ee Introduction | -2- |Main Data j | a ‘Technical Description ote Preparation / Installation Troon I 7 I i Tor | 5 (Operating Instructions Provision / Service Crane i MCV 1891-12,5-21 bed ? | Hochang Machinery Ind. Co., Ltd |, Data Sheets / Spare Parts Hull No.: H1371 netted er a. : SEC. NO. [SHIP DESIGN OFFIGE —— Tari Tye cart | SHIP OUTFITTING DESIGN DEPT No.3 | 318,000 DWT CLASS CRUDE OIL CARRIER TEL NO. [SHIP NO. SHIP NAME 3813 1371 EAGLE VIRGINIA APPROVED avin TAME OF DRAWING cHECKED W._J. MOON PROVISION CRANE (12.6 TON) (VOLUME th DRAWN DRAWING NO. DATE 20020204 SOALE / 6J-5138-001 HYUNDAI HEAVY INDUSTRIES CO.,LTD [CONSOLIDATED NO. ULSAN SHIPYARD, KOREA 10-2-B‘Hydralift Marine Machine Number: Hydralift Marine Project: Provision / Service Crane Hochang Machinery Ind. Co., Ltd Document Title: User Manual Crane MCV 1891-12,5-21 Ajproval, Project Manager Initials / Signature: is / Signature: "Al information and data herein or herewith are confidential and proprietary property of Hydralift Marine and are not to be used, reproduced or diselosed in whole or in part by or to anyone without the written confirmation of Hydralift Marine.@ HvoRAuer REVISION HISTORY [ Rev. [Date Chp._| Page _| Description REFERENCE MANUALS Manual Doe. Number ‘Manual Title er Bi Kamalae Introduction -2- /Main Data Ys. Technical Description 4 Preparation / Installation ise Operating Instructions | Provision / Service Crane 6 MCV 1891-12,5-21 Maintenance Hochang Machinery Ind. Co., Ltd | Hull No.: H1371 ‘Data Sheets / Spare Parts K4954 Parts List / Drawings gry ora hy met, perinoar are| (’) HYDRALIFT@wvorauer TABLE OF CONTENTS ~ Section Chapter 1 INTRODUCTION al Structure and Contents 12 Operator Information . 18 Contact Information. . 44 Document Identification . 14.1 Hydralift Marine . 142 Customer... 0... 15 Location of User Manuals 15.1 Hydralift Marine 1.5.2 Customer 16 Abbreviations. Kaos Page 1:3 18 14 15 15 15 1-6 16 16 1@ nyoRALIFT 1a 12 ~) YY Kasse INTRODUCTION ‘This user manual describes the Provision / Service Crane supplied by Hydralift Marine AS for Hochang Machinery Ind. Structure and Contents ‘The user manual is divided into eight chapters; each chapter taking care of each topic in accordance with NS 5820 (Norwegian Standard). ‘All necessary information is implemented in this manual, The user manual main chapters are listedon front page of each chapter. A chapter index is located on the second page of each chapter. Operator Information No personnel under the age of 18 years is allowed to operate the crane. “At the present time, there are no legislative requirements for certified qualifications for the crane operator. However the operator is required to possess a good knowledge of the cranes safety systems and method of operation. Ifa training program for this crane type is required please contact Hydralift Marine. User Maal@nvoraurr 18 Contact Information Department ‘Telephone _+ 47 ‘Telephone _+ 47 Fax +47. Service 38 04 93 49 91.55 29.30 38.04 93.41 Spare Parts 3804.93.47 91 19 92.35 38 0493 41 Spare Parts 3804.93 46 90 91 08 05 3804.93.41 Switchboard 88 04 95 00 - 38 04 96 06 Company Name Postal Code City Country - Hyéralift Marine N-4606 Kristiansand Norway Rie a —— i Ba@ HyDRALIFT 15 14 Document Identification 14.1 Hydralift Marine 1. Document Source Hydralift Marine _ 2. Document Type UserManual — 3. Document Number _MAK4954 - ae 4. Paper Format “Ad and AS 5. Publishing Software Corel Ventura 8.0 6 Document File Folder _M:\K49\K4954\Manual)\ 7. Document Files 00.VP - 01.VP - 02.VP - 08.VP - 04.VP - 05.VP - 06.VP- (Corel Ventura 8.0) O7.VP -08.VP_ — ) 8. Electronic Manual Files NA 14.2 Customer 1. Customer Hochang Machinery Ind. 2. Project NA eens = 3. Contract: Number NA z een 4. Hull Number “HIS71 - 5. Document Title User Manual . 6 Document Number NA Se eee eee ) 7. Equipment Model Crane MCV 1891-12,5-21 ee ~ 8 Equipment Type Provision / Service Crane = ©. Equipment Tag NA ieee &) Kis ‘User Manual@ wyroraurt 16 5 1.5 Location of User Manuals 1.6.1 Hydralift Marine L original user manual located at the documentation department. 15.2 Customer Fill out the table below where the copies of user manuals are supposed to be stored. Number of — | Location Note Copies Kise ‘User Manwal@ nvorauer . 16 Abbreviations Following is a table of abbreviations used in Hydralift Marine User Manuals. Commercial BV ccs DNV GL HLM ~ kt American Bureau of Shipping Bureau Veritas China Classification Society Det Norske Veritas Germanischer Lloyd Hydralift Marine Korean Register of Shipping Lloyds Register of Shipping ‘Norwegian Marine Directorate Norwogian Petroleum Directorate Center of Gravity Counter Clock-wise Clock-wise Not Applicable Rotation Per Minute Without ~ Uber MianvalProvision / Service Crane MCV 1891-12,5-21 Hochang Machinery Ind. Co., Ltd Hull No.: H1371 a1 Introduction 2 Main Data 3 "Technical Deseription 4 Preparation / Installation 5 Operating Instructions | -6- ‘Maintenance Data Sheets / Spare Parts 8 Parts List / Drawings@ HyoRauirt 22. TABLE OF CONTENTS ) ~ Section Chapter 2 MAIN DATA Page 24 Hydraulic Pressure ...... ee oe 23 22 Pump Capacity. . - 23 23 EL Motor Data... ..-.. ++ 24 24 ‘External Connections... ... - 24 25 Restrictions in Use. Do 25 2.6 Restrictions in Guarantee . 25 2.7 Name Plate . . oe 90 ee ee 25 28 Certificates... 2.0... 0 5 eee ae 25 Figure 2-1 Name Plate 26 ~ Ke ns ‘User Manualed @ wrorauet ao 2 MAIN DATA. Hydralift Marine - Provision | Service Crane ‘Type: MCV 1891-12,5-21 Machine number: 4954 Lifting capacity SWL: 12,57 Working radius - max: 21m Working radius - min: 4.3m Lifting speed at SWL: 0-10 m/min Lifting height: 63m Luffing time: 120 see Slowing speed: 0-0,6 rpm. Slewing sector: 225° limited List / trim: By2 Weight of crane - theoretical w/o oi: ~20'T 2.1 _ Hydraulic Pressure Main pressure: 280 bar Winch up at SWL: 216 bar Winch down at SWL: 230 bar Sib up: 200 bar Sib down: 150 bar Slew right: 230 bar Slew left: 230 bar 22 Pump Capacity Pump capacity: 1x 105 Vmin cc User Manaal@nvoraurr 2,3 El. Motor Data Voltage: Phase: Frequency: Power rating continuous $1: Power rating 86-40% ID: Power rating start up: Rotational speed: Rotation seen from fan end: Enclosure: Insulation class: Temp. rise class: Heater voltage: Phase: Heater power consumption: 2.4 External Connections Electric connection - see drawing: 440 3Ph 60 Hz B7KW 64,34 50,6 kW B14A approx. 1775 rpm CCW (See arrow-sign on fan end) IP 54 F B 220 1Ph 100 W KA954ES1 “Teer Manual@ HyDRALIFT 2.5 26 2.7 ed 28 Nw? Kai95e Restrictions in Use ‘Subject equipment must only be used for the prescribed purpose and within the specified limitations referred to in chapter 5.4. The operator must be qualified according to chapter 5.5. Repairs and modifications must not be carried out without prior written approval from Hydralift, Marine, except for the minor corrections that are described in the maintenance chapter. If such work is carried out by others; Hydralift’s procedures for this kind of work must be followed. Only approved materials and original spare parts must be used. Restrictions in Guarantee Hydralift refuses all responsibility caused by breach of the restrictions described in section 2.5. ‘The guarantee for good performance is strictly linked to the correct and careful application of the instruetions in this user manual. If, during the warranty period, these restrictions are breached, the warranty/guarantee shall no longer be valid. Name Plate "The name plate is located at the main control platform. Name Plate Certificates Certificates are enclosed as separate attachments after this page. Ter Mania() HYDRALIFT i) “ HYUNDAIHULLNO. —: 1371 CRANE TYPE : MCV 1891-12,5-21 MACHINE NO. 2 K4954 y ~ ~ —— aa ~ CERTIFICATES Se EL. MOTOR : HOCHANG SUPPLY HOOK BLOCK :NO.: 74800 SHACKLE :DG, SWL4.8T WIRE : 918mm, 1=219m, No.: 225102 YLeones Paaotsern srnerone ora? TESTCERTIFICATE ie Dato seiikat er basert pa det standard interasjonale formular godkjent av Det Intemasjonale Arbeidsbyra for prove ag undersakelse av laste- og osseinnretringer og redskap ombord pa skip. Caundersonese = This Certicate is based on the standard international form of corticate approved by the International Labour Office fo the test and ‘examination of liting machinery and gear used inthe loading and unloading of ships. “Serlfikat for prove o9 undersakelse av Kjtting, ringer, kroker, sjaklr, evivier, blokker og andre redskaper, for de tas i bruk og etter de har veer forlenget, forstrukket,forandret eller reparert ved sveising. Cortficate of Test and Examination of Chains, Rings, Hooks, Shackles, Swivals and Pulley Blocks before being taken into use, and of such Gear afer it has been lenghtened, overstrained, altared or repaired by welding. Fastsat av SjofartsdireMioratet Prescribed by the Maritme Directorate 17. januar 1978 1 2 3 4 5 6 7 Kiemingsor, | Uvenig diam. ‘Aagivelse av det ‘nl av det Dsto da proven | Amvonct | Tat arbis- lorena avstven som er pret somerprovet | butt | orvevelt_| beating Distinguishing | Ouse Dameter Desctintion of Number | Datecttest | Testloat | ~ Sate Working sumbgt oe marc | of Seave oe tested oped cad ‘SWLIN WIRE 74800 325MM ‘SINGLESHEAVED BLOCK 1 02.05.2001] 36 T 6T “ WITH BECKET AND HOOK ‘SWLIN DRWG: 32111 HOOK F1-325-6 18T HOOK 26-8 FRAMLOCK 23 { €@ Navn og adresse ti fabrkantene eller forhancleme. Mollerodden AS Name and Address of markers or suppliers. P.0.Box 212 {8 Navn og adresse ti den isttusion, dot selskap eller tra som utfarte proven og 501 Haugesund undersakelsen. nena Name and Address of pub service, association, company or frm performing oe the test and examination. FegsoT Heupesund 410 Undertegnedes stiling i ovennevnte inttusion, selskap ele rma, Poston of signatory of pubic service, association, company or firm. ‘Test Superintendent ‘Jog attesterer at ovennevnte redskap ble prevet og undersekt av an sakiyndig person pa den maten som er fastsatt pa baksiden av dette Sertfika, at undersokslsen visto at redskapene utholdt bolastningen uten & f8 skade eller formforancing, og at den tilattearbeidsbelastning ia redskaper er som angi overstdende rubrikk 7. 7 Ceniy thatthe above gear was tested and examined by a competent person in the manner set fort on the reverse side o this certificate, that examination shone rat he gear witsood te test oad wintry or dforaton: and hat ese working eon this gear ig as shown in Col. 7. 02.05 01 : 3) EE Z Q." Undersiet ‘Signatureter wo wa 1 eR Og LUingProducts and Services etter de ha vaert forienget, forstrukket, lorandrat eller reparert ved svelsing. erste! Se ang amtation of caine. ros: eos, hacia, Swivels anc ue ict, ore bing akan kt ue an leh Ge arith been engtiened, Gvrstained, Atared or Hepareg by Provesertifikat nr, .219399. 00 Poevgeerttt Mottakor; HYDRALIFT MARINE AS os Merke: 422157 REV. 2 LAGE! w 3) 4 ©). (6) igen. cgvce av elo or rover) eit, [at | Avena) ie ae Oserponot ear) erprovet" | bie wtor| pee, | belasting bisearting Number | Cato ot tst | | applied ‘ale oe DG SJAKKEL SMS 1577 TYPE:A M-27 1 * 9,6 4,8 *I.H.T.ORG.SERT. cE SF: 5:1 TESTET I SERIEPRODUKSJON DIRECTIVE 91/368/EEC REF:US.FED.SPEC.RR-C-271 SAMSVARERKLERING BRUKSATTEST MA IKKE VARMEBEHANDLES NOTTO BE HEAPTREATED (7) Navn og adresse ti! fabrikantene eller forhandlerne. Namo and adres of makers or suppers. (8) Navn og adresse ti den institusjon, det selskap eller firma som utfarte praven og undersakelsen. Name and address of public servic, assocation, company or fe partoning theleat and examnaton. (2) _Undetegnedes sting i ovennevntointtusjon slskap eller ima, Poston of signatory in pul servi, assoclaon, company ot fim. Jeg attesterer at ovennevnte redskap bie pravet og undersakt den CERTEX NORGE AS ANDREAS JACOBSEN AS SAKKYNDIG av en sakkyndig Parson pa den maten som er fasisat pa baksiden av dette sertfkat, ‘at ndersaleisen vise at redskapen uiholatbelasin ten 3 gery on he on skade oll formforancring og al den lato arbelésbelastning av redskapene er som ang evenstaence rubrikk (2), {he above gear was tested and examinad by a competent person in tha manne’ sat foam ine reves ido sc YO - of ts corte i warancn Swed Wa gar meee the pea tad mou hao cattle an al esas wore od om hs po sos ‘own in Clie). "01 Stavanger, der te CERTE ane DM EEBTEX NORDEA Un ‘Signatre 2000 *) Her oppats redskapens dimensione, hva slags materialer de er laget av og aventuelt den utlrte varmebehanding under ) Her opp gl i s laget av og [produksjonen (Torutsatt ikke Form. nr. 6 bir Drukt For dette formal. The dimensions of he goat, the type of mata of whicn is made and, where appcabl, he heat reatmentrecelved in manufacture shoul be stated (ues orm, No 6s used fr the purpose), ‘Anm.: Se veiledning pa baksiden. Note: Soe arvctonson the reverse a0.eB oii ccna nraterrg innate Lifting Products and Services Provesertifikat nr. 0000225102/010/2001 Test Centificate No. Mottaker- HYDRALIFT MARINE AS. Kundens ordrenr: 426732 K4953 Navi og adresse UI Tabrkant ele Torhanler av taut carier Norge KS [BJERKAS N/ERINGSPARK Nara an toro Be mar omer fe rp | BYGG 5 3471 SLEMMESTAD — i 2 a = 219m ~~ = [hi ~ OO Nominal diameter — eeamm Konstuksjon —~ a ~~) S6LS-EXCEL - a ‘Overfatebehandling ~ ~ - Siding (ese, abel haya vera) ) tomer soci Hotels idee 2160 NIN Dato da taupraven ble utfort 131000 Dat ofan a song ofp _ — _ ‘Axtuell bruddstyrke | soteT ~~ = \"38.107 : ~ Minimum bruddlast Moinum weseng ead Tillat arbeidsbelastning med angiveise av enher git betingelse for den f.eks. en minste skivectameter, en drekte belasting etc Sot wring ond atta any euing conten, a a minum ple arate, dec rae ae nog adresse fl den insitusjon, det selskap eller fia som utferte preven T Stiling i ovennevnte insttusjon, selskap eller firma som utfte preven revlon anecciton of mramed above fein making exten of sory Jeg attesterer herved at de ovennevnte oppgaver er ktge o9 at undersakelsen og preven | cent sboveprtsres are cored ad ha ne easton ants wae cai out ya cpt paaen €2,08L0,¢en 16.05.01 BRIDON INTERNATIONAL RETFORD ‘Materiatcoordinator 1X 219 M WILOCKED HL-THIMBLE ONE END OTHER ENO TAPERED ble foretatt av en kompetent person. Certex Norge A.S CERTEX NORGE Uheerot AS Oh. Have qaL Introduction 2 Main Data 3 Technical Description is Preparation / Installation oa Operating Instructions Provision / Service Crane & MCV 1891-12,5-21 ee Hochang Machinery Ind. Co., Ltd |, Hull No.: H1371 ‘Data Sheets / Spare Parts K4954 Porta List / Drawings adnan or ry my ma, og 9 sy ra ogee ain, lena chal, eran er aie (Dt HYDRALIFT32 ‘TABLE OF CONTENTS ~ Section Chapter 3 TECHNICAL DESCRIPTION Page 38 al General. Safety System Design and Funetion . . Electro | Hydraulic Power Pack Slew System. . ib Winch . oe Figure 8-1 Winch (Typical) 82.6 Control Units... eee . Geer Manual~~ @wvorauer_ 33 Ba 8.1.1 ‘TECHNICAL DESCRIPTION General ‘This crane is of electro hydraulic crane type. This means that an electric motor is used to drive a hydraulic pump. ‘The pump supplies a flow of oil at high pressure, which is utilized as the transmitting force to propel the hydraulic motors as the means to operate the hoisting winch, hydraulic cylinder, luffing the jib and the slewing motion. Safety System ‘The crane is equipped with following safety system: — All movements protected against overload by hydraulic relief valve. ~All control levers are of «dead man type» and goes back to neutral position automatically. — Mechanical automatie stop of jib in upper and lower position. Winch and slew are equipped with a “fail-safe” brake. In case of hose or pipe failure the brake will automatically stop the load. — Emergency winch lowering system. — Hydraulic eylinders is equipped with a load holding valve. This valve is blocking the cylinder in ease of hose failure. — Hook stop limit device. = Slew stop / override arrangement.@ryvorauer 34 a2 B21 B22 Design and Function Ref. Dwg.: K4954G01 ‘K4954H01 ‘KA954EB1 ‘The crane steel construction comprises 3 main parts: — The crane pedestal) foundation as the stationary part. = The crane king as the rotating part. — The crane jib as the luffing part. Electro | Hydraulic Power Pack ‘The crane is equipped with an electro-hydraulic power pack system, consisting of one electric motor as the prime mover. In the center of the stationary part the electric motor is mounted with its rotating shaft extending vertically upwards.The electric motor is equipped with a heating element which reduces its moisture level and facilitates cold start. As the complete power pack is mounted inside the crane king and pedestal adapter, a dry ‘atmosphere space is secured for carrying out service and maintenance. ‘The electric supply to the main electric motor and to the auxiliary equipment is provided from the vessels electric source (chapter 2.4). In the centre of the rotating part the hydraulic pump is mounted with its shaft pointing vertically downwards. ‘Together with a shaft extension, the electric motor and the hydraulic pump is interconnected through a flexible coupling. For the electrical connection between stationary and rotating part of the crane, sliprings are mounted in the crane base in the center of slew unit. ‘The electric motor is connected to a hydraulic oil pump. The pump supplies oil to the jib, slew and winch system, enabling the crane driver to operate all three motions with full load simultancously, and independent. When none of the control handles are operated, oil goes through the oil filter and back to oil tank. ‘The hydraulic oil reservoir is built as an integrated part of the erane king. ‘Slew System Between the top flange of the stationary part and the bottom flange of the rotating part, the slew bearing is bolted to each of the flanges with prestressed bolts. The stationary part (inner ring) of the slew bearing is produced with internal gear teeth, into which the pinion of the slew gear box is meshed. "The slewing bearing used in the crane is of a high quality make and of the balll bearing type, specially designed and calculated for use on deck cranes. ‘The slew gearbox pinion is meshed with the geared innerring of the slew bearing. The slew gear with hydraulic motor is driving the slew motion. ‘The planetary slew gearbox contains a rugged disc brake immersed and working in the gear oil bath. A positive pressure has to be applied to the brake unit to release the brake. User Mantal@ HyDRALIFT ) 32.3 Jib ‘The jib is mounted onto the crane king through the jib bolts and the jib cylinders as shown on the general arrangement drawing. ‘The hydraulic jib cylinder is based on a rugged well proven construction. The cylinder eyes have orkhot bearings of composite type with high loading-capacity. Locking valve is mounted direetly on the cylinder bottom. This is opened by hydraulic pressure ‘when operating jib down and will control the jib in down motion, When driving jib up, the oil pass through a one way valve. If oil pressure disappears the cylinder locking valve will close and the jib motion will stop. 3.24 — Winch "The winch is located on the jib. It consists of a steel winch drum, a foundation with a bolted-on gear box and hydraulic motor and is equipped with an 18 mm wire. The hook stop device is, located on the opposite side of the winch gear. The hook stop functions are as follows: Securing the hoisting wire from being winded completely off the drum, which may cause an in- stant reverse winding on the wire and hook load. — Secure the hook from being hoisted too far up and avoid a collision with the crane boom. | a Winch (Typical) ‘User Manual ‘Ka054@vyoraurr 36 B25 Control Units Reference drawings: K4954EB1 A remote control system is supplied with the crane as the main control console. This system includes a radio or cable remote control option. Following is a brief description of each electrical unit related to crane operation. [-A901] Starter cabinet ‘This cabinet has motor starter circuits for controlling electrical motor on hydraulic power pack. [-A922] Remote control station for starter cabinet ‘This may be used for start and stop of motor. It is also equipped with running lamp and Emergency Stop button.~) Hochang Machinery Ind. Co., Ltd por fhe damon my be repre nda mesa, haan, srg ohare, wil a Introduction 2 Main Data -3- ‘Technical Description ra Preparation / Installation -B Operating Instructions Provision / Service Crane MCV 1891-12,5-21 s: [Maintenance Hull No.: H1371 1. Data Sheets / Spare Parts K4954 8 Parts List / Drawings righ oy ta (i) HYDRALIFT@rvoraurr ‘TABLE OF CONTENTS ~ Section Chapter 4 PREPARATION / INSTALLATION Page 4a General. 2.000 43 41.1 Mounting of Hydralift Marine Cranes. 43 42 Prior to Starting the Crane... . . 50 ae 44 43 Start up, Idle Operation... . . . eee 44 951 a ‘User Manual@ wroravier 43 44 4.1 a054 PREPARATION / INSTALLATION General Asa minimum requirement of the various classification organizations the substructure must be designed to withstand the cranes max. bending moment with a 25% overload. ‘The crane base or counter base with bolting flange welded to the hull substructure is regarded as part of the hull and is therefore a classification item. All welding and machining work on these items at the yard are the responsibility of the yard. The same applies for the classification approval work related to the above items. The crane is normally delivered with the el. motor built into the crane base. 'The el. motor is equipped with a heating element which must be “on” when the crane is not in use. The crane may also be delivered without an el. motor, for connecting to an existing hydraulic system. ‘The crane is normally not delivered with el. motor starter, motor protector, electric cable, lower flange mounting bolts, nuts and washers unless requested and purchased by the customer. Mounting of Hydralift Marine Cranes See the following section before installation of the crane. — ‘The erane is to be welded directly to the deck or some other type of support. — Asa minimum requirement (of the various classification organizations) the deck must be designed to withstand the cranes max. bending moment with a 25% overload. ‘To avoid distortion of the slew bearing, we recommend that the crane base be welded to the substructure before the crane king with slew bearing is connected to crane base. — Check adjoining welding grooves to obtain an even gap through the circumference. Also an evenly distributed heat input is required to avoid distortion. — The flange is obviously more exposed to distortion if the deck stiffeners, platforms ete. are ‘welded to crane base. All such welding has to be completed and the structure has to return to normal temperature before the slew bearing support flange is measured for flatness. For optimal slew bearing life the base flange flatness has to be kept within given tolerances, see the “Slew Ring Wear Test” section in chapter 6. Before mounting the base and king with slew bearing together; check the following points: — The flange machined surface is clean and free from paint and welding slag, etc. = Check the bolt length. Only the bolt types indicated in the parts list are to be used. = The bolt holes in the base flange must match so that the bolts go freely through the holes and without resistance when rotated in the holes. — Hardened washers as indicated in parts list and on the G.A. drawing are to be used under bolt heads. = The tightening torque indicated on the G.A. drawing is based upon a lightly oiled bolt thread surface. We recommend lubricating with MOLYCOTE 1000 because of its relative stability between tightening torque and bolt tension with special consideration given to re-tightening. ~ MOLYCOTE 1000 is also a corrosion inhibitor. = The crane construction is a complete unit with the el. motor built into the crane base. — The el, motor is equipped with a heating element. This must be “ON" when the crane is not in use. User Manal@ HvoRaueT 44 42 43 cc Prior to Starting the Crane 1. Cheek that all hydraulic connections are in accordance with the hydraulic diagram. 2, Check that all hydraulic connections are tightened up firmly. 3. Check that all bolts are tightened with correct torque. 4, Check that all electrical connections are in accordance with the el, interface drawing. 5. Fillup the hydraulic oil tank through the oil filling ball valve, located in front of thr return fil- ter. It is of outmost importance that only pure clean oil is used. Under no conditions must water, dirt or other foreign matter enter the tank. Impurities and moisture will drastically re- duce the efficiency and life span of the hydraulic aystem. 6. The crane have been operated and tested at the production workshop prior to delivery. How- ever, improper storage and handling during transport may result in oil leakage. ‘Therefore, check the oil level at gearboxes (winch/slew) and top up if necessary, making sure touse an approved oil. (See the lubrication chart under the Chapter Maintenance). Allpressure control valves have been adjusted by the manufacturer and must not be altered. Start up, Idle Operation Start the motor for idle operation and check the hydraulic system for leaks. NOT! ROTATION OF THE EL. MOTOR IS CCW (COUNTER CLOCKWISE) SEEN FROM FAN END (REF. ARROW-SIGN). IF MOTOR IS ROTATING IN THE WRONG DIRECTION, INTERCHANGE 2 PHASES AND CHECK AGAIN. ‘The motor/pump must by no means be allowed to run in the wrong direction, as this will adversely affect the life span of the pump. ser MamaDd Hochang Machinery Ind. Co., Ltd Hull No.: H1371 K4954 Coppi ©2001 by Hydrait Maro, er i doament ay be reper edn oa ita ay frm ry yea an pormsin of Hyer Marin -1- Introduction 2. ‘Main Data 2 ‘Technical Description ee | Preparation / Installation Gf oe | JOperating tnstructions Provision / Service Crane @ MCV 1891-12,5-21 Maintenance ‘Data Sheets / Spare Parts 8 Parts List / Drawings () HYDRALIFT@ HyoRaurt ~ Section. bl 52 521 522 523 B24 525 58 54 55 Rectan TABLE OF CONTENTS Chapter § OPERATING INSTRUCTIONS Prestart .... . Normal Operation Start. cee Main Control Console . . . Emergency Stop... . «+ Deactivating Emergency Stops... . « Figure 5-1 Control Console (Typical) Emergency Lowering - Winch»... « Disturbance of Operation. : Hazards and Protective Measures. Operators Qualification Requirements . . . . 52. Page User Manual@ Hvorauer 53 5 5 OPERATING INSTRUCTIONS 51 Prestart Prior to starting the crane /electrie motor, always carry out the following inspections / checks: Deseription 1 | Check oil level in the hydraulic oil tank. It should be approximately middle of sight glass with jib in lower position. 2 | Inspect all hydraulic hoses and connections for sign of leakage. Rectify immediately if any are found. | 3. | Inspect the erane for signs of external damage. Replace or repair if any are found. | 4 | Check that the by-pass indicator arrow on the hydraulic filter | element is pointing to the green area. | Replace filter element immediately if arrow is pointing to the red area. 5 | Run all crane motions without load in the hook in order to cheek for normal performance and check limit switches. 5.2 Normal Operation 521 Start oe Reference drawing: K4954EB1 ‘The crane is started from the main control cabinet. This cabinet is “customer specified area”, but the location is normally inside deck house close to the crane. The reference drawing is typical for this cabinet. Ke Caer Namal@ worauirt BA 522 523 524 Kissa Main Control Console The main control console consists of an open platform located on the side of the crane king. Upon this platform, the valves for controlling ‘the main motions of the crane are mounted. The valves are controlled via handles directly connected to the valve spools. By operating the respective handles, the required motion of the crane will be executed. The control levers will return to neutral position when pressure is released. ‘The control funetions are indicated! by the instruction labels positioned : directly in front of the control Figure 5-1 levers. Control Console (Typical) During operation of the crane the levers must be operated slowly and smoothly in order not to induce a swinging motion in the hanging load or oscillation in the erane construction. Extreme care must also be taken when operating the winch up and jib up motion simultaneously. When the jib angle is noaring it's maximum vertical value and the hook is, close to the hook stop; the load may hit the underside of the jib. Emergency Stop ‘There are three separate possibilities for emergency stop: — Push-button at the main starter cabinet. — Hydraulic emergency stop lever at the main control platform. — Push-button fitted to the remote start / stop box on the pedestal of the erane. ‘A built in check valves and “fail-safe brakes” will ensure that the crane will not lower the load until positive action is taken. Deactivating Emergency Stops Prior to deactivating the emergency stop, ensure that the reason for activating the emergency stop has been identified and any dangerous situations are cleared up. — The electric emergency stops may be reset by pulling them up or just giving ita slight turn in clock wise direction (mushroom type). ‘The electric motor may then be started again before normal operation can take place.@ nyorauet 55 525 54 ‘Ka054 Emergency Lowering - Winch Reference drawing: KA954HO1 Before commencing the emergency lowering procedure, please make sure that emergency lowering pump (NO1) is connected via hoses to quick couplings (N61, N62). = Close valve, N04 (located on winch). = Open valve, N03 (located on winch). — Pump up pressure with pump (NO1) and check that load in hook is lowered. Use pump to refill leak oil from winch motor in order to maintain continuous lowering of load in hook. Disturbance of Operation ‘The crane will stop if the SWL or limit switches on jib or maximum in/out winding on winch is exceeded. Hazards and Protective Measures ‘The following points sum up the safety aspects related to operation: ~The equipment must only be used for the prescribed purpose. — The safe working load (SWL) of the machine must never be exceeded. If the machine is overloaded, construction damages may occur. This may not be noticed during normal use of the machine. Hydralift is not responsible for damage caused by overload. — The equipment is powered by high pressure hydraulic oil. Beware of the risk of pipe/hose burst. — Ifanyone gets hydraulic oil into their eyes or open wounds, wash at once with lots of fresh water. ~ Nopersonnel under the age of 18 years is allowed to operate the crane. — Donot under any circumstances operate the crane when the ships heel and trim exceeds 5° 12 — Do not operate the crane when wind speeds exceed 20 m/s. — No tools or loose items must be left on the crane jib. — The erane is not designed for ice or snow on the structure. Great care must be taken to avoid ice falling down on personnel below the crane. — Do not operate the crane with personnel other than the crane driver on the crane. — ‘The crane driver must always be able to see the hook / load, or be in direct contact with somebody who can see the hook / load. — Do not adjust the various relief valve settings to other values than shown in the in the Hydraulic flow diagram for the erane. “ser Manual@ nyoraurr 56 5.5 Operators Qualification Requirements No personnel under the age of 18 years is allowed to operate the rane. Attthe present time, there are no legislative requirements for certified qualifications for the crane operator. However the operator is required to possess a good knowledge of the cranes safety systems and method of operation. Any intended operator of these cranes is required to gain experience in operating the cranes under the supervision of experienced operators. Ifa training program for this crane type is required please contact Hydralift Marine. sro Tse MaalLo Provision / Service Crane MCV 1891-12,5-21 Hochang Machinery Ind. Co., Ltd Hull No.: H1371 K4954 | Ei {Introduction 2 ‘Main Data -3- | ‘Technical Description ode | Preparation / Installation Operating Instructions |Maintenance ‘Data Sheets / Spare Parts 8 Parts List / Drawings (i) HYDRALIFT@evoren 62 ‘TABLE OF CONTENTS ~ Section Chapter 6 MAINTENANCE Page 61 General. 0.00.0 63 6.1.1 Maintenance Log... - 62 Hydraulic System . . 621 Replenishment and Oit Change 63 Crane Lubrication Schedule . Figure 6-1 Lubrication Chart 63.1 Maintenance and Lubrication Information . . . . Figure 6-2 Crane Lubrication Schedule 64 Oil Change Slew-/Winch Gear Figure 6-3 Slew / Winch Gearbox 65 SlewRing ........-- : 66 Slew Ring Woar Test. . . Figure 6-4 Slew Ring Wear Test Figure 6-5 Slew Ring Measurement Table 6-10 67 Re-tightening of Slew Ring Bolts . ell 68 Wire Rope... 2... 0.0505 Boged 612 6.8.1 Method of Examination .. . . Pe 612 Figure 6-10 Examination of Wire Rope 612 Figure 6-11 Equipment for Wire Rope Examination 612 69 Replacing the Wire... ...- : ae 613 Figure 6-12 Securing Wire to the Winch 6-13 Figure 6-13 Handling of Wire 6-13 6.10 Hook Stop Adjustment... . . peer eu Figure 6-1 Hook Stop Housing 14 611 Brilube Information .... 0.266005 0000 eee 6-15 6.12 Lubricants 617 6.13 Appendices. G17 \ 6.13.1 Appendix A- Corrective Measures Report... ove es 617 ~/ 6.13.2 Appendix B - Major Repairs and Modifications Log I 618 ) ~~ ‘Kao@rvoraurtr 63 611 Kise MAINTENANCE General ‘The following points sum up the safety aspects related to maintenance: = Only qualified and authorised personnel are allowed to carry out maintenance work. — Awarning sign must be placed at the control panel while maintenance is carried out. = Beware of the risk of pipefhose burst. If anyone gets hydraulic oil into the eyes or open wounds; wash at once with lots of fresh water. ~— Nowelding of lugs, brackets ete. must take place on the equipment. = Only original spare parts must be used - this includes hydraulic hoses. If theres any questions about maintenance, please contact Hydralift Service Department. See “Contact Information” in chapter 1. Maintenance Log It is recommended that a Maintenance Log be establised for this equipment, All maintenance, abnormal observations and repairs should be logged. Upon request, the log should be made available to the Hydralift Serviceman. ‘An example on the maintenance log is included back in this chapter. "Wier Manual@woraurr 62 Hydraulic System ‘Dhe operation and lifespan of a hydraulic system is greatly dependant upon the quality of the hydraulic oil, ‘The lubrication schedule in the instruction manual indicates the type of oil to be used and frequency of oil changes. ‘A bydraulic system when in use will always produce particles. The amount and hardness of the particles varies dependant upon how well the system functions and where in the system the particles are produced. Each type of pollutant entering the oil will reduce the quality. In order to avoid reducing the oil quality, or in the worst case, damaging costly components it is of out most importance that ‘the oil quality to be maintained as close to that of new oil for the systems entire lifespan. ‘Therefore are the built in filters which function continuously while the system is in use an important part of the hydraulic system. ‘The hydraulic system flow diagram in the instruction manual indicates the location and type ) of filter used in the system. Regardless of the filter type such as suction filter, pressure filter or return oil filter. ‘The filter element must be changed during each oil change. Cleaning and reusing the filter element is not acceptable. In many cases the filters are equipped with indicators that reveal the condition of the filter. As soon as the indicator signals a dirty or contaminated filter, the filter element is to be replaced immediately. In larger units with system capacities of 1000 litres or more, the oil should be laboratory tested at least every 6 months. The lab report will help in determining the life span of the oil. ‘Under no cireumstances shall a filter operate more than one year without changing the filter element. A clogged filter element causes a BY-PASS through the filter which result in the system operating with un-filtered oil. 6.2.1 Replenishment and Oil Change Replenishment must be carried out through the filling plug which is located in front of the return filter. In order to avoid contamination of the oil, this plug should always be used wether it is oil change or replenishment of oil. ‘When the hydraulic oil has to be changed; always clean the tank thoroughly after the tank have been drained. Remove access plate and check visually for dirt inside the tank. ‘User Mania@ worry 65 63 Crane Lubrication Schedule ‘See the attachment back in this chapter for lubricants. Cylinder and jib bolt have lubrication free composite bearings. They are lubricated only during installation. 1. Lubrication nipples electric motor and slew bearing. 2, Wire sheaves. 8. Slew gearbox and winch gearbox. 4, Jib bolt sealing. 5. Hydraulic system oil. 6. Filter cartridge. 7, Wire and slew ring gear/pinion. NOTE: SEE THE LUBRICANT ATTACHMENT BACK IN THIS CHAPTER. Figure 6-1 Lubrication Chart Kee Pier Maala ) @ HyoRAUFT nouns} |2|]3|4|5 | 6 | 7 |Notes | 50 c ja |e c {100 [ce [c [a A 160 c fa c = | a0 |c |c \B | FIRST 200 HOURS ONLY 20 jc [co [A A c 250 c ja [e goo (c |c (A A c 350 c ja | aoc fc [A A c 450 c [a fe 500 [c lc |B ne|Dealc 550 c la 7 eo |e |c |a A c : 650 c [a |e 70 jc jc [a A c 750 c la so jc je [A A c 850 c ja le soo [oc [oc [a A c | 950 c [a roo |c lc |B ota Dees Figure 6-2 Crane Lubrication Schedule A Cheek oil level |p c D 6.3.1 Maintenance and Lubrication Information System Oil 800 Liters Winch Gearbox | : 1,5 Liters Slew Gearbox | : 2x 8,6 Liters i96% ‘Caer Manual@Hvoraurt 64 Kise Oil Change Slew-/Winch Gear ‘The slew and winch gear needs an oil change every 500 operating hours or at least once per year. Oil quantity is marked on the nameplate. The oil should be drained with the gearbox at operating ‘temperature. ‘To change oil, do as follows: Unscrew the filling plug and the drain plug. — Once the oil has been drained, replace the drain plug. — Fill up the exact amount of oil or up to oil level sight glass. - After filling up, re- place the air filter and the filling plug. In order to check whether there was a sufficient quantity of oil in the . gearbox, the quantity of oil drained, has to be compared with the quantity prescribed. Figure 6-3 Slew | Winch Gearbox Wher Manual@ Hyorauer 65 ca Slew Ring Lubrication and Maintenance The first relubrication of the raceway and the gear has to take place immediately after installation. For every subsequent lubrica- tion, acidfree, non-resinous, water-repel- lantand non-ageing greases with adequate heat resistance properties must be used ex- clusively, see Table 3. The order in which the lubricants are listed is not in order of recommendation. The filling isto reduce friction. toseal andto protect against corrosion. Always grease fiberally until acollar of fresh grease formsat the bearing gaps and seals around the entire circumference. The bearing should be rota- ted during relubrication. ‘Lubricant Questions relating to lubricants should be clarified with the lubricant manufacturer. When automatic lubricating devices are used, pumpability mustbe confirmed by the lubricant manufacturer. Applications at sub-zero temperatures will require special lubricants, for instance Mo- } Gear Lubrication intervals are to be selected ac- cording to the operating conditions: ge- erally every 100 operating hours, roller bearings every 50 operating hours. Shorter greasing intervals in tropical regions must be used in the presence of high humidity. dust or dirt, strong temperature fluctua- tions, and for continuous rotation. Bogie bearings for rail and road vehicles are ‘yeated ina different manner (ask for special details). Before and atter prolonged stoppage of the equipment. relubrication is absolutely ne- cessary. This is especially important after a winter shutdown. When cleaning the equipment, care must be taken 0 prevent cleaning agents from damaging the seals or penetrating into the raceways. Checking of bolts To compensate for settling phenomena, itis necessary to retighten the bolts with the specified tightening torque. During this ‘operation the bolted connection must be relieved of all tensile stresses coming from external loads. This should be checked after approximately 100 operating hours at the latest. Thereafter, checking should be re- peated about every 600 operating hours or every 3 months. Under special operating conditions, or if specific test instructions so require, the in- terval between checks should be changed correspondingly. Checking of the raceway systems In their delivered condition large-diameter antifriction bearings have clearances which uarantee good operating conditions and functional safety. After a prolonged opera- ting time bearing clearanceswill increase. It is, therefore, necessary to check the clear- ance at certain intervals. See page 43 Rothe Erde main catalogue. 68 Ter Manual@ wrorauier 69 66 i964 Slew Ring Wear Test ‘Wear on the slew ring’s ball race will result in a height difference between the crane's base and the rotating part of the slew ring. In order to keep exact control on the wear of the ball race, a measuring plate (approx. 25 x 25 mm) is welded to the upper flange of the crane base. All measurements are made from the upper surface of this plate to the lover edge of the outer slew ring. ‘Measurements are taken with no load in the hook and the jib at the horizontal position. ‘The first measurement is taken at position 1 with the jib dirrectly over the measuring plate. ‘The next measurement is made after rotating the erane 45° in a clockwise direction and so on until all 8 measurements have been made. The measuring positions are numbered in a clockwise sequence as shown in the sketch below. In order to obtain a continous rrunning check as part of the routine service schedule, it is very important that all future measurements are made with the jib in the same position each time. This may be achieved hy dividing the number of fastening bolts on the slew ring by 8, and then rotating the crane this number of bolts relative to the measuring plate for each measurement to be taken. ‘The enclosed table is to be filled out as each measurement is taken. It is important that a complete set of these measurements are made every 6 months. The measuring instruments tobe useded are to have a accuracy of at least + 0.05mm, ‘The first set of measurements are to be recorded upon completion of the instalation of the crane. ‘The maximum allowable deviation between the initial set of measurements and all future measurements are indicated in the table, Should the wear rate suddenly show marked deviation from the expected rate, the measurement rate should be increased. The safe functioning of the slew ring is dangerously reduced if the maximum allowable deviation is exeeded. =) c Figure 6-4 Slew Ring Wear Test User Manval@ wvorauer 6.10 ons SLEW RING WEAR MEASUREMENT TABLE ‘MAX. ALLOWABLE DEVIATION = 2,3 mm Measurements to month ro date of | 1B POSITION basic measur. 1 2 3 4 5 7 8 Dae |B Deviation | 0 0 oO 0 0 oO 0 o Date: | Measure Deviation - <2) Date: | Measure Deviation Date: | Measure Deviation Date: | Measure Deviation Date: Measure | Deviation YY Date; | Measure Deviation Date: | Measure Deviation Date: | Measure | Deviation Figure 6-5 Slew Ring Measurement Table Kisd ‘User Manual@ woraurr 6.7 Kiet Re-tightening of Slew Ring Bolts Ref. drawing: MMBSTAO8 ‘The safe operation of the slewring (bearing) is dependant upon proper tightening of the holts. Itis very important that the bolts are regularly checked and re-tightened if necessary. ‘The required tension / torque indicated is based upon lightly oiled bolt threads and nut / bolt heads. For re-tightening of bolts (grade 12.9) use the following tension / torque moments: Bolt si Mi6 ‘M20 M24 M27 M30 ‘Torque moment: 84 kpm - 833 Nm 66 kpm - 648 Nm 11d kpm - 1116 Nin 170 kpm - 1665 Nm 229 kpm - 2250 Nm ‘The first bolt check is to be made after the first 100 running hours, the following intervals are to be 300 running hours, depending on the use frequency of the crane. In the event that the bolts are loosening up between check intervals, increase the frequency of the bolts checks. er Manual@ wyoraurr 68 68.1 96 auie1a) Wire Rope ‘A long history of examining returned ropes and those in service has clearly shown that internal degradation, mainly by corrosion and fatigue mechanisms, can be a serious and unsuspected cause of rope failure. In several instances, a normal external examination could not have revealed the extent of the internal degradation even in situations where a failure was imminent under normal working conditions due solely to the extent of the internal degradation. Based on this experience, it cannot be an overstatement to say that no rope examination is complete until an assessment of the internal condition at appropriate positions has been made. By the use of simple tools used with care, a 6 or 8 stranded rope and Multi-Strand and “Paragon” type rope up to at least 28 mm diameter can be opened sufficiently to permit a reasonable determination of the internal condition. ‘This examination can be carried out on site providing the rope is not under any tension. Method of Examination ‘The method consists of firmly attaching to the rope two correctly sized clamps about 100 - 200 mm apart. By contra rotating these clamps in the direction to unlay the rope the rope strands will be lifted away from the core. Extreme care is necessary during this operation to ensure that the strands are not excessively moved such that they become permanently deformed. With the small openings now presented, a small probe such as a screwdriver, may be used to manipulate the strands and displace any grease or debris which may be obscuring the Figure 6-10 inner regions, Examination of Wire Rope Because it is generally impracticable to examine a rope internally over its entire length, suitable areas have to be selected. In the case of ropes working over drums, pulleys -— eee or sheaves, it is usual to examine those areas entering or leaving the grooves when maximum —————S HEB loads, particularly shock loads, are experienced, or areas which remain for long periods, in ————— exposed places such as over a jib head pulley. On some running ropes, but usually more relevant to standing ropes such as pendants, the areas adjacent to termination’s should be given particular attention. Figure 6-11 Equipment for Wire Rope Examination User Manual@nvorauiet 6.13 69 Replacing the Wire Handling and installation of the rope should be carried out in accordance with a detailed plan and should be supervised by a competent person. ‘When a new rope is fitted a variation in size compared with the old worn rope will be apparent. The new rope may not fit correctly into the previously worn grove profile and ‘unnecessary wear and rope (eee distortion is likely to occur. 'This may °" be remedied by machining out the grooves before the new rope is installed. Place the rope in a suitable stand which allows it to rotate and be braked to avoid overrun during installation. Roll it out straight ensuring that it does not get contaminated with dirt moisture ete. Connect the rope to the winch as shown on figure 6-1. Dead end is secured by the eyelet shown on - figure 6-3, | ‘Tapes oy iver Ten Yo.RO wie HR AnD TH Figure 6-12 Securing Wire to the Winch Wrong Note the kinks forming Figure 6-13 Handling of Wire Kiet ‘User Mana~~ @ Hyoraurt 6.10 ig6e Hook Stop Adjustment Following is a procedure for adjustment of the hook stop (cam limit switeh). ‘Lower the winch until there is 3 (three) turns of wire on the drum. Loosen / remove the 8 clamping screws. Turn the cam so that it shunts against the roller on top of the control point on the valve. Re-clamp the cam with a clamping screw. Raise the winch to its highest required position and adjust the other cam as described above. ‘To check the control accuracy raise and lower the winch several times. Re-adjust the settings if re- quired. After the final adjustment re-clamp the cams with all 3 of the clamping screws. Finally replace the cover and gasket and tighten all the bolts. Ensure that the connection is correct and no water / dust can enter the unit. NOTE ‘The 2 valves inside the Operation direction unit are not specified of the cams. for a specific up or — ie mokono Determination of the hook-stop system. The switching point settings can vary from crane to crane depending on how the wire, winch or crane is installed 2.x control valves Figure 6-1 Hook Stop Housing “User Manual@ worauer : oo eas 611 Brilube Information qi) H ALIET RE ROPE DI BRILUBE 70 has been developed by BRIDON ROPES LIMITED, for the service dress- Ing of heavy duty working ropes In highly aggressive environments such as off-shore sranes and for the long term protection of standing and running ropes in marine and dockside locations. ‘Typical applications are 1) Offshore cranes 2) Standing rigging 3) Mooring and towing cables 4) Fishing ropes such appcations the resing must prove the BRILUBE 7Dis black hixotropc gl ormulates 0 Int aerial peecioncomcined win esr the bes poesbie coresion protection i Best pose Corl ecangcetoraaton custo hasile oworments over extended peed and a Svronmerea tack ti range of tonperatres. Te gltorm preauces . sonmetstne sere lenig pte resin reat ogo, rune 0 atarcosbomion vets, Sade wari agpesotenoe most aggressive off-shore eee tureot 20°C. renepresstentiowatral andwitraterck gy UBe 70 canbe vecare under jmposureto Uta Vi canbe app by hand or by pur or gaze under prokenged exposure! Ura Ville! sym and his realy proving econ x landing ope overextended periods, inspection ‘The tixovopc nature of BAILUBE 70 eneuros tnd ecenengcheldbe canedoutat moval {od Worl ane inthe go em abe form fom mentnf02 years dopercing upon 55°C to over 100°C. ‘conditions. oo a a ae _ ~ ‘User Manual A954BRILUWBE 70 TYPICAL CHARACTERISTICS Appearance Viscosity (base oil at 40°C) NLGI Flash point closed cup Effective operating range Salt spray test (ASTM B117) Minimum application temperature Black gel 1000 c/st No. 2 200°C “55°C to +100°C. -20°C 1000 hours: GENERAL PRECAUTIONS DO © Keep away from heat and open flame. © Keep container closed. @ Store under cover. Ensure maximum temperature 25°C. Keep away trom food and drink. ‘© Avoid prolonged and frequent skin contact and ‘ensure good standards of personal hygiene. DO NOT © Keep oil rags in pockets or wear contaminated © clothing. Inhale fumes or vapours. © Swallow. FIRE EXTINGUISHING MEDIA ‘© Carbon dioxide, dry chemicals, foam. FRILUI@E 70 HEALTH AND SAFETY RECOMMENDATIONS POTENTIAL HEALTH HAZARDS No significant hazard when properly used in the application for which itis designed. Prolonged and/ ‘0 frequent skin contact may cause some detatting leading to initation and itis recommended that protective gloves be worn”. ORALLD. 159/kg body weight TLV. 100 ppm’ “S00 Cautionary Notice SHW 397 "Efects of Mneral Oi on tho ‘Skin and MS(B)5 "Skin Cancer by Oi" publshed by the Health ‘and Safety Exocutvo. FIRST AID Ingestion _Do not induce vomiting because of the risk of aspiration. Give 1/2 pint of mikx. Seek medical advice. Skin Contact Midlyirtating. Remove by wiping. Wash with soap and water. Eye Contact Mildly initating. Flush with copious ‘amounts of warm water. If neces- ‘sary seek medical advice. ‘SPILLAGE Aspiration If there is any suspicion of aspira- @ Soak up with absorbent clay. tion into the lungs (for example during vomiting) admit to hospital immediately. WASTE DISPOSAL Inhalation Remove from exposure into fresh © Bum or dispose of in an approved area. air, I necessary give artificial ‘© Do not allow fo contaminate water supplies. respiration or oxygen. Seek medical advice. @ HYoRACIET Barstolveien 26, 4636 Kristiansand, Norway Telephone: 47 380 43500 Fax: 47 380 46902 Ki95i Ther Manual612 Lubricants Lubricants used as Hydralift standard together with Esso, Hydro Texaco, Castrol and Mobil is, included as a separate attachment back in this chapter. 6.13 Appendices 6.13.1 Appendix A ~ Corrective Measures Report Te Telefax: CORRECTIVE MEASURES REPORT HYDRALIFT MARINE ~ After Sales Service, N-4606 Kristiansand, NORWAY 47 38 04 93 41 - Telephone: + 47 38 04 95 00 ‘Telephone: Installation / Vessel: | Product: HYDRALIFT MARINE Machine No. Contact Porson: Sign: Date: “Measures | Person in Charge: Ke a) Symptom of Incorrect Function 1b) Source of Trouble _¢) Status Other Functions Sign: Date: 4) Corrective — Teer Manual@wrorauirr 6.18.2 Appendix B - Major Repairs and Modifications Log Date Performed: | Contract Reference: Document or Drawing Reference: 1 ~ - = ‘Description of Major Repairs and Modifications: Date Performed: | Contract Reference: Document or Drawing Reference: Description of Major Repairs and Modifications: i954HYDRALIFT MARINE REF.NO. :LUB-HLI REV. iA QUALITY STANDARD (QS) DATE : 060401 PAGE: 10F2 HYDRALIFT MARINE Kristiansand, Norway PREP. BY :0. Kallhovd APPR. By : . FACTORY LUBRICATION OF HYDRALIFT MARINE CRANES SERVICE LUBRICANT USED BY | NOTES HYDRALIFT MARINE Hydraulic Hydro Texaco System is pressure tested and system Rando Oil HDZ 32 flushed at factory. Hydraulic fluid is only drained after testing where practical. Check compatibility with new hydraulic fluid. Slew/winch/travel gear box | Hydro Texaco Universal tractor oil for with oil immersed multi-plate | Textran TDH Premium transmission, differential brakes. hydraulics, when oil ‘Make: Hamworthy immersed brakes are used. Mineral oil base. General grease points in: | Hydro Texaco Lithium based grease EL, motor Multifak EP2 NLGINo.: 2. Winch, Lead additives. Slew ring (bearing) Colour: dark green. Blocks/sheaves Wheel bearing Spherical bearings in: Hydro Texaco Lithium based grease Main jib bearing Molytex EP2 NLGINo.: 2. molybdenum additives. 3% Slew pinion teeth First: Spray on Kliber Mineral oil based. metal soap Open gear on slew ring rack | Grafloscon Ca 901. complex, powder, graphite an pinion drive Second: Kldber additives Grafloscon A G1 Steel wire Bridon Steel wire is delivered ready Brilube 70 lubricated from wire manufacturer Telescopic Hydro Texaco Lithium based grease ‘Nylatron sliding pads Multifak EP2 NGI No.: 2 (Sliding surface only) Lead additives. Colour: dark green Motor shaft, spline Kltiber No re-greasing required. sleeve Kltiberpaste 46 Mr 401 For assembly only. Threads on: Klber For easy disassembly Bolts, studs, nuts, pipe Klberpaste 46 MR 401 and hose fittingsHYDRALIFT MARINE > QUALITY STANDARD (QS) REFNO. :LUB-HLI = REV. A DATE —: 060401 PAGE :20F2 /HYDRALIFT MARINE, ‘Kristiansand, Norway PREP. BY :0.Kallhovd APPR. By FACTORY LUBRICATION OF HYDRALIFT MARINE CRANES SERVICE ‘NOTES LUBRICANT USED BY HYDRALIFT MARINE, Tubrication for assembly | Kliiber Used for initial lubrication and corrosion protection Klberpaste 46 MR 401 only. of pins and bearing Not for re-greasing. surface, sph. bearings Valve lever housing, Kluber No re-greasing required. wee) spring housing, Kluberpaste 46 MR 401 internally Pins/bolts in shackles Kiuiber For easy disassembly Klilberpaste 46 MR 401 Bolts, studs nut in ‘Klber For easy disassembly hatch covers Kluberpaste 46 MR 401 Dead-weight on wire rope. | Kliiber For corrosion protection, including thimble Kliberpaste 46 MR 401 and easy disassembly. Piston rod extension on Denso tape For added corrosion hydraulic cylinders protection,HYDRALIFT MARINE REF.NO. ; LUB-BP REV, oO QUALITY STANDARD (QS) ° DATE 980921 PAGE: 10F2 HYDRALIFT MARINE Kristiansand, Norway PREP. BY :J. Bamett APPR. By LUBRICATION MANU} BP SERVICE RECOMMENDED LUBRICANT FOR |NOTES/COMMENTS DIFFERENT AMB. TEMPERATURE COLD NORMAL nor 225° TO.0°C | -10° TO 30°C | ABOVE 420°C - Hydraulic Bartran Bartran Bartran Keep the system system HV 22 HV 32 HV 32 clean, Change filter elements Alt Alt Alt: regularly. Change Bartran Bartran Bartran hydr. fluid when HV 15 HV 22 HY 46 recommended by lab., or once every year Slewiwinch? [Tractran9 | Tractran9 | Tractran 9 Change oil afier first 200 travel gear running hours. Thereafter box (with oil every 500 running hours, immersed or once every year multi-plate Top up after every 50 brakes. Make: running hours. Hamworth General Pnergrease |Energrease |Energrease _| Lubricate every grease points |MM-EP2__ |MM-EP2 MM-EP2 second month. HL int do not recommend the use EL. motor of grease Winch with molybdenum Slew ring, additives. (bearing) Blocks/ sheaves Wheel bearing Spherical Energrease [Energrease |Energrease | Cargo-cranes: bearings in: |MM-EP2— | MM-EP2 MM-EP2 Lubricate daily Pivot, when in use. main jib, Alt: Alt: Alt Utility cranes: main hydr. Energrease | Energrease Energrease Lubricate once cylinder 121-M L21-M 1.21-M a month. Open gear Energrease |Energrease |Energrease _| Keep well greased Slew pinion, — |OG 0G 0G at all times, slew ring, rack and pinion driveHYDRALIFT MARINE, ; , QUALITY STANDARD (QS) REF.NO. -LUB-BP REV. :0 DATE :980921 PAGE: 20F2 HYDRALIFT MARINE Kristiansand, Norwey PREP. BY J. Barnett APPR. By LUBRICATION MANUF.: BP. SERVICE RECOMMENDED LUBRICANT FOR [NOTES/COMMENTS DIFFERENT AMB. TEMPERATURE __| coud | NORMAL HOT - -25° TO 0°C | -10° TO 30°C | ABOVE +20°C Steel wire Energol Energol Keep well greased WRP WRP at all times, also. when not in use for prolonged periods. Telescopic Bnergrease |Energrease | Do not use grease jib with 0G 0G with molybdenum Nylatron additives, as this, sliding will reduce the service pads life of the nylon slide pads. Genral notes: Refer to operation and maintenance manual for details of lubrication/grease points, quantities, intervals, ete. See separate chart for initial type of lubrication of crane when delivered. If a different make is to be used, Always check compatibility with «old» lubricant first. Do not mix synthetic lubricants with mineral oil based lubricants.»y HYDRALIFT MARINE REF. NO. : LUB-ESSO_ REV. 10 — QUALITY STANDARD (QS) ot oF DATE —: 060401 PAGE: 10F2 HYDRALIFT MARINE ‘Kristiansand, Norway PREP. BY :O. Kallhovd APPR. By LUBRICATION MANUF.: ESSO/EXXON SERVICE RECOMMENDED LUBRICANT FOR | NOTES/COMMENTS. DIFFERENT AMB. TEMPERATURE COLD NORMAL, HOT -25°T0.0°C_| -10° TO 30°C _| ABOVE +20°C Hydraulic |UnivisN22__[UnivisN32__|UnivisN32 __ | Keep the system clean. system Change filter elements Alt. Alt: regularly. Change . Univis NI |Univis N22 hydr. fluid when ) recommended by lab., ‘or once every year. Slew/winch/_|Unifarm Unifarm Unifarm ‘Change oil after first travel gear 200 running hours. box (with oil | Alt. Alt: Alt: Thereafter every 500 immersed [Torque fluid | Torque fluid | Torque fluid running hours, or once multi-plate |56 2 62 every year. brakes. Make: Top up after every 50 Hamworthy running hours. General grease [Beacon EP2 |BeaconEP2 [Beacon EP2 | Lubricate every second points in: month. HL do not El. motor recommend Winch the use of grease Slew ring with molybdenum (bearing) additives Blocks! ~~) sheaves Wheel bearing Spherical |MPgrease |MPagrease [MP grease | Cargo cranes: bearings in: [Moly Moly Moly Lubricate daily when in use. Main jib. Norway: Norway: Norway: Utility cranes: Molyfett EP |Molyfett EP |Molyfett EP | Lubricate once a month Open gear: | Surret ‘Surret Surret Keep well greased Slew pinion, | fluid 4K fluid 4K fluid 4K at all times. slew ring, rack and Alt: ENL-SS- | Alt: ENL-55__ | Alt.: ENL-55 pinion drive _ | (Norway) (Norway) (Norway)HYDRALIFT MARINE QUALITY STANDARD (QS) REE-NO. | LUBESSO DATE :980821 HYDRALIFT MARINE Ksiansand, Norway PREP. BY : 0. Kalhowd REV. :0 PAGE :20F2 APPR. By LUBRICATION MANUF.: ESSO/EXXON SERVICE RECOMMENDED LUBRICANT FOR DIFFERENT AMB. TEMPERATURE, ‘COLD NORMAL HOT -25°TO.0°C_| -10° TO 30°C_| ABOVE +20°C Steel wire |Surret Surret Surret Keep well greased fluid 4K fluid 4K fluid 4K, at all times, also when not in use for prolonged periods. Telescopic [BeaconEP2 |BeaconEP2 | Beacon EP2 Do not use grease jib with with molybdenum Nylatron additives, as this sliding pads will reduce the service life of the nylon slide pads. General notes: Refer to operation and maintenance for details of lubrication/grease points, quantities, intervals, ete. See separate chart for initial type of lubrication of crane when delivered. Ifa different make is to be used, always check compatibility with «old» lubricant first. Do not mix synthetic lubricants with mineral oil based lubricants.HYDRALIFT MARINE QUALITY STANDARD (QS) HYDRALIFT MARINE Kristiansand, Norway REF. NO. : LUB-TEX DATE — : 060401 PREP. BY : .Kallhovd APPR. By = REV. :0 PAGE: 10F2 LUBRICATION MANUF.: HYDRO TEXACO SERVICE RECOMMENDED LUBRICANT FOR | NOTES/COMMENTS DIFFERENT AMB. TEMPERATURE COLD NORMAL HOT -25° TO 0°C_| -10° TO 30°C_| ABOVE +20°C Hydraulic |RANDO OIL |RANDOOIL |RANDO OIL [Keep the system system HDZ15 HDZ32 HDZ.32 clean. Change filter elements Alt: regularly. Change RANDO OIL, |hydr. fluid when HDZ 46 recommended by lab., or once every year. Slewhwinch’) |TEXTRAN |TEXTRAN [TEXTRAN [Change oil after first travel gear | TD 1DH TDH 200 running hours. box (with oil [PREMIUM |PREMIUM = |PREMIUM | Thereafter immersed every 500 running multi-plate | Alt: Alt: Alt: hours, or once every brakes. Make: |29323.A.8. [29323 AS. 29323 AS. | year. Hamworthy [Transmission Transmission | Transmission | Top up after every 50 OIL Om OIL running hours. General grease |MULTIFAK |MULTIFAK |MULTIFAK [Lubricate every second points in: EP2 EP2 EP2 month. HL do not El. motor recommend Winch the use of grease Slew ring with molybdenum (bearing) additives Blocks/ sheaves Wheel bearing ‘Spherical MOLYTEX |MOLYTEX |MOLYTEX | Cargo cranes: bearings in: | EP2 EP2 EP2 Lubricate daily Main jib. when in use. Utility cranes: Lubricate once a month Open gear. |TEXCLAD [TEXCLAD [TEXCLAD |Keep well greased Slew pinion, |PREMIUM |PREMIUM = |PREMIUM _|atall times. slew ring, | Alt: Alt: Alt: rack and CRATER CRATER CRATER pinion drive |SPECIALX |SPECIALX | SPECIAL X FLUID FLUID FLUIDKristiansand, Norway HYDRALIFT MARINE QUALITY STANDARD (QS) HYDRALIFT MARINE DATE — : 060401... PREP. BY :0.Kallhovd APPR. By REF.NO, :LUB-TEX REV. 0 PAGE :20F2 LUBRICATION MANUF.: HYDRO TEXACO NOTES/COMMENTS intervals, etc. SERVICE RECOMMENDED LUBRICANT FOR DIFFERENT AMB. TEMPERATURE, COLD NORMAL HoT -25° TO.0°C_| -10° TO 30°C | ABOVE 420°C Steel wire CRATER CRATER ‘Keep well greased SPECIALX |SPECIALX _ |atall times, also FLUID FLUID when not in use Alt: Alt: Alt: for prolonged TEXCLAD |TEXCLAD |TEXCLAD _ | periods. PREMIUM __|PREMIUM___|PREMIUM Telescopic MULTIFAK |MULTIFAK |MULTIFAK — |Do not use grease jib with Nylatron | EP2 EP2 EP2 with molybdenum sliding pads additives, as this will reduce the service life of the nylon slide pads. General notes: Refer to operation and maintenance for details of Iubrication/grease points, quantities, ‘See separate chart for initial type of lubrication of crane when delivered. If a different make is to be used, always check compatibility with «old» lubricant first. Do not mix synthetic lubricants with mineral oil based lubricants.~) HYDRALIFT MARINE QUALITY STANDARD (QS) HYDRALIFT MARINE Kristiansand, Norway REF.NO. : LUB-CAS. DATE — : 910926 PREP. BY :J.Bamett__ APPR. By : REV. :A PAGE :10F2 LUBRICATION MANUF.: CASTROL SERVICE [RECOMMENDED LUBRICANT FOR DIFFERENT AMB. TEMPERATURE, COLD ‘NORMAL, HOT -25° TO. 0°C | -10° TO 30°C_| ABOVE +20°C Hydraulic | Hyspin Hyspin Hyspin Keep the system system AWH-MIS |AWH-M32 |AWH-M32_—_| clean. Change filter elements Alt: regularly. Change ‘Hyspin hhydr. fluid when AWEH-M46 _| recommended by lab., or once every year. Slew/winch? |Multiplant — |Multiplant Multiplant ‘Change oil after first travel gear 200 running hours. ox (with oil Thereafter every 500 immersed running hours, or once multi-plate every year. brakes. Make: ‘Top up after every 50 Hamworthy running hours. General grease | Spheerol ‘Spheerol EPL2 |Spheerol EPL2 | Lubricate every second points in: EPL2 month, HL do not El. motor Norway: Norway: recommend Winch Norway: ‘APS2 grease | APS2 grease | the use of grease Slewring | APS2 grease with molybdenum (bearing) additives Blocks! sheaves ‘Wheel bearing Jib bearing Jib cylinder bearings ‘Open gear: | Spheerol SX2 |Spheerol SX2__|Spheerol SX2_ | Keep weel greased at Slew pinion, all times. slew ring, rack and pinion driveHYDRALIFT MARINE QUALITY STANDARD (QS) HYDRALIFT MARINE. Kristiansand, Norway REF, NO. : LUB-CAS DATE — : 9109026 PREP. BY : J. Barnett REV. :A PAGE :20F2 APPR. By =. LUBRICATION MANUF.: CASTROL ‘SERVICE, RECOMMENDED LUBRICANT FOR [NOTES/COMMENTS DIFFERENT AMB. TEMPERATURE COLD NORMAL HOT -25° TO.0°C_| -10° TO 30°C | ABOVE +20°C Steel wire MT-Grease |MT-Grease |MT-Grease |Keep well greased at all times, also Alt: Alt: Alt: when not in use Rustilo 553 |Rustilo $53 | Rustilo 553 __| for prolonged periods. Telescopic CL grease [CLgrease [CL grease Do not use grease jib with, with molybdenum ‘Nylatron sliding | Alt: Alt: Alt: additives, as this, pads Subsea grease | Subsea grease |Subsea grease _| will reduce the service life of the nylon slide pads. General notes: Refer to operation and maintenance for details of lubrication/grease points, quantities, intervals, ete. See separate chart for initial type of lubrication of crane when delivered. If a different make is to be used, always check compatibility with «old» lubricant first. Do not mix synthetic lubricants with mineral oil based lubricants.HYDRALIFT MARINE QUALITY STANDARD (QS) Sa a DATE :060401 PAGE: 10F2 HYDRALIFT MARINE Keitansand, Norway PREP. BY :0.Kallhowd APPR. By : LUBRICATION MANUF.: MOBIL. SERVICE RECOMMENDED LUBRICANT FOR: NOTES/COMMENTS DIFFERENT AMB. TEMPERATURE COLD NORMAL HOT -25° TO.0°C -10° TO 30°C_| ABOVE +20°C Hydraulic DTE 11M DTE 13M DTE 13M Keep the system system Alt: SHC 522 | Alt: SHC 524 | Alt: DTE 15M _| clean. Change Synthetic Synthetic hydr. | Alt: SHC 524 _ | filter elements hydr. fluid. | fluid. Synthetic. regularly. Change Compatible [Compatible [Compatible —_| hydr. fluid when with mineral with mineral oil | with mineral oil | recommended by lab., oil based based hydr. or once every year. hydr. fluid. fluid. Slew/winch/ Mobilfluid Mobilfluid Mobilfluid Change oil after first travel gear 423 422 422 200 running hours. box (with oil Thereafter every 500 immersed Alt: Alt: Alt: running hours, or once ‘multi-plate Mobiland Mobiland Mobiland every year. brakes. Make: |Super Univ. |Super Univ. | Super Univ. _| Top up after every 50 Hamworthy 10W-30_ 10W-30. 10W-30 running hours. General grease | Mobilux Mobilux Mobilux Lubricate every second points in: EP 2 EP2 EP2 month. HL do not El. motor recommend Winch Alt: Alt. Alt. the use of grease ‘Slew ring Mobilith Mobilith Mobilith with molybdenum (bearing) SHC 460 SHC 460 SHC 460 additives Blocks/ sheaves ‘Wheel bearing Spherical Mobilgrease |Mobilgrease |Mobilgrease | Cargo cranes: bearings in: | special special special Lubricate daily when in use. Main jib. Utility cranes: Lubricate once month Open gear’ |Mobiltac 81 |Mobiltac 81 |MobiltacD [Keep well greased Slew pinion, at all times. slew ring, alt Alt: Alt: rack and Mobilith Mobilith Mobilith pinion drive SHC 460 SHC 460. SHC 460.