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PROJECT DOCUMENT

This document and all information and data herein or herewith is the confidential and proprietary property of
HYDRAMARINE AS and is not to be used, reproduced or disclosed in whole or in part by or to anyone without the
written confirmation from HYDRAMARINE AS.

© Hydramarine AS
Equipment:

Hydramarine Knuckle Jib Crane

HMC 1610 LK 50-18 (100-12)

2 As Built 14.11.06 rbj RM

1 Chapter 5 updated 25.10.06 anj
0 KOPI AV SP1837-1 (UNDER ARBEID) 20.10.06 rm
Rev. Reason for issue: Date Auth. Check.
Title:

USER MANUAL

Customer: Project name.:

Aker Promar - Brasil Hull no.: 20

HM project no.: P.O. No.:

SP1868-1 21935

HM doc. no.: Customer doc. no.: No.of attachments: No. of pages:

SP1868-1-15 UM 54

Doc. ID. : SP1868-1-15 UM Page 1 of 54

 HYDRAMARINE
USER MANUAL FOR CRANE

TABLE OF CONTENT:

1 INTRODUCTION ............................................................................................................................. 4
1.1 General ................................................................................................................................................ 4
1.2 Purchase information. .......................................................................................................................... 4
1.3 If problems occur! ................................................................................................................................ 4
1.4 General security conditions. ................................................................................................................. 4
1.5 Training. ............................................................................................................................................... 4

2 MAIN DATA ..................................................................................................................................... 5

2.1 Restrictions in guarantee. .................................................................................................................... 5
2.2 Main data. ............................................................................................................................................ 5
2.3 Weight & outline dimensions. ............................................................................................................... 5

3 TECHNICAL DESCRIPTION .......................................................................................................... 6

3.1 General technical description............................................................................................................... 6
3.2 Construction, main design: .................................................................................................................. 6
3.2.1 Crane pedestal ................................................................................................................................ 6
3.2.2 Electric motor and slip ring: ............................................................................................................. 7
3.2.3 Starter cabinet: ................................................................................................................................ 8
3.2.4 Hydraulic oil tank: ............................................................................................................................ 8
3.2.5 Crane king structure ........................................................................................................................ 8
3.2.6 Slew gear / slew bearing: ................................................................................................................. 8
3.2.7 Crane jib system: ............................................................................................................................. 8
3.2.8 Jib / knuckle cylinder: ....................................................................................................................... 9
3.2.9 Hydraulic winch:.............................................................................................................................. 9
3.2.10 Operators platform: .......................................................................................................................... 9
3.2.11 Hydraulic system: ............................................................................................................................ 9

4 HANDLING, PRESERVATION & INSTALLATION. ..................................................................... 10

4.1 Introduction. ........................................................................................................................................10
4.2 Unloading and Handling......................................................................................................................10
4.3 Preservation. .......................................................................................................................................10
4.4 Installation of unit. ...............................................................................................................................11
4.4.1 Welding to deck structure ...............................................................................................................11
4.4.2 Electrical installation .......................................................................................................................11
4.4.3 Filling of hydraulic system oil into system .......................................................................................12
4.5 First time start up. ...............................................................................................................................12
4.6 Functional and load test. .....................................................................................................................12
4.7 Commissioning test procedure. ..........................................................................................................13

5 OPERATION INSTRUCTIONS ..................................................................................................... 14

5.1 Start up of crane .................................................................................................................................14
5.2 Operation of crane ..............................................................................................................................14
5.3 Safety instructions : ............................................................................................................................15
5.4 Functions built in Safety to crane system :..........................................................................................16
5.5 Radio remote control system : ............................................................................................................17
5.5.1 Radio remote cabinet -A97 .............................................................................................................18
5.5.2 Transmitting unit -A97.1 ..................................................................................................................19

6 MAINTENANCE ............................................................................................................................ 26
6.1 Introduction .........................................................................................................................................26
6.2 Description of maintenance actions. ...................................................................................................26
6.3 Maintenance Program.........................................................................................................................28
6.4 Lubricants ...........................................................................................................................................30
6.5 Lubrication chart .................................................................................................................................31

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6.6 Change of oil filter. ..............................................................................................................................32

6.7 Standard Inspection form for cranes. ..................................................................................................33
6.8 Inspection log. .....................................................................................................................................34

7 COMPONENT PARTS LIST. ........................................................................................................ 35

7.1 Component Parts list...........................................................................................................................36
7.2 Hydraulic Hose list ..............................................................................................................................37
7.3 Ordering Spare parts ..........................................................................................................................38

8 DRAWINGS & DATASHEETS. ..................................................................................................... 39

8.1 Project Drawings. ................................................................................................................................40
8.1.1 General Arrangement. ....................................................................................................................40
8.1.2 Hydraulic Flow Diagram ..................................................................................................................40
8.1.3 Main Assembly. ..............................................................................................................................40
8.1.4 Slew Assembly ...............................................................................................................................40
8.1.5 Electric block diagram .....................................................................................................................40
8.1.6 Starter cabinet, layout .....................................................................................................................40
8.1.7 Circuit diagram, 1 of 2.....................................................................................................................40
8.1.8 Circuit diagram, 2 of 2.....................................................................................................................40
8.2 Data sheets.........................................................................................................................................41
8.2.1 Main hydraulic pump.......................................................................................................................41
8.2.2 Main operating valve.......................................................................................................................41

9 STATEMENTS & CERTIFICATES................................................................................................ 42

9.1 Hydramarine, Declaration of Conformity . ...........................................................................................43
9.2 Certificates, lifting equipment. .............................................................................................................44
9.2.1 Wire certificate ................................................................................................................................45
9.2.2 Hook certificate ...............................................................................................................................46
9.2.3 Wire block certificate.......................................................................................................................47
9.2.4 Shackle certificate (SWL 9,5 T) ......................................................................................................48
9.2.5 El.motor certificate ..........................................................................................................................49
9.2.6 Product certificate for crane foundation ..........................................................................................50
9.2.7 DNV Type Approval Certificate, HMC 1610 Crane Foundation ......................................................51
9.3 Factory acceptance test plan (FAT). ...................................................................................................52

10 RADIO REMOTE CONTROL USER MANUAL ............................................................................ 53

11 NOTES ........................................................................................................................................... 54

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USER MANUAL FOR CRANE

1 INTRODUCTION

1.1 General
The User manual is composed in accordance with the Norwegian Standard 5820.
Operators and maintenance personnel have to read and understand this user manual prior to
operate and maintain the equipment. The owner of the equipment is responsible to ensure
no unauthorised personnel operates or maintain the equipment.

1.2 Purchase information.

Equipment : Knuckle Jib Crane
Type: HMC 1610 LK 50-18 (100-12)
P.O. number : 21935
Machine number : SP1868-1
Prod.Year : September 2006

1.3 If problems occur!

In case of any problems, please contact:

HYDRAMARINE AS
After Sales Department
Andøyveien 23
N-4623 Kristiansand S. NORWAY

Phone: +47 380 18700 24 hours service: +47 916 89751

Fax: +47 380 18701

1.4 General security conditions.

No personnel are aloud in the equipment working area.
All use of the equipment must comply with the company security regulations.

1.5 Training.
Hydramarine AS. can provide tailor-made operation- and maintenance courses to all
Hydramarine equipment.
For more information, contact our Head-office in Kristiansand. We recommend all our
customers to attend our courses.

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2 MAIN DATA

2.1 Restrictions in guarantee.

During the warranty period, all necessary spare parts must be supplied by Hydramarine AS.
The use of spare parts supplied by other suppliers violates and forfeits the warranty.
Unintended use and/or wrong/missing maintenance of the equipment, forfeits the warranty.
Removal and/or loss of the equipment identification plates, also forfeits the warranty.

2.2 Main data.

Crane type: HMC 1610 LK 50-18 (100-12)
Machine number : SP1868-1 September 2006
Safe working load (single part): SWL : 50 kN at max 18m
Safe working load (double part): SWL : 100 kN at max 12m
Working radius max. : 18 m
Working radius min. : 3m
Pump capacity: 121 l/min.
Hoisting speed single line: 0-40 m/min
Hoisting speed double line: 0-20 m/min
Slew sector : 360° unlimited
Slew speed: 1 RPM
List + Trim : 5 + 2º

Electric motor Data:

El. motor type: 14BG 223-4AA96-Z225M
Voltage: 440V / 60 Hz / 3 ph
Heating Element: 220V / 2x42 W
Power / Duty run: 78 kW / S6-40%
El. motor rpm: 1745 rpm
Rotation seen from fan end: Counter clockwise
Motor start method: DOL
Start current direct (%) : ~ 772-515
Nominal current: ~ 126 A

2.3 Weight & outline dimensions.

Total weight ~ 12 000 kg

Outline dimensions of crane:

Reference to following drawing : C.1610.130.GA

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3 TECHNICAL DESCRIPTION

3.1 General technical description.

The HMC 1610 LK 50-18(100-12) knuckle jib crane is designed for long time operation and
stowing in a tough and corrosive marine environment. The crane is designed with major
structural and mechanical over capacity for loading/unloading of cargo vessel.

The crane is designed for efficient and accurate handling of general cargo at max. 18 meter
working radius with single fall.
The jib has a hydraulic knuckle jib with a length of approximately 7 metres giving the crane
good operation capabilities under rough operation conditions.

The crane is delivered as a complete, fully tested, fully sandblasted, fully painted, unit,
adjusted and ready for installation onboard vessel by welding to substructure and connection
of supply to electric motor located inside crane pedestal. The crane is a complete, hydraulic
operated, independent, self contained unit.
The crane can be operated locally from the operators platform on the rotating part of the
crane itself or from the portable radio remote control panel. All selected equipment is chosen
and installed to ensure the lowest possible emission of sound and for good access for
service and repair.

3.2 Construction, main design:

3.2.1 Crane pedestal

The crane pedestal acts as a structural base for the crane system. The pedestal contains the
vertical mounted electrical motor with the hydraulic pump and the oil tank located in above
located rotating king. A flexible coupling is installed in between the el. motor output shaft and
the pump shaft.
An access-hatch for inspection/service is provided in the pedestall structure.
The crane pedestal is designed for welding to deck structure.

3.2.2 Electrical system:

The structure of crane’s electrical system is shown on figure 3.1 Electrical Block Diagram. It
is also enclosed in this manual in chapter 8 Project Drawings.

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Figure 3.1 Electrical Block Diagram

Electrical system consists of following mail elements:

• Starter cabinet –A01;
• Remote Start/Stop panel –A12;
• Main motor –M01;
• Sliprings -A35;
• Radio Remote Cabinet –A97;
• Radio Remote Control –A97.1

3.2.3 Electric motor and slip ring:

The electric power is supplied to the electric motor from the main electric power plant on the
vessel. Power connection is done to the centre located electric motor junction box inside
crane pedestal. The electric motor is mounted in suspension inside the crane foundation, just
below the slew bearing. The electric motor shaft is coupled to the pump shaft by a radial split
flexible coupling. The electric motor is equipped with a heating element which reduces its
moisture level. The electric motor is also equipped with thermistor based temperature
protection.
The slip ring assembly for transfer of electric power to the rotating part of the crane is also
mounted inside the crane pedestal.

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3.2.4 Starter cabinet:

Starter cabinet –A01 (ref. to Electrical Block Diagram in chapter 8.1.5) performs start of HPU
main pump motor. The starter cabinet is supplied by electric power from the main electric
plant on the vessel.
Starter cabinet has following functions:
• start the HPU motor by DOL (Direct On Line) starting method,
• motor protection by means of thermistor relay mounted inside the starter cabinet
• motor overload alarm (activated by thermistor relay)
• power supply for anti-condensate motor heater
• power supply for radio remote cabinet -A97
• providing ammeter readings
• providing hour counter readings
• stop and emergency stop the HPU motor

3.2.5 Hydraulic oil tank:

The hydraulic oil tank of required capacity is integrated as part of the rotating crane king
structure (on rotating part of crane.) The hydraulic oil pump is of high pressure, low noise
gear type and is submerged in the oil tank which reduce the noise level to a absolute
minimum. The tank is equipped with visual oil level indication glass, breather filter, oil filling
filter, and a drain valve for use when changing oil and cleaning of the oil tank. Access to tank
is possible through inspection hatch in side of the crane king.
A well dimensioned oil return filter is installed in the system to remove any impurities from the
hydraulic oil returning from the system to the tank.

3.2.6 Crane king structure

The rotating crane king is installed on top of the rotating slew bearing. The king act as the
main structural element between the pedestal and the jib system.

3.2.7 Slew gear / slew bearing:

The slew bearing is a heavy duty marine slew ring equipped with internal gearing for transfer
of the slew torque from the output pinion of the slew gearbox.
The slew gear system consists of two hydraulic driven planetary gears with built in fail-safe
dynamic multidisc brakes. The brakes is dimensioned to take the full load at the maximum
list, plus any additional dynamic force acting on the slew gear. In the case of hose or pipe
failure, the brake blocks the slewing immediately. A heavy duty hydraulic motor is flanged
onto each gearbox. The slew motors, which is controlled by the main control valve, and the
counter balance valve in the loop, gives smooth and accurate slewing of the crane.

3.2.8 Crane jib system:

The crane jib consists of one hydraulic operated luffing main inner jib section and one
hydraulic operated knuckle jib section. Both jib elements are built of plate elements, steel
profiles and hollow sections. The main inner jib is connected to the king structure by one
main bearings at top of the king and to the rod bearing of the cylinder in the lower end. The
knuckle jib is connected to the inner jib by one bearing and the hydraulic cylinder in the
low/centre. Both jib sections are hydraulically operated, each by one double acting, heavy
duty marine cylinder with integrated counter balance valves. The cylinder are connected to
the jib system with composite bearings.
The hydraulic winch is installed at the top of the cranes knuckle jib structure.

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3.2.9 Jib / knuckle cylinder:

The crane jib luffing motion and knuckle jib motion is driven each by one high quality luffing
cylinder, built especially for use in the marine environment. The cylinder piston rod is
chrome plated in order to obtain improved protection against corrosion. A load holding valve
is mounted direct to the cylinder ports to maintain a constant luffing speed independent of
hook load and to block the jib in case of a hose/pipe failure.

3.2.10 Hydraulic winch:

The winch consists of a steel drum with a flanged on planetary gearbox driven by a fixed
displacement hydraulic motor. The gear box is fitted with a fail-safe multidisc brake. The
brakes are dimensioned to take the full load plus any additional dynamic forces acting on the
winch. In the case of a hose or pipe failure, the brakes block the load immediately. A counter
balance valve is mounted in the winch loop ensuring smooth and accurate winch operation
independent of winch load.

The winch is equipped with a hydraulic hook stop system. This system ensures by-pass of
hydraulic oil when hook reach its upper position.
The winch is equipped with a galvanised non rotating wire rope and a counterweight/swivel
hook of required capacity.

3.2.11 Operators platform:

The crane is equipped with a well dimensioned operators platform representing a
comfortable work place for the crane operator.
The platform is equipped with all main operation handles located in front. Main handles are of
spring centred type, winch on right hand side, jib and knuckle jib in mid section and slew on
left hand side.

3.2.12 Hydraulic system:

The crane king act as the oil reservoir for the hydraulic oil and the hydraulic pump is
submerged in oil for low noise operation. The hydraulic pump is of low noise non-variable
displacement type operating in constant pressure mode.
The main hydraulic control valve is installed in front of the operators platform. The main
control valve divides oil out to each actual crane motion dependant of lever position.

When no lever is operated, the oil will pass by an return to tank. As soon as one lever is
operated, either manually or by the portable radio remote control, a steeples variable oil flow
is directed out to the actual crane motion, giving the motion the required speed.

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4 HANDLING, PRESERVATION & INSTALLATION.

4.1 Introduction.
The purpose with this procedures is:
1.) Ensure that the units are handled / lifted in a safe and correct way to avoid any
damages on personnel or equipment.

2.) Ensure up to 2 years storage without loosing any performance and/or quality that may
reduce the working performance or total lifetime of the unit.

3.) Ensure that the installation/ first time start up, will be performed in a safe and correct
way.

4.2 Unloading and Handling.

The crane are equipped with 2 pairs of lifting lugs, placed on the main jib for safe lifting. See
enclosed General Arrangement for placement (chapter 8).

4.3 Preservation.
Storage prior to installation ( 0- 6 months ) :
The crane is delivered as shown at transport drawing.
If the crane is temporarily stored (until 6 month) before installation at site, following
requirements for preservation to be performed.

Table 4.2.1
Item to be checked Preservation Performed Sign.
To be washed free of saltwater and dried
In general for all items on the
before being stored in house, or under
crane
plastic. Placed on wooden pallets
All loose hydraulic hoses and all
Plugged and blinded with solid metal plug.
ports on hydraulic components
Hydraulic cylinder rods, extended
Apply a layer with grease.
rods

All lubrication nipples All nipples to be filled with standard grease.

To be temporarily protected by applying a

All machined surfaces not
thin layer with tectyle spray or grease. To be
surface protected.
washed off before installation.

Gear box. Filled to normal oil level.

All outside machined surfaces for

Waxed or treated with tectyle product.
interconn. to substructure

Check that all parts of crane is fully painted,

Paint, in general.
according to procedure.

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Storage beyond 6 months :

Storage beyond 6 months to be performed in the same way as for 0- 6 months, including
following additional points:

1. All checkpoints according to table 4.2.1 to be performed every 6th month.

2. Lubrication of all lubrication points at the crane each 6th month according to chapter 6 in
this manual.
3. Power to be connected to heating element at the el. motor of the crane. This is to avoid
condensation in el. motor.
4. All package with electrical components to be stored in house and unpacked to avoid
humidity.

4.4 Installation of unit.

4.4.1 Welding to deck structure

Hydramarine cranes are normally delivered for welding directly to deck or some other
type of substructure.
As a minimum requirement the deck must be designed to withstand the cranes
maximum bending moment with necessary safety factor.
( See general arrangement for forces to substructure)

CHECK THE FOLLOWING:

Deck structure must be free from cracks, rust, oil and other elements that will inhibit
welding of foundation to surface.

The foundation is equipped with a groove at deck, as a minimum this groove must be
filled. Welding must only be done by certified welders.

The crane is delivered as a complete unit 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.

Be sure that no dust or other pollution enter the hydraulic system.

Provide a drain in the foundation in order to avoid damaging the electric motor, due to
condensation etc.

4.4.2 Electrical installation

• Connect starter cabinet –A01 to the vessel power network according to starter circuit
diagram C.1610.130.ES01 (refer to the chapter 8.1.6 Electric circuit diagrams).
Starting method is Direct On Line (DOL).
• Connect the motor –M01 in accordance with the sign at the motor and the circuit
diagram C.1610.130.ES01. Motor is located inside hatch cover of crane foundation.
Notice that motor starting method is DOL.

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• Connect power and control cable to the junction box -JB35 inside of the crane pedestal
according to the circuit diagram C.1610.130.EC01 and C.1610.130ES01 (refer to the
chapter 8.1.6 Electric circuit diagrams).
Only a certified electrician can perform installation.

4.4.3 Filling of hydraulic system oil into system

After installing the crane onboard, fill hydraulic system oil on tank located in crane king.
The hydraulic oil shall be filled through a quick release coupling placed at the systems oil
filter. Oil filter is placed in front of crane king.
Fill the hydraulic system oil in to tank with the correct amount of an approved oil, approx.
1000 litres. The oil level is to be visible at all times. (To be filled until top of level glass).
It is outermost important to use new, clean oil. Under no circumstance water, dirt or other
impurities must be allowed to enter the tank. Impurities and moisture will reduce the
efficiency and shorten the lifetime of the hydraulic system.

4.5 First time start up.

As a final check before starting, check the rotation of the electric motor. The motor must
rotate in an counter/anti clockwise direction seen from the motors fan end. If the motor is
rotating in the wrong direction, interchange 2 phases and check again for counter clockwise
rotation.

Electric motor is located just below the slew bearing of the crane.
Access to the electric motor is possible through hatch in upper part of crane foundation.

The pump must not be allowed to run in the wrong direction for an extended period of
time, as this will adversely affect the life span of the hydraulic pump.

Upon completion of initial test run, check the oil level in the system oil tank, top up if
necessary.

When the system is started the first time there will be air in the system. Let the power pack
run for a couple of minutes without pressure and shut down for 10 minutes before restarting.
The winch and the slew will automatically let out air from it's system when operated. Be sure
that all air in system is ventilated before lifting any load

4.6 Functional and load test.

Execute all functions mentioned in the commissioning test procedure (enclosed), before the
crane starts to operated for its normal function.

Normally the test consist of a normal function test and a load test for 1,25 x SWL.

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4.7 Commissioning test procedure

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5 OPERATION INSTRUCTIONS
5.1 Start up of crane

Prior to crane operation, the electric motor must be started.

Prior to start the motor check that starter cabinet is supplied with power from the vessel
Otherwise, provide starter cabinet with power.

There are two ways of motor operation: local and remote.

1. LOCAL - starting the motor is performed on the starter cabinet located under deck.
Requirements: remote start/stop box switch -S4 “RADIO REMOTE CABINET OFF/ON”
is in OFF position (see figure 5.1).
2. REMOTE
2.1 Starting the motor is performed at the remote start/stop box -A12 located on crane
platform.
Requirements: radio remote cabinet switch -S4 “RADIO REMOTE CABINET OFF/ON” is
in OFF position (see figure 5.1).
2.2 Starting at the radio transmitting unit -A97.1.
Requirements: remote start/stop box switch -S4 “RADIO REMOTE CABINET OFF/ON”
is in ON position. Blue lamp –H2 “RADIO REMOTE CABINET ON” is ON (see figure
5.1).
If switch –S4 is in ON position and lamp –H2 is not ON, check that radio remote cabinet
is provided with power - lamp –H1 “POWER AVAILABLE” is not ON, also check that
following circuit breakers in the radio remote cabinet -A97 are closed: -F1 and -F2.
Check also that circuit breaker –F03 in the starter cabinet –A01 is closed.

When pump is running, the crane is ready for operation.

5.2 Operation of crane

The crane can be operated either from the operators platform at the left side of crane king or
from the portable radio remote control.
The platform is equipped with the following handles/buttons:

Red button at left side : Emergency stop (Electric)

Lever 1 from left : Slew left right
Lever 2 from left : Knuckle jib in/out
Lever 3 from left : Main jib up/down
Lever 4 from left : Winch up/down
Red lever below m. control valve : Hydraulic Emergency stop

The portable radio remote control panel is equipped with the following handles/buttons :
Left joystick : Slew left/right
Main jib in/out
Right joystick : Knuckle jib up/down
Winch up/down
Emergency stop : Red button at right side of panel
See also chapter 10 for Radio remote control system.

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5.3 Safety instructions

Never handle loads heavier than the winch can lift. The jib system are able to lift heavier
loads at reduced radius. When lifting heavy loads, always check that the winch are able to lift
load before any further jib operation.

Observe the risk of collision with the superstructure as a result of crane slewing. Be careful
when override is used.

Max. SWL with single part is 5 ton at max. 18 meter radius. With heavier load than 5 ton,
use double part.
Max. SWL with double part is 10 ton. Working radius with double part, is automatically
regulated to max. 12 meters

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5.4 Functions built in Safety to crane system

Safety systems:
The crane is fitted with the following safety systems:

Emergency stop 1: An emergency stop is fitted on the remote start/stop box near the
operator at operator’s platform
Emergency stop 2: An emergency stop is fitted on the transmitting unit -A97.1 (see
paragraph 5.5.2). Attention! Emergency stop 2 is functional only when
radio remote control is activated (radio remote cabinet is ON and
transmitting unit is activated).
Emergency stop 3: An emergency stop is fitted on the starter cabinet –A01transmitting unit
-A97.1 (see paragraph 5.5.2). Attention! Emergency stop 2 is functional
only when radio remote control is activated (radio remote cabinet is ON
and transmitting unit is activated).

If one of these buttons is activated, the main pump will be stopped and the pressure will be
dropped (see exception for Emergency Stop #2).

Spring centred control valves:

All control levers, separate and joy stick type, are spring centred. In order to operate the
crane the relevant control lever has to be pushed in the required direction to cause the
desired motion. Once the lever is released it will return back to centre position, and the
activated motion will cease immediately.

Overload protection:
All crane motions are protected against overload by hydraulic relief valves. If a particular
motion is tried undertaken which exceeds the load for which the crane is designed, the
relevant relief valve , for the particular motion, will feed the hydraulic oil back into the
hydraulic oil tank. Hence, the crane motion can not be undertaken.

Hook stop system:

The winch is fitted with a hydraulic hook stop system. This system is based on a valve by-
passing oil to tank when hook reach its upper position.

Luffing cylinder limitation:

The hydraulic cylinders for luffing of the crane jib is fitted with a mechanical stroke limitation.
The limitation allows the luffing to be undertaken at full speed.

Load holding brakes:

The hydraulic cylinders for luffing of the crane jib sections is fitted with pilot operated load
holding valves. The valves is mounted direct to the cylinder ports and has a dual function:

1 Maintaining the luffing speed at a constant value independent of the load

2 Blocking the cylinder motion in the case of hydraulic pressure loss. This will
freeze the cylinder in the case of hose or pipe failure.
Fail safe brakes:
Both the winch and the slew gearbox are fitted with hydraulic operated, oil submerged,
failsafe, multidisc brakes. In the case of hydraulic pressure loss due to hose/pipe failure, the
brake will automatically be applied and cease the relevant motion.

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5.5 Radio remote control system

Radio remote control system contains radio remote cabinet -A97 and transmitting unit
-A97.1.

5.5.1 Electrical system:

The structure of crane’s electrical system is shown on figure 5.1 Electrical Block Diagram. It
is also enclosed in this manual in chapter 8 Project Drawings.

Electrical system consists of following main elements:

• Starter cabinet –A01;
• Remote Start/Stop panel –A12;
• HPU main motor –M01;
• Radio Remote Cabinet –A97;
• Radio Remote Control –A97.1

Figure 5.1 Electrical Block Diagram

Motor –M01 could be start/stop from three places:

• from starter cabinet –A01
• from remote start/stop panel –A12
• from radio remote control -A97.1.

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5.5.2 Radio remote cabinet -A97

Radio remote cabinet is shown on the figure 5.2.

Figure 5.2 Radio remote cabinet -A97

Prior to radio remote operation meet following requirements:

• supply radio remote cabinet with a power
• turn on radio remote cabinet -A97 – turn switch -S4 “RADIO REMOTE CABINET OFF
ON” in ON position at the operator panel -A12 (see figure 5.2). Make sure that blue
lamp –H2 “RADIO REMOTE CABINET ON” is ON.
• turn on transmitting unit (see chapter 5.5.3)

Operator panel is shown on the figure 5.2. It is mounted on the crane platform next to the
crane operator.

Figure 5.3 Operator panel -A12

Operator panel has following switchgear:
• -S1: “HPU MOTOR START” green button;
• -S2: “HPU MOTOR STOP” red button;
• -S3 “EMERGENCY STOP” pull-to-release button
• -S4 “RADIO REMOTE CABINET OFF/ON” switch.

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5.5.3 Transmitting unit -A97.1

Standard transmitting unit is shown on the figure 5.4

Figure 5.4 Transmitting unit

A joystick

B EMERGENCY STOP push button

C START push button
D starting key
E START / STOP toggle switch
F speed selector
G battery
H identification plate
L two signalling leds (green and red)
K cable connector

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Figure 5.5 SP1868-1 transmitting unit layout

The transmitting unit is equipped with two joysticks (see figure 5.4):

Left joystick: Slew left/right

Main jib up/down
Right joystick: Knuckle jib out/in
Winch up/down

Power on and starting

Check that starting key is in position “O”, insert battery in its housing
without force. Check that EMERGENCY STOP button is not pressed and
that none of the actuators have been out of neutral position.
Turn the starting key to “I” and activate START pushbutton and release it
when the green light starts to flash.

The transmitting unit only switches on if the battery is

charged enough and if all the actuators are inactive.

Commands
It is possible to control the crane only after the transmitting unit has been radio linked to the
receiving unit (signalled by lightning up of ENABLE pilot light on the receiving unit (see
chapter 10 Radio Remote Control User Manual).
Also start button activates warning horn -E15 (see block diagram C.1610.130.EB01 in the
paragraph 8.1.5 Electrical block diagram). This horn can be used to draw people’s attention
who are working/residing in the crane’s working area. Do not hesitate to use a horn to
prevent possible dangerous situations.

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START / STOP Hydraulic Power Unit

Push the switch forward to start Hydraulic power unit.

Push the switch backward to stop Hydraulic power unit.

Emergency STOP
To immediately stop the crane, press the EMERGENCY STOP button: the
transmitting unit switches off automatically and emergency security circuit
stops hydraulic power unit.
To start operation again, rotate the EMERGENCY STOP button in the
indicated direction and repeat the power on and starting procedures.

EMERGENCY STOP button must be used each time the crane

has to be stopped immediately because of danger situation

Speed selector

normal speed

speed reduction = 40%

Frequency change
In case of interference or conflict with other radio systems, it is possible to change the radio
frequency being used.
With the transmitting unit powered and started, keep the START pushbutton pressed for 5-6
seconds: a prolonged beep accompanied by the switching on of both signaling leds indicates
that frequency has changed. During this operation the receiving unit switches off: press the
START pushbutton again to start working normally.

LED signals
Some transmitting unit operating conditions are signaled by two signaling leds (one green
and one red):

Led
Type of signal
green red
Slow flashing normal operation /
Warning that the Warning that the
Quick flashing battery is almost battery is
not charged discharged
Command
Continuous light
/ operated during
during power on *
the power on
Both lights steadily
Frequency changed
lit simultaneously *
* accompanied by an acoustic signal

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When the battery is approximately 90% discharged, the green light will start flashing at a
faster to inform the operator that the battery requires recharging. If the operator continues to
use the radio control, approximately 3 minutes before the battery is fully discharged, the red
light will start flashing and an acoustic alarm will sound. In this situation, the operator must
return the machine to a condition of safety (by either pushing the stop toggle switch or
pressing the Emergency Stop button), switch off the transmitting unit, and recharge the
battery or fit a fully charged battery.

Power off
Turn the ignition key to “O”.
Always remember to extract the starting key and put it in a safe place.

Automatic power off

The transmitting unit can switch off automatically when:
- the battery is not charged enough and/or
- the radio remote control has not been used for 3 and half minutes

Recharging the battery

Remove the battery from the transmitting unit and insert in the battery charger. The “ON
CHARGING” light will illuminate to indicate that the battery is being charged. Once the
battery is fully charge, the “END OF CHARGING” will illuminate. Battery charging should be
performed at an ambient temperature within the range +5°C to +45°C.

See the supplied booklet or refer to chapter 10 for all

instructions, warnings and technical data regarding the
batteries and the battery charger.

Receiving unit -A87 is described in the chapter 10 Radio Remote Control User Manual.

Wire control
Radio remote system can perform its operation in non-radio mode. It is called “Wire control”.
In this mode battery could be removed from the transmitting unit. Supplied cable of purple
colour is provided for Wire control.
Operator should connect radio remote cabinet and transmitting unit by means of wire control
cable (see figure 5.7).
Radio remote cabinet is equipped with a cable connector (see figure 5.6). It is mounted in the
enclosure bottom.

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Figure 5.5 Radio control cabinet cable connector

Transmitting unit cable connector is located on the left side of the unit (see K on the figure
5.4).

Follow the instructions:

1) remove connector plug from the cable connector on the bottom of –A97 radio control
cabinet (see figure 5.6). The plug can be removed by turning in CCW direction.
2) plug cable into cable connector on –A97 radio remote cabinet
3) remove connector plug from transmitting unit –A97.1 cable connector (see figure 5.4)
4) plug cable loose end into connector on –A97.1 transmitting unit (see figure 5.7)
5) proceed power on and starting procedures: turn on starting key in position “I” and
push START pushbutton
6) push the switch forward to start Hydraulic power unit
7) perform crane operation by means of joysticks
8) when you have finished crane operation push START/STOP HPU switch backward to
stop Hydraulic power unit
9) turn the starting key to “O”. Always remember to extract the starting key and put it in a
safe place
10) unplug cable both from transmitting unit and radio remote cabinet
11) put connector plugs back on the connectors both on the radio remote cabinet and on
the transmitting unit
12) put the cable in the safe place

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Figure 5.7 Wire control

General warnings regarding use of radio remote control

The radio remote control can only be used by operators who:

- have read and understood this manual,
- are qualified and trained
- know “radio remote control + crane” system well.

Each time the transmitting unit is powered, make sure that Emergency Stop button
operates correctly and that, when pressed, crane movements interrupted instantly.
If it doesn’t happen, do not use radio remote control.

The operator should always control that units are whole and the gaskets, bellows
and hoods of actuators (joysticks, selectors, pushbuttons) are whole. If not, the
radio remote control mustn’t be used before being repaired.

To work efficiently and to prevent possible emergency situations, it is necessary to

select position from where it is possible to:
- remain inside the typical working range of the radio remote control
- visibly follow the crane, its movements and a possible load at all times

During operation
The operator must:
- switch off the transmitting unit each time work is stopped
- NEVER leave the transmitting unit unattended with the starting key inserted
- avoid working if the battery is almost flat.

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The operator should never switch on activate the transmitting unit unless ready to
start working. A radio link can be created even outside the active range and from
enclosed places, making the radio remote controlled crane carry out undesired
commands.

In case of danger
If a danger situation arises, the operator must intervene immediately by pressing
the EMERGENCY STOP button, which instantly interrupts crane movements.

As not all damages are caused by the “radio remote control + crane” system, the
operator should be careful even when emergency situations are present in the
working area. The operator should, also in this case, intervene manually by a
activating the EMERGENCY STOP button.

In case of fault
In case of faults or damaged parts, ALWAYS STOP the “radio remote control +
crane” system until the problem has been solved.
Any damaged part can ONLY be replaced by authorised manufacture personnel
and only using original manufacture spare parts.

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6 MAINTENANCE
6.1 Introduction
The maintenance program has been developed by Hydramarine in accordance to our
supplier’s own maintenance program for each component. Conforming to this maintenance
program will ensure long-time, trouble-free operation and eliminate unexpected occurrences.

6.2 Description of maintenance actions.

The maintenance program entails the following actions:
- Lubrication - Inspection
- Overhaul - Replace

Lubrication : Lub.
Lubrication is identified with the following:
• Apply grease to grease nipples.
• Apply lubricant or oil onto surfaces due to friction or corrosion.
• Refill or change oil to system or component.

Inspection : Insp.
Inspection is identified with the following:
• Check component for any damage.
• Check for correct function of each component.
• Check for any unfamiliar noise from each component.
• Check for any abnormal vibration from rotating components.
• Check for correct oil quantity.
• Check paint condition on all components.
• Check for leaks.
• Check for corrosion.
• Check lifting wire for wear.

Overhaul : Ovhl.
Overhaul is identified with the following:
• Remove the component from the unit.
• Disassemble the component and inspect each part.
• Repair if necessary:
- Bearings.
- O-rings, gaskets and seals.
- Wear of mechanical parts due to friction.
- Hydraulic valves fittings and hoses.
- All bolts, nuts and washers.
• Clean all components before mounting assembly.
• Replace or repair components if required, before mounting assembly.
• Repair damaged painted areas.

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Replace : R.
Replace is identified with the following:
• Remove original component and exchange with a new component.

Use the following specifications when servicing the hydraulic parts:

Lubrication Nipples, General, LSS. No. 01

Wire LSS. No. 02
Slew Gearbox LSS. No. 03
Winch Gearbox LSS. No. 04
Hydraulic System Oil LSS. No. 05
Drive pinions LSS. No. 08

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6.3 Maintenance Program.

M= Months, Y= Year, W= Week, H= Hours

PERIODIC MAINTENANCE PROGRAM

Equipment Lub. Insp. Ovhl. R. Action

General inspection for leaks in hydraulic system

Quantity of oil, to be in top of level glass
Crane functionality
General
1W Emergency (operation) (if applicable)
Inspection
Accumulator oil pressure (if applicable)
Check for wire damage
Check for damage of lifting equipment (hook etc.)
Apply grease to all grease nipples. Include wire
1M/ 100H
sheaves, cylinders , el. motor and docking head.
Grease nipples Inspect for proper function, damage, corrosion.
3M/ 100H
(General) Remove excess grease.
! Replace if damaged
1M/ 100H Apply special grease to drive pinion and ring tooth.
Winch/slew gear 1Y/ 500H Check for wear / abnormal tooth clearance
drive pinion ! Replace if damaged
3M/200H Apply grease onto wire
Inspect due to corr. & wear. Rub length
1M/ 200H
of wire with a cloth to detect broken strands.
Wire 3M/ 100H Inspect wire secured to winch drum. Check torque.
! Replace if damaged.
Inspect for corrosion, wear, cracks. Check bolts.
6M/ 200H
Inspect that wire sheave rotates freely.
Wire sheaves
! Replace if damaged.
6M/ 200H Inspect general condition. Check nitrogen pressure
value according to flow diagram. Use Hydrmarine
Accumulators Manometer fill/check instrument. Check mounting
(If mounted) bracket (bolts, nuts)
Overhaul or replace if unable to hold the necessary
! !
charge. Contact H.M. After Sales
Inspect all exposed cylinder rods. Must be free of
6M/ 200H dirt damage and other foreign contaminants. Check
Cylinders condition (paint, leaks, corrosion)
! Overhaul /replace if damaged
Inspect for any abnormal noise, vibration, leaks.
3M/ 100H
Inspect valves (paint, leaks, corrosion).
Winch/slew 5Y Overhaul component.
motor
! Replace if damage.

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M= Months, Y= Year, W= Week, H= Hours

PERIODIC MAINTENANCE PROGRAM
Equipment Lub. Insp. Ovhl. R. Action

Inspect for any abnormal noise,vibration, Tighten

3M/ 100H bolts if required. Inspect general condition (paint
,leaks, corrosion)
Winch/slew 3M/ 50H Check gear oil level
Gearbox
1Y Change oil.
5Y Overhaul component.
! Replace if damage.
Electric Motor Inspect for any abnormal noise, vibration,
3M/ 200H
and hydraulic corrosion, leaks.
pump. 5Y Overhaul the comp.
! Replace if damage
Apply grease
Sliding surfaces 3M/200H 3M/ 200H Check for wear
Adjust sliding pads
Hydraulic hoses, 6M/ 200H Check condition of hoses.
fittings,
couplings ! Replace if damaged.

Inspect for any abnormal noise or function.

6M/ 200H
Inspect condition (paint, leaks, corrosion)
Hydraulic valves Apply grease to the valve levers (the rubber cap
must be removed).
! Replace if damaged.
Mechanical Inspect the entire crane for structural damage.
6M/ 200H
components Check for corrosion. Inspect paint condition.
! Replace component if damaged.
Hydraulic
1Y Take oil sample for analyse. Change if necessary
system oil
6M/ 500H Inspect filter for abnormal contamination.
Hydraulic oil
6M/
filter Replace
500H
Inspect all bolts and nuts on crane. Foundation
Bolts and nuts 6M/ 500H
bolts especially.

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6.4 Lubricants

( Attachment 10 pages )

Quantity of lubricates :

Hydraulic system oil :

HMC 1610 – approx 1000 liters.

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6.5 Lubrication chart

( Attachment 1 page )

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6.6 Change of oil filter.

This system is equipped with a high quality return oil filter. The filter is located in front of the
crane-king structure, with access from the outside. The filter element shall be changed every
500 hours of duty, or more often if required.

How to change the filter element:

1. Ensure there is no pressure on the

return-line.

2. Open the cover and remove the filter-

element.

3. Dismount the split pin and the crown

nut.

4. Remove the filter element and replace.

5. Remove the magnet from the lock bolt

and clean.

6. Mount the magnet on the lock-bolt and

screw up the nut.

7. Mount the new filter element with spring

and spring retainer.

8. Screw up the crown nut until the split

pin hole becomes visible and mount the
split-pin.

9. Mount the cartridge into the house and

put on the spring at the cover side.

10. Screw up the cover. Ensure the O-ring

is clean and undamaged.

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6.7 Standard Inspection form for cranes.

Inspection report no. :

Machine no: SP1868-1

(Use a copy of this report for each inspection)

Inspection date: Checked by: Condition: Actions taken:

General Inspection

Grease nipples

Winch / slew gear pinion

Wire and hook

Wire sheaves

Accumulator ( if mounted)

Cylinders

Winch / slew motor

Winch / slew gear box

Electric motor/ hydr. pump

Sliding surfaces

Hydraulic hoses, fittings etc.

Hydraulic valves.

Hydraulic system oil

Hydraulic oil filter

Bolts and nuts.

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6.8 Inspection log.

MONTHLY INSPECTIONS :
Crane type : Date for Checked by: Condition: Actions taken:
HMC 1610 LK 50-18 inspection:
Inspection report no.:

Check no : 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

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7 COMPONENT PARTS LIST.

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7.1 Component Parts list

Page 36 of 54
 The linked image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. V erify that the link points to the correct file and location.

PROJECT DOCUMENT

This document and all information and data herein or herewith is the confidential and proprietary property of
HYDRAMARINE AS and is not to be used, reproduced or disclosed in whole or in part by or to anyone without the
written confirmation from HYDRAMARINE AS.

© Hydramarine AS
Equipment:

HYDRAMARINE CRANE
HMC 1610 LK 50-18 (100-12)

1 As Built 15.11.06 rbj RM

Rev. Reason for issue: Date Auth. Check.
Title:

COMPONENT PART LIST

Customer: Project name.:

Aker Promar - Brasil Hull No.: 20

HM project no.: P.O. No.:

SP1868-1 21935

Reference drawings.:
C.1610.130.GA C.1610.130.A.. C.1610.130.HF C.1610.130.E..

HM doc. no.: Customer doc. no.: No.of attachments: No. of pages:

SP1868-1-18 CPL 8

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 Title: Component Part List
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Doc.No.: SP1868-1-18 CPL

MM - Mechanical Components in Main System

HM art. Weight
Item no. Description Qty. Note
no. (Kg)

MM-01.1 Foundation 1 1053 H=1400mm

MM-01.2 Adapter flange for el.motor 1 29
MM-02.1 King 1 1613
MM-02.2 Flange for slew gir 2 39
MM-02.3 Filter bracket 1 3
MM-02.4 Hatch for king 1 23
MM-02.5 Weld sockets for king 1 5
MM-03 Main Jib 1 2743
MM-04 Knuckle Jib 1 1186
MM-05.1 Flex. Coupling 10002794 2
MM-05.2 Flex. Couplling 10002793 1
MM-05.3 Machining of Flex. Coupling 2
MM-06.1 Bolt 10002362 56 Slew bearing, upper side
MM-06.2 Nut 10000492 56 Slew bearing, upper side
MM-06.3 Washer 10000782 112 Slew bearing, upper/down side
MM-07.1 Bolt 10002363 4 Slew bearing, down side
MM-07.2 Washer 10000782 4 Slew bearing, down side
MM-08.1 Bolt 10002364 60 Foundation / Slew bearing
MM-08.2 Washer 10000782 60 Foundation / Slew bearing
MM-09.1 Bolt 10000256 4 Hydr. pump
MM-09.2 Washer 10000315 4 Hydr. pump
MM-10.1 Bolt between el.motor/adapter 10000279 8
MM-10.2 Washer 10000316 24 For MM-10.1
MM-10.3 Nut 10000309 16 For MM-10.1
MM-10.4 Bolt between adapter/foundation 10000274 7
MM-10.5 Washer 10000316 7 For MM-10.4
MM-11 Set Bolt 11003466 1 Flex. coupling (El.motor side)
MM-12 Distance piece 1 1 Pos. 03
MM-14.1 Platform 1 154
MM-14.2 Platform, gateway 1 20
MM-14.3 Platform, ladder 1 26 H=1400 mm
MM-15.1 Wire stopper 1 35
MM-16.1 Op. sign. 10003879 1 Slew
MM-16.2 Op. sign. 10003876 1 Knuckle jib
MM-16.3 Op. sign. 10003875 1 Jib
MM-16.4 Op. sign. 10003874 1 Winch
MM-16.5 Op. sign. 10003888 1 Emergency stop
MM-17 Machine no. sign. 10000797 1
MM-18.1 SWL sign. 10000798 1
MM-18.2 SWL sign. 10000798 1
MM-19.1 HM sign. 10003938 2
MM-19.2 HM sign. 10003937 2

MM-20.1 Pinbolt 10001912 16 Hatch king (Fixed by Loctite)

MM-20.2 Nut 10000308 16 For MM-20.1

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Doc.No.: SP1868-1-18 CPL

MM-20.3 Gasket 10000560 1 For hatch king , included in pos.MM-21.2

MM-21.1 Bolt 10000256 18 Hatch foundation
MM-21.2 Pinbolt 10001912 2 For hatch foundation
MM-21.3 Nut 10000308 2 For MM-21.3
MM-22.1 Bolt 10000237 4 Oil filter
MM-22.2 Nut 10000249 4 For MM-22.1
MM-23.1 Bolt 10000273 2 Platform ladder
MM-23.2 Nut 10000309 2 For MM-23.1
MM-23.3 Washer 10000316 4 For MM-23.1
MM-24 Bracket for slip ring 1

MH - Hydraulic Components in Main System

HM art. Weight
Item no. Description Qty. Note
no. (Kg)

MH-01.1 Hydraulic Pump 11001534 1

MH-01.2 Flange 10001808 1 For MH-01.1 (inlet)
MH-01.3 Bolts 10000450 4 For MH-01.2
MH-01.4 O-ring 10001817 1 For MH-01.2
MH-01.5 Flange 10001810 1 For MH-01.1 (outlet)
MH-01.6 Bolts 10000448 4 For MH-01.5
MH-01.7 O-ring 10001815 1 For MH-01.5
MH-01.8 Pump Gasket 10006130 1
MH-02.1 Level Gauge 10003411 1 254mm
MH-02.2 Level Gauge 10000413 1 127mm
MH-03 Drain Valve 10000425 1
MH-04 Air Breather 10000008 1
MH-05.1 Return Filter 10002203 1
MH-05.2 Filter element 10000010 1
MH-06 Main Control Valve 11001533 1
MH-07 Minimess 10001433 1
MH-11.1 Quick rel. coupling 10002649 1 For oil filling
MH-11.2 Quick rel. coupling 10002651 1 For oil filling
MH-11.3 Quick rel. coupling 10002648 1
MH-11.4 Quick rel. coupling 10002650 1
MH-12 H.Emerg.Stop 1” Ball Valve 10000431 1

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Doc.No.: SP1868-1-18 CPL

ME - Electrical Components in Main System

HM art. Weight
Item no. Description Qty. Note
no. (Kg)

-M01 Electric motor 10005228 1 Cert. no. :

-A01 Starter cabinet 1

Enclosure 11003501 1

-K01 Contactor 11006310 1

-K01.1 Auxiliary contact 11006311 1
-F01 Circuit breaker 11003506 1
-F02 Circuit breaker 11003499 1
-F03 Circuit breaker 11003499 1
-F11 Bimetall 70-100A 11006315 1
-F14 Thermistor relay 11006314 1
-T1 Transformer 440/230 11001049 1
-P1 Hour counter 11002190 1
-H11.1 Lamp, green 11002531 1
-H12.1 Lamp, blue 11003174 1
-H13.1 Lamp, white 11002532 1
-H14.1 Lamp, yellow 11002533 1
-S14.1 Pushbutton, green 11002519 1
-S13.1 Pushbutton, red 11002520 1
-S10.1 Emergency Stop button 11002523 1
-A01.10 MARKING LEGEND 11004721 1
-A12 Remote start/stop 11001258 1
-A12.1 Prot. shield 11001257 1 For -A12
1
-A35 Slip rings 11001808
set
-35.1 Collectors 11003078 1
-JB35 Junction box pedestal 11002142 1
-A97 Radio remote cabinet
Enclosure plastic 11003500 1
-F1 Circuit breaker 2A 11003499 1
-F3 Fuse 11002315 1
-F3.1.0 Termiinal fuse block led 11002593 1
-F3.2.0 End plate for fuse 11002592 1
-F3.3.1 Screwless end stop 11002573 1
-F3.3.2 Marker carrier 11002589 1
-A97.1 External Aerial 11002081 1
-A97.1.2 Rotex Seal M25 11002384 1
-E15 Elctronic sounder 11003152 1
-F11 Thermostat 0-60°C 1NC 6A
11002226 1
250VAC
-G1 Power supply
11002222 1
230VAC/24VDC

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Proj.No.: SP1868-1 HYDRAMARINE
Doc.No.: SP1868-1-18 CPL

-R01 SEMICONDUCTOR
11005678 1
HEATER 20W 110-250VAC
-H1 PILOT LIGHT WHITE
11002532 1
230VAC IP65
-H2 PILOT LIGHT BLUE
11003174 1
24VAC/DC IP65
-K1 RELAY 10A 24VDC 1POLE 11001056 1
-K2 RELAY 10A 24VDC 1POLE 11001056 1
-K3 RELAY 10A 24VDC 1POLE 11001056 1
-K4 RELAY 10A 24VDC 1POLE 11001056 1
-K3.1
RELAY SOCKET, 11002236 4
1 CHANGE-OVER CONTACT
-X1.1 -X2.1 Terminal block 2 11002569 22
-X2.2.0 End plate fro
11002571 2
Terminal block 2
-X1.2.0 End plate 2 11002571 1
-X1.3.1 –X2.3.1
11002573 4
Screwless end stop
-X2.1.1 Terminal block 4 11002576 4
-X2.2.1 End plate for
11002578 1
Terminal block 4
-X1.3.2 -X2.3.2 Marker carrier 11002589 2
-X2.3.3 Adjascent Jumper 1-2 11006014 5
-X3.3.3 Adjascent Jumper 1-2 11006014 3
-A87 Receiving unit
11002079 1 IP65, mounted in the -A97
RC Unit 4prop and hpu

WM - Mechanical Components in Winch System

HM art. Weight
Item no. Description Qty. Note
no. (Kg)

WM-01 Winch arrangement 10005242 1 Cert. No.

WM-02.1 Bolts for winch mounting 10001994 8
WM-02.2 Washer 10000317 8
Wire w/open spelter socket inner
WM-03 10019120 1 Cert. no
end, outer end pointed
WM-04 Shackle 10019301 1 Cert. no
WM-05 Swivel hook 10019800 1 Cert. no
WM-06 Wire Sheave 10003038 2
WM-07 Wire block 10007256 1 Cert no.
WM-08 Hook stop wire long 10002399 2

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Doc.No.: SP1868-1-18 CPL

WH - Hydraulic Components in Winch System

HM art. Weight
Item no. Description Qty. Note
no. (Kg)
WH-01 Hydraulic motor 1 Incl. in WM-01
WH-02 Balance Valve 1 Incl. in WM-01
WH-03 Shuttle Valve 1 Incl. in WM-01
WH-04 Hookstop Valve 10002290 1
WH-05 Pilot check valve 1/4” 10002599 1
WH-06.1 Pressure reducing valve 10008852 1
WH-06.2 Valve housing 10008853 1

SM - Mechanical Components in Slew System

HM art. Weight
Item no. Description Qty. Note
no. (Kg)
SM-01.1 Slew Gear 10009537 1
SM-01.2 Adapter-set 10009538 1
SM-01.3 Pinion, M14, Z12, B85 10009539 1
SM-02.1 Slew Gear 10009537 1
SM-02.2 Adapter-set 10009538 1
SM-02.3 Pinion, M14, Z12, B85 10009539 1
SM-03 Slew Bearing 10002274 1
SM-04.1 Bolt, 46219000000 21 For SM-01.1
SM-04.2 Washer, 46701300101 21 For SM-04.1
SM-05.1 Bolt, 46219000000 21 For SM-02.1
SM-05.2 Washer, 46701300101 21 For SM-05.1

SH - Hydraulic Components in Slew System

HM art. Weight
Item no. Description Qty. Note
no. (Kg)

SH-01.1 Hydraulic motor 10009769 1 Serial no. :

SH-01.2 Flange 10001804 2 For SH-01.1
SH-01.3 Bolts 10001895 8 For SH-01.2
SH-01.4 O-ring 10001814 2 For SH-01.2
SH-02.1 Hydraulic motor 10009769 1 Serial no. :
SH-02.2 Flange 10001804 2 For SH-02.1
SH-02.3 Bolts 10001895 8 For SH-02.2
SH-02.4 O-ring 10001814 2 For SH-02.2
SH-03 Balance Valve 10000524 1
SH-04 Balance Valve 10005167 1
SH-05 Check / restrictor valve 10000633 1
SH-06 Restrictor valve 10000420 1

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 Title: Component Part List
Proj.No.: SP1868-1 HYDRAMARINE
Doc.No.: SP1868-1-18 CPL

JM - Mechanical Components in Jib System

HM art. Weight
Item no. Description Qty. Note
no. (Kg)
JM–01.1 Bolt for main jib 1 81
JM–01.2 End cap 1 2 For JM-01.1
JM–01.3 Bolt 2 - For JM-01.1
JM-01.4 Washer 2 - For JM-01.3
JM-02 Main jib bolt house 1 96 For JM-01.1
JM-03.1 Main jib Bearing 10008739 1 -
JM-03.2 Main jib Bearing 10000809 1 -
JM-04 Main jib side bearing 2 -
JM-05 Main jib V-Ring 10002995 2 -
JM–06.1 Bolt for main jib cylinder 1 23 At king side
JM–06.2 End cap 1 2 For JM-06.1
JM-06.3 Bolt 10000296 1 - For JM-06.1
JM-06.4 Washer 10000319 1 - For JM-6.3
JM–06.5 Bolt for main jib cylinder 1 19.5 At jib side
JM–06.6 End cap 1 2 For JM-06.5
JM-06.7 Bolt 10000296 1 - For JM-06.5
JM-06.8 Washer 10000319 1 - For JM-6.7
Trust sheaves for main jib
JM-06.9 4 - Dwg.: C.1610.J008.01 pos. 1
cylinder
JM–07.1 Bolt for knuckle jib 1 58.5
JM–07.2 End cap 1 2 For JM-07.1
JM–07.3 Bolt 2 - For JM-07.1
JM-07.4 Washer 2 - For JM-07.3
JM-08 Knuckle jib bolt house 1 86 For JM-07.1
JM-09.1 Knuckle jib Bearing 10000809 1 -
JM-09.2 Knuckle jib Bearing 10008740 1 -
JM-10 Knuckle jib side bearing 2 -
JM-11 Knuckle jib V-Ring 10002995 2 -
JM–12.1 Bolt for knuckle jib cylinder 2 17
JM–12.2 End cap 2 1.5 For JM-12.1
JM-12.3 Bolt 10000296 2 - For JM-12.1
JM-12.4 Washer 10000319 2 - For JM-12.3
Trust sheaves for knuckle jib
JM-12.5 4 - Dwg.: C.1610.J008.01 pos.2
cylinder
JM–13.1 Bolt for wire sheaves 2 2,5
JM–13.2 End cap 2 0,5 For JM-13.1
JM-13.3 Bolt 10000273 2 - For JM-13.1
JM-13.4 Washer 10000316 2 - For JM-13.3

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 Title: Component Part List
Proj.No.: SP1868-1 HYDRAMARINE
Doc.No.: SP1868-1-18 CPL

JH - Hydraulic Components in Jib System

HM art. Weight
Item no. Description Qty. Note
no. (Kg)

C/c max = 5980 mm

JH-01 Main Jib cylinder 11002514 1 C/c min = 3340 mm
Slag = 2640 mm
For JH-01
JH-02 Balance Valve 10000529 1

C/c max = 5960 mm

JH-03 Knuckle Jib cylinder 11005768 1 C/c min = 3355 mm
Slag = 2605 mm
JH-04 Balance Valve 10000529 2 For JH-03
JH-05 Relief Valve 10001434 1
JH-07.1 Knuckle jib valve 10001193 1
JH-07.2 Mounting plate 10001674 1
JH-07.3 Valve lever 1 0,5
JH-07.4 Wheel 1 0,1
JH-07.5 Valve bracket 1 3
JH-07.6 Sliding bracket 1 2,5
JH-08.1 Double part valve 10001193 1
JH-08.2 Mounting plate 10001674 1
JH-08.3 Shackle valve plate 1 2,5
JH-09 Check valve ¼” 10000493 1

ADDITIONAL
Item HM art. Weight
Description Qty. Note
no. no. (Kg)

Weld socket, ½” 10000088 5

Weld socket, ¾” 10000089 2
Weld socket, 1” 10000090 17
Weld socket, 5/4” 10000091 3
DBI-DUT, No.: 41 10000394 24
DBI-DUT, No.: 51 10000395 54

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 HYDRAMARINE
USER MANUAL FOR CRANE

7.2 Hydraulic Hose list

Page 37 of 54
Title: Hydraulic hose list
Proj.no: SP1868-1
Doc. no: SP1868-1-08 HL HYDRAMARINE

Item no: HM art. no. Hose type Length (mm) Coupling Coupling
MAIN SYSTEM
001 G5K-16 1100 G536-30-16 G537-30-16
002 G1K-20 2400 G336-38-20 G336-38-20
003 G5K-16 1350 G536-25-16 G537-30-16

WINCH SYSTEM
100 M4K-10 1900 G333-18-10 G335-18-10
101 M4K-10 1900 G333-18-10 G335-18-10
102 G5K-16 1400 G536-25-16 G537-25-16
103 G5K-16 1400 G536-25-16 G537-25-16
104 G5K-16 1750 G536-30-16 G537-30-16
105 G5K-16 1800 G536-30-16 G537-30-16
106 M5K-06 650 G333-12-06 G334-12-06
107 M5K-06 1950 G333-12-06 G334-12-06
108 M5K-06 750 G333-12-06 G334-12-06
109 M4K-10 1950 G333-18-10 G336-18-10
110 M4K-08 1950 G333-15-08 G334-15-08
111 M4K-10 1950 G333-18-10 G336-18-10
112 M5K-06 1700 G333-12-06 G334-12-06
113 M5K-06 1300 G333-12-06 G335-12-06
114 M5K-06 2000 G333-12-06 G335-12-06
115 M5K-06 1900 G333-12-06 G334-12-06
116 M5K-06 1100 G333-12-06 G335-12-06
117 M5K-06 2300 G333-12-06 G335-12-06
118 M5K-06 2000 G333-12-06 G333-12-06
119 M5K-06 650 G333-12-06 G333-12-06
120 M5K-06 650 G333-12-06 G335-12-06
121 M5K-06 650 G333-12-06 G333-12-06
122 M4K-08 1600 G333-15-08 G333-15-08
123 M4K-08 1450 G333-15-08 G334-15-08
124 M5K-06 650 G333-12-06 G334-12-06
125 M5K-06 250 G333-12-06 G333-12-06
126 G5K-16 2100 G536-30-16 G536-30-16
127 G5K-16 2000 G536-30-16 G536-30-16
128 M4K-08 2150 G333-15-08 G333-15-08
129 M5K-06 2150 G333-12-06 G333-12-06
130 M5K-06 2150 G333-12-06 G333-12-06
131 M5K-06 1900 G333-12-06 G334-12-06
133 M5K-06 650 G333-12-06 G333-12-06
134 M5K-06 2550 G333-12-06 G335-12-06
135 M4K-10 350 G333-18-10 G333-18-10
Page 2
Title: Hydraulic hose list
Proj.no: SP1868-1
Doc. no: SP1868-1-08 HL HYDRAMARINE

Item no: HM art. no. Hose type Length (mm) Coupling Coupling

MAIN JIB SYSTEM

200 M4K-10 1900 G333-18-10 G334-18-10
201 M4K-10 1950 G333-18-10 G334-18-10
202 M5K-06 600 G333-12-06 G334-12-06
203 M4K-08 1600 G333-15-08 G335-15-08
204 M5K-06 550 G333-12-06 G334-12-06
205 M5K-06 580 G333-12-06 G333-12-06
206 M5K-06 320 G333-12-06 G334-12-06

KNUCKLE JIB SYSTEM

300 M4K-10 2000 G333-18-10 G335-18-10
301 M4K-10 2000 G333-18-10 G335-18-10
302 G5K-16 1300 G536-25-16 G537-25-16
303 G5K-16 1300 G536-25-16 G537-25-16
304 G5K-16 1700 G536-30-16 G537-30-16
305 G5K-16 1600 G536-30-16 G537-30-16
306 M4K-08 4250 G333-15-08 G335-15-08
307 G5K-12 740 G536-25-12 G538-25-12
308 G5K-16 800 G536-25-12 G538-25-12
309 M4K-08 1800 G333-15-08 G334-15-08
310 M4K-10 3000 G333-18-10 G333-18-10
311 M5K-04 3000 G333-10-04 G333-10-04

SLEW SYSTEM
500 M4K-10 1900 G333-18-10 G335-18-10
501 M4K-10 1900 G333-18-10 G335-18-10
502 G5K-16 1200 G536-25-16 G537-25-16
503 G5K-16 1100 G536-25-16 G537-25-16
504 M4K-10 1100 G333-18-10 G334-18-10
505 M4K-10 1150 G333-18-10 G334-18-10
506 M4K-10 1750 G333-18-10 G334-18-10
507 M4K-10 1650 G333-18-10 G334-18-10
510 M4K-08 1500 G333-15-08 G334-15-08
511 M4K-08 1200 G333-15-08 G334-15-08
512 M5K-04 1100 G333-08-04 G334-08-04
513 M5K-04 1200 G333-10-04 G334-08-04

Page 3
 HYDRAMARINE
USER MANUAL FOR CRANE

7.3 Ordering Spare parts

Direct all enquiries regarding service and spare parts to:

HYDRAMARINE
HYDRAMARINE AS
Andøyveien 23
N-4623 Kristiansand S. NORWAY

Phone: +47 380 18700

Fax: +47 380 18701
E-mail: aftersales@hydramarine.no


Remember to refer to actual equipment machine number for exact definition of
components and service advice.

IMPORTANT NOTICE:
During the warranty period, all necessary spare parts must be supplied by
HYDRAMARINE AS. The use of spare parts supplied by other suppliers violates and
forfeits the warranty.

Page 38 of 54
 HYDRAMARINE
USER MANUAL FOR CRANE

8 DRAWINGS & DATASHEETS.

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 HYDRAMARINE
USER MANUAL FOR CRANE

8.1 Project Drawings.

8.1.1 General Arrangement.

8.1.2 Hydraulic Flow Diagram

8.1.3 Main Assembly.

8.1.4 Slew Assembly

8.1.5 Electric block diagram

8.1.6 Starter cabinet, layout

8.1.7 Circuit diagram, 1 of 2

8.1.8 Circuit diagram, 2 of 2

Page 40 of 54
 HYDRAMARINE
USER MANUAL FOR CRANE

8.2 Data sheets.

8.2.1 Main hydraulic pump

8.2.2 Main operating valve

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 HYDRAMARINE
USER MANUAL FOR CRANE

9 STATEMENTS & CERTIFICATES.

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.1 Hydramarine, Declaration of Conformity .

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.2 Certificates, lifting equipment.

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.2.1 Wire certificate

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.2.2 Hook certificate

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.2.3 Wire block certificate

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.2.4 Shackle certificate (SWL 9,5 T)

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.2.5 El.motor certificate

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.2.6 Product certificate for crane foundation

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.2.7 DNV Type Approval Certificate, HMC 1610 Crane Foundation

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 HYDRAMARINE
USER MANUAL FOR CRANE

9.3 Factory acceptance test plan (FAT).

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 HYDRAMARINE
USER MANUAL FOR CRANE

10 Radio Remote Control User Manual

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USER MANUAL FOR CRANE

11 NOTES

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