J.32_TM_RB_573-02_Heavy_Lift_Crane.pdf

HEAVY LIFT CRANE

ALASKAN MARINE

A WORD TO THE OWNER, OPERATOR, AND MAINTENANCE

PERSONNEL ABOUT SAFETY

FAIWRE TO READ THIS MANUAL IS A MISUSE OF THE EQUIPMENT. ANYONE WHO WILL

OPERATE, SERVICE OR WORK AROUND THIS CRANE SHALL FIRST READ THIS MANUAL.

DEATH OR SERIOUS INJURY CAN RESULT FROM IMPROPER OPERATION OR MAINTENANCE

OF THIS EQUIPMENT.

Occupational safety and machine reliability is of prime concern to North American Crane and Equipment Company in the design and production of this crane. The intent of this manual Is to provide of the operator and others who work around this equipment a tool for safe operation of the equipment that will provide machine reliability.

It is the responsibility of the owner to know the specific requirements, governmental regulations, precautions, and work hazards which exist. The owner shall make these known to all personnel working with the equipment or in an area of known hazards, so that all personnel can take the necessary and required safety precautions. FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN DEATH OR SERIOUS INJURY

OR DAMAGE TO THE EQUIPMENT.

It is the responsibility of the operating and service personnel to use and maintain the crane and hydraulic power unit with caution, skill, and sound judgement. Following recognized safety and maintenance procedures will help prevent accidents and damage to the crane and its related components. Modification or improper operation will create a safety hazard and therefore shall not be made without written approval by the owner and/or manufacturer. Safety covers, devices, and placards must remain installed and maintained in proper working condition. All manufacturer name plates and placards must remain on the equipment.

Disconnecting, removing, or otherwise disabling any safety device is a misuse of this equipment and will create a hazardous condition. Likewise, failure to perform routine maintenance and Inspections of the equipment can lead to premature failure of the crane and its components.

As an owner or employer, it is your responsibility to instruct the operator in the safe operation of your equipment and to provide the operator with a safe and properly maintained piece of equipment.

CRANE NOMENCLATURE

The operating and maintenance personnel should familiarize themselves with the various components of this crane and the names of its components. Knowing the correct terminology for the crane components is necessary in order to fully understand this manual. The following glossary of terms are supplied to further this endeavor. Common terms are shown In parentheses O:

Pedestal - The main support column for the crane. Most pedestals supplied by NACE are round and the outside diameter varies with crane capacity. Access openings are usually provided for maintenance of the valves, rotoseal, and drive gears.

Rotation bearing-- (Slew or Swing bearing) . Shear ball or cross roller bearing is mounted to the top of the pedestal column by either welding or bolting. Transfers moment and axial loading to the pedestal while and allowing the crane to smoothly rotated about its center axis.

Turret- The turret assembly provides attachment points for the main boom, boom cylinder(s), and swing drive assembly(les).

Swing drive-- (slew drive). The swing drives are mounted on the turret base and drive against the rotation bearing gears. Our cranes can have up to four (4) drives but, one or two are more common. Each drive consists of: a pinion gear, a planetary gear drive (gearbox), swing brake, and hydraulic swing motor.

Roto-seal - A multi-ported hydraulic swivel that allows the crane to rotate 360° continuously in either direction. If a crane is supplied without a roto-seal, swing stops are installed to prevent 360° rotation.

Slip-ring -- Similar to a roto-seai but, conducts electricity instead of hydraulic fluid. Slip-rings can be used alone, power pack on ride around, or in conjunction with a roto-seal, power pack below and operators cab on crane.

Main boom- The boom section that attaches to the turret and the lift cyllnder(s). The main boom anchors and pivots about the main hinge pin. The main boom provides mounting points for winch(es) and auxiliary padeyes depending on configuration of crane. Another function the main boom is to provide the housing support for the telescope boom, telescope cylinder, and wear pads.

Boom cylinder -- (lift or luff cylinders). Hydraulic cylinder(s) that anchor against the turret assembly and push on the main boom. The boom cylinders determine the lifting and rated capacities of the crane.

Telescope boom - (Extension boom(s)) are the sections (stages) mounted inside one another and are hydraulically extended and retracted. Most of our cranes have either one or two stages and ride on replaceable wear pads.

Telescope cylinder- (Extension cylinder). Hydraulic cylinders that are anchored to the main boom and push against one (1) or more telescope boom sections. The extend cylinder are either single or double (piggyback) extension type.

Main Winch - (Hoist). Consist of hydraulic motor driving a cable storage drum. The torque (line pull) ot the winch is determined by the operating pressure of the hydraulic system and the layer of the wire rope on the winch drum at the time of lift. Load holding is provided by a multi-disk brake unit on the input shaft of the hydraulic motor. The main winch may be single parted or multi-parted, depending on capacity of crane.

Auxiliary winch - (Secondary hoist). One or more hoists Installed on main boom with different ratings. In multiple winch systems. usually are two parted and have three times the capacity of the fastline hoist.

Fasttlne winch - (Whip hoist). A high speed/low capacity winch used to move light loads when it Is not desirable to use the Main Hoist. Constri:Jction and operation is identical to the main hoist, except they are single parted.

Hose w!nch(es)- (Hose handling holst(s)). One or more hoists Installed on main boom with same ratings.

Used to support tong toads or hoses at multiple points. Operation and construction Is Identical to the main holst

Sheave head -- The support structure and sheave group mounted on the end of the main, telescope, or knuckle boom - depending on the type of crane. The number of sheaves mounted in the sheave head is determined by the crane capacity and the winch installed on crane. Most cranes, except Knuckle boom, allow for two (2) or more parts of reeving.

Reeving -- The number of load lines between toad block and sheave head. Normally an even number of 'parts' are used to prevent twisting or wrapping of toad lines. As the number of parts Increase. the greater the lifting capacity of the crane.

Two-blocking -- Contact of the overhaul ball or toad block with the sheave head. Anti-two blocking devices prevent contact with the sheave head and can be of the following types;

Mechanical - tube. stopper, or bars installed on cable or sheave head that prevent damage to sheaves. Usually installed on fixed and knuckle boom cranes.

Hydraulic - Consists of boom tip valve controlling anti-two block system. When tip valve is actuated, flow is shut of to winch and telescope functions.

Electro-hydraulic - Similar to hydraulic system, with switch on boom tip controlling the anti-two block system.

LMI- Load Moment Indicating systems can range from a single pressure gauge tapped into the blind end of the luff cylinder to a micro-processor based load-range-radius readout and control system.

Control valves -- The valves used to control the individual functions of the crane and they can be controlled by the operator either manually, hydraulically, or electrically. Secondary valves Installed in the control valves are the main relief valves, used to limit maximum system operating pressures. and port relief valves. used to limit the operating pressure of the Individual functions.

Cross port relief valve -- (Cushion valve). A special type of relief valve package that relives the operating pressure to the opposite work port. Used In the swing circuit to protect the crane structure from damage during normal operation.

Counterbalance valve - (Load hold or Over center valve). Specialized hydraulic valves that are Installed on functions that are subject to over-hung or over-running loads. This valves are a pilot operated device that meters the amount of oil from the function. thus preventing the function to 'run' ahead of the pump, and stop all oil flow upon loss of pilot pressure.

Operators station - The location of the crane controls and load charts. The operators station can be located at the pedestal, on a ride-around. or remote from crane.

DEFINITIONS

The following list of definitions are Included to prevent any misunderstanding of terminology used throughout the text. This terminology Is in accordance with API Spec 2C and API RP 20 as well as ABS Certification of Cranes.

allowable load capacity - the "nominal" breaking strength of the wire rope divided by a design factor.

Usually 5 for cranes up to 1 0 tons or all cranes used offshore.

boom angle - the main boom or knuckle boom angle above or below horizontal of the longitudinal axis passing through the main hinge pin.

boom extension- Intermediate section of a telescope boom, between fully retracted and fully extended.

center of rotation - the vertical axis around which the crane superstructure rotates.

critical component - any component or structure that will cause uncontrollable load loss should a failure occur.

dynamic loading - loads Introduced into the crane and lifting systems by forces of acceleration and deceleration.

dynamic rating - rated load capacity of a crane when relative motion exists between crane and load to be lifted or stability of vessel is questionable.

falrlead sheave - sheave assembly used to minimize effects of sidelead on rope spooling.

floating crane - a crane and its associated equipment Install aboard a barge or pontoon vessel, or any vessel that exhibits the same seaworthiness.

foundation - supporting structure that the crane attaches to.

intended service - manufacturers rating of crane based on normal operating conditions supplied by the owner and/or operators.

lift capacity- the maximum lift capacity in pounds (kilograms), based on structural competency and the intended service of crane, and operating at design hydraulic pressure.

list - angle of inclination about longitudinal axis of the barge, pontoon, or ship.

load block - the assembly of hook, swivel, sheaves, pins, and frame suspended from the hoisting rope.

load hook - the primary attachment point for connecting load to load block or overhaul ball.

load ratings - rated load capacity at specific load radii or load reach.

normal operating conditions - conditions during which the crane is performing its' functions within the scope of the original or Intended service. During these conditions. the operator is controlling the crane functions.

oftlead - load angle that produces a horizontal shear load on crane structure.

offshore cranes - cranes mounted on bottom supported or floating structures used to move cargo, stores, drill and production equipment, and other material while at sea or unsheltered areas. Crane is subjected to dynamic loadings.

personnel load rating - reduced load rating while handling personnel with crane.

radius, load - the horizontal distance from the center of rotation to the center of the load hook.

range - the theoretical volume ot space the load hook can achieve based on radius and reach.

reach, load - the horizontal and vertical distances from the theoretical intersection of the axis of rotation and main boom centerline, to the center of the load hook.

rated load capacity - the certified lift capacity In pounds (kilograms} based on structural competency, intended service, actual hydraulic system pressure, foundation competency, winch line pull capacity, wire rope strength, reeving, load hook capacity, dynamic factor, and upon stability and freeboard of mounting platform.

rope - refers to wire rope unless otherwise specified.

safe working load (SWL) - rated load capacity of crane independent of boom angle, hook reach, and load radius. This load is generally the same as the load rating of the crane at maximum load radius.

service temperature - temperature range for which the crane is certified to operate as determined by the .intended service.

shall - Indicates a rule or operation that must be followed or accomplished.

shipboard crane - crane mounted on vessel to be used for moving cargo, stores, and other materral while the vessel is within a harbor or sheltered area. Vessels are sufficiently large to negate dynamic effects upon crane.

should - indicates that a rule or operation Is recommended but, the advisability depends upon the facts or conditions or each situation.

sidelead - load angle that produces a side loading on crane structure.

static load rating - rated load capacity of the crane when no relative motion exists between crane and the load to be lifted.

structural competency - the ability of the crane and its components to withstand the stresses imposed by the applied loads.

tackle -an assembly of ropes, blocks. bars, hooks, grabs, etc., used for lifting, lowering, leveling, and pulling that are not part of the load block or hook.

ton - 2,000 pounds (907.2 Kg}, unless otherwise specified.

towing pad - pad eye to which a standing pendant (guy wire) is attached during towing operations for reduction of sidelead forces on the boom.

trim - angle of inclination about transverse axis of barge, pontoon, or ship.

working load - the external load In pounds (kilograms) applied to the crane including the weight of load block and any tackle.

CRANE SAFETY

SAFETY IN EQUIPMENT MAINTENANCE AND INSPECTION

Safe operation depends on you, the condition of your equipment, and your maintenance and inspection procedures.

The single most Important factor in the prevention of equipment failure and accidents is a positive attitude towards safety. The habit of anticipating possible problems normally prevents many accidents from occurring.

The second most important factor is a structured preventative maintenance program that corrects wear and damage before they can lead to major repairs, and in worse case; catastrophic failures that can cause injury or death to personnel, or severe damage to the mounting structure and loss of revenues do to down time.

To this end, Inspection checks can not to be overlooked as a beginning of a comprehensive maintenance program. Below are listed several important inspections that must be performed before and during the operation of the crane. Further detailed inspection requirements are listed In the Maintenance Section.

• Hydraulic power unit-- check for proper oil level and leaks, condition of electrical starter and motor, condition of pumpjmotor coupling, and tightness of all mounting fasteners.

• Hydraulic components -- check for leaks or damage to valves, cylinders, and motors.

• Hose/fittings/lines- check for leaks, abrasion, damage, and loose connections and clamps.

• Structural -- visually inspect complete crane and accessories for damage; especially for cracks and corrosion in weldments, and bends or ripples in boom sections.

• Fasteners-- check all pins, retainers, bolts and nuts. Insure their presence and proper tightness.

• Sheaves -- Check for rope wear, cracks, and bearing condition.

• Lifting hook - check hook for safety latch, twisting and elongation of throat opening.

Check shank for fatigue cracking.

• Wire rope -- check rope for broken wires, kinks, flat spots, and check end attachments for unsafe conditions.

• Covers and guards -- check for proper Installation and presence.

• Safety devices -- insure proper operation and functioning.

• Operating placards and safety signs - check for missing, illegible, and/ or defaced signs and placards.

• Controls - check for proper functioning, response and self centering.

• Failsafe components -- Insure that all brakes and load hold valves are operating correctly.

Make all necessary repairs and replacements prior to operating crane.

This safety checklist does not eliminate the prescribed detailed maintenance requirements covered elsewhere In this or other manuals.

North American Crane and Equipment Company, and United States Coast Guard regulations require that a company shall perform dally and monthly Inspections and maintain records of these inspections for each crane. and that a thorough annual inspection of the crane shall be performed by a competent person, or by a government or private agency recognized by the USCG. The owner shall maintain a record of the dates and results of the inspections for each crane and Its optional equipment.

SAFETY IN EQUIPMENT OPERATION

Crane systems, such as the MCT-1565, are designed for; lifting heavy loads, reach with long distances, and rotating In a know working area. Furthermore. these cranes are installed aboard ships that operate in lnclemental weather and sea conditions, requiring further personnel safety awareness. As such. the object of the safety precautions is to allow trained personnel to operate and work around the lifting system safely. This means with no danger to operator. assisting personnel, material being handled, the environment surrounding the project, or the crane itself.

THE MATERIAL SET FORTH IN THIS SECTION, IS DONE SO PRESUMING THE OPERATORS AND

ASSISTING PERSONNEL HAVE BEEN TRAINED IN OPERATION OF HEAVY UFT SYSTEMS.

PERSONNEL

PRIMARY OPERATOR

The person at the operators station Is the primary safety operator for the system. This responsibility may be shared, in certain circumstances with other personnel; however, the person at the crane controls shall be responsible for insuring that; The readiness of the crane for operation, a safe working environment for assisting personnel, all schedule maintenance has been performed, the crane is operated consistent with its intended service, work loads remain with those values shown in the load chart, and that all safety and operating precautions are strictly adhered to.

The following operator qualifications have been extracted from OSHA 3100, API RP 2D, ASME/ANSI

830.8 and NAVSEA chapter 589.

OPERATOR QUALIFICATIONS

Personnel who shall operate the crane and hydraulic power untt shall be limited to personnel with the following minimum qualifications:

1. Designated, competent, and experienced persons.

2. Trainees or untrained persons under direct supervision of a qualified person.

3. Maintenance and test personnel familiar with the operation of hydraulically operated cranes systems, only as necessary for performance of their duties.

4. Employees of North American Crane and Equipment Company or persons designated by NACE with appropriate experience.

5. Supervisor with a qualified person present.

Operators and trainees shall meet the following physical qualifications:

1. Have vision of at least 20/30 snellen in one eye, and 20/50 in the other- with or without corrective lenses.

2. Be able to distinguish colors regardless of their position.

3. Hearing, with or without hearing aid, must be able to distinguish differentiating sounds of 70 Db@ 10 feet from source(s).

4. A history of mental stability and not subject to seizures, dizziness, or any disability which may cause injury to self or to others present.

5. Shall not be under the influence of alcohol, drugs, or medication that impairs their judgement or abilities.

6. Shall disqualify themselves if they become mentally or physically unfit.

In addition to the above listed requirements, the operator shall:

1. Demonstrate the ability to read, comprehend, and interpret operator's manual, safety codes, placards, gauges, and other information pertinent to correct and safe operation of cranes or similar equipment.

2. Demonstrate to the employer, the ability to operate this type of equipment or provide satisfactory evidence of experience.

3. Be familiar with relevant safety codes and regulations.

4. Recognize and be responsible for all maintenance requirements of the crane and its support equipment.

5. Be thoroughly familiar with the operation and function of the individual components that comprise the crane and hydraulic power unit.

SCOPE OF RESPONSIBILITIES

PRIMARY OPERATOR

The primary operator is responsible for four (4) major modes of crane movement; (1) Rotation (2) Boom elevation, (3) Telescopic boom travel, and (4) Load hook elevation. While at the control station, the primary operator must prevent the following:

1. System overload

2. Anti-two blocking

3. Injury to assisting

All loads and reaches must not exceed those allowed by the loadjradlus chart, located above of the operator's station.

Maintain a minimum distance of 1 FT. between load block and sheave head.

Never swing loads over other personnel, nor operate crane in unsafe manner. Never operate crane while other personnel are working on crane.

4. General danger to personnel and equipment

Before operating crane, check for any broken or damaged equipment Do not operate crane before damaged parts are repaired or replaced.

Never attempt to operate crane in harsh weather and/ or sea states beyond the rated conditions of the dynamic load chart or the cranes intended service.

5. Head and foot injury

6. Hand injury

ASSISTING PERSONNEL

Always wear hard hat and protective toe boots while working around lifting equipment.

Never operate crane while personnel have hands near any moving part.

Assisting personnel are any individuals assigned to help the primary operator during crane operation and include. but not limited to; riggers, signallers, line handlers, and maintenance personnel. All assisting personnel should be familiar with lifting system operations and aware of the following hazards:

1. Injury to self Never allow lifting loads to travel overhead.

Never allow yourself to become "pinned" between the lifting load and an unmovable object

Stay clear of all moving parts.

Only stay in contact with the rigging and load as required perform required functions.

Never ride on the lifted material or object.

2. Slipping and falling Extreme caution should be exercised when work area Is wet.

Keep work area and all crane surfaces clean and free of oil, grease, and like material.

MAINTENANCE SAFETY PRECAUTIONS

Proper maintenance will provide the operating personnel with a lifting system that can be safely and efficiently operated. The following precautions will reduce the possibility of injury during routine maintenance operations:

1. Before attempting to do any maintenance or repair of any crane system or component, isolate crane from hydraulic power unit.

2. Confirm that all pressure is removed from Individual components.

3. Before attempting any repair to the electrical system, disconnect all electrical power.

4. Support main boom andjor telescopic boom for attempting to remove or replace any hydraulic cylinder or swing drive(s).

5. Never attempt work on winch with a load attached to the load line.

6. Confirm that the swing control lever is secured In neutral position before attempting any repairs to the swing drive system.

7. While doing maintenance and repair, never allow oil and/or grease to accumulate in the work area.

8. Survey the repair to be accomplished and determine the correct tools, handling equipment, and parts required before you start the repair.

9. Always use safety harness when doing at sea maintenance or repairs.

1 o. Allow hydraulic system to cool before attempting to do maintenance or repair.

SAFETY TIPS - INTRODUCTION

This section of the safety manual is designed to present some of the daily work problems which may be encountered by the primary operator, assisting personnel, and maintenance personnel.

The primary operator and service mechanic are the key in any safety program. They must study all sections of the safety and operations manual to be aware of the safety tips which are presented to help prevent serious Injury to themselves and assisting personnel.

Operation and Maintenance Safety Tips - Telescoping Boom Cranes

• Control lever movement should be slow and smooth to meter oil flow for safe operation.

Sudden or jerky movement of the controls should be avoided to minimize shock loads to the hydraulic system, structural components, gear train, as well as side loading of the boom.

• Be constantly aware of the boom(s) position when operating the controls,

• Make certain the sheave head and load line are centered directly over the load before lifting.

• Do not drag load with winch or boom(s).

Operator safety tips cont.

• Do not attempt to lift a fixed load. I.E. loads that are frozen to ground or deck.

• Do not sidelead or offl!3ad boom(s) [Towing) without suitable guy wires or boom support structure.

• Know the weight of the load and rigging to avoid overloading the crane. Deduct the weight of load handling devices from the maximum load rating to determine how much weight can be lifted.

• Never rotate or extend a load over anyone. Use hand signals or horn to alert personnel of hazard.

• Keep load as close to ground whenever possible.

• Always use non-conductive tag lines.

• Do not leave loose objects on booms or loads. Remove any object that is not secured fastened to the booms or loads.

• When load is out of the primary operators' line of sight, a qualified assistant signal person shall be used and the primary operator must follow their signals.

• Obey the emergency stop signal from anyone.

• Do not operate crane during electrical storms, in sea states greater than 4-5, or when winds speeds are above 50 knots. Always use dynamic load chart when using offshore. Use extreme caution when operating In poor visibility conditions and always use assisting personnel.

• Stay clear of hydraulic leaks: High pressure and hot oil can cause serious injury.

• Do not attempt to work on crane with hydraulic power unit on.

• Do not leave the crane unattended with a suspended load.

• Never move vessel with crane parked outboard nor when operating next to other vessels.

• Do not pull the overhaul ball or load block into sheave head (two-blocking).

• Insure load hook safety latch is installed and operating.

• Payout load line before or during telescoping of booms to avoid two-blocking.

• Never allow personnel to ride the load line, load, or any non-personnel handling device attached to load line.

• Always maintain a 10:1 safety factor on wire rope when using crane for personnel handling.

• Only use approved Personnel Handling Platforms.

• Use proper multi-part reeving for load to be lifted. Properly route cable for reeving.

Operator safety tips cont.

• Always maintain at least three full wraps on winch drum at all times.

• Know the lifting capacities of the boom and winch. The winch will normally have greater capacity at lower boom angles. Never use the winch to lift an unknown weight without first determining if crane boom cylinders can lift the weight.

• Never lift a load greater than the winch pull capacity by using luff or telescope cylinders.

• Do not drag load with winch.

• Always wind load line on winch with cable under tension.

• Never under-wind winch drum, winch brake becomes in-operative.

• Use sufficient load block or overhaul ball weights to help keep the proper rope lay on the winch.

• Do not use crane to scrape, hammer, or chisel Ice from ships deck.

• When crane is not in use, always park crane In boom rest or lash to deck.

• When operating crane in dynamic conditions, use proper load charts or de-rate the crane accordingly. The same applies when operating crane in low temperature extremes.

• When working on the crane or hydraulic power unit, place warning tags or red tape on starter and crane controls. If Isolation valves are installed in hydraulic system, close and wire in off position.

• Never start or operate crane while maintenance personnel are working the crane and its components. Get authorization from maintenance supervisor or lead mechanic before proceeding.

• If maintenance personnel have been working on crane or hydraulic power unit, never start crane or power unit without first contacting maintenance supervisor or lead mechanic to ascertain readiness of crane.

• If possible, always isolate crane from hydraulic system or electrical system when crane will be idle for extended periods of time. This prevents unauthorized use of crane while away from unit.

• When working on crane or hydraulic power unit, do not allow oil to accumulate and clean up all oil spills immediately.

• Always wear approved safety harnesses when working on elevated structures or performing at sea repairs or maintenance.

• Always use at least two service personnel when performing major repairs.

OPERATION

TRAINING

All crew members must become thoroughly familiar with the operation of the crane controls, the correcting operating procedures, standard hand signals for cranes, maximum lifting capacities, and all safety precautions before placing crane into service. Operator training is essential. Always be prepared for an emergency condition and know what actions are required by the crew. The following pages contain numerous safety precautions and information as well as detailed operating procedures and tips that must be observed while operating the crane. This section, like all of the manual. must be read carefully before operating the unit.

The health and safety of each crew member Is of primary Importance. Consequently, each member has an obligation to himself and to their fellow crew members, to assure that all safe operaling procedures are followed. All operating regulations recommended by the manufacturer, the employer, and required by local, state, and federal regulatory agencies must be observed. The operating procedures set fourth are North American Crane and Equipment Company's recommendations and do not necessarily cover the employer and governmental regulations. Each operator must know and follow these procedures.

Become thoroughly familiar with all equipment checks. You must be able to make complete inspection and capable of spotting any abnormality or malfunction before using equipment, while using crane, or after project is completed. There Is a high degree of reliability built into this unit, but there is always a possibility of mechanical or power failure due to incomplete servicing, improper operation, or abnormal wear. An operator must never take another's word. Always inspect the unit yourself.

Each crew member must receive through instructions on the care and maintenance of this crane and power unit, thus enabling him to Identify and anticipate any problems that may occur. Understanding how the equipment operates will help you recognize when lt Is not functioning correctly and that repairs or adjustments are required.

90% of all crane failures can be anributed to untrained or unskilled operators. The skilled operator understands how the equipment operates and what the limitations of the equipment are. Most crane failures are do to overloading of the crane and Its components. This manual, a load rating chart, and boom angle indicator are provided to prevent overloading of the crane -- only If the operator reads and uses these items. It is of utmost importance that the operator reads and understands the load chart, failure to do so places himself and all other personnel at risked and almost assures a crane or component failure.

An equally Important factor Is the understanding what the limitations of the are. This requires that personnel operating the equipment, fully comprehend how the crane works and what cranes are designed to do and what cranes are not designed to do. Never guess that the crane can do a certain job - always know!

CONTROLS

INTRODUCTION

The controls on the crane can be divided into two {2} categories; (1) primary and (2) secondary.

Primary controls can be considered any device that the operator must use or check to operate crane.

Secondary controls can be considered any device that the operator must be aware of and use should it become necessary. Below are listed both types of controls and their use. All crane primary controls are mounted at the operators station, except the boom angle indicator(s); which are mounted on either side of the main boom.

PRIMARY CONTROLS

Swing Control:

Extension Control:

Boom Control:

Winch Control:

Load Chart:

When facing the control station, is the first lever on the left. Pull lever to swing (slew) crane right (clockwise). Center (neutral) lever to hold crane position.

Push lever to swing crane left (counter-clockwise).

Second lever from left. Push lever to extend booms. Center (neutral) lever to hold boom length. Pull lever to retract booms.

Third lever from left. Pull lever to raise boom (luff up). Center (neutral) lever to hold boom height. Push lever up to lower boom (luff down).

Forth lever from left. Pull lever to hoist load. Center (neutral) lever to hold load.

Push lever to lower load.

This chart gives the crane capacities at differing boom angles, load radiuses, and boom extension(s). Precautionary notes and general operating instructions are located below the main chart.

Boom Anale Indicator: Located on either side of main boom. Indicates relative boom angle from horizontal and when used with load chart - provides lift capacity of crane.

Load Moment Indicator: The LMI system provides the operator a constant readout of the loads, boom angle, and load radius. The system will also alert the operator, with and audible alarm, when an overload condition Is approached. See LMI operators manual for complete details of system.

Motor Start/Stop:

Boom Lights:

Wiper Switch:

Warning Horn:

The power pack motor Start/Stop button is located to the left of the control console. Pull the button to start the power unit and push the button to stop the power unit. The button is illuminated when the power unit is operating.

The boom light control switch is located to the left of the control console and turns the boom lights ON or OFF.

The wiper switch is located to the left of the control console and turns the windshield wiper ON or OFF.

The warning horn push button is located to the left of the control console and

D

HEATER

• LOOKING

D

.------ SW I NG

WINDSHIELD

WIPER

PUM?

PRESSURE

GAGES

LMI READOUT

BOOM EXTEND

LUFF

TOWARDS SHEAVE

c

HEAD

c

DRAWING NUUBER

GA-5150

REVIS IONS

DATE CRAJJE S/N ZONE REV DESCRI PTION

12-2D-95 MCT-1565-95-1019 1-A Lfu. DESCR IPTI Ot4

12-2D-95 MCT-1565-95-1020

12-2D-95 !.ACT-I 565-95-1021

12-2D-95 uc;r-1565-95- 1022

12-2D-95 MCT-1565-95-1023

12-2D-95 UCT- 565-95-1024

~OAD MOMEI T INDICATOR

CONTROL CONSOLE

.... -0 0 ~ 0

! ~8~81 ~808 i - [Dffi[!J(!] mmmm mmoB

SECTION A-A

CRANE CONTROL CONSOLE

A

DATE APPROVALS

oo-oo-oo

WARN ING HORN

BOOM LIGHTS

WINDON WIPERS

MOTOR START/ STOP

~~~~~.--------~--------------------------------------~ 1 ~-=-:---w_AL_T_o"_v_s-iN ort.h American Alaska Marine Crane Do\Tt - · 12-2o-95

B

Crane and Equipment Co. ~~~~~·

CRANE OPERATOR CAB LAYOUT

FOR MCT-1565

DRAWING NUMBER ~v.

GA-5150 0

SHt:C "'U~SEF

O. N. A. I OF I

A can be operated by pushing. The warning horn should be used to advise assisting personnel that a possible danger may exist.

Cab Light: The cab light provides Illumination of the operating controls during night operations and is located above and behind the operators seat.

Sight Level gauge: The sight level gauge is located on the hydraulic reservoir and provides visual indication of the current fluid level in the reservoir.

Temperature Gauge: The temperature gauge is located at the bottom of the sight level gauge and provides visual indication of operating temperature.

SECONDARY CONTROLS

Relief Valves:

Port Relief Valves:

The main relief valves are located at the inlet end of each valve bank and are used to limit the maximum pressure to the crane components.

Port relief valves are installed on the work ports of the telescope (out) and both ports of the boom cylinder valve. The valves are used to limit the operating pressure of these functions below the pressure of the main relief valves. See HS-7752 for settings.

Counterbalance Valves: Are located at the blind end of each boom cylinder and on the blind end of the telescope cylinder. They are used to adjust the maximum load holding capability of the cylinders and to prevent over-running the cylinders when retracting with full loads.

Pressure Gauges:

Unloader valve:

Anti-Two Block:

Filter Indicator:

The pressure gauges are located to the lett of the LMI readout and provide an analog indication of the current operating pressures of the hydraulic system.

The operators can use the gauges as a backup to the LMI system and as a measuring tool for the condition of the hydraulic system.

The unloader valve is used to increase the speed of the boom and winch functions during light load operations. The operation the unloader can be monitored with the pressure gauges. This valve should be set @ 1700 - 1800 psi g.

The anti-two block system prevents the load block from contacting the sheave head. The only adjustment is the reaction time of the system, which should be set at 1-3 sec.

The filter indicator provides visual indication when the filter elements needs to be changed. During cold start-ups, the Indicator may show that the filters are bypassing and should be ignored.

OPERATING PROCEDURES

EQUIPMENT FAMILIARIZATION

All personnel operating the crane and assisting the crane operators must become thoroughly familiar with location and operation of the crane and power unit controls, the correct operating procedures, maximum lifting capacity of the crane, and all relevant safety precautions before operating the crane.

This crane is a complex piece of machinery and can be overloaded easily if not properly operated. All functions of the crane are hydraulically controlled and use standard industrial components. Hydraulic power is supplied to the crane by the platform mounted power unit. Carefully follow the operating procedures outlined below. The load ratings and support requirement of the crane during towing operations must be strictly adhered to.

PRE-OPERATIONAL EQUIPMENT CHECKS

Before operating the crane, the condition of the crane, hydraulic power unit, and their components must be verified for operational readiness. Perform any routine or mandatory maintenance at this time. The following items should be checked each time the crane is placed In service and after each project is completed.

Electrical System

The electrical system Includes the slip-ring, inter-connecting wiring, cab controls, LMI system, boom lights, cable reel, and anti-two block switches. The operator and/or assisting personnel should perform the following inspection checks:

WARNING: THE ELECTRICAL SYSTEM CONSISTS OF BOTH HIGH AND LOW VOLTAGES;

EXTREME CAUTION MUST BE USED WHEN INSPECTING THE ELECTRICAL SYSTEM.

• Inspect the all wiring harnesses for damage or chaffing.

• Inspect enclosures for adequate sealing and/or damage.

• Insure that the slip-ring torque arm bar is in place and retaining bolts are present.

• Insure that the slip-ring covers are in place and seals are intact.

• Inspect all boom appliances for operation and integrity.

• Insure operation of anti-two block switches.

• Insure integrity and operation of anti-two cable reel and wiring.

• Insure operation of LMI system.

• Insure integrity and operation of boom length reel and wiring.

• Insure operation of warning horn.

PRE-OPERATIONAL CHECKS cont.

Hydraulic Control System

The hydraulic control system Includes the hydraulic power unit, all inter-connecting lines between power unit and crane control valves and their connections. There are no unusual or special components designed into the system. The operator and/ or assisting personnel should perform the follow checks:

• Inspect for any signs of leaking and pools of oil. Always determine and correct cause of leaking before placing crane Into service.

• Check hydraulic reservoir level and add correct grade of fluid it required. Determine why oil level was low before placing crane Into service.

• Check all hose and fittings for signs of leaking. The hoses should be free of cuts or abrasions (chaffing) through the outer covering. Insure that all hoses are free of twisting or kinking.

• If suction valve at hydraulic power unit is not wired open. insure that valve is open prior to starting unit. Open any shut-off (isolation) valves between power unit and crane.

• Check crane control valves for binding or damage. DO NOT PLACE CRANE INTO SERVICE IF CRANE CONTROLS WILL NOT SELF CENTER. Check for loose parts, corrosion, and proper alignment.

• Drain off any accumulation of water in pedestal base.

lifting System

The lifting system consists of the main and telescope booms, the luff and extend cylinders, winch and rigging, and all associated mounting hardware. The crane operator and(or assisting personnel shall check the following before placing crane into service and after job is complete:

• Main and telescope booms for damage, excessive corrosion, cracked welds, bends or ripples In boom sections, and misalignment.

• Check all cylinder, hinge, and boom pins for proper lubrication and for excessive wear. Insure that all pin retainer bolts are present.

• Check luff and extend cylinder hose and fittings tor damage or leakage.

• Missing or broken winch mounting bolts.

• Check that all bolts and fasteners are present and that retainers are in place.

• Check winch for leakage, loose parts, abnormal wear, proper alignment, and correct oil level.

• Check wire rope for proper spooling on winch drum.

• Check wire rope for damage. Such as; broken wires, flatted wires, excessive corrosion, kinks and twists, and blrdcaglng. See Lubrication and Maintenance section for complete wire rope inspection instructions.

• Insure sheaves are free turning.

• Inspect wire rope end connection signs for pullout or damage.

• Inspect load hook for cracking, throat separation, shank stretching, missing safety catch, and ability to swivel freely. REPLACE IF HOOK SHOWS ANY DAMAGE.

Swing Drive System

The swing drive system Includes the drive motor, planetary gear reduction drive and brake, pinion gear, and rotation bearing. The operator andjor assisting personnel should check the following:

• Ring and pinion gears for proper lubrication, loose or missing mounting bolts, excessive or abnormal wear, and misalignment.

• Drive motors for loose or leaking fittings, damaged hoses, and loose or broken mounting bolts.

• Gear boxes for loose or broken mounting bolts.

• Rotational bearing for proper lubrication, integrity of seal, loose or broken mounting bolts, and excessive wear or "play".

CTD /EM SYSTEM

The CTD /EM system consists of the through bore slip-ring, EM sheave, EM guide rollers, main boom pad eye, towing padeyes, and owner furnished equipment that attaches to the main boom. The operator andjor assisting personnel shalf check the following before preforming any launching or towing operations:

• Perform system and maintenance inspection prior to handling any Instrumentation package. Any deficiencies must be corrected before operation.

• Insure the towing guy wires are adequate for the towing operation and the correct tension is being maintained during towing operations.

• Insure the lower CTD /EM guide rollers turn freely and are not grooved.

• Insure the main CTD/EM sheave is turning freely.

• Inspect the main CTD/EM sheave groove for wear and damage that could harm the EM cable.

• Inspect the upper seal area where the EM cable passes through the slip ring center bore. Apply water proof sealant as required to prevent leakage into the slip ring.

• Insure that EM cable has adequate clearance through the slip ring bore and dose not contact the seal tube.

• Inspect the boom padeyes for wear and cracking of welds. Repair before attempting a towing operation. Padeye bores can be built up with hard facing welding rod.

CTD /EM SYSTEM cont.

• Inspect the EM over-boarding sheave block and shackle, owner furnished materials, for wear and/or damage. Repair or replace as required.

• Insure that EM cable does not contact the guide roller retainer bar.

• Inspect EM cable for damage as It Is played out. A severely damaged cable can cause loss of the Instrumentation package.

GENERAL OPERATING INSTRUCTIONS

1. Start power unit. If oil temperature Is below 40°F, allow unit to Idle for 10 · 15 Min. before operating crane. Power up the LMI system and allow unit to stabilize before attaching load to the load line. Select the correct number of parts of reeving for the current crane configuration.

2. Check functioning of all controls by operating each system through one (1) complete cycle.

This Is especially Important if crane has been idle for long periods of time. serviced, or repaired.

If any system does not function properly, correct condition before continuing.

3. All crane control movements must be done with precise-controlled manipulations to prevent sudden starting and stopping of crane functions. This Increases the life of the crane by eliminating unnecessary shock loads while providing a safe working environment for the assisting personnel. The controls should be carefully actuated to began function and then slowly actuated further until the desired function speed is achieved.

4. When lifting loads, always monitor load and boom angle indicator(s) to prevent overloading of the crane. Whenever possible, use the shortest possible retracted length required to achieve desired load radius. The LMI system Is calibrated for STATIC or SHIPBOARD operations only.

The operator must use the load charts for offshore operations to prevent overloading of crane.

Do not rely upon the overload indication feature during OFFSHORE operations.

5. When operating winch control, avoid "snapping• load line when hoisting. Always remove slack line before Increasing hoisting speed. NOTE: With multi-part reeving this is less of an concern because hooks speeds are relatively slow compared to single part reeving.

6. Use both winch and telescope controls to maintain load height when Increasing (decreasing) load radius without changing boom elevation.

7. When removing (placing) loads onto a moving deck or from (to) a moving deck to(from) a fixed platform. the operator should learn to time the deck movement to optimum time to hoist (lower) load. Under ideal timing, the load is hoisted (lowered) when the crane (load) are essentially static. This occurs during two periods of wave action • at crest and trough.

8. When both the crane and load are on two separate moving platforms, The operator should learn to time deck movements of both vessels for the optimum moment to hoist (lower) load.

Under ideal timing, the load is hoisted (lowered) when the crane (load) are essentially at equal velocities. This occurs during two periods of wave action • when climbing a wave and when descending a wave.

GENERAL OPERATING INSTRUCTIONS cont.

9. If load is not visible to operator at all times, assisting personnel shall guide crane movements using approved hand signals.

10. When stopping movement of crane, slowly center control valve and do not cross over center position until crane function has stopped. Rapid reversal of crane function can impose undue shock loads on the equipment and shorten life of crane.

1 1. Always check operational area for obstructions within the boom(s) or load path. Allow at least 2 ft clearance from obstruction to boom(s) or load.

12. When operating crane as a shipboard unit, the crane must be derated if vessel list (or trim) exceeds 5° in either axis.

13. When using the LMI system, the following functions are provided; See operators manual for complete information on LMI system.

A.

B.

c.

D.

WARNING:

E.

F.

G.

Hook load - "1" + "select". Provides current load on load block.

Boom Length - "2" + "select". Provides the current length of telescope boom extension.

Boom Angle - "3" + "select". Provides current boom angle.

Line Parts - "4" + "select". Provides current number of parts of line reeving the LMI system is calibrated for.

IF THE ACTUAL NUMBER OF PARTS ARE DIFFERENT FROM THE CALIBRATED

NUMBER OF PARTS, SEVERE OVERLOADING OF THE CRANE CAN OCCUR AND

DAMAGE TO CRANE WILL ENSUE.

Load Radius - "5" + "select". Provides current load radius of the load hook.

Scan- •g• + "select". Provides continuous readout of Load, Boom Length, and Boom Angle in 2 second intervals.

Warning indicator.

1. 105% -Amber indicator light. Increase boom angle or decrease boom length to prevent further overloading of crane.

2. 110%- Red indicator light with audible alarm. Immediately land load with winch or increase boom angle with luff cylinders, or reduce boom length with telescope cylinder.

14. When stopping crane always observe the following:

A. Land any attached load. If load must be suspended, tag crane control with notice of such and warning barricades should be placed beneath suspended load.

B. Place crane boom in boom rest or suitable secure boom to prevent crane from inadvertently swinging.

C. Place all controls In neutral position.

D. Shut off power unit and lock disconnect switch in "off' position to prevent unauthorized operation of crane.

E. Perform crane Inspection and tag any abnormalities found. Operators and/or assisting personnel shall notify Maintenance personnel of any deficiency found .

15. When using crane for personnel handling.

WARNING: CRANE MUST BE APPROVED FOR PERSONNEL HANDLING AND REQUIRED

ADDITIONAL SAFETY DEVICES AND SPECIALIZED EQUIPMENT. AT BOTTOM OF

LOAD CHART IS INDICATION WHETHER CRANE IS APPROVED FOR PERSONNEL

HANDLING OR NOT. --NEVER USE AN UNAPPROVED CRANE FOR PERSONNEL

HANDLING-

A. Perform system and maintenance Inspection prior to handling personnel and any deficiencies must be corrected before operation.

B. When handling personnel, all crane controls shall be operated in a precise-controlled manor. If control valves have adjustable travel stops, they should be adjusted to allow only 1 / 2 of normal travel.

C. Only agency approved Personnel Handling Platforms or Harnesses shall be used.

D. All crane safety devices must be operational before using crane for personnel handling.

E. When personnel platform Is stationary, all brakes and locking devices must be set

F. Never exceed the Rated Personnel Handling Capacity of crane or wire rope, whichever is less.

G. Only personnel handling approved load hooks shall be used during personnel handling operations.

H.…