Data Book 1 Installation, Operations and Maintenance Customer: Mustang Kiewit Project: Peregrino, WHP-A East & West Tag No: PA-58-W-9500 & 9510 P.O. No: 253-21135-301-000 Model: $7216JU & S5624JU SeaTrax SIN: 4532 & 4533 Document No: D-005 | SEATRAX MARINE GRANESData Book 1 Table of Contents Section 1 Introduction and Design Features ] Fail Safe O Support & Slew 0 Anti-Two Block System Section 2 Operating Instructions Basic Operating Instructions Hand Signals for Crane Operators Specific Operating Instructions Console Arrangement Drawing Section 3 Inspection and Maintenance | Initial Start-Up and Commissioning Procedure 0 Commissioning Checklist Inspection Check List Bolt Installation and Inspection Procedure Specifications for Large Diameter Nuts and Bolts Main Block and Overhaul Ball Inspection O Wedge Sockets © Boom Lock Operation O Hydraulic Boom Hoist Limit System Jo0aSection 4 General Documentation O Vendor Document Register Production Schedule General Assembly C.G, Components Boom General Arrangement Electrical One Line Diagram Electrical Schematic and Bill of Material Pneumatic Schematic and Bill of Material Hydraulic Schematic and Bill of Material Kingpost Interface OU Preservation Procedure © Start-Up Spares List Two Year Spares List Utilities Schedule Sub-Contractors List Weight/Center of Gravity Control ouoaoe 1oac ootSection 5 Performance Data 0 Crane Load Chart Data Package (Imperial) © Load Charts (Imperial) Crane Load Chart Data Package (Metric) Load Charts (Metric) Load Test Procedures Load Test Report (Completed on Site) Section 6 Lubrication © General Information Lubricant Types Gearbox Fill Points Lubrication Chart Engine and Gear Oils Grease and Hydraulic Oils Crane Lubrication Points Section 7 Rigging 1 Wire Rope Specifications General Information O Reeving Diagrams © Erection and Installation Procedure ooot oo ooeSection 8 Prime Mover Manual 3 Caterpillar 3406C Section 9 Load Indicator O MIPEG 2000 Non-Recording Section 10 General Bill of Materials and Component Data © General Bills of Material © Component Data © Bearings, Upper and Lower © Hoist Assemblies © Hoisting Block, Load and Overhaul Sheaves Brakes, Actuator and Shaft Gearboxes Pumps Filters Motors Starters Valves Controls Additional EquipmentSection 2 Operating Instructions _| Basic Operating Instructions Hand Signals for Crane Operators O Specific Operating Instructions © Console Arrangement Drawing_ © P.O, Box 840687, Houston, Texas 77284 ans 9 September 2008 Basic Operating Instructions Applicable to All Diesel SeaTrax® Marine Cranes Crane Operator 1 Cranes should be operated only by the following personnel: Operators designated by the employer. Trainees under the direct supervision of designated Operators. © Maintenance / Test personnel or Inspectors in performance of their duties. Crane Operator Qualifications 0 Able to read and understand instructions. a Fully qualified through training and experience. Passed a practical examination. 20/30 through 20/50 vision or better, with good depth perception. a Able to distinguish between red, green, and yellow Hearing adequate for the specific operation oa history of epilepsy or a disabling heart condition should be sufficient reason for disqualification, Operator Cab 1 Necessary clothing and personal belongings should be stored in such a manner as to not interfere with safe crane operation, All loose articles should be properly stored. 1 There should be no obstructions to clear vision Refueling J. Cranes should not be refueled with the engine running, )) Fuel tanks should be filled in a manner that fuel spills or overflow will not ran onto engine, exhaust or electrical equipment on the rig. BOI-SOI STANDARD CRANES_R03.doe Page | of 13,Fire Extinguisher 1. Charged fire extinguishers should be in the cab or vicinity of the crane. 11 Operating and maintenance personnel should be familiar with the use and care of the fire extinguisher provided. Pre Start-Up Inspection This inspection should be performed every time the crane is started up and should take less than ten minutes to perform. It does not take the place of the required Level 1 inspection (see “Inspection Checklist’ in the Inspection and Maintenance section of Data Book 1), ‘The Operator should visually check for damaged or sub-standard items as follows: J Atboom tip: Slings to be used. Load block and shackle. Wire rope on sheaves at block and boom tip. ‘Wedge socket and corresponding wire rope. Boom tip for any loose or hanging items Along full length of boom: © Loose or hanging items © Loose or missing boom connection bolts ‘© Leaks on Main / Aux assembly On gantry: © Cracked or wom sheaves. ‘© Broken sheave thrust washers. 5 5 © Wedge socket and corresponding wire rope. At base of crane: (© Disconnected utilities such as electrical or pneumatic lines. © Cracks or stressed paint areas in the Kingpost or Platform Pedestal © Oilspills Crane Deck: © Oil spills. © Out of service signs O Atengi © Engine oil © Engine emergency shutdown. ‘BOI-SOI STANDARD CRANES_RO3 doe ge 2 0f 13© Pump Drive Oil Le © Oilspills. © Out of service sign Start engine: © Check engine oil pressure, © Check Control circuit pressure. Crane Operating Practices O Operator should familiarize himself with the equipment and its proper care. An operator should not operate when physically or mentally unfit, An operator should not start crane if'a "warning sign’ is located on crane. Before starting engine, operator should see that all personnel are in the clear, a Operator will test all controls at the start of a new shift An operator must never divert attention while operating. The operator must have the authority to stop and refuse to handle the load until safety has been assured. The operator is ultimately responsible for safe operation. (Before leaving cab, operator should: © Land any attached load, ©. Set the stew (swing) brake © Pullup the “Hyd. Pilot Control” (may also be called “Hydraulic Controls”) knob in the console to release/disable controls, (© Stop prime mover and reset the “Engine Stop” knob (if equipped). G_ Operator should report defects, adjustments, or repairs required to supervisor and next ‘operator upon changing shifts © When extensions are added to the boom, the Load Rating Charts must be changed, © To reduce unnecessary stress, boom up to maximum angle before stopping the prime mover. The boom rest should only be used during transportation or in high wind. © When setting the boom in the rest, lower the boom until it barely touches the rest. DO NOT slacken the cables! Easing the cables risks “bird nesting” the rope on the drum, Hand Signals © Abhand signal chart, similar to the one included in t conspicuously. is section, should be posted 1 One designated person should be assigned to give signals before the load is lifted. BOL-SOI STANDARD CRANES_R03.doe Page 3 of 13‘The operator should respond to signals only from the appointed signal man, but should obey an "emergency stop" signal at anytime, no matter who gives it No response should be made unless signals are clearly understood. © For operations not covered by standard signals or for special conditions, additions or ‘modifications to the standard signals may be required. In such cases these signals should bbe agreed on in advance by operator and signal man and should not be in conflict with standard signals. a G._Ifinstruction must be given to the operator by other than by the established signal system, crane motions should be stopped. Operator should never start machine movement until signal man or complete load is within his range of vision, Attaching the Load Do not wrap hoist rope around the load. ‘Load should be attached to hook by means of slings or other approved devices. All hooks should have safety latches. oooo0 Inspect slings daily. Immediately remove defective slings from service, Provide protection between sling and sharp surfaces. aaa Provide proper storage for slings while not in use. Do not choke stings in 2 splice. oo Unused legs of a multi-leg sling should be secured Moving the Load © Before the lift, the person directing the lift should determine that: © Hook is brought over load in such a manner as to minimize swinging. Hook is centered over load Multiple part lines are not twisted. Rope is properly seated on sheaves if there is a slack rope condition. Load is secured and properly balanced. Lift and swing paths are clear. Load is free to be lifted. 20000 BOI-SOI STANDARD CRANES J Page 4 of 13© During lif, Crane Operator should ensure: © Crane is NOT used to drag load. (© Acceleration and deceleration of moving load is accomplished in a smooth manner. (© Controls are engaged smoothly to avoid excessive stress on crane components. © Load, boom, of other parts of erane do not contact any obstruction. © No extemal force side loads the boom, © No personnel ride on the load unless in a personnel carrier. © NEVER carry a load over personnel. ©. Hoist brakes are tested each time a load approaching the rated load is to be handled. ° ‘A minimum of five full wraps of wire rope should remain on all hoist drums at all times, © Sudden starts and stops are avoided when rotating. This will reduces stress on the structure and avoids swinging the load, © Tag lines are used to control the load. Holding the Load O The operator will not leave his position at the controls while the load is suspended. 1D Do not permit personnel to stand or pass under a suspended load. Personnel Transfer All hooks should have a safety latch and latch should be closed securely. O._ Load should be under power both up and down. 1D. Crane should not be operated until proper pre-determined hand signals have been given. a Iferane operator's view of primary signal person is obstructed, an additional signal person should be provided to relay signals to crane operator. While transferring personnel raise personnel carrier just high enough to clear all obstructions, swing over the water in such a manner as to minimize swinging, raise or lower it smoothly, position it slightly above the landing area and gently lower it to the deck, 2 Do not raise or lower a loaded personnel carrier directly over a vessel. 1 Personnel carriers should be designed for the intended purpose. Personnel to be lifted on a personnel carrier should use an approved personnel flotation device. © Personnel riding on a net type personnel carrier should stand on the outer rim facing inward. BOISOI STANDARD CRANES_R03.doc Page 5 of 13,Oo Loaded personnel carrier weight must not exceed: (© 1/3 the static rated load at the specific radius, (© 1/10 the breaking strength of the hoist rope times the parts of line used. © Load blocks and overhaul balls are stamped with the rated personnel capacity. On-Platform Lift Procedure a oo ae a a Center load block over load Use Static Load Chart to verify crane capacity at the required working radii Lift load slowly (about 6 to 12 inches) off deck, stop and check hoist brake Lift load a safe height (about 3 to 4 feet) off deck Make sure path is clear, never move load over personnel. ‘Move load slowly across deck ‘When load reaches an obstacle, lift load high enough to clear the obstacle, swing over the obstacle and lower the load to a safe height. This reduces the possibility of excessive damage to the load, deck, or other items if a failure was to occur. Move load to final position Slowly lower load to deck Platform to Boat Lift Procedure a a a Center load block over load Verify crane capacity at the required working radii by reviewing the Dynamic Rated Load Chart applicable to the current operating condition. Lift load slowly (about 6 to 12 inches) off deck, stop and check winch brake, Lift load to @ height sufficient to clear any nearby obstructions. ‘Make sure path is clear - never move load over personnel, Slowly move load across deck. Once load clears edge of platform, lower load to 20 feet above water - never lower load over boat, ‘Swing load to deck of boat Lower load to deck. ‘Make sure slings have sufficient slack to avoid jerking the load back off deck in swells. BOL-$O1 STANDARD CRANES_ R03.doe Page 6 of 13Boat to Platform Lift Procedure a a aqoaa a Verify weight of load Set boom angle to safe crane capacity by using the appropriate Dynamic Rated Load Chart applicable to the current operating condition, Center load block over load Increase engine speed to maximum ‘When boat hits valley of wave, take slack out of slings, Increase hook speed as boat rises to peak of wave Lift load off boat about 15 feet Swing load clear of boat. Lift load only high enough to safely clear edge of platform deck. Make sure path is clear. ‘Swing slowly over platform Lower load to safe height off deck. ‘Swing load slowly into position. Boom out to the required radius without exceeding the maximum radius for the specific load as indicated by the ‘Onboard (Deck Lifts) Rated Chart’ in the Performance Data section of Data Book 1. Lower load slowly to deck BO}-SO1 STANDARD CRANES_R03.doe Page 7 of 13RAISE BOON RAISE ROOMAND LOWER LOAD send hua pad od fx fingers fet song oven ‘sds Hand Signals for Crane Operators LOWER BOOM LowER BOOM AND RAISE LOAD xd a domo sed es Engr dot hog aro mone dee & > souk FP toxic SWING THs DIRECTION Een ame wit einges indy aston af 9, sto? xen fra ad fd inhooatl pasion and rae lang esos. ‘The above signals are basic for operating boom equipment. Any other signals to be used | uring operation should be agreed upon by the operator and signalman beforehand. These signals should not be in conflict with the basic signals. Any one hand signal can be modified to indicate slow or cautious movement by placing the palm of the unused hand # short distance in front of the direction-indicating finger. No response should be given to unclear signals. The operator is ultimately responsible for the safety and operation of the crane. BOI-SOI STANDARD CRANES_R03.doeBOL-SOI STANDARD CRANES_R0S.doe __— © P.0, Box 840687, Houston, Texas 77284 ons A ae None Specific Operating Instructions For Cranes with Console Mounted Instruments Please refer tothe Console Arrangement drawing atthe back of ths section, Primary Motion Controls This crane is equipped with low pressure, hydraulic remote Control Levers (Joysticks) ‘mounted in the armrests of the Operator's chair. These controllers are spring loaded to the neutral (centet) position and provide independent, proportional, infinitely variable speed control for all of the primary crane motions. 3 When performing simultaneous operations involving two or more of the primary motions, the diesel engine should be operated at a constant speed between 1,800 and 2,170 rpm. Individual joysticks should be used to independently control the speed of the various crane motions. J) The “Left Hand” controller is a dual axis “Joystick” and controls the Swing (Slew) and Boom (Luff) hoist motions. ‘The “Right Hand” controller has two independent single axis “Joysticks.” The inside Control Lever controls the Auxiliary Hoist. The outside Control Lever controls the Main Hoist. Swing (Slew) Motion The Left Hand Joystick is moved to the left of center to “Swing Left” (counterclockwise), ‘of moved to the right of center to "Swing Right” (clockwise). Speed of rotation is proportionate to the amount of Control Lever movement from the center position, Start and stop swing motion as slowly and smoothly as possible to avoid possible damage to equipment or injury to personnel from a wildly swinging load. For open loop slew system, the crane is free to swing or drift when the joystick is in the center position, provided the swing brake pedal is not depressed and swing lock lever is not engaged. For closed loop slew system, the crane will hydrostatically lock once the joystick is in the center position. Ifthe free slew valve is activated, the crane is free to swing or drift with a heavier loadBoom Hoist (Luff) Motion 11 The Left Hand Joystick is “pulled” back to raise the boom (reduce the radius) or “pushed” forward to lower the boom (increase the radius). a Boom Hoist motion is always under the control of the hydraulic system and cannot overrun, or freewheel in the lowering mode. Please refer to our ‘Description of Fail-Safe Features* document in the Introduction and Design Features section of Data Book | for more information on this subject, o The speed of movement, in both directions, is proportionate to the engine speed and amount of control lever movement from the center position. (The Boom Hoist brake(s) automatically set and lock the boom in position when the control lever is centered. 1 Simultaneous operation of both above motions is accomplished by moving the left hand joystick diagonally. Speed of operation of both motions is independently proportional to the displacement of the contral lever from the center position, For example, itis possible to raise the boom at maximum speed while the crane swings very slowly to the left Main and Auxiliary Hoist Motions 1 The appropriate right hand joystick is “pulled” back to raise the main or whip line (take in cable) or “pushed” forward to lower the main or whip line (pay out cable. 11 Hoist motion is always under the control of the hyydraulic system and cannot overrun or freewheel in the lowering mode. Please refer to our ‘Description of Fail-Safe Features’ document in the Introduction and Design Features section for mote information on this, subject. 1 The speed of movement, in both directions, is directly proportional to the amount of Control Lever movement from the center position. (0 Hoist brakes automatically set and lock drums when the joysticks are centered. In case of 2 mechanical failure, releasing the controls will set the brakes and stop drum. rotation, Boom Lock © The Boom Lock has been designed to hold the boom in place during service of the motor ot ‘gearbox. © DONOT engage the Boom Lock while the drum is turning brake. DO NOT engage the Boom Lock and drive the hoist in the down direction: this can damage the lock assembly and gearbox. is not designed asa ° BOL-SOI STANDARD CRANES_RO3.doe Page 10 0f 13Swing (Slew) Brake(s) Dynamic braking is accomplished by “cross controlling” the Left Hand Joystick, For example; ifthe crane is swinging to the left at high speed and the joystick is then centered, the erane will continue to “coast” to the left. Moving the joystick away from center to the right will apply a "braking torque" to the crane motion, hence stopping rotation more quickly. 1D The crane and its associated swing system machinery are protected from damage during this operation by means of torque limiting hydraulic valves. These valves will limit the amount of swing torque available during acceleration and deceleration of the crane, However, tis strongly recommended that swing motion should start and stop as slowly and. smoothly as possible to avoid possible damage to equipment or injury to personnel from a wildly swinging load. (With an open loop swing system the crane and load can be held in position against the wind by means of the Foot Pedal Brake (if equipped) or centering of the joystick, when equipped with the hydrostatic drive, “Cross controlling,” as described above, is the preferred method for stopping rotation. (1 With a closed loop swing system the crane will hydrostatically lock once the slew joy stick is centered, The crane will not move until given direction. If equipped with a free slew valve the crane will be able to follow a heavy load minimizing a side load a ‘The crane may be locked in position indefinitely by means of the “Swing Lock” brake fever ‘mounted in the control console. When this lever is in the “Engaged” position, the crane is locked against rotation, Any attempt to rotate the crane by means of the swing control lever, while the lock is engaged, will result in the hydraulic swing motor being stalled against the lock. This is not harmful and will not damage any portion of the swing machinery. Console Mounted Instruments and Controls © “Air Pressure” Gauge: indicates pneumatic pressure. © “Pilot Circuit Pressure” Gauge: displays hydraulic pressure in the Control Circuit, “Slew Pressure” Gauge: shows hydraulic pressure in the Slew/Swing Circuit, “Boom Hoist Pressure” Gauge: shows hydraulic pressure in the Boom Hoist Circuit 5 “Load Hoist Pressure” Gauge: shows hydraulic pressure in the Main or Auxiliary hoist circuit, depending on which is in use. “Swing Lock” Brake Lever: engages or releases the slew shaft brake, This lever should be placed in the lock “engaged” position whenever the operator leaves the cab. Place the lever in the lock "released" position to rotate the crane. ©. “Hyd, Pilot Control” (or “Hydraulic Controls”) Knob: safety feature that disables the Main/Auxiliary and Boom/Swing controls. This prevents accidents when the erane is not being operated. Simply pull up on the knob to release/disable the controls, and push down to engage/enable them. BOI-SOI STANDARD CRANES_RO3.doc Page 11 of 13,a od “Hyd, Oil Level” Gauge: denotes the level of hydraulic oil in the reservoir. (optional) “Hyd. Oil Temp.” Gauge: hows temperature of the hydraulic oil in the suetion hoses. “Fuel Level” Gauge: shows the amount of diesel available to fuel the prime mover. (optional) “Upper Wiper” Control Valve: starts and stops the upper pneumatic windshield wiper on the upper window (option). “Front Wiper” Control Valve: starts and stops the lower pneumatic windshield wiper on the main window. Black “Horn” Button: when pressed the hom - mounted below the cab - will sound. The hom will also sound automatically shortly after shutting down the diesel prime mover, when engine oil pressure subsides beneath a preset level. “Coolant Temp.” Gauge: displays diesel engine coolant temperature “Oil Pressure” Gauge: shows pressure for the diesel engine lubricating oil “Alarm Reset”: silences the diesel engine low oil pressure alarm. The latch must be reset immediately after the engine is shut down to prevent the horn from sounding as oil pressure subsides, Otherwise, the hom will sound continuously until the latch is reset Green “Engine Start” Button: energizes the pneumatic starting motor for the diesel engine, Press the button to start the engine, and release it once the engine is running. “Tachometer”: indicates diesel engine rpm. “Engine Stop” Knob: used to stop the diesel engine under normal circumstances. When pulled out, this prevents fuel from flowing to the injectors, properly stopping the engine and disengaging the hydraulic controls, Push the knob to its original position after the engine has stopped. “Engine Emergency Shutdown” Knob: pulling out shuts down intake airflow to the diese] engine turbochargeris), thus choking the engine to a stop. This will render all of the Primary Control Levers inoperative and lock all Hoist Brakes. This knob should only be used in the event of an emergency, e.g., 2 “runaway” engine that will not shut down normally. © Torrestart after resolving the emergency, first push down the “Engine Emergency Shutdown” knob in the operator's cab, then go to the engine house and reset the shut-off valve located between the intercooler and turbocharger. Inline engines will have a single shutoff valve, while V-configurations will have two. BOI-SOI STANDARD CRANES_R03.doc Page 12 of 13Foot-Operated Secondary Controls The Right Side “Foot-Operated Throttle Pedal” controls the speed of the diesel engine SeaTrax recommends an engine speed between 1,800 and 2,170 rpm while performing simultaneous operation of the primary crane motions. © The “Swing Brake Pedal” - if equipped - is used to hold the crane against the wind, Do not apply this brake suddenly, while crane is rotating, © The “Emergency Hoist Brake” Knob - if equipped — is on the cab floor to the left of the operator's chair. If there isa failure in some part of the hoist mechanism and the load or boom begins to free-fall, the operator should REMOVE their hands from the controls and step on this knob, ‘© Letting the joysticks self-center allows the hoist brakes to engage automatically, which can slow or stop the falling load. © Stepping on this knob down dumps pilot system pressure and automatically applies all hoist brakes (© The valve must be reset before the crane operations can be resumed. To do this, simply reach down and pull the knob up (it will only move 3/4"). [BOL-SOI STANDARD CRANES_RO3.do¢ Page 13 of 13Section 3 Inspection and Maintenance O Initial Start-Up and Commissioning Procedure 1 Commissioning Checklist 0 Inspection Check List Bolt Installation and Inspection Procedure Specifications for Large Diameter Nuts and Bolts Main Block and Overhaul Ball Inspection Wedge Sockets Boom Lock Operation Hydraulic Boom Hoist Limit System Hydraulic System Adjustments Hoist Drum Brake Maintenance Boom Butt Bushing Replacement Swing Bearing System Service Emergency Slewing Procedure ©) Emergency Load Lowering Procedure oc onDooaor 100Cc 4a SEATRAX ”.0: Box 840687, Houston, Texas 77284 Phone: 713 896 6500 Fax: 713 896 6611 fa nPIQR REG. NO. 356 12 Mae 2008| Initial Start-Up and Commissioning Procedure Initial Start-Up: The testing of all functions will commence upon satisfactory completion of al fit-out activities. (Complete all check sheets contract preferred items attached). Crane Operation: SLEW DRIVE: 1. Verify the slew and Kingpost gears have been lubricated. 2. Verify lube oil reservoir tank is % full. BOOM: 1. Verify that the Boom Point Sheaves have been lubricated. 2. Verify main hoist wedge socket is installed properly and the condition of the wire rope. 3. Verify the Anti Two Block Frame swings without excess force. 4, Verify all electrical connections on boom have been made. 5, _ Verify all boom connection bolts have been tightened to the correct torque using the correct torque values. (See the “Bolt Installation and Inspection Procedure’ in the Inspection and Maintenance section of Data Book 1.) 6. Verify gearbox lube levels, referring to Lubrication in Data Book 1 Lubricate shaft bearing on hoist ends. 8. Verify that cable anchor “H” blocks are tight on hoist drums 9. Verify that all tools and debris have been removed from the Boom. 10, Verify that the Boom Butt Pins have been greased and that the Safety Bolts have been installed. InSart.Commision_R03.doe Page 1 of4GANTRY: 1. Verify Gantry Sheaves have been lubricated. 2. Verify all ladders, safety gates, and platforms have been fitted correctly and secured. Verify Upper Bearing bolts have been tightened to the correct torque using the torque values in the Inspection and Maintenance section of Data Book 1 4, Verify all tools and debris has been removed from the Gantry. UPPERWORKS: 1. Verify Boom Hoist gearbox lube level and correct oil type is used. 2. Verify fuel and hydraulic tank levels. Lubricate shaft bearing on hoist end, 4, Verify lower bearing shoes are installed and greased. 5. Verify Hoist drum cable anchors are tight. 6. Verify the Access Ladder has been fitted correctly and is secure. 7. Verify all walkways have been cleared of tools and debris, RIGGING: 1. Verify luffing rope is reeved correctly, lubricated, and wire rope is undamaged. Verify that Load & Aux rope is reeved correctly, lubricated, and wire rope is not damaged, 3. Verify the Main block is reeved with the correct number of falls (2, 4, 6, etc.) 4, Check the Bridle Block Assembly sheaves are lubricated and reeved correctly (if fitted), 5. Check Pendant Lines (if fitted) to insure hairpins are installed and cables are in satisfactory condition, Verify Main Block Sheaves, Main Block Bearing, and Aux swivel have been lubricated. IniSiardkCommision_ ROS doc Page 2 of 4Engine/Cab Area: PRE-START UP: Before starting the engine the following checks must be made: 1. _ Verify the coolant in the radiator is to the correct level and that the water contains the correct amount of Anti-freeze for adverse climatic conditions. 2. Verify the engine oil is to the correct level and correct oil type is used. 3. Verify multi pump drive lube oil level and correct oil type is used. 4, Check air filter for cleanness and the plastic wrapper has been removed. CAB: 1. Check control mechanisms including function levers, throttle, and engine start and stop, and brakes for freedom of movement and for proper operation. 2. Verify hom function. 3. Verify cab mounted electrical systems perform as required. 4, Check load indicator system is Operational 5. Check electrical supplies are correct, Commissioning: This procedure details the specific actions to be performed prior to placing the crane into service for first use. Note: It is essential to verify all fluid levels before initial start-up (See Lubrication in Data Book 1). 1. Verify initial start-up sections are fully complete. 2. Visually check for leakage or damage in the hydraulic system. ‘Check the air and non-mechanical systems for leakage and contamination. Verify available air supply is of sufficient pressure and volume for safe operation, 5. Visually check wire rope for evident deterioration and damage, or improper reeving, Verify installed rope is of the correct diameter, type and properly lubricated, 6. Visually check for loose or missing components such as walkway sections, ladders and supports, bolts, pins, keepers or cotter pins. InuSendsConumision_RO3 doe Page 3 of 4ee FRA X" ?.0- Box 840687, Houston, Texas 77284 ScATRAo Phone: 713 896 6500 Fax: 713 896 6611 10, LL. 12, 13 14. 15. faa REG. NO. 8 Perform a ‘walk-around’ visual examination of the crane; crane boom, and support structure to ensure no damage exists and that structural installation has been completed, Ensure the correct load rating charts for the current configuration and all required alternate configurations are available for use by the crane operator at the primary control station, Check boom hoist limit and anti-two block devices for proper operation. Care should be exercised to prevent damage to crane components. Visually check condition of loose gear to be used, such as slings, sling hooks and shackles. Check all control locks and emergency controls. Hi-Low Boom Kickout: High: Adjust to 12" from boom stops. Low: Adjust to platform requirements, Horizontal, 1 boom rest. NEVER disconnect this system. elow Check boom angle/radius indicators (mechanical and electronic if equipped) over full range and verify accuracy (see the Load Indicator section in Data Book). Inspect sheaves for damage, rope path alignment, and freedom of movement. Correct deficiencies as required by the above prior to use. nist Commison_ROB doe Page 4 0f 4SEATRAX' P.O. Box 840687, Houston, Texas 77284 — Phone: 713 896 6500 Fax: 713 896 6611 Commissioning Checklist DESCRIPTION CRANE AND RIGGING NES TSE ECHO] item No. Tem Description Ye [No | NA A) Slew Area 7 Siew Pinion Grease 2 Tube Off Tank % Full B) Boom 3 ‘Boom Point Sheaves 4 “Ani Two Block Freme A Boom Butt Pins é ‘Connection Boks 7 “Gearbox lube level. (Lubrication secon: Data Book 1) 3 Shaft bearing greased 9 Tool & Debris Removal ©) Gantry 19 Gantry Sheaves rn Taders, Safety Cages & Platforms 2 Connection Pins iB Tool & Debris Removal COMMENTS ——eaaa“'eo ‘COMPLETED BY CLIENTAPPROVED | CAVAPPROVED ] SIGNATURE DATE Commis Ceci Rev. doe Page 1 of $ss RAX” ?.0. Box 840687, Houston, Texas 77284 SEATRAX Phone: 713 896 6500 Fax: 713 896 6611 Commissioning Checklist SYSTEM: MECHA. item No Tem Description Yes | No | NA D) Upperworks 14 Ensure Hydraulic Tank suetions are open veil ans) 5 ‘Gearbox lube level. (Lubricaion section: Data Book 1) 16 Hyd, Tank Level 23” below top of tank) 7 Fuel Teak Deve en ee Ty Lower Bearings 9 Dram Anchors 20 ‘Acvess Ladder 21 Handrails (removable) Fa Tool & Debris Removal E) Rigging 3B Taffing Rope 3 Load & Auniliany rope 25 Main Block Assembly 26 “Headache Ball Assembly 7 Release Lines 3 Wold Lines COMMENTS: COMPLETED BY | CLIENTAPPROVED [CA APPROVED SIGNATURE DATE —_] CComaies Chest Rev. doe Page 2 of 5epi neen P.O. Box 840687, Houston, Texas 77284 ems SeATRA Phone: 713 896 6800 Fax: 713 896 6611 H REGISTERED A sronc $0.08 Ttem No. tem Description Yes | No | NIA A) PreStart Up Ca Radar Coan Bl Engine Oil Level (Check Dip Stick) Pump Drive Fluid Level (Check Dip Stick) B) Cab a Slew Le Slow Right 6 ‘Main Hoist Lever Pull, Load Up ‘Main Hoist Lever Push, Load Down 8 ‘Auxiliary Hoist Lever Pull, Load Up 9 ‘Auxiliary Hoist Lever Push, Load Down 10 Slew Brake “Parking Brake” (console mounted) ny Slew Brake ‘Dynamic” (foot pedal if equipped) 2 Engine Start Switch 3 Engine Throwtle Control 4 Engine Stop Handle 15 Hom Function 16 Up and Down Limit Switches, Main Up and Down Limit Switches, Aux COMMENTS ‘COMPLETED BY CLIENT APPROVED CA. APPROVED SIGNATURE DATE Commits Checklist Rev. doe Page 3 of 5———— | ' P.O. Box 840687, Houston, Texas 77284 SoArReA’ Phone: 713 896 6500 Fax: 713 896 6611 Checklist Item Description Yes | No | NA ‘Slew Pinion Guard Bridle Block Assembly Pendant Lines + Al Receiver 5 Windshield Wipers 6 Engine Over speed Shut Down 7 ‘Safe Load Indicator Function 3 Hoist Limit Switch Function 9 Slew Limit Switch Function 10 Machinery Guards tr Safety Guards Electrical System B TTelephone/Alarm System Function 1 Radio Antennas Damage 5 ‘UF Radio Function 6 oud Hail Amp Funeton 7 Deck Lighting 8 Flood Lights 9 Aircraft Waring Lights COMMENTS: ] ‘COMPLETED BY CLIENT APPROVED, CA APPROVED SIGNATURE, DATE Commas Chest Re. doe Page 4 of 5——— SEATRAX —— P.O. Box 840687, Houston, Texas 77284 Phone: 713 $96 6500 Fax: 713 896 6611 DYES Commissioning Checklist DESCRIPTION: PREFERRED ITEMS SYSTEM: MECHAE &T T tem No. rem Description Yer | No | NA 20 Emergency Lights | 21 Cab Lights “Engine Compartment Lights Power Supplies 4 Cieuit Breakers, Function 25 Heater Fan, Function 26 Hydraulic Oil Heater 27 “Annunciator Function | 28 Audible Alarm Function 29 Fire Alarm System 30 Fire System | 31 ‘Smoke Detector 2 Fire Detector 33 Earth Connections 34 ‘Earth Continuity Test 35 ‘AIC Unit Function 36 | Load indicator Function COMMENTS: [COMPLETED BY | ‘CLIENT APPROVED, Ca APPROVED ‘SIGNATURE, | DATE | (Commiss Checklist Rev. doe Page $ of $==; aw 7 SEATRAX 2.0: 80x 840687, Houston, Texas HE Phone: 715 896 0500 Fax: 713 896 6611 284 i) ovis Arnica ‘psi 28,2008 Inspection Checklist Inspection Frequency ‘The "Duty Cycle," or frequency of operation of Offshore Cranes varies from almost continuous use (MODUS) to sitting idle for months at a time (unmanned production platforms), Therefore it is not possible or practical for the crane manufacturer to provide universal inspection programs, based on frequency of use, which ate applicable to all possible situations. ‘Therefore, the following Inspection Checklist is to assist owners and operators in development of ‘an appropriate Preventative Maintenance Program applicable to their unique application, All items should be checked by a qualified inspector. Records of every inspection, modification, or repair, should be kept to formulate any maintenance trends that may develop. These records are to be kept for at least two years. NOTES: This list does not include items covered in the Lubrication section of Data Book 1. Cracked/chipped paint or rust can signify hidden structural deterioration. Level 1 Regular Inspection (Pre-Use) Level 2. Periodic Inspection (Monthly), Level 1 plus these items Level3 Intensive Inspection (Quarterly), Levels 1 and 2 plus these items Level 4 Annual Inspection (Yearly), Levels 1-3 plus these items Inspect or verify the followi Cab Area: Level 1: © Outof service «Remove any obstructions to clear operator vision (includes eleaning windows if necessary), «All instruments function properly © All engine instruments operate properly. ‘© Crane functions for proper operation, ‘© Throttle operates smoothly, from idle (950 rpm) to wide open throttle (WOT) (2,170 rpm). ‘+ Control levers operate freely and return to neutral when released « Allhoists operate smoothly Inspection Cbcist Re. doe Page 1 of7Level 2: Document console mounted Hour Meter reading and verify function (if equipped). Load charts are in place and legible. Fire extinguisher is accessible and charged. (if equipped). Air conditioner / heater function (if equipped). Cab lights and electrical equipment (if equipped). Safety alarms for proper function. (if equipped) ‘Windshield wipers function and condition (if equipped). ‘Window pivot mechanism (if equipped). Crane functions for proper operation: ‘Swing brake pedal holds. Boom limit system set at the correct positions. Console mounted controls operate as described. Floor mounted Emergency Hoist Brake disables all hydraulic controls (if equipped). Load indicator display (if equipped). Emergency kill handle rapidly stops engine when pulled. (Reset after test) Level 3: Remove inspection plate beside seat and check for leaks. Joysticks and console controls for leaks Level 4: Load Indicator accuracy Vibration dampeners in good shape. Rear / Wing Deck: Level 1: Hydraulic or fuel leaks / spills Fuel level. Level 2: Boom hoist cable. Boom dog function. Brake band wear and condition, Clevis pin on brake linkage and eccentric shaft. Gearbox oil level(s) and condition. Hose abrasion. Level 3: Gearbox mounting bolts Motor mounting bolts. Hoist frame to upperworks mounting bolts. Frame, drum, and tumtable structure for deterioration. ‘* Brake to brake drum core welds. « Inside of brake drum area (where cable anchors are located) * Spline hub to drum weld. Inspection Chests Rev..doe Page 2 0f7© Complete hoist frame. * Boom hoist platform. ‘© Wire rope “H” blocks on hoist drum are tight. ‘* Brake and boom lock retaining bolts. Bearings and seals for visible wear. © Eccentric shaft and bushings for visible wear. «Proper adjustment of brake linkage and condition. © Hoist brake test: Disconnect brake actuator “pressure to release” line. Run hoist in the down direction at full power to ensure brake holds While testing brake, check the maximum hoist pressure. Tur table structural welds from gantry pin connections to boom pin connections. Level 4: + Remove outer bearing cover to inspect bearings and seals. ‘© Welds and structure for deterioration © Fuel and hydraulic level gauges for accuracy (if equipped). © Fuel and hydraulic tanks for water. © Grating condition and loose or missing retainers. © Handrail connections. Valve Cabinet: (42 and 60 Series only) Level 1: + Valves, hoses, and filter for leaks. * Filter indicator is green. Level 2: + Electrical cable or hose abrasion. Level 3: «No additional inspection required Level 4: + No additional inspection required Engine House: Level 1: «Engine oil level ‘© Pump Drive fluid level (if applicable). ‘* Suction hoses are completely open (if applicable) * Fuel, oil, or coolant leaks. # Out of service signs. Inspection Chest Re doe Page 3 of7Level 2: * Document Hour Meter reading and verify function (if equipped). * Condition of engine oil. * Condition of pump drive lubricant. (if applicable) * Condition and level of engine coolant. * Air cleaner condition, + Filter indicators are green. Hose abrasion, ‘Hydraulic oil is approximately 2 inches below top of tank. Level 3: + Engine mounting bolts. ‘+ Engine belt tightness and condition. + Engine mounted emergency kill operation + Engine mounted starter button operation, + Drain air line dryer of water accumulation (if equipped). + Airline lubricator level (if equipped). + Exhaust system for leaks. Level 4: * Welds and structure for deterioration. + Pump drive vent for contamination. (if applicable) + Suction hose deterioration or leaks + Engine shut-down linkage and operation. (in cab) * Engine emergency shut-down linkage and operation, (in cab) ‘© Engine mounted kill operation. (at engine) * Oil cooler and radiator, clean as required to ensure proper airflow. ‘+ Vibration dampeners for deterioration. * Air receiver for water, leaks, or corrosion (if equipped) + Handrail connections. Swing Area: Level 1: «Hydraulic leaks around swing motor and boom hoist limit assembly. * Condition of front shoe bearings and retainers. Level 2: ‘+ Boom butt pin bushings and retainers, ‘* Condition of all shoe bearings. ‘© Lube oil level in reservoir ‘+ Boom Kick-out for leaks. + Hose abrasion. Inspection Checliet Re. doe Page 4 of 7Level 3: © Pinion gears and bolts. Level 4: Lower Pinion gear partially to lubricate and inspect splines. ‘© Slew retaining bolts (clean bolt and threads, apply loctite 271, and torque to 600 ft.lbs.) ‘© Welds and structure for deterioration, Main and Au: Level 1: © Hydraulic leaks. ary Hoists: Level 2: ‘* Hoist wire rope for wear or damage. * Brake band wear and condition, Proper adjustment of brake linkage and condition. Clevis pin on brake linkage and eccentric shaft. Gearbox oil level and condition. Hose abrasion. Level 3: * Gearbox mounting bolts. * Motor mounting bolts. * Hoist frame to boom mounting bolts. * Wire rope “H” blocks on hoist drum are tight. * Seals for visible wear. ‘© Eccentric shaft and bushings for visible wear. © Hoist brake test: ‘+ Disconnect brake actuator “pressure to release” line. «Run hoist in the down direction at full power to ensure brake holds. ‘© While testing brake, check the maximum hoist pressure. Level 4: ‘+ Remove outer bearing cover to inspect bearings and seals. * Brake Actuator retaining bolts ‘* Frame, drum, and boom butt structure for deterioration. ‘* Brake to brake drum core welds. ‘Inside of brake drum area (where cable anchors are located). Spline hub to drum weld. © Complete hoist frame. Boom Base and Straight Sections: Level 1: Visually inspect for attachment flanges that do not touch, * Missing bolts or nuts. Inspection Checklist Rev. doe Page S of7Level 2: ‘+ No additional inspection necessary. Level 3: + Boom chords and lacing for damage, deformation or corrosion, * Bolts torque to correct values without stretching Level 4: ‘+ Welds at connection plates (between boom sections). ‘+ Boom base vertical foot plates (plates where pivot pins attach), + Rub rails have at least 1/8” material remaining, + Walkways/grating condition and mounting bolts (if equipped). Boom Point and Jib Extension Level 1 Loose gear (slings, hooks, and shackles). ‘© Main rope at dead end for broken strands. Level 2 All sheaves in point area for obvious damage or split thrust washers, ‘© Boom suspension and load support plates for deformation or deterioration, ‘+ Bridle and bridle sheaves are in acceptable condition (if equipped). ‘* Pendant lines and spelter sockets for deterioration (if equipped). + Load block: Sheaves for obvious damage. Shackle for missing hairpin or nut (if equipped). Shackle, ot hook, for excess wear or deformation. Grease seal is undamaged, Hook eyelet (stinger pin), or hook, rotates freely. Latch closing properly (if equipped). © Aux line ‘© Auxiliary hook for cracks in throat or deformation, ‘Hook safety latch for damage and proper operation. ‘© Stinger cable for broken strands or deterioration, ‘+ Free rotation of swivel joint. + Latch closing properly. Level 3 Point rub rails have at least 1/8” material remaining. ‘© Bolts torqued to correct values without stretching Suspension wire rope. Unbolt and lift overhaul ball to inspect dead end, bushing, swivel, and pins. Anti-two block frame for damage and freedom of movement. Aircraft warning light illuminates (typically with engine running). Inspection Chestit Re oe Page 6 0f7Level 4 © Jib extension structure, ‘© Dead-end connection welds «Remove shafts and sheaves on point and load block to clean and inspect bearings. Gantry Level 1 * Gantry sheaves for obvious damage © Air swivel for damage or leakage (if equipped). * Electric swivel for freedom of movement and damage (if equipped). * Boom hoist cable dead end. Level 2 Dead end plate connection. * Sheaves for damage, wear, cracks, or split thrust washers. All gantry mounted electrical equipment working properly. Upper bearing for excessive wear. Jib crane is secured (if equipped). Level 3 © Gantry to upperworks flange bolts. © Welds and structure for deterioration, * Lower flanges * Bearing area * Sheave area « Rear beam splices at angle ‘* Boom spring stops in good condition (if equipped). Level 4 ‘+ Ladder and handrails for damage or missing bolts © Walkways/grating condition and mounting bolts. ‘+ Remove shaft and sheaves to clean and inspect bearings. ingpost Level 4 Only © Welds and structure, Inspection Checklist Rev. doe Page 7of7epg SEATRA XS eee tea a yams a 2 dy 2003 Bolt Installation and Inspection Procedure Installation + Ensure all Bolts, Nuts & Flat Washers comply with SeaTrax ‘Specifications for Large Diameter ‘Nuts & Bolts’ found in the Inspection and Maintenance section of Data Book | Visually check that boom section connector pads are flush (N/A on SB Series). These are designed as heavy, non-precision joints. The components have been welded out using jigs, which hold the fabrications in position, but due to weld draw, the bolted splice connections may not be an exact fit. Although a majority of the pad will be touching, small gaps are common. ‘These gaps are NOT critical and do not affect the stability of the connection provided the bolts have been torque to the correct value. ‘© Install all bolts with the threads down so water will not collect between the threads and nuts. Boom bolt heads must face the boom point. + Place a hardened flat washer under the nut of each bolt that complies with SeaTrax ‘Specifications for Large Diameter Nuts & Bolts.” Torque all bolts according to size & grade (see chart on next page). Subsequent Inspections: + Visually check that boom connector pads are flush. There may be some gap due to uneven surfaces between the two pads, but the gap should not be continuous throughout the entire pad area. A good way to check the bottom bolts is to raise the boom slightly out of the boom cradle before checking for gaps. Check to see if gap closes when boom is set back in the cradle * Check the torque by applying proper torque with a torque wrench. If the nut tums, record this condition and recheck after 12 - 24 hours of operation. If the nut tums again, change the bolt, nut and hardened flat washer. Square Tube Boom With 24,6, or 8 Bolt Pad Bol Inspection Provedure ROD Soe Page | of2Recommended Torque Poe GRADE 8 ; BOLT SIZE = bebetinehaied pear DRY TORQUE | WET TORQUE Pn N@Keseta FT-LBS FT-LBS any 28 10,000 6,400 7,300 4,700 100 2,185 1,200 860 600 i 400 275 160 100 80 50 32, 20 TONOT USE LUBRICANT ON TEFLON COTTE 1” and larger must comply with SeaTrax ‘Specifications for Large Diameter Nuts & All others are Grade 8 1. For wet torque, Molybdenum Disulfide Grease is the only approved lubricant. Other lubricants require different torque values. DO NOT USE ANY LUBRICANT ON TEFLON COATED BOLTS) 2. The torque’s listed above are lower t an maximum allowable for each respective bolt size due to the low load requirement in this particular application Stainless steel bolts are typically used on non-structural items where specific torque is not required, therefore they are not included in this table. Please direct all questions concerning this procedure to: Service Manager SeaTrax Inc. 13223 Spencer Rd. (FM 529) Houston, Texas 77041 U.S.A. tel: (713) 896-6500 fax: (713) 896-6611 Bol inspection ProsLargeBoltSpees_RO2.doe Page | of | SEATRAX’ P.O, Box 840687, Houston, Texas 77284 "713 896 6800 Fax: 713 896 6611 31 July 2003 Specifications for Large Diameter Nuts and Bolts For Hoist Mounting, Gantry Connections, & Boom Connections All nuts and bolts one inch (1”) diameter and larger must be ordered as follows’ Bolt © ASTM A 354 (current issue) Grade BD Hex Head Bolts, 5. Dimensions to be in accordance with ANSVASME B18.2.1 Threads to be Unified National Coarse per ANSI BI.1 Finish to be Fluorokote #1, blue. Grade Marking to be six (6) radial lines on the head per ASTM A 354 Section 15, Certification per ASTM A 354, Section 14 is required, (Includes “Mill Certs”) Nuts 1 ASTM A 194 (current issue) Grade 2H Heavy Hex Nuts 0 Dimensions to be in accordance with ANSI/ASME B18.2.2 for Heavy Hex Series © Threads to be Unified National Coarse per ANSI B1.1 Finish to be Fluorokote #1, blue. Grade Marking to be “2H” per ASTM A 194 Section 11 Certification per ASTM A 194, Section 13 is required, (Includes “Mill Certs”) Washers ASTM F 436 Hardened Flat Washers (1 ea. under each nut)(1 a, under each bolt head) Finish to be Fluorokote #1, blue, Acceptable alternative for bolts with 1” to 2'4” diameters is as follows’ Bolts © SAE J429 (current issue) Grade § Hex Head Bolts 5 Dimensions to be in accordance with ANSASME B18.2.1 Threads to be Unified National Coarse per ANSI B1.1 Finish to be Fluorokote #1, blue. Grade Marking to be six (6) radial lines on the head per ASTM A 354 Section 15 “Mill Certs” are required Nuts and Washers No Acceptable alternativeenn P.O. Box 840687, Houston, Texas 77284 ons | 4 Apt 2001 Load Block and Overhaul Ball Inspection General ‘Never use a hook whose throat opening has increased, or whose tip has bent to the point the locking pin can not be inserted through the locking latch and hook body. Inspect the shackle eyelet in the hook for deformation or damage. If itis significantly deformed, the hook should be taken out of service. Latehes will not work properly on hooks with bent or worn tips. Always visually inspect any shackle before using and verify it is the correct rating (tons) for that load, and that itis not visibly deformed or missing the nut or cotter pin. Inspect the bolt of the shackle to insure it is not bent or damaged. ‘Never repair, alter, rework, or reshape a hook by welding, heating, buming, or bending. Non-conforming hooks should be replaced. Load Block Inspection Visibly verify that the load block sheave(s) have been properly greased, are in good. condition, and rotate freely. There should be no visible cracks in the load block weldment. ‘The load block bearing should be properly greased and rotate freely. During the annual inspection, the shaft and sheaves must be removed, cleaned, and thoroughly inspected. Overhaul Ball Inspection ‘Visually inspect the “stinger line” (from overhaul ball to hook) checking for broken wires, damaged hook or loose/missing bolts/pins. During the quarterly inspection, remove the bolts at the bottom of the overhaul ball and slide it up. Inspect the bushing (at the top of the block), swivel, pins, wedge socket, and wire rope See the Rigging section of Data Book | for proper methods of inspecting wire rope (stinger cable). Load Bick and Ove Bal doe Page 1 of |a AX* 2.0. Box 840687, Houston, Texas 77284 SeATRAD Phone: 713 896 6500 Fax: 713 896 6611 1 Ags 1999 Wedge Sockets Securing rope dead end in a wedge socket Wedge socket will be installed with the live load side of the wire rope in line with the wedge socket pin. One wire rope clamp is to be used in conjunction with the wedge socket (on the “Terminator” style), This style wedge socket is assembled by attaching a clamp through the wedge, and securing to the dead end of the line. LOAD DEAD END LIVE LOAD SIDE 3 7 TIMES ROPE DIAMETER (MIN.) WEDGE Wherever a cable clamp is used, it MUST be torqued to the manufacturer's specifications. Wide Socks. doc Page 1 of2rr, P.O. Box 840687, Houston, Texas 77284 SeATRAX Phone: 713 896 6500 Fax: 713 896 6611 A ign. N. Other allowable methods for securing dead ends (per API RP2D) Use wire to loosely attach rope 4 Minimum 7 times rope diameter Maximum 3 times rope diameter Cable Clips : Torque values shown are based upon the threads being clean, dry and free of lubricant. Wedge Socket. doe Page 20ne, TR, © P.O, Box 840687, Houston, Texas 77284 Sean Phone: 713 896 6500 Fax: 713 896 6611 Boom Lock Boom Lock Function: ‘The Boom Lock has been designed to hold the boom in place during service of the motor or gearbox. DO NOT engage the Boom Lock while the drum is turning, it is not designed as a brake. DO NOT engage the Boom Lock and drive the hoist in the down direction. This can damage the lock assembly and gearbox. Boom Lock Operation: ‘The new boom lock has been specifically designed to require two people to operate because crane operators tend to use it for more than a maintenance tool and forget it is engaged. To engage the Boom Lock, have a maintenance person stand on the gearbox side of the boom hoist and locate the handle for the Boom Lock. With one hand, push the handle forward. As the handle moves forward, the latch will release. With the other hand, pull the latch up against the handle. ‘Allow the handle and latch to move to the back under the pressure of the spring. The operator can now very gently boom down until the boom lock is fully engaged and the boom stops lowering (the boom point may move less than a foot). DO NOT continue to drive into the locking pawl, itis not designed to take the immense force generated by a motor and gearbox. Visually verify that the pawl is fully engaged in the ratchet mechanism, To release the Boom | Zee user teven secoxen Caio, oe ‘boom up slowly asthe | maintenance person holds the latch and | pushes the Boom Lock Handle forward until the latch can drop over the pin. Slowly lower 2D ‘boom to ensure the paw! x has fully released. | ss O | Ap | ake - SF) wages ee cca Boom Lock Handle doe Page | of 1—— P.O, Box 840687, Houston, Texas 77284 SEATRAX Phone: 713 896 6800 Fax: 713 896 6611 14 December 2004 Hydraulic Boom Hoist Limit System GENERAL SeaTrax cranes are equipped with a mechanically operated hydraulic Boom Hoist Limit system, which limits the maximum, and minimum angles to which the boom can be moved. The boom limit system consists of a "boom kick-out" weldment which rotates about the boom pivot point, with an extension lever which attaches to the boom, so it moves up and down exactly as the boom does. On the circular section of the kick-out are mounted two Cam Plates ‘with a ramped surface on each. Each plunger slide actuates a piston, which operates a cartridge- mounted hydraulic control valve. These valves are mounted inside the valve body, which is bolted to the upperworks at the boom pivot point. OPERATION When the left hand joystick is pulled back, hydraulic oil from the control circuit is sent to the up side of the boom control valve. Between these two points is the boom kick-out. As the boom is raised, the arm of the kick-out raises also until Pinger Slide "A" contacts its piston, This actuates the cartridge valve and dumps pressure from the joystick to the tank; therefore, the control valve no longer receives the signal to boom up. As the boom is lowered, the arm of the kick-out moves down until Plunger Slide "B" contacts its piston, again causing oil pressure 10 ‘dump back to the tank. ADJUSTMENT: Refer to the Boom Kick-out drawing in the General Bill of Materials and Component Data section of Data Book 1 Each Plunger Slide plate has two curved slots, which allow the plate to move back and forth along @ fixed radius, corresponding to a range of different boom positions. The "A" plunger slide should typically be adjusted to provide a minimum of 12" of clearance between the boom and the boom stops when the valve kicks out at maximum angle. If the distance is not correct, loosen the two %" bolts attaching the plunger slide, and move it in the proper direction to produce the desired result. NOTE: For cranes equipped with Counter-Luffing boom stops, this adjustment should be limited to six to eight inches of full compression on the boom stop cylinders. ‘The Boom Hoist Kick-out should be tested several times while raising the boom, first low speed and then full speed, to ensure that the boom does not contact the boom stops with excessive force. The next step is to adjust the low angle limit on the kick-out system. The "B" plung: slide should be adjusted so that the valve kicks out when the boom is horizontal, 12" below the boom cradle. Adjust the plunger slide as necessary, and re-tighten the bolts. The kiek-out may require periodic readjustment throughout the life of the crane, This system is a SAFETY FEATURE and should NEVER be disconnected. Boom Limit_Hydraulic_R2.doe Page of!KEATS Dt P.O. Box 840687, Houston, Texas 77284 SEATRAX Phone: 713 895 6500 Fax: 713 896 6611 —_ STDEMAS Rev. 1013301 fe serQREC. NO Fane 1, 2006 Hydraulic System Adjustments for High Pressure Cranes Pressure Relief Valves Pressure relief valves are installed in a circuit to make certain that system pressure does not exceed safe pre-set limits, Relief valves are intended to relieve occasional excess pressures arising during the course of normal operation. Excess fluid is allowed to return to the reservoir through an outlet port in the valve while full adjusted pressure is maintained in the system, Check pressure by observing the gauge located on the operator's console. NOTE: All hydraulic system adjustments should be performed only when the engine and hydraulic system are at normal operating temperature. If the crane is cold and has not been run, start the engine and run the crane to allow the hydraulic oil to warm to near normal operating temperature. Main/Auxiliary and Boom Hoist (Refer to Control Vaive and Pump Drawings) 1, Locate the pump and corresponding control valve and brake actuator. 2. On the brake actuator, disconnect and plug the line running from the brake release valve to the brake release actuator (brake line closest to hoist frame). 3. Look at the pump from the back. Find the regulator assembly (this is located 90° clockwise from the suction pipe). There are two adjustment screws on the backside (there may be a cone shaped cover over them that must be removed. Only adjust the one furthest clockwise. Loosen the jam nut and tum this screw all the way in, DO NOT adjust the other screw. 4. On the control valve, locate the pressure relief valve (this may be covered by @ disposable orange cap). Loosen the jam nut and back out the screw one full turn. 5. Start the engine and let it run for five minutes. 6. Have the operator drive the corresponding hoist in the full down position at full throttle This should be held during the complete adjustment process. (Since the brake release line has been disconnected the hoist should not move.) Page 1 of3=;7aD ne P.O, Box 840687, Houston, Texas 77284 SEATRAX tinue: 3s00 6500 Faves socat! ous ——— STDFM-A3 Rev. 1" 04/3171 aa 7. Read the pressure on the corresponding pressure gauge in the cab. It should be about 2000 psi 8. On the control valve, slowly turn the screw in until the pressure reaches 6,000 psi. Lock the jam nut at this pressure. 9. Return to the pump and back out on the adjustment screw until the pressure drops to 5,800. Lock down the jam nut, 10, Reconnect the brake release line. Pressure adjustment on the pump and valve is now complete. For Safety, DO NOT set operating pressures above 5,800 ps NOTE: Since the main hoist and auxiliary hoist share the same pump, control valve, and relief valve, all auxiliary hoist relief valve adjustments are completed using the main hoist, as, detailed above. Slew Pump Charge Pressure or Slew Filter Relief Valve NOTE: All adjustments are done at full throttle with the slew joystick fall right or left 1, Install 1,000psi gauge in the “ port of the slew pump. Adjust the slew filter relief valve cartridge clockwise until it bottoms. Start engine and let it run for five minutes. Adjust charge pressure relief valve adjustment clockwise until 1,000psi gauge in the G” port of the slew pump reads 550psi 5. Adjust the slew filter relief valve cartridge counter clockwise until 1,000psi gauge in the “G” port of the slew pump reads S00psi.. 6 Adjust charge pressure relief valve adjustment counter clock wise until 1,000psi gauge in the “G” port of the slew pump reads 300psi Lock down adjustments and verify pressure a ume 220 Page 2 ofATES Rar 2.0. Box 840687, Houston, Texas 77284 SEATRAY Phone: 713896 6500 Fax: 713 896 6611 ——— STDFMAS Rev. 1 OVTOL fa NPI BEG. NO. come Slew Pump High Pressure Relief Valve *NOTE: Perform steps 4&5 as quickly as possible to prevent overheating of the pump. Flow should not be permitted to spill over the high-pressure relief valves for longer than 10 seconds, especially at higher pressures. 1. Block the output flow from the high pressure ports A&B or lock the hydraulic motor by applying the brake. Tum both high pressure relief valve adjusting screws counterclockwise until the spring tension is completely relieved, then turn both adjusting screws one full turn clockwise 3. Tum Pressure Over-Ride adjustment screw in (clockwise) until firm resistance is encountered DO NOT FORCE THE ADJUSTMENT BEYOND THIS POINT. 4, Stroke the pump in one direction and adjust the high-pressure relief for that flow direction to a pressure, which is 500 psi higher than the required Pressure Over-Ride setting, 5. Repeat step 4 for the opposite direction of flow. Control System Relief Valve 1, Start the engine and let it idle for five minutes. 2. Allow the engine to warm up and the engine to idle (about 950 RPM). Read the Control System pressure gauge while the engine is idling. The gauge should read approximately 600 psi +50 psi with the crane at normal operating temperature, 3. If the pressure is not correct, find the control system pressure relief valve. Loosen the rear knurled jam nut and screw the front knob into valve (clockwise) to raise pressure, or unscrew (counter-clockwise) to lower pressure until gauge reads 600 psi. If the pressure does not increase, the control system filter may require replacement if installed in the line before the relief valve. (Refer to the hydraulic schematic under the General Documentation section of Data Book 1.) 4. Raise engine to maximum RPM and check the pressure gauge: it should read no higher than about 700 psi. If the pressure is substantially higher, this may indicate a problem with the relief valve. Long term usage in this condition can artificially shorten the life of seals in the control system. Contact SeaTrax® for assistance in resolving this problem.= = P.O, Box 840687, Houston, Texas 77284 APIQRREG.NGL 6 August 2008 Hoist Drum Brake Maintenance Inspection, Adjustment, Testing and Replacement GENERAL ‘The main, auxiliary and boom hoists on SeaTrax® marine cranes are equipped with drum type brakes utilizing external brake bands. The brake band is tightened around a drum via by the force of @ brake actuator acting on a linkage. The exact arrangement differs based on crane model and customer configuration, however the principles of inspecting, adjusting, testing and replacing the brakes are the same. When a hoist is not being operated, its brake actuator holds tension on the brake band by use of an internal spring(s) extending a piston rod. This is attached to @ brake push rod connected to a brake lever, which tightens the brake band to set the brake. When a hoist is operated, hydraulic pressure to the brake actuator forces an internal piston to retract the piston rod — compressing the spring(s) ~ acting on the brake push rod and brake lever to release the brake. BRAKE SHOWN IN APPLIED POSITION HoistDrumBrakeMaint_ROO.doc Page 1 of4INSPECTION The brake band and associated components should be periodically inspected for wear or deformation: © Brake band: Should have a jam nut and lock washer on the inside - toward the band - with a flat washer and adjusting nut on the outside Brake band lining: Sufficient thickness, ie., the rivets are not wearing into the drum. Band weldment: Check for cracks or deformation Nuts: Tight and properly torqued 1 Brake band bushing (eccentric pin rotates within): Check for wear ~ this is the most commonly wor part. Eccentric pin: © Check for wear — damage can occur once the brake band bushing wears through, ©. Orientation: the pin MUST be at the point nearest the drum while the brake is engaged. Having the eccentric pin in the wrong position can cause the brake to apply improperly and/or result in excessive wear and eventual failure. Brake arm: The brake lever arm must be near vertical while the brake is engaged: a 90° angle (= 5°) to the brake pushrod. Brake actuator and associated hoses: Check for leaks 2. Shoulder bolts and cotter pins: Check condition and tightness. Brake: Holds when tested. TESTING To test that a brake will hold when applied: 1. Disconnect brake actuator “pressure to release” line. 2. Rum hoist in the down direction at full power to ensure brake holds. 3. Ifbrake squeals or does not hold, see ADJUSTMENT. 4, If the drum does not turn, reattach all hoses: testing is complete. HoistDrumBrakeMaint_RO0.doc Page 2 of 41 ADJUSTMENT All adjustments and testing should be done with no load unless otherwise stated, Follow these steps to adjust the tension on a drum brake: Inspect each brake assembly as noted previously under INSPECTION 2. If the eccentric pin or brake arm on each brake assembly are not positioned correctly, they must first be reset to the positions described under INSPECTION 2.1-Loosen the jam nut several tums. 2.2.Back out the adjusting nut until itis at the end of the threads. 2.3.Release the joystick to reset the brake and fully engage/extend the brake actuator; at this point there should be no tension on the brake band, 2.4.Adjust the eccentric pin and brake arm to the point nearest their correct position 2.5.Gently push joystick in the down direction while tightening the adjusting nut: this will cause the brake to reiease before the motor has sufficient pressure to tum, easing adjustment of the brake band nuts. WARNING: Keep body parts and clothing away from rotating drum. 2.6,Periodically release the joystick and check the angle of the brake arm (it should remain near vertical, ie., at a 90° angle (= 5°) to the brake pushrod. 2.7.Tighten the jam nut and test the brake in the down direction. 2.8.1f the brake holds, adjustment is complete, if not, go to the next step. Loosen jam nut, release brake, and tighten the adjusting nut 1 turns. Tighten jam nut and test brake. Lf brake fails to hold, repeat steps 3 and 4 only one more time, If the brake still fails to hold, then either the brake band or actuator is faulty (assuming that all parts are installed correctly.) 6.1.Remove the brake band and inspect the lining. If the rivets are not wearing against the drum and the band is not oil soaked, then reinstall the band, Otherwise, replacement is necessary. 6.2. Remove and disassemble the brake actuator: the most common causes of failure are worn seals ‘or broken springs. Ifthe piston cylinder is not scarred, then the actuator can be rebuilt, but replacement is suggested, HojstDrumBrakeMaint_RO0.doe Page 3 of 4NEW BRAKE BAND INSTALLATION NOTE: If the joystick is gently moved forward, the brake will release before the motor has enough pressure to tum. This will make it easier to adjust the auts holding the brake band. 1 4 Remove band nut and flat washer. Remove cotter pin from eccentric pin. Slide the threaded end of the brake band out of the hoist frame. Remove band eyelet hole from eccentric pin. Remove '” bolt and retainer cap from brake arm. Remove eccentric pin from hoist frame. Inspect the complete eccentric pin for grooves or excessive wear. A pin should be replaced if there are any grooves in the small pin portion. Inspect the two eccentric pin bushings in the hoist frame. Replace as needed. 9. Clean and install eccentric pin (do not lubricate pin or bushings). 10. Rotate eccentric pin to correct position and install brake arm, retaining cap, and bolt with lock washer. Coat bolt threads with Loctite 242. 11. Remove the jam nut and lock washer from the old band and install them on the new band (if new pparts are not supplied). If new nuts or washers are installed, they must adhere to the SeaTrax “Specifications for Large Diameter Bolts and Nuts” in the Inspection and Maintenance section of Data Book 1 12. Install brake band over drum and insert the eyelet over the eccentric pin, 13. Insert cotter pin through the eccentric pin, and threaded portion of band through the hoist frame. 14, Release tension from the brake actuator and install the flat washer and band nut. 15. Now you MUST burn-in the new band. NEW BRAKE BAND “BURN-IN” If the brake band must be replaced, itis necessary to “burn-in” the new band to prepare the brake lining for operation and to conform the band assembly to that particular drum. Once a band is burned-in to a drum. do not use it on a different drum: IT MAY NOT HOLD. When buming-in a new band, the hoist must rotate in the UP direction only. 1. Lower the hoist to its lowest position. ‘While raising the hoist at wide-open throttle, tighten the band nut until the hoist begins to strain but does not stop. Hydraulic pressure should be within the 1,800 to 2,000 psi range as indicated by the Hoist Pressure Gauge in the operator's console. 3. When the hoist is at its highest point, loosen the nut slightly. 4, Repeat steps 1-3 until the band starts to smoke, 5, Once the band is smoking, leave the band nut tight and wait until the band cools down. 6. Afier the band has cooled, follow the steps in the preceding ADJUSTMENT section. ceMaint_RO0.doc Page 4 0f 4ry SEATRAX" 2.0. 80x 840687, Houston, Texas 77284 Phone: 713 896 6500 Fax: 713896 6611 28 June 2001 Boom Butt Bushing Replacement This procedure describes the replacement of boom butt bushings on all SeaTrax® cranes, 1, Lay boom into boom rest. Remove all tension from boom suspension, Tightly secure boom to boom rest with strap, or other adequate method, to keep boom from shifting in boom rest 4. Disconnect boom high/low angle kickout assembly from upper works. Remove keeper bolts from boom butt pins. 6. Connect adequate means of support to boom butt section and first straight section of boom, as shown in Figure 1. Note: Adequate support would require support of 75 % of boom estimated weight, Lift boom butt slightly to remove all tension on pins. ‘Once tension has been removed, drive out boom butt pins. Lift, or lower, boom to gain easy access to the bushings, Drive out boom butt bushings. Note: Old bushings can be cut with a hacksaw to ease removal. 10, From the outside of the boom, install new bushings with a large soft face hammer. 11, Lubricate bushing with the appropriate grease. 12. Perfectly align hole in upper works with hole in boom butt. 13. Drive boom butt pins into boom. 14, Install keeper bolts. 15, Assemble boom high/low angle kickout assembly back onto upper works. 6. Lubricate the pins with at an appropriate amount of grease, Remove strap securing boom to boom rest. 18, Tighten boom suspension and raise boom out of boom rest. 19, Ensure the boom high/low kickout is adjusted properly, Son un Bate Ree 2 Page 1 of2rr SEATRAX™ 2.0. Box 840687, Houston, Texas 77284 —— Phone: 713 896 6500 Fax: 713 896 6611 fa sre RENO. Figure 1. TYPICAL SEATRAX CRANE LIFT ATTACHMENT FOR BOOM BUTT BUSHING LOCATION OF SLING ATTACHMENT IS AT BOOM BUTT 20° SECTION CONNECTION Page 2 of 2on “© P.O. Box 840687, Houston, Texas 77284 SSATRAX poses 134966500 Foes 73 966611 =a a srga ms. 008 June 1,2006 Swing Bearing System Replacement Procedure For S Series Cranes Introduction ‘The SeaTrax Marine Crane uses a unique swing bearing system, which allows inspection or replacement with hand tools only. A separate crane is not required to lift a SeaTrax crane completely off the fixed Kingpost. Operation ‘The SeaTrax bearing system consists of two sets of bearings. The upper bearing is a circular bushing block, which is located at the top of the Kingpost. A circular steel frame at the top of the gantry surrounds the bearing. Above this is the bearing thrust plate and collector ring assembly. The vertical force component due to the crane and horizontal force component (the overturning moment) of the crane and load is transferred to the fixed Kingpost through the cylindrical section of the upper bearing at the top, and through the bearing shoes at the bottom. The lower bearing shoes pin directly to the turntable at the base of the Upperworks. Bearing Wear ‘The upper bearing should be replaced if 14" (50%) of the 1" thick material has worn away from its inside diameter, or from the horizontal surface. ‘The lower bearing shoes should be replaced when no more than %" (30%) of the 4” thick material has worn away from the middle of the shoe. If the plastic bearing material wears away to the point of metal-to-metal contact, the crane will make a dragging noise or may refuse to swing, especially with a heavy load. If metal-to-metal contact occurs, the crane should be stopped immediately and the problem corrected. Continued use of the crane can damage the kingpost-bearing surface and require extensive repairs. Tools Required for Bearing Replacement © Three 50-ton hydraulic pancake jacks Four 1"-8 x 5” Large UNC Bolts ' Series Swing Bearing Replacement02 doe Page 1 of 7SEATRAX" 2.0. 80x 840687, Houston, Texas 77284 —— Phone: 713 896 6500 Fax: 713 896 6611 A cra so Lower Bearing Shoe Replacement 1 10 Put the boom in the boom rest with slacked lines to decrease the load on the bearing shoes. Remove rear shoes to allow movement. Center the Upperworks on the Kingpost by placing three 50-ton pancake jacks on the ring gear below the Upperworks (2 on the sides and one in the front). Remove the front shoe retaining pins and pull the shoe assemblies straight up. Remove the four screws, which mount the plastic shoe to the steel shoe support. Install the new shoes to the steel shoe support and tighten the mounting screws. Apply a liberal amount of EP multi-purpos and the bearing surface of the Kingpost. rease to the bearing surface of the new shoe Install the front shoe assemblies to the turntable and reinstall the retaining pins. Release hydraulic jack to allow the Front Shoes to come to rest against the Kingpost. Install the Rear shoes. Grease cach bearing with a grease gun. The crane is now ready to operate. NOTE: The side and rear shoes do not wear out as rapidly as the front shoes, and in an emergency they can be rotated with the front shoes until new ones arrive. S Series Swing Bearing Replacement02 doc Page 2 0f7SEATRAR 10.ter ster jms. tor ——————— Phone: 713 896 6800 Fax: 713 896 6611 Upper Bearing Replacement 1 Lower the boom to the boom rest and slacken the boom suspension lines, Raise the upper works about 1” using three 50 ton pancake jacks. The jacks should be placed on the ring gear, below the upper works, one on each side and one in the front of the crane. Use the jack to lift and center the post in the upper bearing. On the 90 Series and up, the bull gear has 4 jack supports located under it: you will need to place the jacks over these spots or you will isk bending the bull gear. Pancake Jack Placement (see #2) 3. Unbolt and remove the 4 post retainer blocks. Remove all the bolts from the bearing thrust plate. Post Retainer Bearing ‘Thrust Plate ' Series Swing Bearing Replacement02 doc Page 3 of 7fe | P.O. Box 840687, Houston, Texas 77284 Ooms SEATRAX forsee [CID NES SEATRA> A sri 50. 4 The bearing thrust plate and the bearing are in halves make sure that each split is align for easy removal. Place the post retainer blocks under the bearing thrust plate (making sure NOT to let the block extend over the bearing) and insert 41 14"-6 x 4” bolts on the outside of the plate. 5 Pull the upper bearing up by replacing 4 bolts (1””-8 x 4 1/2” UNC threads) through the top of the bearing thrust plate and screw into the bearing. Make sure the bolts are tightened evenly to ensure the bearing will pull up straight. S Series Swing Bearing Replacement02 doc Page 4 of 7———— © P.O, Box 840687, Houston, Texas 77284 SSATRAX fer Te 6500 Fa 713896 st] —_— A SPOR NO 6 Begin tightening the 4 bolts (1”-8 x 5”) and the bearing will begin to pull out. Bearing partially raised 7 Continue tighten the bolts until the bearing is touching the thrust plate. Bearing against bottom of cover plate ' Series Swing Bearing Replacement02 doc Page S of 7SEATR. AX 2.0. Box 810687, Houston, Texas 7284 Phone: 713 896 6500 Fax: 713 896 6611 ——— scan 80.98 9. These cranes have a 2 piece upper bearing. The bearing is split at the 3 o°clock and 9 o'clock position with the boom is at the 12 o'clock position. Now place the 4 1” bolts in the bearing and lift it out. Ifthe top of the Kingpost is resting against the front or back of the bearing, use the jacks to make adjustments. Boom suspension lines need to have slack in them, 10 Itmay be necessary to stack spacers and repeat steps 6 thru 9. Ifthe bearing can not be pulled by hand then note the position of the kingpost in the hole, Reposition with jacks to remove the load off the bearing. Repeat for second half of bearing. 11 Clean and inspect kingpost top for any noticeable wear or damage per API RP 2A. Kingpost top ' Series Swing Bearing Replacement02 doc Page 6 of 7__ © P.O. Box 840687, Houston, Texas 77284 Lubricate the new bearings with EP grease and s position that they were removed, 13. Bolt the bearing thrust cover plate and the post retaining blocks down and torque to specs. 14 Rey eat above procedure to remove the other bearing piece. 15 Remove the three 50 ton pancake jacks from beneath the Upperworks. | _s Series Swing Best Replacement? doc Page 7 of 7