for yoke slew limit CW has
269 Yoke slew stop CW
been reached.
Limit for yoke slew limit CCW has
270 Yoke slew stop CCW
been reached.
Check the power supply to the
271 Yoke loadcell module error PLC load cell card failure card, if necessary contact
National Oilwell
Either the transmitter is defect, or
Reading of the analogue input
272 BrkW - Yoke loadcell the connections/fuse to the
signal to the PLC is not possible.
transmitter is/are damaged.
Either the transmitter is defect, or
Reading of the analogue input
273 BrkW - Yoke load sense the connections/fuse to the
signal to the PLC is not possible.
transmitter is/are damaged.
Yoke tilt limit has been reached Tilt the yoke back to horizontal
274 Yoke tilt limit
(> 5 ˚) position.
Activate winch tension mode.
Yoke connected Winch tension A yoke is connected without
275 This button is available from the
not active winch tension activated
mode select screen
 Document number V3054-Z-MA-007
Revision 4
Page 79 of 90

1.6.9.44 How to Recover after PLC Breakdown

The majority of failures that may happen on the crane during operation are related to problems outside the PLC. If
the control system fails, one should pay attention to sensors, power supply or incorrect use of the equipment. This
should be checked before starting the troubleshooting on the PLC and/or PLC program.
However, if the PLC fails, the crane will be out of operation, therefore this component is critical.

The PLC consists of one CPU, several input and output cards, weighing modules and counter cards. If an error
occurs on one of the cards, a red error lamp will light up on the card and sometimes also on the CPU module. In
this case the fault is often located on the input signal or in the card itself.

CPU failure rarely occurs. This could happen in the event of a thunderstorm or irregularity in voltage supply etc. In
these cases the CPU must be replaced.
NOTE:
Contact NOV before replacing the CPU.
Procedure for replacing the CPU and recovering of the PLC program:
Turn of the power to the PLC by disengaging the correct fuse. Refer to the electrical drawings to find the
1.
correct circuit breaker.
2. Disconnect the power supply to the CPU, either by taking out the 24V plug or disconnecting the cables.
3. Remove the defect CPU by unscrewing the screw (-s) located underneath the CPU module.
4. Swap the memory card (located under the front cover) from the broken CPU to the new one.
Mount the new CPU; be especially aware of the small contacts on the back plate when mounting the new
5.
module. Do not over tighten the fastening screws. Reconnect the 24V power (plug or cables).
6. Power up the system. The small switch on the CPU front panel must be set to “run” position.
Ensure that the PLC starts normally, i.e. after very short period of time the green run lamp shall light up and
7.
no red lamps on the PLC shall be on.
Check that the PLC has uploaded the program from the memory card by trying to activate a non critical
8.
function, i.e. wipers or horn.
Verify that the boom angles are correct and recalibrate if necessary. See segment regarding boom angle
9.
settings in this document.
Verify that the slew zero setting is correct and recalibrate if necessary. See segment regarding slew zero
10.
setting in this manual.
Verify the telescope position (if applicable) and recalibrate if necessary. See segment regarding telescope
11.
settings in this manual.
Verify that yoke slew position is correct and reset yoke slew if necessary. See segment regarding yoke slew
12.
reset in this manual.
Verify the load cell values for the main winch (if applicable) and reload/recalibrate if necessary. See
13.
segment regarding load cell calibration in this document.
Verify the load cell values for the yokes and reload/recalibrate if necessary. See segment regarding yoke
14.
load cell calibration in this document.
NOTE:
When reloading load cell values for a yoke, the particular yoke must be connected (Only applicable for offshore
cranes with more than one yoke).
 Document number V3054-Z-MA-007
Revision 4
Page 80 of 90

1.7 Load Handling

The crane has the following available modes

1 Fall Sealift Internal Lift Personnel Lift
Winch mode 2 Fall Sealift Internal Lift
5 Fall Sealift Internal Lift
Yoke mode 20” Gripper Yoke

1.7.1 Load Measuring System

Information regarding the Load Measuring System

The cranes lifting capacity, depending on working radius, working height, selection of falls, significant wave height
and lifting mode, will be shown on the load indicator in the operator display.

The load is continuously measured and shown on the operator display.

Internal lift/Sea lift mode

The transition between Internal lift and Sea lift is done automatically by the Crane Control System. The crane
mode switches automatically from Internal lift to Sea lift when the crane enters the sea lift sector. The crane mode
switches back automatically to Internal lift when it leaves the sea lift sector.
NOTE:
If the load is too high when trying to enter Sea lift mode, an alarm will be triggered: “Load is too high for sea lift
mode”. The crane will remain in Internal lift mode. Ref. the Load Chart
When the crane is in Sea lift mode, the CT and AOPS functions are enabled.
These functions are not available in Internal lift mode or in Personnel lift mode (if applicable).

Operating the CT Mode:

CT mode can be used for tightening up the wire while hooked up to a load on another vessel. Ref. the load
handling procedures for Sea lift on the consecutive pages
NOTE:
The CT function can only be activated in Sea lift mode
WARNING!
DO NOT OPERATE THE CT MODE WITH A HANGING LOAD
CAUTION!
DO NOT OPERATE THE CT MODE CONTINUOUSLY FOR MORE THAN 5 MINUTES
 Document number V3054-Z-MA-007
Revision 4
Page 81 of 90

1.7.2 Procedures

1.7.2.1 Personnel Lift

Operational Limitations for Personnel Lift (Except for in Emergency Situations):

Lifting Capacity 1,5 tons
Lifting-/Lowering Speed Less than 30 m/min
Mean Wind Velocity Less than 10 m/s
NOTE:
Suspended work platforms/baskets should not be used in winds exceeding 7 m/s
Significant Wave Height Less than 2 metres
There shall be no limitations in visibility, and the lifting of personnel is only to be
Visibility
performed in full daylight
Personnel lift shall not be performed in adverse weather conditions such as, but
Other Weather Limitations not limited to; electric storms, snow, ice, fog or sleet or similar that can affect the
safety of personnel
NOTE:
Overload protection systems are disabled when in Personnel Lift mode
NOTE:
The operator is responsible for following applicable rules and regulations for personnel lift
WARNING!
LIFTING OF PERSONNEL MUST ONLY BE PERFORMED USING LIFTING ACCESSORIES ESPECIALLY
DESIGNED FOR LIFTING OF PERSONS IN THE MARINE ENVIRONMENT.
NOTE:
The crane operator and the slinger man shall conduct a test lift with the equivalent mass of that to be lifted applied
to the lifting accessories.
# Sequence Description
1. Prior to operation of personnel lift, confirm that there is no load in the hook.
2. During operation of personnel lift, the crane operator must have continuous communication with the
personnel that is to be lifted, the assistant-/signal man and the slinger.
3. Select Personnel Lift from the Control Cabinet IB001 (Key switch to “On” position)
4. Check that the Personnel Lift lamp on the Operator Display is lit (yellow)
5. Use slow, gentle, controlled and cautious movements when operating the crane. Avoid sudden
movements.
6. The operator shall remain at the main operator station for as long as personnel are in the lifting
accessories (E.g. personnel basket)

1.7.2.2 Internal Load Handling

# Sequence Description
Plan the lift (weight, working radius, significant wave height).
1.
Study the load charts and derating tables.
Check that the correct winch (if applicable) and fall is selected (can only be selected when in off-
2.
mode)
3. Check that the joystick switch is on.
4. Slew the crane over load.
5. Lower the main hook.
6. Hook on the load.
7. Lift the load.
8. Slew / lift / adjust the working radius.
9. Lower the load on to deck.
10. Disconnect the hook from the load.
11. Lift the hook away from the load.
12. Drive the crane back to the starting position.
 Document number V3054-Z-MA-007
Revision 4
Page 82 of 90

1.7.2.3 Sea Lift

LOAD HANDLING FROM SUPPLY VESSELS

# Sequence Description
1. Plan the lift (weight, working radius, significant wave height).
Study the load charts and derating tables.
2. Slew the crane booms over the supply vessel. Check that the mode changes from Internal Lift to
Sea Lift when the crane enters the sea lift sector.
3. Check that crane boom is inside allowed height for load handling from supply vessels (bar graph on
the operator display).
4. Lower the hook to the supply vessels deck.
5. Connect the load to the hook.
6. Push the “CT” button on right hand joystick. The CT lamp on the operator display will start flashing.
7. Pull the winch joystick towards hoisting to tighten up the wire. As soon as the wire tightens, the
crane goes into CT mode.
8. When the load is on a wave top, push the CT-button again while keeping the joystick in hoist
position, and lift the load free from the supply vessel. The CT lamp will extinguish.
9. Slew back over the platform.
10. Check that the mode changes from Sea Lift to Internal Lift when the crane leaves the sea lift sector.
11. Lower the load.
12. Disconnect the load from the hook.
13. Lift the hook away from the load and other obstructions.
14. Drive the crane back to the starting point or to Sequence # 2.

LOAD HANDLING TO SUPPLY VESSELS

Sequence Description
1. Plan the lift (weight, working radius, significant wave height).
Study the load charts and derating tables.
2. Slew crane/adjust working radius to get the hook over the load.
3. Lower the hook.
4. Attach the load to the hook.
5. Lift the load.
6. Check that the mode changes from Internal Lift to Sea Lift when the crane enters the Sea Lift sector.
7. Slew/lift/adjust the working radius over the supply vessels deck. Check that the cranes boom tip is
inside allowed height for load handling from supply vessels (bar graph on the operator display).
8. Land the load on the supply vessel.
9. Pay out enough wire for the hook to be disconnected safely.
10. Release the hook from the load.
11. Pull the joystick to lift the hook away from the supply vessel.
12. Slew the hook over the platform. Check that the mode changes from Sea Lift to Internal Lift when
the crane leaves the Sea Lift sector.
13. Drive the crane back to Sequence # 2 for a new lift or back to the boom rest.
 Document number V3054-Z-MA-007
Revision 4
Page 83 of 90

1.7.2.4 Preparing the Crane for Yoke Operation

# Sequence Description
1. Dismount the hook. The hook should be stowed in a stand where it is easy to reach when the crane
is to be rigged with hook again. Keep a wire slack of about 3 - 4 meters. Try to avoid driving the
winch out without the hook connected due to the risk of slack wire on the winch drum.
2. Lower the boom and place the knuckle boom end close to deck level where fastening of the wire to
the knuckle boom end can be performed in a safe way.
3. Connect the wire to the pad eye located at the knuckle boom end by use of the two fall bolt.
NOTE:
The weak link connection (10T) to be connected between the wire and the pad-eye as shown on the wire
reeving drawing (OC3932KM02-M0001)
4. Tighten up the slack very carefully by driving the winch up.
5. Enter the mode selection screen on the operator display
6 Press the winch tension button and ensure that the button becomes highlighted.
7. Observe that the wire tightens up. The wire tension can be monitored on the load cell info page
(Main Menu→ System Menu→ Test Menu→ Loadcells). The wire tension should vary between 1,5
to 3 tons, depending on the winch turning direction. The automatic winch tension will maintain this
tension and keep the wire tight independent of boom and knuckle boom movements.
8. The crane is now ready for connecting a yoke. For details on connection and disconnection of yoke,
ref. the User Manual for the yoke that is to be connected.
WARNING!
TO AVOID THE WIRE FALLING BACK TO THE WINCH, ALWAYS KEEP THE BOOM TIP HEIGHT BELOW
MINUS 2M WHEN THE HOOK IS DISCONNECTED FROM THE WIRE

1.7.2.5 Hook Stop Up Setting

# Sequence Description
1. Before hook stop up is set, the boom must be in its lowest position and the knuckle boom must be
folded completely in.
2. Run the winch to the new position for stop-point up (Normally about 1-2 m below the wire sheave
bracket).
3. Enter the Winch Limits screen display (Main Menu→ System Menu→ Limits Menu→ Main Winch
Limits) Push the “Set Up Limit” button to reprogram the system for this new position.
4. “Actual length” and ”Limit up length” will now be changed.

1.7.2.6 Hook Stop Down Setting

# Sequence Description
1. Run the winch to the position for stop-point down (5 safety turns left on the winch drum).
2. Enter the Winch Limits screen display (Main Menu→ System Menu→ Limits Menu→ Main Winch
Limits) Push the “Act Down Limit MW” button and a password screen will appear. If the correct
username and password is entered the “Set Down Limit Button” is activated, and the new down limit
can be set.
3. Please observe that the “Actual Length” is zeroed after down limit has been set.
 Document number V3054-Z-MA-007
Revision 4
Page 84 of 90

1.7.2.7 Slew Zero and Sealift Sector Setting

# Sequence Description
1. Position the crane with the boom pointing forward against the vessels bow parallel to the vessels
side. If the crane is placed on a rig, it should be pointing against the accommodation parallel to the
rig side.
2. Enter the Crane Slew Limits (Slew Zero) screen (Main Menu→ System Menu→ Limits Menu→
Crane Slew Limits)
3. Press the “Slew Zero” button and a password screen will appear. If the correct username and
password is entered, the operator can push the “Slew Zero” button again. The slew counter is then
reset and the crane position will be shown as degrees in clockwise direction on the operator display.
4. Enter the Sea Lift Sector screen from the Crane Slew Limits (Slew Zero) screen and press the “Sea
Lift Sector” button and a password screen will appear. If the correct username and password is
entered, the “Set Left/Right Limit” buttons will appear
5. Position the crane at the left hand side of the sealift sector and press “Set Sea Lift Left Limit”
6. Position the crane at the right hand side of the sealift sector and press “Set Sealift Right Limit”. The
setting of the sea lift sector is now complete
7. Operate the crane in and out of the sealift sector from both sides and observe that the mode info text
shows “Sea Lift Mode” in the sealift sector and “Internal Lift” in the internal lift sector.

1.7.2.8 Slew Limit Sector Setting

# Sequence Description
1. Position the crane close to an obstruction where the crane should stop automatically.
2. Enter the Slew Limit Sectors screen (Main Menu→ System Menu→ Limits Menu→ Crane Slew
Limits→ Set Slew Limit Sectors)
3. Press “Slew Limit Sector 1” and a password screen will appear. If the correct username and
password is entered, the operator can push the button again and the “Set Left/Right Limit 1” buttons
will appear.
4. Push “Set Left Limit 1” or “Set Right Limit 1”, depending on the location of the obstruction related to
the cranes position.
5. Repeat this procedure at the other side of the obstruction.
6. Operate the crane into the slew limit sector at both sides and observe that the crane stops (if
applicable) or triggers an alarm
 Document number V3054-Z-MA-007
Revision 4
Page 85 of 90

1.7.2.9 Boom Angle Setting

# Sequence Description
1. The boom angle potentiometers are calibrated when the crane is new and this operation shouldn’t
normally be necessary to be repeated later. However, in some cases this has to be done e.g. if a
potentiometer is replaced etc. It is very important that the potentiometers are within their sensing
range, i.e. the slider on the potentiometer must operate on the 120 degree resistor field.
2. Enter the “Boom Angle Settings” screen (Main Menu→ System Menu→ Limits Menu→ Boom Angle
Settings)
3. Press the “Act” button and a password screen will appear. If the correct username and password is
entered, the “Act” button can be pushed a second time. This will activate the “Set” buttons.
4. Lower the main boom to the down most position. Press the “Set” button at the Lower Main Boom
Angle field.
5. Hoist the boom to the upper most position and press the “Set” button at the Upper Main Boom
Angle field.
6. This operation must sometimes be repeated two times before the PLC has received the new values.
7. Operate the boom into min. and max. angle and verify that the ramping at the end stops work
properly, and that the angle sensors show the same values (if the crane is equipped with two boom
angle sensors).
8. Perform the same operation for the knuckle boom.
9. Operate the knuckle boom into min. and max. angle and verify that the ramping at the end stops
work properly, and that the angle sensors show the same values (if the crane is equipped with two
knuckle boom angle sensors)
10. Press “Act” again to deactivate the “Set” buttons.

1.7.2.10 Winch Load Cell Calibration

# Sequence Description
1. Load cell calibration must sometimes be performed. This could be for periodically maintenance
purpose or e.g. if the load cell has been replaced.
2. Enter the “Main Winch Load Cell" screen (Main Menu→ System Menu→ Limits Menu→ Main Winch
Load Cell). The screen is password protected
3. Press the “Act” button to activate the “Set” buttons
4. Enter an adjustment weight into the system (This is done by pushing the Adj. weight tab, and
entering the adjustment weight by use of the pop-up key-pad). This is the weight the load cell is to
be calibrated against. Be sure that the weight of the load is correct. If uncertain, use a calibrated
load cell to verify the test load.
5. Lift the load carefully by using the boom. Push the “Set” button at the Adjust field.
6. Unload by lowering the boom. Make sure that the hook is approx. 2 meters from the knuckle boom
end. There should be no load in the hook. Push the “Set” button at the Zero field.
7. Press “Act” again to deactivate the “Set” buttons.
 Document number V3054-Z-MA-007
Revision 4
Page 86 of 90

1.7.2.11 Reload Winch Load Cell Values

# Sequence Description
1. Reload of load cell raw values from an earlier calibration must sometimes be performed. This could
be e.g. if the load cell amplifier card has been replaced.
2. Enter the “Reload Main Winch Load Cell” screen ((Main Menu→ System Menu→ Limits Menu→
Main Winch Load Cell→ Reload) The “Main Winch Load Cell” screen is password protected
3. Find the raw values noted down from an earlier calibration or contact NOV for these data’s.
4. Press “Act” to activate the “Set” buttons.
5. Enter the values for respectively; Range, Zero and Adjust.
6. Press the “Reload” button for setting of these values.
7. If the load cell is showing a value different from zero, the “Zero” button can be pressed to obtain an
accurate reading when the hook is unloaded.
8. Press “Act” again to deactivate the “Set” buttons.
9. Verify the load cell with a test load. Be sure that the weight of the load is correct. If uncertain, use a
calibrated load cell to verify the test load.

1.7.2.12 Yoke Load Cell Calibration

# Sequence Description
1. Load cell calibration must sometimes be performed. This could be for periodically maintenance
purpose or e.g. the load cell has been replaced.
2. Enter the “Yoke Load Cell" screen (Main Menu→ System Menu→ Limits Menu→ Yoke Load Cell).
The screen is password protected
3. Press the “Act” button to activate the “Set” buttons
4. Enter an adjustment weight into the system (This is done by pushing the Adj. weight tab and
entering the adjustment weight by use of the pop-up key-pad). This is the weight the load cell is to
be calibrated against. Be sure that the weight of the load is correct. If uncertain, use a calibrated
load cell to verify the test load.
5. Lift the load carefully by using the boom. Push the “Adjustment Weight” button at the adjust field.
6. Unload by lowering the boom. There should be no load in the yoke. Push the “Set” button at the
Zero field.
7. Press “Act” again to deactivate the “Set” buttons.

1.7.2.13 Reload Yoke Load Cell Values

# Sequence Description
1. Load cell calibration must sometimes be performed. This could be for periodically maintenance
purpose or e.g. if the load cell has been replaced.
2. Enter the “Reload Yoke Load Cell” screen ((Main Menu→ System Menu→ Limits Menu→ Yoke
Load Cell→ Reload) The “Yoke Load Cell” screen is password protected
3. Find the raw values noted down from an earlier calibration or contact NOV for these data’s.
4. Press “Act” to activate the “Set” buttons.
5. Enter the values for respectively; Range, Zero and Adjust.
6. Press the “Reload” button for setting of these values.
7. If the load cell is showing a value different from zero, the “Zero” button can be pressed to obtain an
accurate reading when the hook is unloaded.
8. Press “Act” again to deactivate the “Set” buttons.
9. Verify the load cell with a test load. Be sure that the weight of the load is correct. If uncertain, use a
calibrated load cell to verify the test load.
 Document number V3054-Z-MA-007
Revision 4
Page 87 of 90

1.8 Emergency Operation

1.8.1 Emergency Lowering Procedure

Emergency Lowering Procedure

The hand pump (NO1) for emergency operation is located outside the king, and the selector valve (NO4) is
located inside the king. Use the selector valve to choose what functions to operate.

When pumping the hand pump, the pressure will open the counter balance valve (for the main boom or knuckle
boom) and the boom will be lowered. The lowering can be stopped at any time by closing the valve on the hand
pump. For slew brake release, the pressure will open the brakes on the gears, thus making it possible to slew the
crane by an external force.

The lowering can be stopped at any time by closing the valve on the hand pump.
NOTE: (applicable when there is load in the yoke)
Follow the emergency lowering procedure for the crane to lower the load and the yoke to the deck. There is also a
main valve located in the crane king. Follow the posted signs to control the emergency functions of the yoke.

Selector valve

The emergency lowering procedure is posted Emergency hand pump

adjacent to the emergency hand pump

Typical pictures

In case of an emergency, follow the Emergency Lowering Procedure on next page.

Document number V3054-Z-MA-007
Revision 4
Page 88 of 90
 Document number V3054-Z-MA-007
Revision 4
Page 89 of 90

1.8.2 MOPS

MOPS – Information and Procedures

MOPS (Manual Overload Protection System)

MOPS Function Test Procedure

1. Hook up the test load, SWL x 0.5
2. With the load placed on deck, tighten the wire
rope. Do NOT lift!
3. Activate the MOPS push-button
4. Run the boom up, not more than 0.5 metres
5. Verify that the winch is paying out wire
6. Deactivate MOPS

The MOPS push-button is located inside the operator cabin. The push-button is permanently marked and
protected against inadvertent activation. The MOPS allows the winch to pay-out wire if the hook is
stuck/hooked to another vessel, thus preventing overloading of the crane.

The MOPS system is a manually activated system and is therefore available independently of crane mode* or
load situation (* = MOPS cannot be activated in personnel lift mode, if applicable).

If activated, the system will be kept in this mode until released by the operator.

The MOPS system has two independent power supply sources and will still work if there are no pumps
running.
WARNING!
MOPS MUST ONLY BE USED IN AN EMERGENCY SITUATION.
WARNING!
ACTIVATION OF THE MOPS PUSH-BUTTON WILL DROP THE LOAD AND MAY CAUSE DAMAGE TO
THE HYDRAULIC MOTORS.
NOTE:
MOPS to be tested every 6 months (ref. procedure above).
 Document number V3054-Z-MA-007
Revision 4
Page 90 of 90

1.9 Disturbance of Operation

If the equipment does not function as intended, consult the alarm list in this section. In case of other
operational errors or equipment breakdown please contact NOV’s service department for assistance, ref.
the document ‘Introduction’ for contact details

1.10 Training Programs for Operating and Maintenance Personnel

National Oilwell Varco Norway AS recommends that personnel involved in the operation and maintenance
of the subject equipment undergo an NOV-provided training program. This is to ensure that operation and
maintenance of the equipment are performed by qualified and competent personnel.

Training programs are subject to separate agreement and described separately. Please contact NOV for
more information.

1.11 Attachment

The following document is attached in Standard Documentation:

Literature Title
CARE AND MAINTENANCE OF THE AIR CONDITIONER, SIMCOOL.
 Document number V3054-Z-MA-001 section 5
TABLE OF CONTENTS Revision: 1
Page: 1

Vol. Section Title Add. code Rev. Document number

Other document number

1 5 Maintenance Instructions
Maintenance Instructions, OC3932KCE Knuckle Boom Crane No. 0 V3054-Z-MA-005
1 Pride No. 2

R5325 Deep Ocean Clarion (Former Pride 2)

V3054 OC3932KCE-(17-85)-(42-18)(27) No 1

www.nov.com
 Maintenance Instructions
OC3932KCE Knuckle Boom Crane No. 1
Pride No. 2

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Pride 2 V3054 OC3932KCE Knuckle Boom Crane No 1
ADDITIONAL CODE SDRL CODE TOTAL PGS
8 38 This document contains proprietary and confidential National Oilwell Varco Norway AS
information which belongs to National Oilwell Varco; it is Servicebox 401
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in N-4604 Kristiansand
MAIN TAG NUMBER DISCIPLINE part; or use of this design or distribution of this information Norway
to others is not permitted without the express written
consent of National Oilwell Varco. This document is to be
CLIENT PO NUMBER returned to National Oilwell Varco upon request and in Phone +47 38 19 20 00
any event upon completion of the use for which it was Fax +47 38 19 26 04
loaned.
© Copyright National Oilwell Varco - 2010

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

V3054-Z-MA-005 0
 Document number V3054-Z-MA-005
Revision 0
Page 3 of 38

TABLE OF CONTENTS

1 MAINTENANCE INSTRUCTIONS .................................................................................... 5

1.1 Introduction ............................................................................................................. 5
1.2 General Description ................................................................................................ 5
1.2.1 Corrections and Minor Repairs .................................................................... 5
1.2.2 Major Repairs and Modifications.................................................................. 6
1.2.3 Maintenance Not Recommended Done by User.......................................... 6
1.3 Safety Summary ..................................................................................................... 7
1.4 General Maintenance Information ........................................................................... 8
1.4.1 Special Tools ............................................................................................... 8
1.4.2 Fire Extinguisher .......................................................................................... 8
1.4.3 Lifting Lugs .................................................................................................. 8
1.4.4 Other Lifting Means ..................................................................................... 8
1.5 Maintenance Instructions ........................................................................................ 9
1.5.1 Mechanical System ...................................................................................... 9
1.5.1.1 Main Winch- and Slew Gearboxes.......................................................... 10
1.5.1.2 Illustration Drawing – Main Winch Gearbox, Brevini SLW4003 .............. 11
1.5.1.3 Illustration Drawing – Slew Gearbox, David Brown RE3513 ................... 12
1.5.1.4 Steel Wire Rope ...................................................................................... 13
1.5.1.5 Rope Examination Record ...................................................................... 14
1.5.1.6 Rope Sheaves ........................................................................................ 15
1.5.1.7 Hoisting System ...................................................................................... 17
1.5.1.8 Crane Blocks and Swivels ...................................................................... 18
1.5.1.9 Slewing System ...................................................................................... 20
1.5.1.10 Axial Reduction Measurement .............................................................. 22
1.5.1.11 Measurement Value Recording Table .................................................. 23
1.5.1.12 Maximum Permissible Slew Bearing Clearance Table ......................... 24
1.5.1.13 Luffing System ...................................................................................... 25
1.5.1.14 Tightening Torque for Bolts................................................................... 27
1.5.1.15 Recommended Lubricants Table .......................................................... 28
1.5.2 Hydraulic System ....................................................................................... 29
1.5.2.1 Return Oil Filter Change ......................................................................... 32
1.5.2.2 Calibrated Equipment ............................................................................. 33
1.5.2.3 High Pressure Filter Cartridge Change ................................................... 34
 Document number V3054-Z-MA-005
Revision 0
Page 4 of 38

1.5.2.4 Breather Filters ....................................................................................... 34

1.5.2.5 Accumulators .......................................................................................... 34
1.5.2.6 Oil Coolers .............................................................................................. 34
1.5.3 Electric System .......................................................................................... 35
1.6 Operational Errors and Equipment Breakdown ..................................................... 38
1.7 Attachments .......................................................................................................... 38
 Document number V3054-Z-MA-005
Revision 0
Page 5 of 38

1 MAINTENANCE INSTRUCTIONS

1.1 Introduction

The equipment owner is solely responsible for preparing and maintaining a record-keeping system
(Maintenance Log) in accordance with the instructions given in this manual. Inspection records,
maintenance records, repair records and re-manufacture records should be filed in the log.

Cranes shall undergo a thorough examination at least every 12 months by a competent person, or more
frequently if required by the Norwegian Maritime Directorate
(Only applicable to cranes that are to comply with NMD regulations)

It is also of great importance that owners/operators reports failures and problems to the manufacturer, so
that critical items can be identified. Areas of major concern shall, without hesitation, be brought to the
attention of the manufacturer.

1.2 General Description

When planning the maintenance operations other sections in the user manual are often referred to and
should be used as backup.

The following documents may be referred to in the Maintenance Instructions

Document Name Document No. Section

Introduction for User Manual 74309174 Introduction
Product Data Sheet Z-DS-001 Data Sheet
Technical Description Z-SA-001 Technical Description
Operating Instructions Z-MA-007 Operating Instructions
Drawings & Parts Lists NA Drawings & Parts Lists
Standard Documentation Z-MA-010 Standard Documentation

1.2.1 Corrections and Minor Repairs

Always inform National Oilwell Norway AS (NOV) of any corrections and minor repairs to identify possible
consequences.

This section describes how to carry out a selection of corrections and minor repairs. The user is not
supposed to carry out any corrections or minor repairs other than those described below. The user is
however welcome to contact NOVs service department to discuss any corrections and repairs. If
authorised by the service department, work permits and procedures will be issued as required.
 Document number V3054-Z-MA-005
Revision 0
Page 6 of 38

1.2.2 Major Repairs and Modifications

Major repairs and modifications have to be discussed with and approved by NOVs service department
before the work can start. These may also be followed up with full load and functional tests. The service
department will involve NOVs design engineers as necessary and a conclusive report and proposal will
be issued.

NOV provides, upon request, instructions concerning overhaul and repairs at special shops. If agreed,
NOV also keeps all documentation for modification or rebuilding of the equipment.

For all queries concerning welding procedures, preparations for welding or repair of welded parts and test
reports of NDT, refer to the Manufacturing Record Book.
If the MRB is not available, contact NOV to process a request for insight to the MRB.

1.2.3 Maintenance Not Recommended Done by User

Maintenance Not Recommended Done by User

Without approval and instructions from NOVs service department, the user shall not carry out the
repair/modification work listed below. The list is not exhaustive, and the general rule is that maintenance/repairs
not described in the Maintenance section requires NOVs approval before carried out.
- Adjustments, repairs and replacements of mechanical, electrical or hydraulic components with load carrying
or safety functions
- Adjustments, repairs and replacements of components sealed by the supplier
- Adjustments of the main pumps
- Reprogramming of the PLC
 Document number V3054-Z-MA-005
Revision 0
Page 7 of 38

1.3 Safety Summary

The following types of safety messages may appear in various segments of this section
WARNING: Must be observed to prevent serious personnel injury.
CAUTION: Must be observed to prevent damage of equipment and/or loss of operating effectiveness.
NOTE: Must be observed for correct and efficient operation.
It is the responsibility and duty of all personnel involved in the operation and maintenance of this equipment to
fully understand the SAFETY measures, by which hazards are reduced or eliminated. Personnel must
familiarize with all aspects of safety and operation of the equipment before starting any operation or
maintenance.
The following points sum up the safety aspects related to Maintenance
WARNING:
DO NOT CARRY OUT ANY MAINTENANCE OR CLEANING WORK ON THE CRANE WHEN THE CRANE IS
RUNNING, UNLESS FOR ANY MAINTENANCE WORK FOR WHICH CRANE OPERATION IS DESCRIBED
IN A SPECIFIC PROCEDURE.
CAUTION:
DO NOT MIX GREASE CONTAINING BARIUM WITH LITHIUM OR CALCIUM BASED GREASE. IF BARIUM
IS MIXED WITH LITHIUM OR CALCIUM, THE GREASE MAY HARDEN. IF TYPE OF GREASE IS
CHANGED, MAKE SURE THAT GREASED SURFACES ARE THOROUGHLY CLEANED.
Do not attempt adjustments or repair work if you are not qualified to do it.
Do not work on the PLC, or other safety and control systems unless you have special training for this and
have permission from NOV.
Ensure to use certified lifting equipment and follow the lifting instructions in the manual when lifting heavy
equipment and components.
When the crane is not to be started (for instance during repair/maintenance on the crane), activate an
“Emergency Stop” switch and set the “System On” switch in off position.
Inform necessary personnel about the maintenance activities and fence off the area if needed.
Always wear personal safety equipment like ear protection and eye goggles when working with running
machinery.
Ensure that hydraulic pressure is evacuated from hydraulic lines and pressure vessels before disconnecting
them.
Ensure that heavy equipment and components are properly supported and secured before disconnecting.
Ensure that electric power cables are disconnected before working on electrical equipment.
Do not run equipment containing rotating parts with removed protection covers.
Take care when working with rotating shafts, gears and their driving and driven members
No welding is to be performed on lifting gear like shackles, hooks, swivels, and blocks or akin.
Do not use naked lights in the proximity of openings due to the possible build up of explosive gases.
Always use a safety harness to prevent falls when doing inspections or maintenance work in unsecured
areas on the crane.
Keep the crane as clean and tidy as possible during maintenance operations
Remove oil spills from the machinery and floor, and keep oil soaked rags and similar in fireproof containers.
Only original spare parts ordered through National Oilwell Varco must be used, as modifications may have
been performed by NOV on standard parts. Non-modified parts may interfere with the original performance.
Use of non-modified parts will also influence the terms of warranty.
 Document number V3054-Z-MA-005
Revision 0
Page 8 of 38

1.4 General Maintenance Information

Means for lifting and moving of components are provided for all crane parts too heavy to be handled by
hand (more than 25 kg). This does not include the crane cabin and the main booms.

1.4.1 Special Tools

The following special tools are provided:

Reference can be made to:
- Standard Documentation, Sub-vendor Literature
Tentec tensioning tool for the slew bearing fasteners
Tentec hydraulic hand pump for the tensioning tool
Tentec flexible hose for the tensioning tool

1.4.2 Fire Extinguisher

The fire extinguisher located inside the crane cabin should be implemented into the rig/vessels
maintenance routines for such equipment.

1.4.3 Lifting Lugs

Lifting lugs are located:

Above each slew gearbox
Above each main boom cylinder
Above heavy equipment in the machine room and pedestal adapter

1.4.4 Other Lifting Means

Lifting points are provided for heavy components including the:

Booms
King
Electro motors
Hydraulic cylinders
Winch
Boom and cylinder pins
 Document number V3054-Z-MA-005
Revision 0
Page 9 of 38

1.5 Maintenance Instructions

1.5.1 Mechanical System

Inspection and maintenance of the Mechanical System

Reference can be made to:
- Technical Description
- Product Data Sheet

On the structural parts of the crane, various types of damage can occur, such as wear, tear, overload,
Crane Structural

fatigue, and collision damages.

General wear and abrasion of the paintwork should be touched-up regularly to maintain the integrity
System

provided by the Surface Protection System (ref. Product Data Sheet).

If other types of more severe physical damage occur, the damage should be assessed, repairs decided
upon and, if necessary, the crane derated in co-operation with the crane manufacturer or another
competent person.
Damage to the closed box compartments should be repaired immediately according to project
specification to prevent further damage caused by corrosion on the unprotected surfaces inside the box.

CAUTION:
ALL WELDING ON PRIMARY STRUCTURES SHOULD BE PERFORMED BY CERTIFIED WELDERS AND
ACCORDING TO APPROVED PROCEDURES ONLY.

CAUTION:
TO AVOID LEAKAGE OF MOISTURE INTO THE SEALED COMPARTMENTS, AND THUS CREATING RISK
OF INTERNAL CORROSION, NO HOLES MUST BE DRILLED IN THE “CLOSED BOX” CONSTRUCTIONS.
Main Steel
Structure

Check for signs of damage/bumps in the steel. Confer with NOV for evaluation of loss in strength. Check
for damage to the surface treatment and make sure to repair it as soon as possible.
If a suspected overload has occurred, 15% of the welds in the load carrying path should be checked with
MPI, for detection of possible cracks. If any cracks are detected, contact NOV for assistance.
Steel Structure
Secondary

Check for signs of damage in the steel. Repair or replace if necessary. Check for damage to the surface
treatment and make sure to repair it as soon as possible. Check bolts for fastening on the gratings,
stairs, ladders and platforms and secure if necessary.
Parts
Wear

Inspect and replace rope guides, door hinges, rubber dampers for the cabin, oil coolers and wind screen
wipers if necessary. Grease door hinges in grease nipples.
 Document number V3054-Z-MA-005
Revision 0
Page 10 of 38

1.5.1.1 Main Winch- and Slew Gearboxes

Inspection, lubrication and maintenance of the Main Winch- and Slew Gearboxes
Reference can be made to:
- Drawings & Parts Lists, Lubrication Chart
- Drawings & Parts Lists, King/Pedestal – Slew Ring Bearing & Slew Gear
- Standard Documentation, Gearbox Datasheets
Check that the oil is filled to the correct level before initial use. Top up if necessary. The oil should be changed when
warm to allow contamination to drain off. After the initial 5-600 running hours for the slew gear, and initial 50-200
running hours for the main winch gear, drain the oil and check for discoloration and foreign matters. If the oil has a
dark or black color, this indicates overheating of the gear. Oil change then has to be carried out at more frequent
intervals. If the oil has a whitish or cloudy color, this indicates penetration of water. NOV should disassemble the
gearbox and check for interior corrosion, possible leaks and check if the seals need to be changed. If the oil contains
more than 0,15% and/or larger than 25 m foreign matters, the gearbox should be disassembled and visually
inspected for signs of excessive wear. If wear due to grinding, scores, scuffs, pits, flaking, cracks or plastic
deformation are detected, the gear wheels should be replaced and/or a general overhaul of the gear box carried out
by NOV.

NOTE:
To allow trapped air to vent through the filling hole/breather plug and stabilize the oil level, a period of approx. 30
minutes should be allowed after filling or topping the oil level before closing the filler cap.
Main Winch Gearbox Slew Gearbox
Lubrication Ref. the Lubrication Chart in Drawings & Parts Lists

Clean the gearbox in the area of the oil seal and check for leaks. If there are any signs
Every 200 hours
of leakage, fit new seal

Every 500 hours Check torque tightness

Every 2500 hours (or

Change oil
once a year)

Replace seals Contact NOV for assistance

For recommended torque, ref. the
For recommended torque, ref. the
datasheet for the slew gearbox and the
datasheet for the main winch gearbox.
drawing „King/Pedestal – Slew Ring
Check To increase fastening of gear, it is
Bearing & Slew Gear‟. To increase
mounting bolts recommended to use Loctite 640 on
fastening of gear, it is recommended to use
flange surfaces and Loctite 242 on bolt
Loctite 640 on flange surfaces and Loctite
threads
242 on bolt threads
Check brake linings and
Contact NOV for assistance
springs

The sprag clutch must be verified for

Sprag clutch inspection
correct function after 3000 working NA
(if applicable)
hours. Contact NOV for assistance

Replacing gearboxes Contact NOV for assistance

Lubrication Information
Description Model/make No. of units Quantity pr. unit
Main Winch Gearbox Brevini SLW4003 2 14,6 litres
Main Winch Gear Brake Brevini SLW4003 2 0,08 litres
Slew Gearbox David Brown RE3513 4 12,6 litres
Slew Gearbox Brake David Brown RE3513 4 0,3 litres
 Document number V3054-Z-MA-005
Revision 0
Page 11 of 38

1.5.1.2 Illustration Drawing – Main Winch Gearbox, Brevini SLW4003

Greaser for oil sealing

Grease oil filling hole

Brake releasing hole

Oil level

Brake oil level plug/-drain plug Gearbox oil drain hole

Filling/breather, level and drain plugs

 Document number V3054-Z-MA-005
Revision 0
Page 12 of 38

1.5.1.3 Illustration Drawing – Slew Gearbox, David Brown RE3513

Grease nipple

Oil level plug

Lifting points

Oil brake release

Drain plugs
 Document number V3054-Z-MA-005
Revision 0
Page 13 of 38

1.5.1.4 Steel Wire Rope

Inspection, lubrication and maintenance of the Steel Wire Rope

As far as possible, inspect all visible sections of the rope (which experience has shown to be liable to
deterioration) with the object of detecting general deterioration or deformation. The more common visible signs
are corrosion, broken wire strands, distortions and excessive wear. These may come from long service life, poor
maintenance, mechanical damage, bad coiling or wrong grooving. Ref. to ISO 4309 for practise of examination
and discard of steel wire ropes.
CAUTION:
IF A NEW STEEL WIRE ROPE IS TO BE FITTED ON THE WINCH, THE NEW ROPE MUST BE BETWEEN
THE FOLLOWING DIMENSION:
MINIMUM: 34,68MM
MAXIMUM: 35,36MM
CAUTION:
DURING USE (WEAR AND TEAR) THE ROPE MUST NOT REACH LESS THAN NOMINAL ROPE
DIAMETRE.
Lubrication

Ref. the Lubrication Chart in Drawings & Parts Lists.

Keep well greased at all times. Grease generously if the wire has been in contact with sea water.

Examination of the steel wire rope shall be performed following an accepted international standard.
Reference can be made to ISO 4309 or equivalent.

Daily observation: As far as possible, all visible parts of any rope should be observed each working day
with the object of detecting general deterioration and deformation. Particular attention should be paid to
the rope at the points of attachment to the appliance/winch. Any appreciable change suspected in the
rope condition shall be reported and the rope examined by a competent person based on an accepted
international standard.
Examination

Periodic examination: To be carried out by competent persons based on an accepted international

standard. In order to determine the frequency of such periodic examination, consideration shall be given
to the following:

a) the statutory requirements covering the application in the country of use;

b) the type of crane and the environmental conditions in which it operates
c) the classification group of the crane
d) the results of previous examinations;
e) the length of time the rope has been in service

Special examination in accordance with 3.4.2 (ISO 4309)

NOTE:
Discard criteria are described in section 3.5 (ISO 4309)
Always replace the rope with required dimension, length, quality, type, surface treatment, and end
Replacing Steel Wire Rope

fittings. When in doubt, ask NOV or rope manufacturer for a compatible rope. Always ensure to have a
valid certificate for the rope and that the rope has not been damaged during transport. The new rope
must be reeled on to the winch from a reel drum with a tension of 20 % of SWL. To facilitate reeling, use
a thinner rope as a forerunner fixed to the winch drum. When attaching the rope to the drum, use
prescribed clamp locks and bolt torque according to the winch assembly drawing in Drawings and Parts
Lists
Before normal use, spool the rope in and out a few times with 10-20% SWL tension, in order to settle the
rope.

WARNING:
WHEN ATTACHING THE ROPE TO THE DRUM, USE PRESCRIBED CLAMP LOCKS AND BOLT
TORQUE ACCORDING TO THE WINCH ASSEMBLY DRAWING IN DRAWINGS & PARTS LISTS.
 Document number V3054-Z-MA-005
Revision 0
Page 14 of 38

1.5.1.5 Rope Examination Record

ROPE EXAMINATION RECORD ACCORDING TO ISO 4309: 2004 (E) (Typical Example)
Crane reference: Rope application:
............................................................. .........................................................................................
............................................................. .........................................................................................
Rope details: ................................................................................................................
Brand name (if known) ........................................................................................................
Nominal diameter ............. mm
Construction ..................................................................................................................
a
Core : IWRC FC WSC
a
Wire finish : Uncoated Zinc/Gal.
a
Direction and type of lay : Right: sZ zZ Z Left: zS sS S
Permissible number of visible broken wires: .................... in 6d and .................... in 30d
Allowable reduction of diameter: 10 % or 3 %
Date installed (yy/mm/dd): .................................Date discarded (yy/mm/dd): ..........................
Visible Reduction of Abrasion of Damage and Positions in Overall
Corrosion
broken wires diameter outer wires deformations rope assessment

Number in b
length Actual % below b b Degree and b
Degree Degree Degree
dia. nominal nature
6d 30 d

Other observations/comments:

Performance to date (cycles/hours/days/months/etc.): ............................................................................................

Date of examination (yy/mm/dd) ................... Name (print) ................................. Signature…………………………
a
Tick as applicable.
b
Describe degree of deterioration as: slight; medium; high; very high; or discard.
 Document number V3054-Z-MA-005
Revision 0
Page 15 of 38

1.5.1.6 Rope Sheaves

Inspection, lubrication and maintenance of the Rope Sheaves

1. Check the general condition of the rope sheaves

2. Ensure that the rope sheaves can be rotated by hand

3. Check for excessive abrasion and wear
The groove radius is to be 0,52d < r < 0,57d. The groove dimension is to be checked using a groove
4.
gauge or similar, ref. Fig. B. Rectify or replace if necessary
5. The sheave groove shall be smooth and without excessive wear. Rectify or replace if necessary
Grease the sheave bearings liberally in all grease nipples until a collar of fresh grease is squeezed out
6.
through the seals
Permissible Wear on Wire Sheaves
Maximum allowable wear at any position in the sheave groove shall not exceed the larger of 1.5mm or 0.15xd
(Steel wire rope nominal diameter)
Lubrication

Ref. the Lubrication Chart in Drawings and Parts Lists

Keep well greased at all times
Replacement of Rope

Always replace the rope sheave (-s) with required dimension, type, material, documentation and
Sheave (-s)

surface treatment (Contact NOV for assistance). Support the sheave and hang off with a sling. Remove
lock bolts and lock plate from pin. A pulling device with a bolt should be connected to one side of the
pin. Remove pin carefully and collect all loose parts. Check pin for damage and replace if necessary
(check with NOV). Remove sheave (-s) with bearings and place the new sheaves. Lightly grease the
pin and insert, using the pulling device if necessary

The degree of excessive wear and abrasion can be measured by use of a groove gauge and by measuring as
shown below in Fig. A

The groove geometry is to be The measurement value (between A

checked using a groove and B) shall not exceed 1,5mm, or
gauge or similar, ref. Fig. B 0.15xd (wire rope nominal diameter),
whichever is the larger.
B

Fig. A

Sheave Nominal Wire rope dia. (mm) A-B new (mm)

Wire sheave 34mm 51mm
 Document number V3054-Z-MA-005
Revision 0
Page 16 of 38

Rope Sheaves – Illustration Drawings

CORRECT WRONG WRONG

Sheave groove correctly Sheave groove too narrow Sheave groove too wide
supporting the steel wire rope
Fig. B
for approximately 33% of its
circumference
 Document number V3054-Z-MA-005
Revision 0
Page 17 of 38

1.5.1.7 Hoisting System

Inspection of the complete Hoisting System

- Visually inspect the complete hoisting system for defects and wear.
Inspection
Routine

- Listen for unknown sounds in the gearboxes and other bearings.

- Make sure that the gear ring has sufficient greasing
- Check bolt tension of winch fastening
- Painting and preservation is in accordance with the Product Data Sheet

Main winch
 Document number V3054-Z-MA-005
Revision 0
Page 18 of 38

1.5.1.8 Crane Blocks and Swivels

Inspection, lubrication and maintenance of the Crane Blocks and Swivels

Reference can be made to:
- Drawings & Parts Lists, Installation Drawings and Lubrication Chart
- Standard Documentation, Loose Gear Certificates
General

The swivel (-s) can be loaded up to the rated SWL. Only fully reeved crane block (-s) can be loaded up to
the rated SWL

Equipment with swivelling- and/or moving parts always contains a safety hazard. Care shall be taken when
Precautions

working with or repairing such equipment. If the equipment is used incorrectly, this could cause breakage
Safety

which again can lead to injury, or in the worst case fatalities.

Repair and reeving (if applicable) shall be carried out by trained personnel only, and in accordance with the
supplied maintenance instructions and wire reeving drawings in Drawings & Parts Lists (if applicable)
The crane shall be completely isolated (turned off) before such operations are carried out.
WARNING:
WHEN THE SUBJECT EQUIPMENT IS IN USE, DO NOT PUT HANDS (OR OTHER LIMBS) IN BETWEEN
SHEAVES, SIDE PLATES, GUARDS, IN THE AREA OF BECKET, HOOK, HOOK NUT, CROSS HEAD OR
ANY OTHER PLACE WHERE LIMBS CAN GET CAUGHT AND SERIOUSLY INJURED. TAKE GREAT CARE
TO AVOID CLOTHING BECOMING TRAPPED.
1. The working load limit (SWL) shall never be exceeded
2. Crane blocks shall be used for vertical lifts only
Limitations of

Rigging blocks shall be used only as in the design specifications. Blocks should not be used for
3.
towing unless specifically designed and marked for that purpose
Use

4. Swivels shall be used in either vertical- or horizontal plane only

5. Horizontal and vertical lead sheaves shall be used as indicated in description
6. Shock or side loading shall not be applied unless the equipment is designed for this purpose
7. The load shall always be placed in the seat of the hook or eye. NEVER AT POINT!
NOTE:
Every 500 operating hours, or every 4 years, the hook (-s) and nut (-s) are to be dismantled and inspected
Inspections shall be performed:
- Weekly on frequently used equipment
- Each time it is used, if the equipment is used infrequently
When performing these inspections, particular attention shall be paid to the following:
1. Wear in the hook, centre pin and becket
Inspection and Maintenance

2. Threads in the hook and nut (Every 500 operating hours or every 4 years)
3. Play in sheave bushes or bearings
4. Spacer bolts, nuts and lynch pins
5. Check for cracks in welds
6. Condition of safety catch and grease nipples
7. Wear holes in side plates and becket
8. Swivelling function
9. Rotation resistance on the rope sheaves
10. Signs of corrosion and overload/damage
11. General condition
If cracks or heavy gouges appear, the equipment shall not be used and qualified opinion shall be sought
(Contact NOV). If grooved and the section is reduced by more than 5%, the item shall be replaced with
certified gear and documentation from the manufacturer. Repairs should be by grinding.
If the holes in the cross head, side plates, becket, eyes or yaws are enlarged by more than 5%, the item
shall be replaced with certified gear and documentation from the manufacturer. Repairs shall only be
performed by responsible personnel. Great care shall be taken when re-assembling the equipment, and
captivating parts, e.g. grub screws, lynch pins etc. Check and refit only with correct sizes and threads.
WARNING:
NO WELDING IS TO BE PERFORMED ON LIFTING GEAR LIKE SHACKLES, HOOKS, SWIVELS, BLOCKS
OR AKIN.
 Document number V3054-Z-MA-005
Revision 0
Page 19 of 38

Inspection, lubrication and maintenance of the Crane Blocks and Swivels (continued)
As a general rule, sheaves, cross heads and bodies should be lubricated through the grease nipples:
1. Each week for frequently used equipment
2. Monthly for infrequently used equipment or each time it is used
3. Double sealed or shielded bearings do not require lubrication
4. Grease generously if the equipment has been in contact with sea water
For subsea hooks it is important to rotate the hook when greasing to be sure that the bearing is
5. filled with grease. Always grease before subsea operations to prevent saltwater penetrating into the
bearing.
NOTE:
The crane block (-s), swivel (-s) and sheaves shall be greased liberally in the grease nipples until a collar of
fresh grease is squeezed out through the seals. Ref. the Lubrication Chart in Drawings and Parts Lists
NOTE:
If the hook (-s) is equipped with two grease nipples, remove the upper one when lubricating the lower one.
This is done to remove air inside the unit.

Swivel Hook (typical) Crane Block (typical)

 Document number V3054-Z-MA-005
Revision 0
Page 20 of 38

1.5.1.9 Slewing System

Inspection, lubrication and maintenance of the Slewing System

Inspect the slew bearing, slew gear, seals and fasteners for external signs of damage, corrosion, excessive wear or
insufficient clamping.
Slew Bearing
The slew bearing has two different lubrication points; the raceway,
marked with a [●] and the gear marked with a [▲]
Lubrication and Maintenance

The first re-lubrication of the raceway and lubrication of the gear

must be carried out immediately after installation. For this and all
subsequent lubrication, the lubricants named in the Recommended
Lubricants table in this section and in the Lubrication Chart in
Drawings & Parts Lists are to be used.

The raceway grease is a KP 2 K grease, i.e. lithium-saponified

mineral oil of NLGI Grade 2 with EP additives.
Slew bearing section
The grease filling is there to reduce friction, seal the bearing and
provide protection against corrosion. Therefore, the slew bearing
must always be greased liberally in all grease nipples until a collar
of fresh grease forms around the whole circumference of the bearing gaps and seals.
Remote Lubrication of the Slew Bearing

Lubrication of the slew bearing is done via

a lubrication central placed on the cabin-
platform. The lubrication points/grease
nipples are divided into 3 groups (one for
each 120° sector around the entire
circumference of the slew bearing)
Ref. the drawing Remote Lubrication of
Slew Bearing in Drawings and Parts Lists

Lubrication central on the Illustration drawing. The lubrication

cabin-platform channels in red colour.
# Description
1. Start lubricating at any desired point
2. Rotate the crane 30° to one side, and lubricate again
3. Rotate the crane 30° towards the same side as in # 2, and lubricate again
4. This is repeated for a total of five 30° rotations, until the 120° sector is covered. Three points are lubricated
pr. rotation, i.e. the entire circumference of the slew bearing is now lubricated
CAUTION:
WHEN CLEANING THE EQUIPMENT, CARE MUST BE TAKEN TO PREVENT CLEANING AGENTS FROM
DAMAGING THE SEALS OR PENETRATING INTO THE RACEWAYS.
 Document number V3054-Z-MA-005
Revision 0
Page 21 of 38

Inspection, lubrication and maintenance of the Slewing System (continued)

Lubrication Intervals for the Raceway [●]

To be selected according to the operating conditions: generally for ball bearings every 100 operating hours, for
roller bearings every 50 operating hours. Shorter greasing intervals may be necessary for continuous operation in
tropical regions, in the presence of high humidity or significant temperature fluctuations, and for continuous rotation.
If there are standstill times between bearing installation and equipment start-up, respective maintenance
procedures will be required, e.g. re-lubrication under rotation no later than after 3 months and every 3 months
thereafter.

Before and after prolonged shutdown of the crane, re-lubrication and greasing is necessary. This is especially
important after a winter shutdown.
NOTE:
The seals must be checked at least every 6 months. For correct operation the seals must be free from dirt. When
cleaning, prevent the cleaning agent from contacting the seals or from entering the raceways system. If any of the
seals are found to be damaged, they must be replaced. Re-lubricate the unit after inspection.
Lubrication Intervals for the Gear [▲]
HRE recommends automatic gear lubrication. In case of hand lubrication, pinion and gear are to be greased
sufficiently with grease recommended in the recommended lubricants table and in the lubrication chart. Weekly
gear lubrication is recommended. The gear should always have sufficient grease.
Checking the Slew Bearing Fasteners
It must be guaranteed that a sufficient high bolt preload force is maintained during the total life of the bearing.
Due to practical experiences, a retightening of the bolts with the necessary tightening torque is recommended for
compensation of settling phenomena.

Check intervals as a recommendation:

After the first pretension (crane commissioning) the bolts shall be checked after approx. 100 working hours or after
3 months of operation.
Thereafter the inspection shall be performed on an annual basis.

Annual inspection:
At the annual inspection the pretension is to be checked on 25% of the bolts (3-6 bolts from each sector of the 4
sections).

If, however, no loss of preload is found, a next annual check is sufficient.

If a deviation of significance is discovered on any of the inspected bolts, an extended inspection and re-tensioning
operation shall be considered.
By deviation of significance it is meant that the bolt has lost more than 10% to 15% of the initial pretensioning load.

For necessary pull force, see the drawing „King/Pedestal – Slew Ring Bearing & Slew Gear‟ in Drawings & Parts
Lists.
NOTE:
During re-tightening of the slew bearing bolts the surrounding painting may become damaged.
Therefore after the bolts have been re-tightened, the surrounding area shall be cleaned and re-painted following the
surface protection specification given in the “Product Data Sheet”.
After re-painting, the gap between the washer and the flange structure shall be filled with “Sikaflex” or equivalent
material. For the future the thread-protector shall be re-filled with standard EP2 grease before re-installed.
Checking the Raceway System
For assessing the condition of a bearing, NOV recommends that its normal wear rate is determined. The wear
present in the raceway system shows itself by a change in the axial motion of the slew bearing.
In order to keep exact control of the wear on the roller race, a measuring plate (approx. 25 x 25 mm) is welded to
the upper flange of the crane pedestal.

NOTE:
Dial gauges used should have an accuracy of 0.01 mm.
 Document number V3054-Z-MA-005
Revision 0
Page 22 of 38

1.5.1.10 Axial Reduction Measurement

Fig.1: Roller Slew Bearing – basic test set-up for axial reduction measurement
Axial Reduction Measurement

The first measurement should be performed when the crane is put into operation for the first time in order to
obtain a base value for subsequent repeat measurements. The measuring points shall be scraped free from paint
so that the measurements are done on bare steel and are accurate. After measuring the paint system shall be re-
painted according to specifications.

Mark the respective measuring points on the circumference of the slew bearing‟s outer ring, according to fig.
1.
1, the boom is to be above measuring plate in position 1.

Before the measuring starts, stop the crane with the booms as close to max radius as possible and placed
2.
outside the cradle (same boom angle, load and radius for all measurements)

3. Insert the boom angles in Measurement Value Recording table, fig. 2

4. Measure (m) with dial gauges from top of measuring plate and underside of outer ring

5. Insert the recorded values in Base Measurement section of table 2

6. The Base Measurement shall be returned to NOV DCC

 Document number V3054-Z-MA-005
Revision 0
Page 23 of 38

1.5.1.11 Measurement Value Recording Table

Measuring
Base Test Test Test
Point Boom Angles Working
Load Measurement Measure Measure Measure
MB l KB Radius
No Degrees in millimetres ment ment ment

1.

2.

3.

4.

5.

6.

7.

8.

Tester:

Signature:

Date:

Fig.2: Value recording in axial reduction measurement

The axial reduction measurement should be repeated every twelve- (12) months as a minimum, under identical
conditions. This with regard to boom angles, load, working radius, hook/falls being used and the positions of the
measuring points

In case of heavy wear, the measuring time intervals should be shortened.

CAUTION:
IF THE DEVIATION FROM THE BASE MEASUREMENTS EXCEEDS THE MAX. VALUES SHOWN IN THE
TABLE (FIG 3), PLEASE CONSULT NOV’S SERVICE DEPARTMENT.

NOTE:
The owner of the crane is solely responsible for performing and recording the Axial
Reduction Measurement in accordance to the described procedure.

The Base Measurement values recorded the first time shall also be sent to: National Oilwell Norway AS (attn:
Project Manager) in order to update NOV‟s as-built documentation.
 Document number V3054-Z-MA-005
Revision 0
Page 24 of 38

1.5.1.12 Maximum Permissible Slew Bearing Clearance Table

Track diameter up to [mm] Roller diameter [mm]

16 20 25 28 32 36 40 50 60
Permissible increase in bearing clearance [mm]
→400 0.20 0.22 0.24
→500 0.20 0.22 0.24 0.26 0.28 0.31
→630 0.25 0.27 0.29 0.31 0.33 0.36 0.38
→800 0.25 0.27 0.29 0.31 0.33 0.36 0.38
→1000 0.30 0.32 0.34 0.36 0.38 0.41 0.43
→1250 0.40 0.42 0.44 0.46 0.48 0.51 0.53 0.60
→1500 0.50 0.52 0.54 0.56 0.58 0.61 0.63 0.70
→2000 0.62 0.64 0.66 0.68 0.71 0.73 0.80 0.90
→2500 0.74 0.76 0.78 0.81 0.83 0.90 1.00
→3150 0.86 0.88 0.91 0.93 1.00 1.10
→4000 0.96 0.98 1.01 1.03 1.10 1.20
→5000 1.96 1.11 1.13 1.20 1.30
Fig.3: Roller bearing slewing rings (HRE Table 13)

Grease Samples from the Raceway

Another mean of wear assessment is by grease sample analysis. It is recommended to take grease samples
parallel with the wear measurement for lab analysis. It is thus possible to determine the wear rate and the
actual condition of the raceway system.

Please contact National Oilwell Norway AS for further details, ref. to the document „Introduction‟ for contact
details
 Document number V3054-Z-MA-005
Revision 0
Page 25 of 38

1.5.1.13 Luffing System

Inspection, lubrication and maintenance of the Luffing System

Reference can be made to:
- Drawings & Parts Lists, Lubrication Chart
- Drawings & Parts Lists, Remote Lubrication of Cylinder Bolts
Inspect the boom cylinders, cylinder bolts, boom bolts and fasteners for external signs of damage, corrosion,
excessive wear or insufficient clamping.
The cylinder piston rods are maintenance free and coated with multilayer chrome to obtain good corrosion
protection and a long service life. This however, is not sufficient for a continuous long term exposure to a
Boom Cylinders

harsh marine environment. The recommended continuous exposure time should not repeatedly exceed 8
hours.

Therefore, when the crane is not in operation, all cylinders shall be retracted in order to maintain a
sufficient corrosion protection of the rods.

Record any leaks from and/or wear on the cylinder rod. If noticeable leaks and or wear occur, do not
hesitate to contact NOVs service department.
Cylinder Bolts
Boom and

Keep unpainted or machined surfaces greased at all times.

Inspect every 3 months.
If bearings or bolts need to be replaced, contact NOV for assistance.

Lubrication of the cylinder bolts is done via a

lubrication central placed on the cabin-
platform.
Ref. the drawing Remote Lubrication of
Cylinder Bolts in Drawings and Parts Lists

Illustration drawing. Remote

Lubrication central on
lubrication of cylinder bolts (The
cabin-platform
lubrication channels in red colour)

Continued on the next page

 Document number V3054-Z-MA-005
Revision 0
Page 26 of 38

Inspection, lubrication and maintenance of the Luffing System (continued)

Lubrication points for remote lubrication of cylinder bolts =

Section view of boom

Bolts ≤ 200mm (if stainless):

Cylinder Bearings and

The cylinder- and main boom bearings are made of self lubricated composite materials. During installation,
Main Boom Bearings

the bearings shall be initially greased to shorten the bedding-in period.

General:
The cylinder- and main boom bearings are made of self lubricated composite materials. During installation,
the bearing shall be initially greased to shorten the bedding-in period.

Lubrication is required for corrosion protection of the bolt itself. Therefore, the lubrication chart calls for
periodic lubrication of the bearing The lubrication is distributed through the lubrication channels in the
bearing. Ref. the Lubrication Chart.
 Document number V3054-Z-MA-005
Revision 0
Page 27 of 38

1.5.1.14 Tightening Torque for Bolts

Tightening Torque for Bolts

Tightening torque for Hexagon head/socket fixing bolts M4 to M48 (strength classes 8.8, 10.9 and 12.9) based
on a lightly oiled condition (friction coefficient= 0,125 +/- 10%)

NOTE:
Figures do not apply to slew bearing fasteners, winch and slew gearbox fasteners.

Values in Nm
Size 8.8 HDG 10.9 Black 12.9 Black
M4 3 4 5
M5 6 8 9
M6 10 13 16
M8 26 32 38
M10 50 62 76
M12 87 109 131
M14 137 174 208
M16 210 266 320
M18 294 371 444
M20 412 519 623
M22 554 699 839
M24 712 897 1075
M27 1028 1296 1555
M30 1402 1776 2121
M33 1894 2381 2861
M36 2440 3092 3696
M39 3135 3955 4742
M42 3363 4906 5894
M45 4026 6036 7306
M48 5832 7354 8822
 Document number V3054-Z-MA-005
Revision 0
Page 28 of 38

1.5.1.15 Recommended Lubricants Table

FACTORY LUBRICATION OF NATIONAL OILWELL VARCO EQUIPMENT

SERVICE TYPE OF LUBRICANT NOTES

Hydraulic system Texaco Rando Oil HDZ The system is pressure tested and
46 flushed at factory. Hydraulic fluid is only
drained after testing where practical.
Check compatibility with new hydraulic
fluid.
Gearboxes See the Gear Suppliers Ref. Standard Documentation for the
datasheet and the Gear Suppliers datasheet, and Drawings
Lubrication Chart and Parts Lists for the Lubrication Chart
General grease points on the el. motor (- Texaco Multifak EP2 Lithium based grease NLGI No.: 2. Lead
s), winch, slew ring (bearing), blocks, additives. Color: Dark green.
sheaves and wheel bearing
Boom bearing and cylinder bearing Texaco Multifak EP2 Lithium based grease NLGI No.: 2. Lead
(Orkot or similar) additives. Color: Dark green. NB! The
bearing is self-lubricating. Do not use
grease with molybdenum or silicon
additives.
Slew pinion teeth, open gear on the slew First: Spray on Klûber Mineral oil based. Metal soap complex,
ring rack and pinion drive Grafloscon CA 901. powder, graphite additives.
Second: Klûber
Grafloscon A G1
Steel wire rope EMS/EP700 Steel wire is delivered ready lubricated
from wire contractor.
Telescopic jib with nylatron sliding pads Texaco Multifak EP2 Lithium based grease NLGI No.: 2 Lead
(Sliding surface only) additives. Color: Dark green
Motor shaft, spline and sleeve Texaco Multifak EP2 Used for initial lubrication.
Threads on pipe- and hose fittings Parker Hanifin Niromont- For easy disassembly. Parker‟s item:
Flüssig Eoniromontfluessx
Lubrication for assembly and corrosion Texaco Multifak EP2 Used for initial lubrication.
protection of pins, bearing surface and
spherical bearings.
Valve lever housing, Klüber; Spring Klüber; Klüberpaste 46 No re-greasing required.
housing, Klüberpaste 46 MR 401 MR 401
internally
Pins and bolts in shackles Klüber; Klüberpaste 46 For easy disassembly
MR 401
Threads on bolts and studs Klüber; Staburags NBU- For easy disassembly
30K
Dead-weight on wire rope (incl. thimble) Klüber; Klüberpaste 46 For corrosion protection and easy
MR 401 disassembly
Piston rod extension on hydraulic SLIDER 2000 special For additional corrosion protection. No
cylinders grease. Alternatively: re-greasing required.
Petrolon Slick 50
Actuated PTFE grease
 Document number V3054-Z-MA-005
Revision 0
Page 29 of 38

1.5.2 Hydraulic System

Inspection, lubrication and maintenance of the Hydraulic System

Reference can be made to:
- Product Data Sheet
- Technical Description
- Drawings & Parts Lists
Check the complete hydraulic system thoroughly for irregularities and/or leaks before starting- and when the
crane is running. Retighten carefully or change leaking parts if any are found.

WARNING!
DO NOT WORK ON THE SYSTEM WHEN THE SYSTEM IS PRESSURISED. THE SYSTEM CONTAINS
ACCUMULATOR (-S). DEPRESSURISE THE SYSTEM BEFORE PERFORMING MAINTENANCE.
Hydraulic

Possible leaks are easier detected if the machine room and areas around cylinders and oil coolers are
Leaks

kept clean and tidy at all times. Draining of the machine room is done via ball valves underneath- or in
front of the king plate.
If leaks are detected, rectify or replace immediately.
Hydraulic
Hoses

The hydraulic hoses shall be checked every week for leakage and every 6 months for mechanical wear
etc. The hydraulic hoses shall be replaced every 5 years.

WARNING!
READ THE SAFETY PRECAUTIONS BEFORE STARTING ANY WORK ON HYDRAULIC SYSTEM

CAUTION:
TIGHTENING BOLTS CANNOT STOP LEAKS FROM FITTINGS AND FLANGES, AS SOFT SEALS LIKE O-
RINGS AND DOWTHY RINGS WILL EITHER BE DAMAGED OR HARDENED. ALWAYS REPLACE WITH
NEW RINGS.

The safe operation and lifespan of a hydraulic system greatly depends on the quality of the hydraulic oil.
Maintenance

A hydraulic system in use will always produce particles. The amount and hardness of the particles varies
dependent on how well the system functions and where in the system the particles are produced.
It is of utmost importance that the oil quality is maintained and have a minimum cleanliness of NAS 1683
class 8 or ISO 4406 18/15 at all time, to give trouble-free operation, long service life and prevent
degrading, or in the worst case, damaging costly components.

The condition of the hydraulic oil is a good indicator of the condition of the hydraulic system in total. NOV
recommends that oil samples are analysed by a laboratory, every 500 running hours or every 6 months.
Oil Sampling

The analysis shall include the following tests:

Analysis

I Density.
II Viscosity at +40 C.
III Water content, % by volume.
IV Tan (total acid number)
V Flashpoint.

Continued on the next page

 Document number V3054-Z-MA-005
Revision 0
Page 30 of 38

Inspection, lubrication and maintenance of the Hydraulic System (continued)

Run the hydraulic system at maximum flow and at normal operating temperature for a minimum of 30
minutes. This is necessary to ensure good distribution of particles in the fluid. Select a “Minimess”
(pressure measuring point) in the system that is located downstream of the machine/actuator, typically
on the return line. Use clean sample bottles.

NOTE:
Do not open the bottle until just before taking the sample (-s).
Taking Oil Samples

NOV recommend using a kit with 4 pcs. 100-ml sample bottles from “Cotax”. Use a high pressure
“Minimess test hose” with 1/4” needle valve. With the system running, connect the “Minimess hose” to
the “Minimess pressure measuring point”. Open the needle valve and fill the first litre in a bucket. This
fluid sample may be contaminated from the needle valve and test hose, and shall not be used for
analysis. With the needle valve open, continue to fill the 100-ml sample bottle. Do not close the needle
valve. When the sample bottle is full, move the minimess hose/needle valve over to the bucket, without
interrupting the flow. Now close the needle valve. Cap the sample bottle. Be careful not to dip fingers in
the oil sample. Mark the bottle with date and fluid type:
(Typical: Hydraulic Mineral Oil, Texaco Rando 46), and where in the/which system the sample was
taken.
Send the bottle(-s) to a laboratory for analysis, together with a report sheet specifying all data and
which type of analysis that is required.

NOTE:
The laboratory test result shall be filed in the “Maintenance log”.
Hydraulic Oil
Changing

Change the hydraulic oil when the lab analysis recommends or once every year.
Drain the oil tank with the oil at service temperature, with a hose connected to the ball valve for oil
drainage. Clean the interior of the tank and inspect for damaged paint and repair if required. Fill new,
unused oil through the fill plug at the return filter.

Change the oil filter cartridges after the initial 50 operating hours. Subsequently all filter cartridges must
be changed every 1000 operating hours and at each oil change.
Oil Filters

NOTE:
If one of the filter indicators signals a contaminated filter, it is recommended that all filter cartridges are
replaced immediately. A clogged filter element causes oil bypassing the filter which results in the
system operating with unfiltered oil. Cleaning and reusing filter cartridges is not acceptable.
Oil Level

The oil level shall be in the middle of the upper oil level glass when the boom is parked in lower
position.
Other Hydraulic
Components

Lifetime of hydraulic components depends on many variables in its environment and is thus difficult to
predict. Frequent hydraulic oil analysis will give a good indication on the condition. Assessment should
be done on the consequences if a component breaks down during operation and whether this
component shall be a critical spare part or replaced before break down occurs.

CAUTION!
DO NOT MIX DIFFERENT HYDRAULIC OILS. IF A DIFFERENT BRAND IS TO BE USED, ALWAYS CHECK
COMPATIBILITY WITH THE CURRENTLY USED OIL TYPE FIRST.
 Document number V3054-Z-MA-005
Revision 0
Page 31 of 38

Return filters

Pressure transmitters
Breather filter

Oil level glasses

High pressure filters

Hydraulic hoses

Oil coolers
Accumulator
 Document number V3054-Z-MA-005
Revision 0
Page 32 of 38

1.5.2.1 Return Oil Filter Change

# Description
1. Check that the pressure is evacuated in the filter line.
2. Unscrew the cover (pos. 2) and remove the filter cartridge holder (pos.1).
3. Disassemble the by-pass assembly (pos. 10).
4. Remove the filter cartridge (pos 9.)
5. Clean the magnet (filter holder, pos 8) thoroughly.
6. Install the new filter cartridge (pos 9) with spring and spring holder.
7. Assemble the by-pass assembly (pos 10).
8. Screw on the head nut (pos 4) until the hole for the cotter pin is visible.
9. Install the filter holder (pos 8) in the housing (pos 11) and set the top spring in place
10. Check that the o-ring (pos. 6) is clean and undamaged.
11. Screw on the cover (pos 2).

1. Housing 5. Washer 9. Element 13. Plug

2. Cover 6. O-ring 10. By-pass Assembly 14. Seal
3. Stud 7. Seal 11. Diffuser / Funnel 15. Visual Indicator
4. Nut 8. Filter Holder 12. O-ring