13603 Manual Complete.pdf

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

FOR

ELECTRO-HYDRAULIC

EXTENDIBLE BOOM CRANE

MODEL NUMBER: EB70-60-25

APPLETON MARINE, INC.

SERIAL NUMBER: 13603

VT HALTER MARINE, INC.

P.O. NUMBER: V10712

MANUFACTURED BY:

APPLETON MARINE, INC.

P.O. BOX 6007

APPLETON, WI 54915-6007

PHONE: (920) 738-5432

FAX (920) 738-5435

JANUARY 2005

TABLE OF CONTENTS

VT HALTER MARINE, INC. / S.O. 13603, PAGE 2

1. GENERAL DESCRIPTION Page

1.1 Crane

1.2 Hydraulic Power Unit

1.3 Load Monitor System

1.4 Remote Control Chestpak

1.5 Remote Hook Load Display

1.6 AMI Warranty

2. INSTALLATION

2.1 General

2.2 Crane

2.3 Interconnecting Wiring

2.4 Interconnecting Piping

2.5 Initial Start-Up

3. OPERATION

3.1 Precautions and Warnings

3.2 Pre-Start Checks

3.3 Hydraulic Power Unit Operation

3.4 Swing Operation

3.5 Boom Luffing Operation

3.6 Boom Telescoping Operation

3.7 Winch Operation

3.8 Load Monitor System Operation

3.9 Emergency Release Procedure

3.10 Shutdown and Storage

4. MAINTENANCE AND SERVICE

4.1 General

4.2 Grease Fittings

4.3 Boom Luff Cylinder

4.4 Boom Telescope Cylinder

4.5 Swing Drive

4.6 Winch

4.7 Turntable Bearing

4.8 Hydraulic Control Valve

4.9 Electric Motor

4.10 Hydraulic Tank

VT HALTER MARINE, INC. / S.O. 13603, PAGE 3

4.11 Return Filter

4.12 Hydraulic Pump

4.13 Trouble Shooting

4.14 Recommended Lubrication

5. DRAWINGS Section

5.1 Crane Assembly, AMD-1581

5.2 Piping Assembly, AMD-1582

5.3 Electric Assembly, AMD-1583

5.4 Power Unit Assembly, AMD-1584

5.5 Crane Outline, BMD-0524

5.6 Hydraulic Schematic, CMD-0628

5.7 Electric Schematic, CMD-0629

6. MANUFACTURERS’ INSERTS

6.1 Turntable Bearing, YMD-8543 . . . . . . . . . . . A

6.2 Swing Drive and Brake, YMD-7208 . . . . . . . . . B

6.3 Swing Motor, YMD-9102 . . . . . . . . . . . . . . C

6.4 Counterbalance Valve Manifold, YMD-9298 . . . . . D

6.5 Luff Cylinder, YMD-8885 . . . . . . . . . . . . . E

6.6 Telescope Cylinders, YMD-8888, YMD-8892 . . . . . E

6.7 Winch, YMD-8886 . . . . . . . . . . . . . . . . . F

6.8 Overhaul Ball and Hook, YMD-9538 . . . . . . . . . G

6.9 Anti-Two Block Device, AMD-1223 . . . . . . . . . H

6.10 Hydraulic Swivel, YMD-3136 . . . . . . . . . . . I

6.11 Hydraulic Control Valve, YMD-8893 . . . . . . . . J

6.12 Boom Angle Indicator, AMD-0699 . . . . . . . . . . K

6.13 Emergency Load Release Manifold, YMD-8853 . . . . L

6.14 Electric Slip Ring, YMD-8901 . . . . . . . . . . . M

6.15 Load Pin, YMD-8890 . . . . . . . . . . . . . . . . N

6.16 Boom Angle Transducer, YMD-8902 . . . . . . . . . O

6.17 Boom Length Transducer, YMD-8891 . . . . . . . . . P

6.18 Electric Motor (30 hp), YMD-8889 . . . . . . . . . Q

6.19 Electric Motor (40 hp), YMD-9445 . . . . . . . . . Q

6.20 Gear Coupling, YMD-6377 . . . . . . . . . . . . . R

6.21 Gear Coupling, YMD-4774 . . . . . . . . . . . . . R

6.22 Hydraulic Pump, YMD-7780 . . . . . . . . . . . . . S

6.23 Hydraulic Pump, YMD-9446 . . . . . . . . . . . . . S

6.24 Return Filter, YMD-7506 . . . . . . . . . . . . . T

6.25 Motor Controller/PLC Enclosure, YMD-9449 . . . . . U

6.26 Remote Control Chestpak, YMD-9450 . . . . . . . . U

VT HALTER MARINE, INC. / S.O. 13603, PAGE 4

6.27 Remote Hook Load Display, YMD-8878 . . . . . . . . U

6.28 Turret Enclosure, YMD-8879 . . . . . . . . . . . . U

6.29 Remote Control Junction Box, YMD-8880 . . . . . . U

6.30 Umbilical Cable, YMD-8881 . . . . . . . . . . . . U

6.31 Hydraulic Manifold, YMD-7855 . . . . . . . . . . . V

7. TEST PROCEDURE AND ACCEPTANCE REPORT, TMD-0797 . . . . W

8. RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . X

VT HALTER MARINE, INC. / S.O. 13603, PAGE 5

GENERAL WARNINGS AND PRECAUTIONS

1. KEEP ALL SHIELDS AND COVERS IN PLACE. DO NOT OPERATE EQUIPMENT WITH

GUARDS REMOVED.

2. CONSULT INSTALLATION, OPERATION, AND MAINTENANCE MANUAL BEFORE

OPERATING OR SERVICING EQUIPMENT.

3. INSPECT RIGGING DAILY.

4. DISCONNECT POWER SUPPLY BEFORE PERFORMING LUBRICATION OR

MAINTENANCE PROCEDURES.

5. THIS EQUIPMENT IS NOT INTENDED FOR USE IN LIFTING OR MOVING PERSONNEL.

6. MAINTAIN AT LEAST FIVE DEAD WRAPS OF WIRE ROPE ON THE WINCH DRUM AT

ALL TIMES.

7. REMOVE ALL LOADS FROM THE HOOK BEFORE PERFORMING ANY MAINTENANCE

ON THE UNIT.

WARNING

VT HALTER MARINE, INC. / S.O. 13603, PAGE 6

1.0 GENERAL DESCRIPTION

1.1 CRANE The crane is a pedestal mounted, extendible boom unit designed for service in an outdoor marine environment. Power for the unit is derived from a 30 horsepower electro-hydraulic power unit. The crane is rated to handle 8,100 pounds at an outreach of 42 feet dockside and at an outreach of 20 feet during an on vessel lift in 2.5 meter waves. Refer to the crane capacity chart for additional crane capacities. The maximum crane outreach is 60 feet. The crane is designed and certified in accordance with the American Bureau of Shipping (ABS) Guide for the Certification of Cranes and API Specification 2C. The hydraulic components are designed in accordance with the U.S. Coast Guard guidelines for “failsafe” operation (i.e. all functions will cease and hold in the event of hydraulic or electric power failure).

The crane is ABS certified and carries the API 2C monogram. The total approximate crane weight is 22,500 pounds.

1.1.1 PEDESTAL The crane foundation consists of a 36 inch diameter column with a ½ inch wall thickness designed to be welded to the vessel foundation. The total pedestal height is approximately 14 feet. An 18 inch diameter access hole in the side of the pedestal provides access to interconnecting piping and wiring, and allows servicing of the hydraulic swivel and electric slip ring. The access hole is furnished with a removable cover plate and gasket. The pedestal interior includes ladder rungs and provisions for creating a maintenance platform if required.

1.1.2 TURRET The turret is a weldment fabricated from structural steel plate. The turret is connected to the pedestal through the turntable bearing. The turntable bearing is designed to handle the rotational and overturning crane reactions. The turret provides anchor points for the boom and boom luff cylinder.

1.1.3 BOOM The telescoping boom consists of three box type weldments fabricated from high strength structural steel plate. The fully retracted boom length is 25 feet. The maximum extended boom length is 60 feet. The boom heel is outfitted with high strength bronze bushings which pivot on a heat-treated stainless steel pin. The extendible portion of the boom rides on high strength lubricated bronze slide pads. The boom tip is outfitted with steel sheaves using anti-friction roller bearings. These also ride on heat-treated stainless steel pins.

The boom tip includes a swivel fairlead.

1.1.4 HYDRAULIC CONTROL VALVE The multiple section hydraulic control valve for operating the crane's swing, telescope, winch, and luff functions is mounted on the turret and rotates with the crane. It is a blocked-center control valve with electric pilot controls and manual lever overrides. The control valve features spring-centered to neutral, proportional spool

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sections. The farther the spool is moved off its centered, neutral position, the greater the delivered flow of hydraulic fluid. All spools are of the motor spool type, and each control valve section includes a 24 VDC proportional solenoid to allow operation of the crane functions from the remote control chestpak. Through the parallel circuitry of the control valve, multiple functioning of all four crane functions is possible (the control valve must be partially metered to accomplish multiple functioning).

1.1.5 SWING SYSTEM The crane swing system consists of four planetary speed reducers with output pinions that drive on the external turntable bearing gear. Two of the planetary speed reducers are powered by straight shaft, low speed, high torque hydraulic motors. Rotational speed is variable from 0 to 1.0 RPM. The swing system is capable of rotating the crane up a 5 degree static inclination during dockside operation. Each planetary speed reducer incorporates a spring set, hydraulic release brake for positive static braking of the swing system. The brakes are released by pressure from the swing counterbalance (holding) valve manifold mounted on the crane turret. The cartridge type, dual counterbalance valves control flow to prevent cavitation. This keeps the crane from swinging ahead of the pump in a list condition. The crane is capable of 360 degree continuous rotation due to the hydraulic swivel and electric slip ring.

The swing system is equipped with emergency release capabilities in the event of a loss of hydraulic power.

1.1.6 BOOM LUFFING SYSTEM Raising and lowering of the boom is accomplished by a single 9 inch bore hydraulic cylinder. The cylinder is equipped with a heavy chrome plated rod and an integral cartridge type load hold valve. The load hold valve provides load control while lowering the boom, and the ability to hold the load in the event of loss of hydraulic pressure (e.g.

burst hose or hydraulic power unit failure). The boom can be luffed from horizontal to a maximum position of 80 degrees above horizontal. Minimum luffing time from horizontal to the maximum boom angle (0 to 80 degrees) is approximately 45 seconds.

The boom luffing system is incorporated with the overload safety feature. In the event of an overload condition, the boom lower function will become inoperable to prevent an increase in load conditions.

1.1.7 BOOM TELESCOPING SYSTEM Extending and retracting of the boom is accomplished by dual 4.5 inch bore hydraulic cylinders. Each cylinder is equipped with a chrome plated steel rod and dual integral cartridge type load hold valves. The load hold valves provide load control while extending and retracting the boom, and the ability to hold the load in the event of loss of hydraulic pressure (e.g. burst hose or hydraulic power unit failure). The boom can be telescoped from 25 feet to a maximum length of 60 feet in approximately 90 seconds.

The boom telescoping system is incorporated with both the overload and anti two-block safety features. In the event of an overload condition, the boom extend function will become inoperable to prevent an increase in load conditions. If during a boom extend operation the anti two-block limit is triggered, the extend function will also become inoperable to prevent the overhaul ball and hook from being pulled into the boom tip sheave.

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1.1.8 HOISTING SYSTEM The hoisting system consists of a planetary winch and associated rigging. A high efficiency hydraulic gear motor powers the winch. The winch is supplied with a brake valve to control the winch while lowering a load. A spring set, hydraulic release multiple disc brake is incorporated into the winch drive train to provide static braking. The winch is rigged for single part operation with 5/8 inch diameter 6 x 37 classification, EEIP IWRC wire rope and a top swivel overhaul ball and hook with a safety latch. It is supplied with enough rope to provide approximately 100 feet of hook travel. The winch is capable of lifting 8100 pounds at an average speed of 60 feet per minute.

The hoisting system is incorporated with both the overload and anti two-block safety features.

In the event of an overload condition, the hoist raise function will become inoperable to prevent an increase in load conditions. If during a hoist raise operation the anti two-block limit is triggered, the raise function will also become inoperable to prevent the overhaul ball and hook from being pulled into the boom tip sheave.

The hoisting system is equipped with emergency load lowering capabilities in the event of a loss of hydraulic power.

1.2 HYDRAULIC POWER UNIT The electro-hydraulic power unit is located below deck, remote from the crane. The power unit includes the two electric motors, two hydraulic pumps, a common hydraulic reservoir, and a common motor controller/PLC enclosure.

1.2.1 ELECTRIC MOTOR Each electric motor is an ODP, AC squirrel cage induction type motor. The port motor is rated for 30 horsepower at 1750 rpm and the starboard motor is rated for 40 horsepower at 1750 rpm. Both are suitable for continuous duty with a 1.15 service factor.

Electric power requirements for the port motor are 600 VAC/3 phase/60 Hz at 29 full load amps.

Electric power requirements for the starboard motor are 600 VAC/3 phase/60 Hz at 41 full load amps. Each motor is furnished with a pump mounting adapter and an anti-condensation heater (120 VAC/single phase/60 Hz, 50 Watts).

1.2.2 MOTOR CONTROLLER/PLC ENCLOSURE The motor controller/PLC (programmable logic controller) enclosure is an IP22 fiberglass enclosure that includes dual full voltage, non-reversing motor starters, a common disconnect, and motor circuit protection. It is supplied with a 600 VAC primary to 120 VAC secondary transformer for the space heaters and control power. It contains two 24 VDC power supplies for the crane controls and load monitor system. The enclosure also houses the PLC components for the crane. The enclosure door controls include a POWER AVAILABLE indicator light (white), a LOCAL/REMOTE MODE selector switch, two (port, starboard) illuminated START pushbuttons (green), and two (port, starboard) STOP pushbuttons (red).

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1.2.3 HYDRAULIC PUMP The hydraulic pumps are variable displacement, pressure compensated, axial piston type pumps. The pumps are supported by the electric motor pump mount and are driven through a gear type coupling. Port pump delivery is 21 gallons per minute at 2900 pounds per square inch. Starboard pump delivery is 30 gallons per minute at 2900 pounds per square inch. Each hydraulic pump is equipped with an unloading solenoid valve to prevent the motor/pump combination from being started under load. The timer for this unloading valve is incorporated into the PLC program.

1.2.4 HYDRAULIC RESERVOIR The reservoir is a 175 gallon fabricated steel tank equipped as follows:

- Return line filter with dirt indicator

- Tank access covers

- Tank breather

- Magnetic sump plug

- Sight level / temperature gauge

The interior of the tank has a protective coating to prevent corrosion and tank contamination.

1.3 LOAD MONITOR SYSTEM The crane includes a PLC based load monitor system.

The system continually monitors and displays the current hook load and warns the operator in the event of an overload condition

1.3.1 LOAD PIN The load pin is of the shear type and located at the boom tip. The load pin measures the line tension and converts it into a 4 to 20 mA electrical signal. The pin material is heat-treated stainless steel.

1.3.2 BOOM LENGTH SENSOR The boom length sensor is a cable extension position transducer. As the boom extends, cable is spooled from the transducer, producing a 4 to 20 mA electrical signal. An internal spring maintains constant tension on the cable and serves as the retraction mechanism.

1.3.3 BOOM ANGLE SENSOR The boom angle is measured by a rotary position sensor, mounted on the side of the heel pin. The sensor measures the boom angle and converts it to a 4 to 20 mA electrical signal. The sensor is equipped with a stainless steel input shaft and is housed in a waterproof enclosure.

1.4 REMOTE CONTROL CHESTPAK The remote control chestpak is housed in an IP66 fiberglass enclosure. The chestpak controls include a POWER AVAILABLE indicator light

VT HALTER MARINE, INC. / S.O. 13603, PAGE 10

(white), an illuminated START pushbutton (green), a STOP pushbutton (red), two dual axis joysticks (with pushbuttons for the warning horn), and an Allen-Bradley PanelView 300. The PanelView displays the crane capacity (pounds), the actual load on the hook (pounds), the lift radius from the center of crane rotation (feet), and the current lift mode. Calibration of the load pin, angle transducer, and length transducer is possible through the PanelView.

Inputs from the load pin, boom length sensor, and boom angle sensor are processed in the motor controller/PLC enclosure and sent to the remote control chestpak PanelView. Likewise, inputs from the remote control chestpak joysticks are processed in the motor controller/PLC enclosure and sent to the hydraulic control valve for function actuation.

1.5 REMOTE HOOK LOAD DISPLAY The remote hook load display is an IP66 fiberglass enclosure located at a remote location from the crane. This remote hook load display contains two digital units that show the current hook load for both the starboard and port cranes.

VT HALTER MARINE, INC. / S.O. 13603, PAGE 11

VT HALTER MARINE, INC. / S.O. 13603, PAGE 12

2.0 INSTALLATION

2.1 GENERAL Refer to the following drawings when installing the crane:

2.1.1 Crane Assembly, AMD-1581

2.1.2 Piping Assembly, AMD-1582

2.1.3 Electric Assembly, AMD-1583

2.1.4 Power Unit Assembly, AMD-1584

2.1.5 Crane Outline, BMD-0524

2.1.6 Hydraulic Schematic, CMD-0628

2.1.7 Electric Schematic, CMD-0629

2.2 CRANE

2.2.1 The crane pedestal is designed to be welded to the vessel foundation. The crane’s foundation pedestal consists of a 36 inch diameter column with a ½ inch wall thickness. The weld between the crane pedestal and the vessel foundation must provide complete penetration and must be 100% ultrasonically inspected. Refer to the Crane Outline drawing, BMD-0524, for the required welding. The structural integrity of the vessel foundation remains the responsibility of the installing activity. Per American Bureau of Shipping requirements, the foundation must be designed for the following crane foundation reactions:

Crane Weight: 22,500 lbs

Axial Thrust: 38,000 lbs

Radial Load: 7,300 lbs

Overturning Moment: 1,200,000 ft-lbs

Slewing Torque: 250,000 ft-lbs

2.2.2 Set the crane pedestal onto the vessel foundation. Rotate the pedestal tube so that the

VT HALTER MARINE, INC. / S.O. 13603, PAGE 13

access hole is oriented in the desired manner. Adjust the pedestal to a vertical plumb position.

Weld the pedestal tube to the vessel foundation as described above.

2.3 INTERCONNECTING WIRING

2.3.1 See AMD-1583, Electric Assembly, and CMD-0629, Electric Schematic, for location of interconnecting electrical requirements for the crane. The hydraulic power unit requires 600 VAC/3 phase/60 Hz power for operation.

2.3.2 The following connections need to be made:

• Incoming power to motor controller/PLC enclosure

• Motor controller/PLC enclosure to pedestal-mounted junction box

• Motor controller/PLC enclosure to remote control junction box (2 locations)

• Motor controller/PLC enclosure to remote hook load display

Supply and installation of the interconnecting wiring is the responsibility of the installing activity.

2.4 INTERCONNECTING PIPING

2.4.1 See AMD-1582, Piping Assembly, and CMD-0628, Hydraulic Schematic, for location of interconnecting piping requirements for the crane.

2.4.2 The following connections need to be made at the bottom of the pedestal:

• Pressure Line: Minimum line size – ¾ inch nom dia 12,000 psi min burst

• Return Line: Minimum line size – 1 inch nom dia 4,000 psi min burst

• Drain Line: Minimum line size – ½ inch nom dia 2,000 psi min burst

All interconnecting piping should have a minimum cleanliness grade of 8 to NAS 1638, 6 to SAE, or 17/14 to ISO 4406. Supply and installation of the interconnecting piping is the responsibility of the installing activity.

2.5 INITIAL START-UP

2.5.1 Lubricate the entire unit and check all fluid levels. See "MAINTENANCE AND

SERVICE”.

2.5.2 See "OPERATION" for an explanation of the crane controls.

2.5.3 Make sure all control valve sections are in their center, neutral position.

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2.5.4 Make sure all guards and covers are in place.

2.5.5 Make sure the crane boom is not lashed down.

2.5.6 Clear the crane work area of personnel and equipment.

2.5.7 Turn on the incoming 600 VAC power to the motor controller/PLC enclosure. Move the disconnect lever to the ON position. Check to see that the POWER AVAILABLE indicator light is on. This light is located on the front cover of the motor controller/PLC enclosure. Turn the MODE selector switch to the LOCAL position to prevent operation from remote locations.

2.5.8 Remove the hydraulic pump mount access covers. Jog each electric motor (port and starboard) by pressing the START pushbutton and immediately pushing the STOP pushbutton.

Each motor should rotate counterclockwise when viewed from the shaft end. A rotation direction arrow is visible on each pump mount for assistance. If the rotation is incorrect, shut off the incoming power and reverse any two of the three 600 VAC power leads. Jog the motor again to verify proper pump rotation. Reattach the pump mount access covers.

2.5.9 Start the hydraulic power unit and allow it to run for a few minutes. The pressure should be approximately 2900 psi. If the pump pressure reading is out of specification setting, refer to Section 4.12.2 for readjustment procedures. Slowly actuate each crane function using either the manual control valve handles or the remote control chestpak joysticks. Operate each function for several minutes to purge all air from the hydraulic system. Make sure each chestpak joystick operates the functions as labeled. Check for proper operation of all crane electrical functions and the anti two-block device. Turn off the power unit and check for proper operation of the emergency load release function.

2.5.10 Check for hydraulic leaks.

2.5.11 Check for proper operation of the load monitor system. Use known test weights or a calibrated dynamometer to check for proper calibration of the system. Verify the crane capacity settings in all lift modes.

2.5.12 Conduct final crane load testing as required.

2.5.13 The unit is now ready to be put into service.

VT HALTER MARINE, INC. / S.O. 13603, PAGE 15

3.0 OPERATION

3.1 PRECAUTIONS AND WARNINGS

1. KEEP ALL SHIELDS AND COVERS IN PLACE. DO NOT OPERATE EQUIPMENT WITH

GUARDS REMOVED.

2. CONSULT INSTALLATION, OPERATION, AND MAINTENANCE MANUAL BEFORE

OPERATING OR SERVICING EQUIPMENT.

3. INSPECT RIGGING DAILY.

4. DISCONNECT POWER SUPPLY BEFORE PERFORMING LUBRICATION OR

MAINTENANCE PROCEDURES.

5. THIS EQUIPMENT IS NOT INTENDED FOR USE IN LIFTING OR MOVING PERSONNEL.

6. MAINTAIN AT LEAST FIVE DEAD WRAPS OF WIRE ROPE ON THE WINCH DRUM AT

ALL TIMES.

7. REMOVE ALL LOADS FROM THE HOOK BEFORE PERFORMING ANY MAINTENANCE

ON THE UNIT.

1. INSPECT UNIT BEFORE AND AFTER EVERY USE, SERVICING OR REPLACING ANY

DAMAGED COMPONENTS.

2. MAKE SURE THE UNIT IS PROPERLY LUBRICATED BEFORE OPERATION.

3. TO EXTEND THE LIFE OF THE LUFFING AND TELESCOPING CYLINDER RODS, KEEP

THE CRANE IN A FULLY RETRACTED, FULLY LOWERED POSITION WHEN NOT IN

USE TO MINIMIZE CYLINDER ROD EXPOSURE TO SALTWATER SPRAY.

CAUTION

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3.2 PRE-START CHECKS Before starting or operating the unit, check the following:

3.2.1 Make sure that the unit has been properly lubricated and serviced. See

“MAINTENANCE AND SERVICE.”

3.2.2 Make sure all control valve sections are in their center, neutral position.

3.2.3 Make sure all guards and covers are in place.

3.2.4 Make sure the crane boom is not lashed down.

3.2.5 Clear the crane work area of personnel and equipment.

3.3 HYDRAULIC POWER UNIT OPERATION

3.3.1 To energize the hydraulic power unit, move the disconnect lever (located on the door of the motor controller/PLC enclosure) to the ON position. The white POWER AVAILABLE indicator light on should be illuminated. If the light is not illuminated, see the “TROUBLESHOOTING” section of the manual.

ELECTRIC POWER MUST BE SUPPLIED TO THE MOTOR CONTROLLER/PLC

ENCLOSURE TO OPERATE THE ANTI-CONDENSATION HEATERS WHEN THE POWER

UNIT IS NOT RUNNING. LEAVE THE DISCONNECT LEVER IN THE ON POSITION UNLESS

SERVICING THE UNIT.

3.3.2 Further operation of the power unit can be done from either the power unit or the remote control chestpak. On the chestpak, the POWER AVAILABLE indicator light should be illuminated. If the light is not illuminated, check the motor controller/PLC enclosure to determine if the MODE selector switch is in the REMOTE position. To start the power unit, press the green START pushbutton. Allow the power unit to run for a few minutes before operation. To stop the power unit, press the red STOP pushbutton.

3.4 SWING OPERATION

3.4.1 The swing function can be actuated at the hydraulic control valve or on the remote

CAUTION

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control chestpak. To swing the crane to the left, push the left joystick to the left. To swing the crane to the right, push the left joystick to the right. The joystick should be moved smoothly and deliberately, not with a jerking motion.

3.4.2 The swing control is a spring-centered, proportional control. When the joystick is released, it will automatically return to the neutral position. In the neutral position, all motion stops, and the swing load hold valve is automatically set. Moving the joystick progressively farther from the neutral position in either direction will increase the rate at which the crane swings.

3.4.3 To sound the audible warning horn located on the turret enclosure, press the pushbutton located on the top of the joystick.

3.5 BOOM LUFFING OPERATION

3.5.1 The boom luffing function can be actuated at the hydraulic control valve or on the remote control chestpak. To luff the crane boom down, push the right joystick forward. To luff the crane boom up, pull the right joystick back. The joystick should be moved smoothly and deliberately, not with a jerking motion.

3.5.2 The boom luffing control is a spring-centered, proportional control. When the joystick is released, it will automatically return to the neutral position. In the neutral position, all motion stops, and the luff cylinder load hold valve is automatically set. Moving the joystick progressively farther from the neutral position in either direction will increase the rate at which the boom luffs.

3.5.3 To sound the audible warning horn located on the turret enclosure, press the pushbutton located on the top of the joystick.

3.5.4 The boom luffing system is incorporated with the overload safety feature. In the event of an overload condition, the boom lower function will become inoperable to prevent an increase in load conditions. The boom raise function will not be affected in this situation.

3.6 BOOM TELESCOPING OPERATION

3.6.1 The boom telescoping function can be actuated at the hydraulic control valve or on the remote control chestpak. To extend the crane boom, push the left joystick forward. To retract the crane boom, pull the left joystick back. The joystick should be moved smoothly and deliberately, not with a jerking motion.

3.6.2 The boom telescoping control is a spring-centered, proportional control. When the joystick is released, it will automatically return to the neutral position. In the neutral position, all motion stops, and the telescope cylinder load hold valve is automatically set. Moving the joystick progressively farther from the neutral position in either direction will increase the rate at which the boom telescopes.

3.6.3 To sound the audible warning horn located on the turret enclosure, press the pushbutton located on the top of the joystick.

3.6.4 The boom telescoping system is incorporated with both the overload and anti two-block

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safety features. In the event of an overload condition, the boom extend function will become inoperable to prevent an increase in load conditions. If during a boom extend operation the anti two-block limit is triggered, the extend function will also become inoperable to prevent the overhaul ball and hook from being pulled into the boom tip sheave. The boom retract function will not be affected in either of these situations.

3.7 WINCH OPERATION

3.7.1 The winch function can be actuated at the hydraulic control valve or on the remote control chestpak. To lower the hook, push the right joystick to the right. To raise the hook, push the right joystick to the left. The joystick should be moved smoothly and deliberately, not with a jerking motion.

3.7.2 The winch control is a spring-centered, proportional control. When the joystick is released, it will automatically return to the neutral position. In the neutral position, all motion stops, and the spring set brake is automatically set. Moving the joystick progressively farther from the neutral position in either direction will increase the rate at which the winch raises or lowers the hook. The pushbutton on the top of the joystick will sound the audible warning horn located on the turret enclosure.

3.7.3 To sound the audible warning horn located on the turret enclosure, press the pushbutton located on the top of the joystick.

3.7.4 The winch system is incorporated with both the overload and anti two-block safety features. In the event of an overload condition, the hoist raise function will become inoperable to prevent an increase in load conditions. If during a hoist raise operation the anti two-block limit is triggered, the raise function will also become inoperable to prevent the overhaul ball and hook from being pulled into the boom tip sheave. The hoist lower function will not be affected in either of these situations.

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3.8 LOAD MONITOR SYSTEM OPERATION

3.8.1 The following is a description of the Allen-Bradley PanelView 300 features.

F6F5

F1 F2 F4

F8F7

F3

Function Keys (F1-F8) Use the function keys to initiate functions on the terminal display.

Cursor Keys Use the up or down cursor keys to move the cursor up or down in a list or to increment/decrement values. Use the left or right cursor keys to select an object with an indicator bar, or to enter configuration mode.

Numeric Entry Keys 0-9 Enters numeric values.

. Enters a decimal point.

- Enters a negative value.

← Clears entered digits or cancels the scratchpad.

↵ Stores an entered value.

VT HALTER MARINE, INC. / S.O. 13603, PAGE 20

Keypad Terminal Display Initiate the function of a displayed object by pressing the corresponding function key (F1-F8).

3.8.2 To use the remote control chestpak and the load monitor system, the motor controller/PLC enclosure disconnect should be in the ON position and the MODE selector switch should be in the REMOTE position. The remote control chestpak should be connected to the remote control junction box with the umbilical cable and the chestpak POWER AVAILABLE indicator light should be illuminated.

3.8.3 From the main introduction screen, press F1 to access the main menu. To operate the crane, press F1 again to enter the operate screen.

3.8.4 The PanelView displays the crane capacity (pounds), the actual load on the hook (pounds), and the lift radius from the center of crane rotation (feet). The crane capacity is dependent on the lift mode. Within the operate screen, F1 can be used to toggle between lift modes. The available lift modes are DOCKSIDE STATIC; AT SEA, ON VESSEL (2.5 meter waves); AT SEA, OFF VESSEL (2.5 meter waves); and AT SEA, ON VESSEL (4.0 meter waves). The lift mode should be selected based on the prevailing conditions. An overload condition will cause the chestpak audible alarm to sound.

3.8.5 Within the operate screen, press F2 to turn the boom floodlight on and off. The status will be displayed on the keypad terminal display.

3.8.6 If two remote control chestpaks are plugged in to operate one of the cranes (port or starboard) at the same time, the chestpak audible alarm will sound and a message will be displayed on the PanelView. All crane functions will become inoperable. To regain control of the crane functions, one of the chestpaks must be unplugged.

3.8.7 The PanelView has been set up and calibrated at the factory. Options are available to calibrate the load pin, boom angle sensor, and boom length sensor. The pump unloading time delay can also be set. If the PanelView appears to be out of calibration, consult the factory for assistance. If adjustments must be made without factory assistance, reference Section U of the manual and follow the onscreen instructions.

3.9 EMERGENCY RELEASE PROCEDURE Both the hoisting and swing systems are equipped with an emergency release feature. This allows the load to be lowered or the crane to be swung in the event of a loss of hydraulic power. The emergency release system utilizes a manually operated hand pump and selector valve to release the winch or swing brakes. The selector valve can then be used to reset the brakes.

3.9.1 EMERGENCY WINCH RELEASE

1. Select the desired component (winch) by pulling the control knob to the “release” position (pull out). The emergency load release manifold is located on the side of the crane turret.

VT HALTER MARINE, INC. / S.O. 13603, PAGE 21

2. Slowly stroke the hand pump lever until the winch drum starts to turn. Lowering speed is controlled by the hand pump pressure.

DO NOT OVER PRESSURIZE THE HAND PUMP. THIS WILL CAUSE THE WINCH TO

SPEED EXCESSIVELY. CAREFULLY MONITOR THE WINCH DRUM SPEED AND SUPPLY

ONLY THE HAND PUMP PRESSURE REQUIRED TO MAINTAIN THE DESIRED LOWERING

SPEED.

3. To stop the winch and set the brakes, push the control knob to the “set” position (push in).

4. For normal operation, the control knob should be in the “set” position (pushed in).

3.9.2 EMERGENCY SWING RELEASE

1. Select the desired component (swing) by pulling the control knob to the “release” position (pull out). The emergency load release manifold is located on the side of the crane turret.

2. Slowly stroke the hand pump lever until the crane starts to swing.

DO NOT OVERSPEED THE SWING DRIVES WHEN SWINGING THE CRANE DOWNHILL IN

A LIST CONDITION.

3. To swing the crane uphill in a list condition, attach a tagline to the boom tip. Use a deck winch or a manual chain block to supply sufficient side load force to swing the crane if necessary.

4. To stop swinging the crane and set the brakes, push the control knob to the “set” position (push in).

5. For normal operation, the control knob should be in the “set” position (pushed in).

3.10 SHUTDOWN AND STORAGE

3.10.1 Whenever the crane is not in use, the boom should be placed in the fully lowered and retracted position with the hook secured.

3.10.2 The motor controller/PLC enclosure disconnect should be left in the ON position to power the anti-condensation heaters.

VT HALTER MARINE, INC. / S.O. 13603, PAGE 22

4.0 MAINTENANCE AND SERVICE

4.1 GENERAL

4.1.1 Proper maintenance of the crane and power unit is important for optimum performance and long life.

4.1.2 Always take care not to contaminate lubricants or oils. Clean all dirt from areas to be serviced.

4.1.3 A "LUBRICATION DATA" chart showing type, quantity and frequency of inspection/replacement is given in Section 4.14 of the manual.

BEFORE PERFORMING ANY MAINTENANCE ON THE UNIT, DISCONNECT AND LOCK

OUT ALL POWER SOURCES.

REINSTALL ALL GUARDS AND COVERS BEFORE PLACING THE UNIT BACK INTO

SERVICE.

4.2 GREASE FITTINGS All pressure grease fittings should be replenished every 8 hours of operation, or monthly, using marine grade grease. Be sure each fitting is taking grease. If the fitting does not take grease, move the part to relieve any internal pressure. If the fitting still refuses to take grease, replace the fitting.

4.3 BOOM LUFF CYLINDER

4.3.1 See manufacturer's insert, Section E.

4.3.2 The boom luff cylinder should be stowed in the fully retracted position for protection, especially during prolonged idle periods. For additional protection, a light coating of wax should be applied monthly to the entire rod surface.

4.3.3 The luff cylinder counterbalance valve is factory set. DO NOT adjust this valve. Consult

VT HALTER MARINE, INC. / S.O. 13603, PAGE 23

the factory for service.

4.4 BOOM TELESCOPE CYLINDERS

4.4.1 See manufacturer's insert, Section E.

4.4.2 The boom telescope cylinders should be stowed in the fully retracted position for additional protection, especially during prolonged idle periods.

4.4.3 The telescope cylinder counterbalance valves are factory set. DO NOT adjust these valves. Consult the factory for service.

4.5 SWING DRIVES

4.5.1 See manufacturer's insert, Section B.

4.5.2 The oil level in the swing drives should be checked every three months. The oil level is checked through the plug on the top of the swing drive housing. If the oil level is low, add SAE 80W-90 gear lube through the fill plug on top of the swing drive.

4.5.3 Each swing drive should be drained and refilled annually. Before draining, operate the drives for several minutes to agitate the oil. The drain plug is located on the bottom of the swing drive. Refill the swing drive with SAE 80W-90 gear lube. Capacity is approximately 2.5 pints per drive.

4.5.4 The swing counterbalance valves are factory set. DO NOT adjust these valves. Consult the factory for service.

4.6 WINCH See manufacturer’s insert, Section F.

4.7 TURNTABLE BEARING

4.7.1 See manufacturer’s insert, Section A.

4.7.2 The turntable bearing should be greased every 8 hours of operation, or monthly. The bearing should be greased at both fittings using marine grade grease. The grease fittings are accessible at the cover plate on the side of the turret.

4.7.3 The gear and pinion teeth should be brushed or swabbed with an open gear compound every 8 hours of operation, or monthly. The crane should be rotated in increments until all of the teeth have been swabbed.

4.7.4 The bearing bolt torque values for both the pedestal and turret sides of the bearing should be checked annually. Each bolt on the pedestal and turret should have a torque value of 1,363 ft-lbs.

4.8 HYDRAULIC CONTROL VALVE

VT HALTER MARINE, INC. / S.O. 13603, PAGE 24

4.8.1 See manufacturer's insert, Section J.

4.8.2 To adjust the hydraulic control valve relief, start the hydraulic power unit. Adjust the pump compensator until the relief valve begins to crack and oil can be heard passing over it.

Read the pressure. If the setting is out of specification (3000 psi), loosen the relief valve locknut on the adjusting screw and turn the screw in to increase the pressure and out to decrease the pressure. Retighten the locknut and reset the pump compensator to the specification setting.

4.9 ELECTRIC MOTOR See manufacturer's insert, Section Q.

4.10 HYDRAULIC TANK

4.10.1 The hydraulic tank oil level should be checked as required. An oil level sight gauge is provided on the side of the tank. The oil level should be maintained at the high mark. Fully retract the luff and telescope cylinders before checking the oil level. If oil is needed, it can be added through the ¾ inch NPT port on top of the tank. Use VG 46 hydraulic oil.

4.10.2 The hydraulic tank should be drained, flushed, and refilled with new oil annually. Drain the tank by removing the plug from the drain valve and opening the valve. Remove the clean out covers and flush out any dirt that may have accumulated. Change the return line filter elements. Reinstall the filter and covers. Close the drain valve and install the drain plug. Refill the tank with oil (capacity: approximately 175 gallons).

4.11 RETURN FILTER

4.11.1 See manufacturer’s insert, Section T.

4.11.2 The return filter element should be changed when indicated by the visual dirt alarm located on the filter head. Oil must be flowing through the filter head for the dirt alarm to function. When checking the filter, turn on the power unit and activate a crane function to circulate oil through the filter head. If the dirt alarm indicates a dirty filter, change the filter element.

4.11.3 NOTE: In cold weather, the dirt alarm may indicate the need for element replacement until the oil warms to its operating temperature.

4.11.4 To change the filter element, remove the six screws holding the filter cap in place.

Remove the cap and o-ring. Pull out the spring, bypass valve, and filter elements. Replace the elements with part number YMD-3383-R. Reinstall the bypass valve, spring cap, and o-ring.

4.12 HYDRAULIC PUMP

4.12.1 See manufacturer’s insert, Section S.

4.12.2 To adjust the pump compensator setting, start the power unit. Remove the pump

VT HALTER MARINE, INC. / S.O. 13603, PAGE 25

compensator cover screw and loosen the locknut to the compensator. Turn the adjustment screw in to increase the pressure and out to decrease the pressure. Read the pressure on the pressure gauge located at the power unit. Specification setting is 2900 psi. Retighten the locknut and reinstall the cover screw.

4.12.3 NOTE: If the pump compensator specification setting cannot be attained, check the control valve relief setting.

4.13 TROUBLE SHOOTING The following trouble shooting charts are provided for minor repairs that may be necessary during operation of the crane. When performing repairs or maintenance on the unit, turn off all sources of power. Repair work and maintenance procedures should be done with care assuring no further damage to the unit. When servicing the power unit, be careful not to get dirt in the hydraulic fluid. Other servicing should be done by a qualified service representative. If you need assistance, contact Appleton Marine, Inc.:

Appleton Marine, Inc.

P.O. Box 6007 Appleton, WI 54915-6007 Phone: (920) 738-5432 Fax: (920) 738-5435

4.14 LUBRICATION RECOMMENDATION The following lubrication chart has been included to aid in servicing the crane. The chart includes information on the type and quantity of lubricants, frequency of inspection and replacement of lubricants, and manufacturer’s recommended products.

VT HALTER MARINE, INC. / S.O. 13603, PAGE 26

TROUBLE

PROBABLE CAUSE

REMEDY

A) Power unit will not start.

1) No incoming power.

Check to see if the POWER AVAILABLE indicator light on the motor controller/PLC enclosure is illuminated. Make sure the disconnect lever is in the ON position and there is incoming power to the unit. The power unit requires 600 VAC/3 phase/60 Hz power to operate.

2) Overload heater elements have tripped out.

Allow motor to cool for about 5 minutes and try to start again.

3) Fuse is blown.

Check fuses in motor starter circuit and replace.

4) Failure of one or more components in motor starter circuit.

An electrician should make a trouble shooting check of the starting circuit.

B) Electric motor is running but no pump pressure or flow.

1) Oil level in hydraulic reservoir is low.

Check fluid level and add additional fluid as required.

2) Coupling failure.

Disassemble electric motor/hydraulic pump coupling and inspect for damage.

TROUBLE SHOOTING

VT HALTER MARINE, INC. / S.O. 13603, PAGE 27

3) Pump failure.

Replace pump or obtain service from a factory authorized service representative.

C) Winch will not lift load.

1) Load is over capacity.

Refer to load chart for maximum crane capacities.

2) Pump compensator set too low.

Check pump compensator setting (2900 psi) and readjust as necessary.

3) System relief valve set too low.

Check system relief valve setting (3000 psi) and readjust as necessary.

4) Anti two-block system engaged.

Check the position of the hook to make sure the anti two-block limit switch is not tripped.

5) Winch failure.

Obtain service from a factory authorized service representative.

D) Winch will not lower load.

1) Pump compensator set too low.

2) System relief valve set too low.

VT HALTER MARINE, INC. / S.O. 13603, PAGE 28

3) Winch brake valve failure.

Disassemble winch brake valve and inspect for contamination or damaged parts.

4) Winch failure.

E) Luff cylinder will not raise the load.

2) Pump compensator set too low.

3) System relief valve set too low.

4) Cylinder failure.

F) Luff cylinder will not hold the load.

2) Cylinder counterbalance valve out of adjustment.

The counterbalance valve is factory set. Consult factory for adjustment procedure.

3) Cylinder counterbalance valve failure.

Replace counterbalance valve cartridge.

VT HALTER MARINE, INC. / S.O. 13603, PAGE 29

4) Luff cylinder failure.

Obtain service from factory authorized service representative.

G) Telescope cylinder will not hold the load.

2) Cylinder counterbalance valve out of adjustment.

The counterbalance valve is factory set. Consult factory for adjustment procedure.

3) Cylinder counterbalance valve failure.

Replace counterbalance valve cartridge.

4) Telescope cylinder failure.

Obtain service from factory authorized service representative.

H) Swing function will not operate.

1) Excessive side load.

Refer to design calculations for side load conditions.

2) Swing brake not releasing.

A minimum of 250 psi is required to release the swing brake. Check the brake release pressure.

3) Swing counterbalance valve not releasing.

Replace swing counterbalance valve cartridge.

VT HALTER MARINE, INC. / S.O. 13603, PAGE 30

4) Swing motor failure.

Replace swing motor or obtain service from a factory authorized service representative.

5) Swing drive failure.

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